Permobil Explorer Mini User manual

Service manual American English
Explorer Mini

Introduction
This is the Service Manual of your product. The Service Manual is not
a stand-alone document, but rather a complement to the User’s Manual.
It is intended for technical personnel who maintain and repair Permobil
power wheelchairs. It is important that anyone who performs
maintenance and repairs described in this manual reads and understands
the content of this manual so that the work is performed professionally.
This Service Manual is not intended for end users or their care ivers.
They must contact their local Permobil dealer for any maintenance or
repair needs.
Always state the chassis number when contactin Permobil to ensure
that the correct information is provided.

Text
Produced and published by Permobil
Edition: 1.1
Date: 2019-08-22
Order no: 336201 eng-U

How to contact Permobil
Permobil Inc.
300 Duke Drive
Lebanon, TN 37090
USA
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.permobilus.com
Head office of the Permobil group
Permobil AB
Box 120
861 23 Timrå
Sweden
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.permobil.com

Explorer Mini Contents
1 Important information..................................................................................................................................... 9
1.1 Warranty .................................................................................................................................................9
1.2 Technical support ......................................................................................................................................9
1.3 pare parts and accessories........................................................................................................................9
1.4 Ordering documentation ............................................................................................................................9
1.5 crapping and recycling.............................................................................................................................9
2 afety instructions.........................................................................................................................................10
2.1 Descriptions of admonitions ......................................................................................................................10
2.2 Warnings and precautions........................................................................................................................10
3 pecifications................................................................................................................................................12
3.1 Overview ...............................................................................................................................................12
3.2 Wiring diagram ......................................................................................................................................13
3.2.1 Base module ...........................................................................................................................................13
3.2.2 Batteries .................................................................................................................................................13
3.3 erial number stickers ..............................................................................................................................14
3.3.1 erial number on the base module .............................................................................................................14
3.3.2 erial number sticker on the nVR2 power module .........................................................................................14
3.3.3 erial number sticker on the control panel ...................................................................................................14
4 Repairs ..........................................................................................................................................................15
4.1 Cushion .................................................................................................................................................15
4.1.1 Removing the cushion...............................................................................................................................15
4.1.2 Attaching the cushion...............................................................................................................................15
4.2 Tray top .................................................................................................................................................16
4.2.1 Removing the tray top ..............................................................................................................................16
4.3 Attaching the tray top...............................................................................................................................16
4.4 eat.......................................................................................................................................................17
4.4.1 Removing the seat....................................................................................................................................17
4.4.2 Installing the seat .....................................................................................................................................18
4.5 Table and backrest unit.............................................................................................................................20
4.5.1 Removing the table and backrest unit..........................................................................................................20
4.5.2 Installing the table and backrest unit ...........................................................................................................22
4.6 Base module ...........................................................................................................................................25
4.6.1 Top cover ...............................................................................................................................................25
4.6.2 Bottom cover...........................................................................................................................................33
4.7 Drive wheels ...........................................................................................................................................40
4.7.1 Removing the drive wheels ........................................................................................................................40
4.7.2 Installing the drive wheels .........................................................................................................................41
4.8 Caster wheels..........................................................................................................................................42
4.8.1 Removing the caster wheels.......................................................................................................................42
4.8.2 Installing the caster wheels ........................................................................................................................43
4.9 Control panel..........................................................................................................................................44
4.9.1 Removing the control panel .......................................................................................................................44
4.9.2 Installing the control panel ........................................................................................................................47
4.10 Batteries .................................................................................................................................................51
4.10.1 Charging the batteries..............................................................................................................................51
4.10.2 Removing the batteries .............................................................................................................................53
4.10.3 Installing the batteries...............................................................................................................................55
4.11 Circuit breakers.......................................................................................................................................57
4.11.1 Electrical fault .........................................................................................................................................57
4.11.2 Removing the main circuit breaker .............................................................................................................57
4.11.3 Installing the main circuit breaker...............................................................................................................59
4.11.4 Removing the start button..........................................................................................................................61
4.11.5 Installing the start button ...........................................................................................................................62
4.12 Drive unit ...............................................................................................................................................63
4.12.1 Removing the drive units ...........................................................................................................................63
4.12.2 Installing the drive units ............................................................................................................................65

