Permobil Chairman HD3 User manual

SERVICE MANUAL
Chairman HD3
US

Produced and published by Permobil AB, Sweden
Edition no.3, 2009-08
Article no.: 201161-US-0
How to contact Permobil
Head Office of the Permobil group

Contents
4
Contents
Introduction ..................................................................................................... 5
Technical support......................................................................................... 5
Spare parts .................................................................................................. 5
Warranties.................................................................................................... 5
Maintenance ................................................................................................ 5
Rating plates ................................................................................................... 6
Chassis ........................................................................................................ 6
Pilot+ output stage....................................................................................... 6
Control panel ............................................................................................... 6
Operating the seat elevator manually........................................................... 7
Covers.............................................................................................................. 8
Batteries........................................................................................................... 9
Drive wheels.................................................................................................... 10
Support wheels ............................................................................................... 11
Brake release cables ...................................................................................... 12
Magnetic brakes.............................................................................................. 13
Drive motors.................................................................................................... 16
Seat elevator ................................................................................................... 18
Seat elevator cables ....................................................................................... 19
Seat elevator motor ........................................................................................ 19
Seat elevator drive belt .................................................................................. 20
Changing the seat elevator drive belt.......................................................... 20
Adjusting the belt tension ............................................................................ 20
Pilot+ output stage ......................................................................................... 21
SLS drive stage............................................................................................... 21
Control panel................................................................................................... 22
Seat control panel........................................................................................... 22
Circuit breaker and fuses .............................................................................. 23
Circuit breaker ............................................................................................. 23
Charge fuse ................................................................................................. 23
Fuse for seat/lights ...................................................................................... 24
Brake release sender...................................................................................... 24
Seat electronics .............................................................................................. 25
Seat function board ..................................................................................... 25
Safety senders............................................................................................. 25
Adjusters...................................................................................................... 26
Troubleshooting.............................................................................................. 27
Distribution chart............................................................................................ 29

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 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.

6
Rating plates
Rating plates
Chassis
Pilot+ output stage
Control panel
Fig. 1. Chassis identification number
Fig. 2. Pilot+ output stage identification number.
Fig. 3. Control panel identification number.

7
Fig. 5. Use the seat elevator crank to
raise the seat.
Operating the seat elevator manually
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. Remove the rear cover, see page 8.
3. In order to make the seat elevator move more
easily, disconnect the cable connector under
the cover next to the charge socket, see fig. 4.
4. Raise/lower the seat using the seat elevator
crank supplied, see fig. 5.
Fixed seat post
1. Remove the cover and plastic plug from
the seat.
2. Loosen the seat tube clamp screw (6:2).
3. Crank up the seat using the seat elevator
crank supplied, see fig. 5.
4. Lower the seat and turn it so that the locating
screw (6:1) seats in its groove.
5. Tighten the seat tube clamp screw.
Torque: 11 ft.Ib.
Fig. 6. Fixed seat post.
1
2
Fig. 4. Disconnect the connector to make the
seat elevator move more easily.
Warning! Using a drilling machine during the
manual operation of the seat lift is not allowed.
There is a risk of material damage.

Fig. 8. The front cover is attached by two
screws at the front edge.
Fig. 7. Chassis cover attachment points.
8
Covers
Removal
1. Raise the seat to its highest position.
2. Remove the battery cover first, it is attached
by two knobs on each side. The cover can be
removed more easily if the brake release
lever is in the forward position.
3. Remove the rear cover, it is attached by five
screws. Unscrew the rubber pads on the seat
support. Disconnect the rear light cable at the
connector in the cable.
4. Remove the seat elevator cover, it is attached
by two screws on the top of the chassis.
5. Remove the front cover, it is attached by two
screws on the front edge.
Fitting
Fitting is the reverse procedure.
Covers
A
B
C
D
A. Front cover
B. Seat elevator cover
C. Battery cover
D. Rear cover

9
Batteries
Batteries
NB! Use protective goggles when working on
batteries.
Removal
1. Put the wheelchair on a level surface.
2. Raise the seat. To raise the seat manually,
see page 7.
3. Put the circuit breaker in the “OFF” position,
see fig. 9.
4. Remove the battery cover and rear cover,
see page 8.
NB! Take care when removing the rear cover; the
rear light cable is attached to the electronic unit.
5. Disconnect the battery leads, positive
terminals first.
6. To make access to the battery easier, you can
also disconnect the electrical connections for
the drive motor, magnetic brake, lights and
brake release sender. Make a careful note of
the location of the cables for reconnection.
7. Lift out the batteries.
Fitting
1. Lift the batteries into position, with the poles
at the back, see fig. 10.
2. Reconnect the battery leads, negative first.
3. Attach the electrical connections for the drive
motor, magnetic brake, lights and brake
release sender, if you disconnected
them earlier.
4. Refit the covers.
5. Put the circuit breaker in the “ON” position,
see fig. 9.
6. Lower the seat. For manual lowering,
see page 7.
Fig. 10. Battery connections
Fig. 9. Circuit breaker/Battery isolator.
On Off

10
Drive wheels
5
4
3
2
1
Fig. 12. Wheel attachment.
1. Front wheel
2. Washer, TBRSB 8.4x26x5
3. Washer, Nordlock M8x16.6, glued.
4. Bolt, Eslock MC6S M8x35
5. Hubcap
Fig. 11. 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 (5), bolt (4) and
washers (2 and 3), see fig. 12.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight, see fig. 11.
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 and
check for fit.
3. Lubricate the shaft with a thin layer of copper
paste (Würth 0893800x, Art. no.: 1820540).
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. Put the washers (2 and 3) onto the bolt (4) and
tighten the wheel, see fig. 12.
Use a torque wrench to tighten the bolt to
24 ft-Ibs. Install the hub cap (6), see Fig. 12.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.

