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

Shock absorber
11
Fig. 14. The shock absorber is mounted
with two screws.
Passenger weights
- 110 Ib.
110 - 155 Ib.
155 - 200 Ib.
200 - 264 Ib.
Setting
0 - 3/32 inch
3/32 - 5/32 inch
5/32 - 1/4 inch
1/4 - 3/8 inch
Fig. 15. The shock absorber is adjusted using the return damping valve and the adjustment nut.
1
2
Replacement and adjustment
of shock absorbers
Removal
1. Run the seat up to its highest position. See page 7
for instructions to manually raise the seat.
2. Switch off the main power switch.
3. Detach the front fender on the side on which the
shock absorber is to be replaced, see page 8.
4. Jack up the chair so that the wheel is free on the
side concerned.
5. Unscrew and remove the screw on the shock
absorber's upper fastener, see fig. 14:1.
6. Unscrew and remove the screw on the shock
absorber's lower fastener, see fig. 14:2.
Adjustment of the shock absorber
Before the new shock absorber is mounted, it must be
adjusted to the proper value.
Return damping valve
To get standard setting, screw the return damping valve
fully clockwise by hand. Then screw the valve fully
counterclockwise, counting the ”clicks”. Then screw the
valve halfway clockwise i.e. halve the number of ”clicks”.
Screw the valve clockwise (open the valve) for
softer damping, or counterclockwise (close the valve) to
have harder damping.
The spring force
The spring force can be set to suit different passenger
weights using the adjustment nut. Increase the
dimension for a harder suspension, decrease the
dimension for a softer suspension.
NB! Make sure the stop spring is in the right position,
see fig. 15.
Fitting
Mounting is performed in reverse order.
Return damping valve
Adjustment nut Setting
Stop spring

12
Wheel lock release cable
Removal
1. Run the seat up to its highest position.
See page 7 for instructions to manually raise the seat.
2. Remove the covers, see page 8.
3. Remove the wheel lock release cover, see fig. 16-17.
4. Loosen the locking nut(18:2).
5. Screw the adjustment screw in(18:1) completely.
6. Loosen the cable by the magnetic wheel lock by
drawing the cable sleeve forwards and in front of
the cable through the slot in the cable holder,
unfasten the wheel lock release cable from the
magnetic wheel lock.
7. Loosen the cable at the release lever.
Fitting
1. First mount the cable by the magnetic drum, and
subsequently by the release lever.
2. Adjust the length of the cable sleeve using the
adjusting screw(18:1), so that the wheel lock
realease sensor(18:3) is activated immediately,
before the cable pulls the release arm.
3. Check that the wheel cannot turn round before the
wheel lock realease sensor(18:3) has been
activated.
4. Check that the wheel can be turned when the
wheel lock is disengaged by the release lever.
5. Tighten up the locking nut (18:2).
6. Remount the wheel lock release cover as well as
other covers.
Wheel lock release cable
Fig. 18. Mechanism for wheel lock release.
Fig. 17. Screws (qty. 2). wheel lock
release cover.
Fig. 16. Wheel lock release cover.
1 2 3

13
Fig. 19. The magnetic wheel lock's
electrical connection.
Magnetic wheel lock
Fig. 20. Loosen the wheel lock release cable.
Fig. 21. Detach the magnetic wheel lock.
Magnetic wheel lock
Removal
1. Run the seat up to its highest position.
See page 7 for instructions to manually raise
the seat.
2. Switch off the main power switch on the control
panel.
3. Set the main fuse to the “OFF” position,
see page 30, fig. 66.
4. Detach the covers, see page. 8.
5. Loosen the magnetic wheel lock's electrical
connection, see fig. 19.
6. Draw the cable casing forwards and in front of
the cable through the slot in the cable holder,
unfasten the wheel lock release cable from the
magnetic wheel lock, see fig. 20.
7. Jack up the chair on the side concerned.
8. Loosen the shock absorber's upper fastener,
follow the instructions for detaching shock
absorbers through and including point 5,
see page 11.
9. Bend the spring strut downwards in order to
gain easier access to the magnetic wheel lock.
10. Unscrew the three screws holding the wheel
lock, see fig. 21. Take note of the position of the
wheel lock release arm as well as the position
of the rubber seal for purposes of later
remounting. Detach the wheel lock with the
wheel lock disk and cover.

14
Magnetic wheel lock
Fitting
1. Using the adjustment screws, adjust the
setting of the magnetic wheel lock as per the
instructions on the back side of the magnetic
wheel lock, see fig. 22.
2. Place the wheel lock disc on the magnetic
wheel lock.
3. Put the lock onto the motor.
Fig. 22. The wheel lock setting
is adjusted using the two
adjustment screws.
Fig. 23. Magnetic wheel lock, wheel lock disk,
cover and rubber seal dismounted.
Fig. 24. Magnetic wheel lock, wheel lock
disk and cover mounted.