Contents Explorer Mini
4.13 nVR2 power module ................................................................................................................................67
4.13.1 Removing the nVR2 power module.............................................................................................................67
4.13.2 Installing the nVR2 power module ..............................................................................................................68
5 Adjustments...................................................................................................................................................69
5.1 eat.......................................................................................................................................................69
5.1.1 Adjusting the seat height...........................................................................................................................69
5.1.2 Table and backrest unit.............................................................................................................................70
5.2 Locking and unlocking the Explorer Mini .....................................................................................................71
5.2.1 Locking ..................................................................................................................................................71
5.2.2 Unlocking...............................................................................................................................................72
6 Troubleshooting ............................................................................................................................................73
6.1 Troubleshooting guide..............................................................................................................................73
6.2 Control panel diagnostics .........................................................................................................................75
6.2.1 LEDs on the battery indicator .....................................................................................................................75
6.2.2 LEDs on the maximum speed indicator ........................................................................................................75
6.2.3 Rapidly flashing, one to ten LEDs................................................................................................................75
6.2.4 Example of error messages and remedies....................................................................................................76
6.2.5 Repairing defective units...........................................................................................................................76
Index..............................................................................................................................................................77

Explorer Mini Important information - Warranty
1 Important information
All information, pictures, illustrations and specifications are based upon
the product information available at the time this manual was released.
Pictures and illustrations used in this manual are representative examples
and not intended to be exact depictions of the various parts of the
wheelchair.
We reserve the ri ht to make chan es to the product without prior
notice.
If you are visually impaired, this document can be downloaded at www.
permobil.com. Use the ma nifyin tool in your PDF reader to achieve
desired text and picture size.
It is also possible to obtain information concernin our products from
our website: www.permobil.com.
1.1 Warranty
Contact your dealer or Permobil Inc. USA for information about the
warranty period for this product.
Product Warranty Information sets forth the conditions of the warranty.
For further information about applicable warranties, see https://
permobilus.com/support/warranties/.
NOTICE
Unapproved replacement of parts
If any part is replaced without approval from Permobil, the wheelchair
warranty will become void. Permobil accepts no liability for any loss that
occurs as a result of a control system component being opened, ad usted or
modified without permission.
1.2 Technical support
In the event of technical problems, contact your dealer or call Permobil
Inc. USA on 1-800-736-0925.
Be prepared to provide the wheelchair serial number, located on the
chassis, to ensure proper support. See
3.3
Serial number stickers , Pa e 14.
1.3 Spare parts and accessories
Spare parts and accessories must be ordered throu h your dealer.
The expected service life of this product is five years.
1.4 Ordering documentation
Should you need another copy of this manual, one may be ordered
from Permobil. Ask for the order number specified on the back cover.
1.5 Scrapping and recycling
Contact Permobil for information about scrappin a reements in force.
9

Explorer Mini Safety instructions - Descriptions of admonitions
2 afety instructions
2.1 Descriptions of admonitions
The followin admonitions describin warnin s, remarks and
explanatory texts are used throu hout this manual to draw attention to
items of si nificant importance to safety:
DANGER!
Danger admonition
Indicates a dangerous situation which, if not avoided, could result in death as
well as serious damage to the product or other property.
WARNING!
Warning admonition
Indicates a hazardous situation which, if not avoided, could result in serious
in ury or death as well as damage to the product or other property.
CAUTION!
Caution admonition
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate in ury as well as damage to the product or other property.
NOTICE
Notice admonition
Indicates an important but not hazardous situation which, if not avoided, could
result in damage to the product or other property.
Provides information about the conditions or circumstances under which
the information given applies.
2.2 Warnings and precautions
WARNING!
Use supplied screws and recommended tightening
torque
Use the supplied screws and the tightening torques recommended in this
service manual to reduce the risk of damage to the wheelchair and to prevent
causing in ury to the user.
10

