Permobil C300 User manual

Permobil C300
SERVICE MANUAL
Power wheelchair
UK

How to contact Permobil
Head Office of the Permobil group
Permobil BV
Zuiddijk 1
5705 CS Helmond
Holland
E-mail: [email protected]
Tel: [phone]
Fax: [phone]
Permobil AB
Box 120, 861 23 Timrå, Sweden
Tel: [phone]. Fax: [phone]
E-mail: [email protected]
Produced and published by Permobil AB, Sweden
Edition no.3, 2009-06
Order no.: 205206-UK-0

4
Contents
Contents
Introduction....................................................................................................... 5
Identification plates .......................................................................................... 6
Covers................................................................................................................ 8
Batteries........................................................................................................... 10
Front wheels.................................................................................................... 12
Rear wheels..................................................................................................... 13
Support wheels ............................................................................................... 14
Support wheels dampers............................................................................... 14
Wheel forks ..................................................................................................... 15
Shock absorbers............................................................................................. 16
Slewing brackets ............................................................................................ 17
Wheel lock release ........................................................................................ 18
Plastic rail ................................................................................................... 18
Magnetic wheel lock ................................................................................... 19
Wheel Lock Release Sensor ...................................................................... 20
Drive motor...................................................................................................... 21
Seat elevator ................................................................................................... 22
Manual Raising/Lowering of the Seat elevator ........................................... 22
Removing the Seat elevator ....................................................................... 23
Fixed seat post................................................................................................ 24
Service Position .......................................................................................... 24
Adjusting the Seat Height ........................................................................... 24
Removal ...................................................................................................... 25
Seat tilt ............................................................................................................ 26
CS-seat ........................................................................................................... 27
Corpus-seat .................................................................................................... 28
Control panel pilot+........................................................................................ 30
Seat control panel ....................................................................................... 30
Control panel VSI............................................................................................ 31
Pilot+ controller .............................................................................................. 31
SLS drive stage............................................................................................... 33
Fuses................................................................................................................ 34
Main Fuse.................................................................................................... 34
SLS fuse ...................................................................................................... 35
Fuse for seat/lighting ................................................................................... 35
Control System ............................................................................................... 36
Trouble shooting............................................................................................. 37
Cabling overview VSI ..................................................................................... 40
Cabling overview Pilot+ ................................................................................. 42
Distribution Chart VSI ................................................................................... 44
Distribution Chart Pilot+ ............................................................................... 46
Index ............................................................................................................... 49

5
Introduction
Introduction
The Service Manual is intended for technical personnel who maintain and repair electric 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. 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 BV Holland
at [phone].
Spare parts
Spare parts must be ordered through your dealer.
Warranties
All wheelchairs are supplied with a two-year product guarantee. Batteries and charger are supplied with
a one-year warranty
Maintenance
See the information in the Owner’s Manual.

6
Identification plates
Identification plates
Chassis
Chassis identification number.
Pilot+ controller identification number.
Control panel Pilot+ identification number.
Pilot+ controller
Control panel Pilot+

7
Identification plates
Control panel VSI
Control panel VSI identification number.

8
Covers
Fixing points of the front cover.
Covers
Removing the Chassis Cover
The cover is mounted with hook and loop fastener
at the rear and with two knobs at the front. See
figure.
1. Move/fold the leg rests out and, if necessary, raise
the seat.
2. Switch off the main power switch on the control
panel.
3. Remove the two knobs that hold the cover at
the front.
4. Release the hook and loop fastener by lifting
the cover straight up. Then remove the cover
by pulling it backwards.
Fitting
Fit the cover in the reverse order.
Covers.

9
Covers
Lift the chassis cover a little at the front so that
the front battery cover comes free.
Removing the Rear Battery Cover
The cover is fitted with two guide lips.
1. Switch off the main power switch on the control
panel.
2. If the chassis cover has not been removed, lift
its rear edge so that the rear battery cover
comes free. Raise the seat if necessary.
Remove the rear battery cover by pressing its
guide lips straight out on both sides and then
lifting it upwards/backwards.
Fitting
Fit the cover in the reverse order.
Removing the Front Battery Cover
The cover is wedged in under the chassis cover.
1. Move/fold the leg rests out.
2. Switch off the main power switch on the control
panel.
3. If the chassis cover has not been removed,
remove the two knobs that hold it in place at
the front. Lift the chassis cover a little at the
front so that the front battery cover comes free.
Raise the seat if necessary. Remove the front
battery cover by lifting it upwards/forwards.
Fitting
Fit the cover in the reverse order.
Lift the chassis cover a little at the back so that
the rear battery cover comes free.
Fixing points of the rear cover.

