Permobil Chairman 2k User manual

SERVICE MANUAL
Chairman 2k/2s
US

Produced and published by Permobil AB, Sweden
Edition no.7, 2006-01
Article no.: 201158-US-0
How to contact Permobil
Head Office of the Permobil group
Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Permobil AB
Box 120, 861 23 Timrå, Sweden
Tel: [phone]. Fax: [phone]
E-mail: [email protected]

Contents
4
Contents
Introduction.................................................................................................. 5
Technical support...................................................................................... 5
Spare parts ............................................................................................... 5
Warranties ................................................................................................ 5
Maintenance ............................................................................................. 5
Identification plates ..................................................................................... 6
Chassis..................................................................................................... 6
Pilot+ output stage.................................................................................... 6
Control panel ............................................................................................ 6
Operating the seat elevator manually ....................................................... 7
Covers........................................................................................................... 8
Batteries ....................................................................................................... 9
Drive wheels............................................................................................... 10
Replacement and adjustment of shock absorbers ............................... 11
Wheel lock release cables ........................................................................ 12
Magnetic wheel locks................................................................................ 13
Drive motors............................................................................................... 16
Seat elevator .............................................................................................. 18
Seat elevator cables .................................................................................. 20
Seat elevator motor ................................................................................... 21
Seat elevator drive belt ............................................................................. 22
Adjusting the belt tension ....................................................................... 22
Control panel.............................................................................................. 23
Seat control panel ..................................................................................... 23
Pilot+ output stage .................................................................................... 24
SLS drive stage.......................................................................................... 25
ESP Module ................................................................................................ 26
Circuit breaker and fuses ......................................................................... 30
Circuit breaker ........................................................................................ 30
Charge fuse ............................................................................................ 31
Fuse for seat/lights ................................................................................. 31
Distribution chart ...................................................................................... 32
Troubleshooting......................................................................................... 34

5
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 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 warranties for this chair.
Maintenance
See the information in the Owner’s Manual.
Introduction

6
Identification plates
Fig. 1. Chassis Serial Number
Fig. 2. Pilot+ Controller
Fig. 3. Joystick/Control Panel
Identification plates
Chassis
Pilot+ power module (Controller)
Joystick

Operating the seat elevator
manually
Electric seat elevator
If the seat elevator will not move normally because
the battery is flat or the adjusting mechanism is
broken.
1. Remove the cushion and plastic plug from
the seat.
2. Raise/lower the seat using the seat elevator
crank supplied, see fig. 4.
Fixed seat post
1. Remove the cover and plastic plug from
the seat.
2. Loosen the seat tube clamp screw (5:2).
3. Crank up the seat using the seat elevator
crank supplied, see fig. 4.
4. Lower the seat and turn it so that the locating
screw (5:1) seats in its groove.
5. Tighten the seat tube clamp screw.
Torque: 11 ft.Ib.
Warning! Using a drilling machine during the
manual operation of the seat lift is not allowed.
There is a risk of material damage.
7
Fig. 4. Use the seat elevator crank to
raise the seat.
Operating the seat elevator manually
Fig. 5. Fixed seat post.
1
2

8
Fig. 8. The side cover is mounted
with three screws.
Covers
Detachment
1. Run the seat up to its uppermost position.
See page 7 for instructions to manually raise
the seat.
2. First remove the seat lift cover. It is mounted
with four plastic plugs which can be flipped up
using a screwdriver.
3. Unscrew the knob at the far back of the
chassis cover, see fig. 7.
4. Push the cover back and lift it up at the
same time.
5. Loosen the three screws that are holding the
front fender on each side, see fig. 8.
NB! The front fender can be detached without
dismounting the chassis covers.
Mounting
Mounting is performed in reverse order.
Covers
Fig. 7. The chassis cover is fastened with a knob.
Fig. 6. The seat lift cover is mounted with four
plastic plugs.

9
Batteries
Batteries
NB! Use protective goggles when working with
batteries.
Removal
1. Place the wheelchair on a level surface.
2. Put the circuit breaker in the “OFF” position.
It is accessible through a cut-out in the chassis
cover, see fig. 9.
3. Lift the chassis cover up a little by loosening
the knob holding the cover on, see fig. 9.
4. Open the battery covers by loosening the knob
and dropping the covers down, see fig. 10.
5. Draw the respective batteries straight out
using the battery strap, see fig. 11.
6. Loosen the battery connections. See the decal
on the inner side of the battery covers.
7. Lift the batteries out.
Insertion
1. Lift two new batteries into place. Put the strap
back around the new batteries in order to
facilitate removal.
2. Connect the battery connections. See the
decal on the inner side of the battery covers.
3. Push the batteries back into the chassis.
4. Close the battery covers and tighten the knob,
see fig. 10.
5. Tighten the knob for the chassis cover, see fig. 9
6. Set the main fuse to the “ON” position. It is
accessible through a cut-out in the chassis
cover, see fig. 9.
Fig.10. Battery cover knob.
Fig. 11. Draw out the battery.
Fig.9. Circuit breaker 63A (On/Off) and
the chassis cover knob.
On Off

10
Fig. 12. Puller 304103-99-0.
Drive wheels
Removal
1. Switch off the main switch.
2. Lift up the chair and support it on blocks, so
that the wheels are off the ground.
3. Undo and remove the hubcap (6), bolt (3) and
the three washers (1 and 2), see fig. 13.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight, see fig. 12.
Fitting
1. Check the axle and rim for any damage. If
necessary, you should clean these parts of dirt
and rust. If any parts are damaged, they
should be replaced.
2. Check that the key fits solidly in the keyway of
the axle. If necessary, install the new key (4 or
5) and check for fit.
3. Lubricate the shaft with a thin layer of copper
paste (Würth 0893800x, Art. no.: 1820540).
Drive wheels
Fig. 13. Wheel attachment.
Warning! Other types of bolts or washers are not
to be used..
Warning! Do not use any other type of thread lock.
Warning! Do not use any type of lubrication in the
threaded hole in the axle or on the bolt.
If necessary, you should clean these parts.
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.
NB! Hitting too hard with a rubber mallet could
cause damage to the gear.
5. Mount the three washers (1) and (2) onto the
bolt (3) and secure the wheel. Use a torque
wrench to tighten the bolt to 24 ft-Ibs (33Nm).
Install the hub cap (6). See Fig. 13.
NB! The washer (1) should be placed with the
most flat side inwards.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.
1. Washer, 8 HB 305 Fe/Zn 5 C2 (TBRSB 8,4x26x5)
2. Shim washer DIN 988 8 A2 (DB 8x14x0.5 Rostfri)
3. Bolt, ISO 4762 M8x25 10.9 Fe/Zn 5 C2 /
Locking coat DIN 267-28
4. Key DIN 6885A 6x6x16
5. Key DIN 6885A 6x6x22
6. Hubcap
6
3
2
1
4
5
2