Explorer Mini Safety instructions - Warnings and precautions
CAUTION!
Maintenance by a qualified service technician
Only qualified service technicians should perform the maintenance and repair
specified in this manual. Read all instructions carefully before proceeding. If
any questions arise, contact Permobil for assistance.
CAUTION!
Do not use removable parts to lift or move
Do not lift or move the wheelchair by any of its removable parts. Doing so
could lead to personal in ury and property damage, including damage to the
wheelchair.
CAUTION!
Do a check after a collision
In the event of a collision with a wall, door or other fixed ob ect when
operating the wheelchair, always make sure all parts of the wheelchair are
undamaged before operating it again. Failure to do so could lead to personal
in ury.
11

Explorer Mini Specifications - Overview
3 pecifications
3.1 Overview
Figure 1. Explorer Mini overview.
A. Backrest (part of the table and backrest unit)
B. Cushion
C. Tray top
D. Seat
E. Caster wheel
F. Drive wheel
G. Joystick
H. On/off button
I. Table (part of the table and backrest unit)
J. Column
K. Base module
L. Serial number
M. Start button
N. Main circuit breaker
12

Explorer Mini Specifications - Wiring diagram
3.2 Wiring diagram
3.2.1 ase module
Figure 2. Wiring diagram for the electronics in the base module.
A. Battery savin module
B. Drive unit, left
C. nVR2 power module
D. Contact to the left drive unit
E. 24 V input
F. Contact to the ri ht drive unit
G. Contact to the control panel
H. Main circuit breaker
I. Drive unit, ri ht
J. Batteries
K. Start button
3.2.2 atteries
Figure 3. Wiring diagram for the batteries and position
of the wiring diagram for the batteries.
The wirin dia ram for the batteries is positioned at the bottom cover
of the base module.
-
+- +
A
B
C
D
E F G
H
I
J
K
13

Explorer Mini Specifications - Serial number stickers
3.3 Serial number stickers
3.3.1 Serial number on the base module
Figure 4. Position of the serial number sticker.
Figure 5. Information on the serial number sticker.
The serial number sticker is attached between the caster wheels at the
base module.
Information on the serial number sticker:
A. Made in (country of final assembly) by (address to site of final
assembly).
B. Federal Law (United States) restricts this device to sale by or on the
order of a healthcare provider.
C. Maximum user wei ht.
D. Model name of the product.
E. Serial number.
F. EAN code.
G. Device identifier (01), Date of assembly (11), Serial number (21).
3.3.2 Serial number sticker on the nVR2 power
module
Figure 6. Position of the serial number sticker on the
nVR2 power module.
The serial number sticker is attached at the back of the nVR2 power
module, facin the bottom of the base module. It is only visible when
the nVR2 power module is removed from the Explorer Mini.
3.3.3 Serial number sticker on the control panel
Figure 7. Position of the serial number sticker on the
control panel.
The serial number sticker is attached at the bottom of the control panel.
It is only visible when the control panel is removed from the Explorer
Mini.
14

Explorer Mini Repairs - Cushion
4 Repairs
CAUTION!
Maintenance by a qualified service technician
Only qualified service technicians should perform the maintenance and repair
specified in this manual. Read all instructions carefully before proceeding. If
any questions arise, contact Permobil for assistance.
WARNING!
Use supplied screws and recommended tightening
torque
Use the supplied screws and the tightening torques recommended in this
service manual to reduce the risk of damage to the wheelchair and to prevent
causing in ury to the user.
NOTICE
Replace worn screw
Worn screw must be replaced.
4.1 Cushion
4.1.1 Removing the cushion
The wheelchair has a removable cushion. There are four screws,
attached to the cushion, that hold the cushion in place.
Figure 8. Remove the screws from the attachment points
on the backrest.
1. Remove the four screws from the attachment points on the
backrest.
2. Remove the cushion from the backrest.
4.1.2 Attaching the cushion
Figure 9. Attach the cushion with the screws in the
attachment points on the backrest.
1. Put the cushion in place on the backrest.
2. Put the four screws into the attachment points on the backrest and
ti hten them by hand.
15