15
4. Thread a screw through in order to align the parts.
Mount the rubber seal with the drainage hole
downwards. Take note of the position of the wheel
lock release arm, mount the wheel lock so that the
wheel lock release arm is aligned with the motor's
cable fastener. Then firmly screw in the magnetic
wheel lock with the three screws.
5. Test to verify the wheel lock is adjusted: wheel
should not turn easily when turned by hand.
Release wheel lock by pushing the release
arm toward the motor and turn wheel by hand.
It should move easily.
6. Remount the shock absorber, see page 11.
7. Put the electrical connections for the magnetic
wheel lock back together, see fig. 26.
8. Mount the wheel lock release cable, see fig. 27.
9. Mount the covers, see page 8.
Magnetic wheel lock
Fig. 26. The magnetic wheel lock's
electrical connection.
Fig. 25. Align the parts up against each
other with one of the fastening screws.
Mount the rubber seal
Fig. 27. Mount the wheel lock release cable.

16
Drive motor
Removal
1. Run the seat up to its highest position.
See page 7 for instructions to raise seat
manually.
2. Switch off the main power switch on the control
panel.
3. Put the circuit breaker in the “OFF” position,
see fig. 28.
4. Detach the seat lift and chassis covers as well
as the front fender on the side where the drive
motor will be replaced, see page 8.
5. Jack up the relevant side of the wheelchair.
6. Detach the drive wheel, see page 10.
7. Loosen the electrical connections to the motor
and the magnetic wheel lock, see fig. 29.
8. Draw the cable casing forwards and in front of
the cable through the slot in the cable holder,
unfasten the wheel lock release cable from the
magnetic wheel lock, see fig. 30.
Drive motor
Fig. 29. Electrical connections for drive
motor and magnetic wheel lock.
Fig. 30. Unfasten the wheel lock release cable.
Fig. 28. Circuit breaker 63A (Off/On)
On Off

17
9. Unscrew and remove the screw holding the
lower shock absorber fastener (31:1) and bend
the shock absorber upwards.
10. Loosen the three screws holding the motor
approx. 1 revolution, see fig. 31:2.
11. Detach the spring strut by unscrewing and
removing the screw on the back edge of the
spring strut, see fig. 31:3.
12. Detach the drive motor by unscrewing and
removing the three screws holding the motor,
see fig. 31:2.
Fitting
Fitting is performed in reverse order.
NB! Check that the drive motor: transition ratio is
correct. The ratio is shown on the transmission
identification decal, see fig. 32.
Drive motor
Fig. 31. Detachment of drive motor
3
1
2
Fig. 32. Transmission identification decal.

18
Seat lift
Fig. 35. Loosen the screws
on the lower fastener.
Fig. 33. Lift out the seat.
Seat lift
Removal
1. Raise the seat using the accompanying seat
lift crank, see page 7. Raise the seat until it will
not go any higher while you crank, i.e. the seat
lift is “not engaging”.
2. Switch off the main power switch on the
control panel.
3. Set the circuit breaker to the “OFF” position,
see page 30, fig. 66.
4. Detach the seat lift and chassis covers,
see page 8.
5. Clip off the wiring bundle tie mounted on the
cabling between the seat and the chassis.
6. Remove the seat lift motor's cable connection,
pay attention to the placement of the cables
for purposes of later remounting, see page 21.
7. Lift out the seat, place it on its side next to the
chassis, see fig. 33.
NB! The seat is heavy, hence there should be two
people to do this. Be careful with the cabling.
8. Unscrew and remove the two screws on the
seat lift's upper fastener, see fig. 34.
9. Remove the two screws on the seat lift's lower
fastener, see fig. 35.
10. Detach the seat lift by drawing it straight up.
11. Clip off the wiring bundle tie holding together the
seat lift cabling, follow the cabling to its end, and
loosen the contact at the SLS Drive, as well as
the conductor joint located beside the SLS Drive.
Fig. 34. Unscrew and remove the screws
from the upper fastener.

Seat lift
19
Fig. 39. Seat without seat tilt, the upper part of
the seat lift is mounted with four screws.
Fig. 36. The seat plate is mounted with two screws.
The upper part of the seat lift is mounted on the
seat and can be detached as described in the
following.
12. Unscrew and remove the two screws holding
the seat plate, see fig. 36.
13. If the seat is equipped with seat tilt, unfasten
the actuator’s front bracket, see fig. 37. Draw
the seat tilt mechanism apart, see fig. 38.
NB! Check which set of holes in which the seat
frame is mounted to the seat lift platform, in order
to replace it correctly later.
14. Unscrew and remove the four screws holding
the seat lift, see fig. 38 and 39
Fitting
Fitting is performed in reverse order.
Fig. 37. Unfasten the front bracket on
the seat tilt actuator.
Fig. 38. Seat with seat tilt, the upper part of the
seat lift is mounted with four screws.

20
Seat lift cable
Seat lift cable
Removing
1. Remove the seat lift; follow the instructions on
page 18.
2. Remove the seat lift sensors. Note the position
of the sensors for refitting, see fig. 40-41.
Fitting
Fitting is the reverse procedure.
Fig. 40. Attachment of the
sensors to the seat lift.
Fig. 41. Attachment of the sensors to the seat lift.
1 2 3 2 4 5 6 7
1. Screw
2. Lever switch plate
3. Lever switch
4. Insulating plate
5. Seat lift
6. Star washer
7. Nut