10
Batteries
Batteries
Lift/pull the battery out of the chassis.
Battery connections.
Front battery removed.
Fitting
1. Lift a new battery into the chassis using the
battery belt. Leave the battery belt on the
battery. Place the battery with the battery
terminals at the front.
2. Connect the battery connections on the new
battery. See also the sticker on the battery
cover.
3. Refit the battery cover. See page 9.
5. Disconnect the battery connections. See also
the sticker on the battery cover.
6. Lift/pull the battery out of the chassis using the
battery belt.
Removing the Front Battery
1. Place the wheelchair on a level surface.
2. Move/fold the leg rests out, and if possible,
raise the seat lift
3. Switch off the main power switch on the
control panel.
4. Remove the front battery cover. See page 9.
Be careful when using metal objects when working with
batteries. A short-circuit can easily cause an explosion.
Always use safety gloves and safety goggles.
WARNING
Be careful when using metal objects when working with
batteries. A short-circuit can easily cause an explosion.
Always use safety gloves and safety goggles.
WARNING

11
Batteries
Removing the Rear Battery
1. Place the wheelchair on a level surface.
2. Switch off the main power switch on the control
panel.
3. Remove the rear battery cover. See page 9.
4. Disconnect the battery connections. See also
the sticker on the battery cover.
5. Lift/pull the battery out of the chassis using the
battery belt.
Fitting
1. Lift a new battery into the chassis using the
battery belt. Leave the battery belt on the
battery. Place the battery with the battery
terminals at the rear.
2. Connect the battery connections on the new
battery. See also the sticker on the battery
cover.
3. Refit the battery cover. See page 9.
Lift/pull the battery out of the chassis.
Battery connections.
Rear battery removed.
Be careful when using metal objects when working with
batteries. A short-circuit can easily cause an explosion.
Always use safety gloves and safety goggles.
WARNING

12
Front wheels
Puller 304103-99-0.
Front wheels
Removal
1. Turn off the main power switch on the control
panel.
2. Lift the wheelchair chassis and support it on
blocks so that the wheel is off the ground.
3. Remove the hubcap (1), bolt (2) and the three
washers (3 and 4); see figure.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight; see figure.
Fitting
1. Check that the wheel shaft and rim are
undamaged. Clean as necessary to remove
dirt and rust. Replace damaged parts.
2. Check that the key is firmly attached and
undamaged; fit a new key if necessary.
3. Lubricate the shaft with a thin layer of copper
paste (Würth 0893800x, Art. no.: 1820540).
64321
Fitting of rim.
5
Do not use any type of lubrication in the threaded hole in the
axle or on the bolt.
WARNING
Other types of bolts or washers are not to be used.
Do not use any other type of thread lock.
4. Fit the wheel onto the axle. The use of hand
force only is preferred, but, if need be,
carefully use a rubber mallet, whose head
diameter is no less than 1.5 inches (38 mm), to
ensure that the rim is fully seated upon the motor.
The washer (4) should be placed with the most flat side
inwards.
The bolt must be used once only. Removed bolt is not
allowed to be refitted.
Hitting too hard with a rubber mallet could cause damage to
the gear.
5. Mount the three washers (3) and 4) onto the
bolt (2) and secure the wheel. Use a torque
wrench to tighten the bolt to 33Nm.
Install the hub cap (1). See Fig. 13.
NOTE
WARNING
NOTE
NOTE
WARNING
1Hubcap
2Bolt, ISO 4762 M8x25 10.9 Fe/Zn 5 C2 / Locking
coat DIN 267-28
3Shim washer DIN 988 8 A2 (DB 8x14x0.5 Stainless)
4Washer, 8 HB 305 Fe/Zn 5 C2 (TBRSB 8,4x26x5)
5Front wheel
6Key DIN 6885A 6x6x22
Pos. Description

13
Rear Wheels
Rear Wheel.
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 to be removed is free of the
ground.
3. Remove the hub cap 1.
4. Remove the nut 2. Apply pressure to the screw
6 using an Allen key.
5. Remove the washer 3, wheel 4, axle 5 and
screw 6.
Fitting
1. Check that the axle and rim are not damaged.
If necessary, clean to remove dirt and rust.
Replace damaged parts.
2. Fit the wheel on the axle using just your
hands. Check that the wheel is fully located on
the axle.
3. Fit the screw 6 in the wheel fork.
4. Fit the axle 5, wheel 4, washer 3 and nut 2,
and tighten the wheel.
5. Fit the hub cap 1.
Tightening torque: 24 Nm.
Fitting of rim.
542
1
No other type of screws, nuts and washers than those stated
here may be used.
No other type of lock coating or lock liquid may be used.
Screws and nuts must only be used once. Once removed,
screws and nuts must therefore never be refitted.
NOTE
WARNING
WARNING 63
1Hubcap
2Locking nut, ISO 7040 M6 8 Fe/Zn 5 Cl
3Washer, ISO 2768-c, 8,5x23x3
4Rear Wheel
5Axel, ISO 2768-m Ø15
6Bolt, ISO 10642, M8x70, 10.9 Fe/Zn 5 C1
Pos. Description