Explorer Mini Repairs - Tray top
4.2 Tray top
4.2.1 Removing the tray top
Figure 10. Push the tray top upward.
Put your fin ers in the hole that is positioned at the bottom of the table.
Push the tray top upward and lift off the tray top.
NOTICE
Do not drive the wheelchair while the tray top is
removed
Do not let the child drive the Explorer Mini while the tray top is removed. The
child may press the maximum speed buttons and affect the speed of the
wheelchair by mistake.
4.3 Attaching the tray top
Figure 11. Put the tray top in place.
Hold the tray top with its metal inserts facin downward. Put the tray
top on the table.
16

Explorer Mini Repairs - Seat
4.4 Seat
4.4.1 Removing the seat
An adult or health-care provider must decide if seat removal is
applicable for the child, takin into consideration his or her a e and
capacity.
The center of ravity is affected when the seat is removed.
The table and backrest unit must be in the hi hest position before you
can remove the seat. Otherwise there will not be enou h space to
remove the seat.
1. Put the table and backrest unit in its hi hest position. For
instructions on how to adjust the hei ht of the table and backrest,
see 5.1.2.1
Adjustin the hei ht of the table and backrest unit .
Figure 12. Prepare removal of the seat.
2. Remove the ti htenin knob (A) from the column.
3. Pull out the plun er knob (B).
Figure 13. Remove the seat from the column.
4. Push down the seat and slide it off the column.
Figure 14. Put back the tightening knob.
5. Put back the ti htenin knob and ti hten it by hand.
17

Explorer Mini Repairs - Seat
4.4.2 Installing the seat
The center of ravity is affected when the seat is installed.
The table and backrest unit must be in the hi hest position before you
can install the seat. Otherwise there will not be enou h space to install
the seat.
1. Put the table and backrest unit in its hi hest position. For
instructions on how to adjust the hei ht of the table and backrest
unit, see 5.1.2.1
Adjustin the hei ht of the table and backrest unit .
Figure 15. Remove the tightening knob from the column.
2. Remove the ti htenin knob from the column.
Figure 16. Pull out the plunger knob (A) from the seat.
3. Pull out the plun er knob (A).
Figure 17. Push the seat into the groove on the column.
4. Push the seat into the roove on the column.
5. Carefully move the seat up or down to a settin .
18

Explorer Mini Repairs - Seat
Figure 18. Release the plunger knob (A) and put back
the tightening knob (B).
6. Release the plun er knob (A). A click si nals that the plun er knob
is locked.
7. Put back the ti htenin knob (B) and ti hten it by hand.
19

Explorer Mini Repairs - Table and backrest unit
4.5 Table and backrest unit
4.5.1 Removing the table and backrest unit
Use a protective mat to prevent damage to the table and backrest unit
and the surface.
The followin tools are necessary for this task:
• Torque wrench.
• Allen socket, 4 mm.
• Screwdriver or pliers.
Figure 19. Positions for the on/off button (A) and the
main circuit breaker (B).
1. Put the Explorer Mini on a flat surface.
2. Press the on/off button (A) to turn off the power.
3. Turn off the main circuit breaker (B).
Figure 20. Remove the tray top.
4. Put your fin ers in the hole that is positioned at the bottom of the
table. Push the tray top upward and lift off the tray top.
5. Make sure that the LEDs on the control panel are off.
Figure 21. Remove the four plastic plugs from the
screws.
6. Remove the four plastic plu s from the screws. Use a screwdriver or
pliers to loosen the plastic plu s.
20