14
Support Wheels & Support Wheel Dampers
Support Wheels
Support wheels may be fitted in three different
positions; low, medium and high. These fitting
positions are marked L, M and H.
Low
With the support wheels fitted in the lower
position, low, the wheelchair inclines less before
the support wheels meet the ground, but the
accessibility of the wheelchair is reduced
somewhat.
Medium
The support wheels are fitted as standard in the
middle position, medium. This position suits most
users.
High
With the support wheels fitted in the top position,
high, the accessibility increases somewhat, but it
also means that the wheelchair may incline more
before the support wheels meet the ground.
Removal
1. Switch off the main power switch on the control
panel.
2. Remove the screw. See figure.
Support wheels may be fitted in three different
positions; low, medium and high.
Removing the support wheels entails an increased risk of the
wheelchair tipping over. The wheelchair must not be driven
when the support wheels are not fitted.
WARNING
Support Wheel Dampers
Removal
1. Switch off the main power switch on the control
panel.
2. Remove the chassis cover. See page 8.
3. Unscrew and remove the two screws that hold
the support wheel damper in place. See
figure.
Fitting
Fit the damper in the reverse order.
Fitting
1. Switch off the main power switch on the control
panel.
2. Fit the wheel with the screw, washer and nut in
the desired position. See figure.
Support wheel damper.
H
M
L

15
Wheel Forks
Wheel fork with friction brake.
Wheel Forks
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 cap from the top of the link arm.
See figure.
4. Remove the friction plate. It is fitted with one
screw from above. See figure.
5. Remove the wheel fork. It is fitted with a nut
from above. See figure.
Fitting
Fit the wheel fork in the reverse order.
Fit the O-ring on the friction plate. See figure.
No other type of lubricant than that stated here may be used.
Lubricate the O-ring with Lubricant friction brake,
Part. no: 1820405
Fit the O-ring In the groove of the friction plate.
Tighten the nut holding the wheel fork in place with
a torque wrench.
Tightening torque: 33 Nm.
Tighten the screw holding the friction plate in place
with a torque wrench.
Tightening torque: 15 Nm.
NOTE
NOTE
1Plastic plug
2Bolt, ISO 10642 M8x20 10.9 Fe/Zn 5 C1/
Locking coat DIN 267-28
3O-ring Ø24.2x3 EPDM
4Friction plate ISO 2768-m Fe/Zn 12C1
5Nut, DIN 934 M14x1.5 8Fe/Zn 8C1
6Bearing, 6002-2RS1 (15x32x9)
7Circlip, DIN 472 Ø32
8Spacer, ISO 2768-m Fe/Zn 12C1 (Ø20 h9)
9Spacer, ISO 2768-m Fe/Zn 12C1
10 Bolt, ISO 2768-m Stainless
Lubricant friction brake, Momentum, PRO AA 2/0,025
Pos. Description
1
2
3
4
5
8
9
10
11
7 6

16
Shock Absorbers
Shock Absorbers
The shock absorbers may be fitted in two different
positions, a standard position(suitable for all users)
and a position that produces slightly softer
suspension(recommended for user’s with a body
weight of 150 lbs or less).
Removal
1. Raise the seat; seat elevator to the highest
position; fixed seat tube to the service position.
See page 24. If the seat elevator does not
work normally because the batteries are
discharged or the actuator is defective, the
seat can be raised/lowered manually.
See page 22.
2. Switch off the main power switch on the control
panel.
3. Remove the chassis cover. See page 8.
4. Lift up and chock up the wheelchair chassis so
that the wheel in question is free of the ground.
5. Unscrew and remove the two screws that hold
the shock absorber in place. See figure.
Fitting
1. Fit the shock absorber on the chassis with
screws and washers.
2. Using screws, washers and nuts, fit the other
end of the shock absorber in the position on
the link arm that suits the user best.
3. Fit the chassis cover. See page 8.
4. Lower the seat to its normal height.
Adjustment
The shock absorber’s spring force should be
adjusted to the correct value; see figure.
The spring force can be adjusted for various user
weights with the adjusting nut. Reduce the
adjustment distance for harder suspension;
increase the adjustment distance for softer
suspension.
Adjustment can be done with the shock absorber
mounted in the chassis, but make sure the
wheelchair isn’t under influence of any load.
Shock Absorber
Adjustment of shock absorber spring.
Shock Absorbers fitted in standard position.
Adjustment nut
User weights Setting
Adjustment of shock absorber spring
0 - 100 Kg.
Above 100 Kg. (standard)
48 mm.
46 mm.
Setting
Do not have any load in the wheelchair when adjusting.
NOTE
Never adjust the spring to a setting less then 46 mm.
NOTE

17
Slewing brackets
Slewing bracket attachment.
Removal/fitting of slewing brackets.
Slewing brackets
Removal
1. Raise the seat; seat elevator to the highest
position; fixed seat tube to the service position.
See page 24. If the seat elevator does not
work normally because the batteries are
discharged or the actuator is defective, the
seat can be raised/lowered manually.
See page 22.
2. Switch off the main power switch on the
control panel.
3. Remove the chassis cover.
4. Lift up and chock up the wheelchair chassis so
that the wheel in question is free of the ground.
5. Remove the front wheel, see page 12.
6. Remove the lower shock absorber bracket.
See page 16.
7. Remove the link arm, it is fitted with screw and
washer.
For removal of wheel forks and wheels, see the
respective chapters.
Fitting
Fit the link arm in the reverse order.
Tighten the screw holding the link arm in place
with a torque wrench.
Tightening torque: 15 Nm.
Do not use a Pneumatic impact wrench.
NOTE

18
Wheel Lock Release
Wheel lock release sensor.
If the wheel lock release arm is moved
backwards on the left magnetic wheel lock,
the plastic rail can be pulled out of the chassis.
Wheel lock release
Wheel Lock Release
The wheel lock release consists of a plastic rail, a
wheel lock release sensor and a magnetic wheel
lock on each drive motor.
Removing the Plastic Rail
1. Raise the seat; seat elevator to the highest
position; fixed seat tube to the service position.
See page 24. If the seat elevator does not
work normally because the batteries are
discharged or the actuator is defective, the
seat can be raised/lowered manually.
See page 22.
2. Switch off the main power switch on the control
panel.
3. Remove the chassis cover. See page 7.
4. Remove the wheel lock release sensor,
see page 20.
Before inserting the plastic rail, make sure the wheel lock
release sensor is removed.
NOTE
1. Insert the plastic rail on the right side of the
chassis.
2. Check that the rail is correctly located by the
wheel lock release sensor. See figure.
3. Push the rail in further so that its end emerges
on the left side of the chassis.
4. If the wheel lock release arm is moved
backwards on the left magnetic wheel lock,
the plastic rail can be moved into place.
5. Refit the wheel lock release sencor, see
page 20.
6. Refit the chassis cover. See page 7.
7. Lower the seat to its normal height.
5. If the wheel lock release arm is moved
backwards on the left magnetic wheel lock, the
plastic rail can be pulled out of the chassis.
Fitting the Plastic Rail
Before removing the plastic rail, make sure the wheel lock
release sensor is removed.
NOTE

19
Wheel Lock Release
The electrical connections of the wheel locks are
positioned on the inside of the chassis, on
each side of the seat lift/seat post.
The magnetic wheel lock is
fitted with three screws
Magnetic wheel lock.
Removing the Magnetic wheel lock.
1. Raise the seat; seat elevator to the highest
position; fixed seat tube to the service position.
See page 24. If the seat elevator does not
work normally because the batteries are
discharged or the actuator is defective, the
seat can be raised/lowered manually.
See page 22.
2. Switch off the main power switch on the control
panel.
3. Remove the chassis cover. See page 8.
4. Disconnect the electrical connection of the
magnetic wheel lock. See figure.
5. Unscrew and remove the three screws that
hold the wheel lock in place. See figure.
Fitting the Magnetic Wheel lock
Fit the magnetic wheel lock in the reverse order.
Fit the magnetic wheel lock with the release arm
facing upwards.

20
Wheel Lock Release
Wheel lock release sensor
is fitted with two screws.
Removing the wheel
lock release sensor.
1. Raise the seat; seat elevator to the highest
position; fixed seat tube to the service position.
See page 24. If the seat elevator does not
work normally because the batteries are
discharged or the actuator is defective, the
seat can be raised/lowered manually.
See page 22.
2. Switch off the main power switch on the
control panel.
3. Remove the chassis cover. See page 8.
4. Disconnect the electrical connection of the
wheel lock release sensor, it´s positioned on
the top of the front battery.
5. Remove the wheel lock release sensor. It is
fitted with two screws. See figure.
6. Remove the plate fitted on the wheel lock
sensor. It is fitted with two screws and nuts.
Fitting the Wheel Lock Release Sensor
Fit the wheel lock release sensor in the reverse
order.
Wheel lock release sensor.