Support wheels
11
Support wheels
Removal
1. Switch of the main switch.
2. Remove the drive wheel on the relevant side,
see page 10.
3. Remove the two screws, see fig. 13.
Fitting
Fit the support wheel and spacer plate using the
two screws, as shown in fig. 14.
Adjusting
The degree of flex of the support wheels can be
adjusted using the adjusting screw on front of the
bracket. For the Chairman HD3, the support
wheel should always flex as little as possible, i.e.
the adjusting screw should be tightened right
down. When the adjusting screw is tightened right
down, it is locked by the lock washer fitted to it,
see fig. 15.
Fig. 15. Adjusting the support wheels
Fig. 14. Fitting the support wheels.
Fig. 13. Removing a support wheel.

12
Brake release cables
Fig. 16. Brake release mechanism.
12
Brake release cables
The upper cable controls the left brake unit and the lower cable controls the right brake unit.
Removal
1. Make sure the brakes are engaged.
2. Raise the seat elevator to its highest position.
3. Remove the battery and seat elevator covers, se page 8.
4. Slacken the locknut, see fig. 16:2.
5. Screw the adjusting screw fully in, see fig. 16:1.
6. Detach the cable at the magnetic brake and brake release mechanism.
Fitting
1. Attach the cable to the magnetic brake, then to the release lever.
2. Adjust the length of the cable sleewe using the adjusting screw (16:1), so that the cable is tensioned
but does not pull the brake release arm.
3. Check the operation. Operate the release lever to release the brake and check that the wheel can turn.
4. Tighten the locknut (16:2).
5. Refit the covers.

13
Fig. 18. Magnetic brake release cable.
Magnetic brakes
Removal
1. Raise the seat elevator to its highest position.
2. Switch off the main switch on the controlpanel.
3. Put the circuit breaker in the “OFF” position,
see page 23.
4. Remove the battery cover and rear cover,
see page 8.
5. Remove the battery from the side you are
working on, see page 9, to facilitate removal of
the magnetic brake.
6. Disconnect the electrical connector from the
magnetic brake, see fig. 17.
7. Pull the cable sleeve forwards and take the
cable out through the slot in the cable mounting.
Unhook the brake release cable from the
magnetic brake, see fig. 18.
8. Unscrew the three screws that hold the brake,
see fig. 19. Note the position of the brake
release arm for refitting. Remove the brake,
complete with the disc and cover.
Magnetic brakes
Fig. 17. Magnetic brake electrical connection.
Fig. 19. Magnetic brake fixing bolts.

14
Fitting
1. Fitting new brakes, use the adjusting screws to
adjust the magnetic brake, as described in the
instructions on the back of the magnetic
brake, see fig. 20.
2. Fit the brake disc into the magnetic brake.
3. Fit the cover.
Magnetic brakes
Fig. 20. Adjusting the magnetic brake
using the two adjusting screws.
Fig. 21. Magnetic brake, brake disc
and cover removed.
Fig. 22. Magnetic brake, brake disc
and cover fitted.

15
4. Insert a bolt to align the parts. Note the position
of the brake release arm; fit the brake so that it is
aligned with motor’s cable mounting. Secure the
magnetic brake using the three bolts.
5. Connect the magnetic brake electrical
connector, see fig. 24.
6. Fit the brake release cable, see fig. 25.
7. Fit the batteries, see page 9.
8. Fit the covers, see page 8.
Magnetic brakes
Fig. 24. Magnetic brake electrical connector.
Fig. 23. Align the parts with one another using
one of the fixing bolts.
Fig. 25. Magnetic brake release cable.

16
Drive motor
Removal
1. Raise the seat to its highest position.
2. Switch the main power breaker off.
3. Put the circuit breaker in the “OFF” position,
see fig. 26.
4. Remove the battery cover and front cover,
see page 7.
5. Remove the battery on the side concerned,
see page 9, to facilitate removal of the motor.
6. Raise the relevant side of the chair on blocks.
7. Remove the wheel, see page 10.
8. Disconnect the electrical connectors to the
motor and magnetic brake.
9. Pull the cable sleeve forwards and take the
cable out through the slot in the cable mounting.
Unhook the brake release cable from the
magnetic brake, see fig. 28.
Fig. 27. Magnetic brake and drive motor
electrical connectors.
Drive motor
Fig. 28. Magnetic brake release cable.
Fig. 26. Circuit breaker/Battery isolator.
On Off

17
10. Remove the three bolts holding the motor.
11. Turn the motor sideways to free the wheel shaft.
Pull the motor straight forwards.
Fitting
Fitting is the reverse procedure.
Drive motor
Fig. 29. Drive motor mounting bolts.
Fig. 30. Removing a drive motor.

18
Fig. 31. The seat elevator is attached
by four screws.
Seat elevator
Removal
1. Put the circuit breaker in the “OFF” position, see page 23.
2. Raise the seat using the seat elevator crank provided, see page 7. Raise the seat as far as it will
go, until the gear starts to jump.
3. Remove all of the covers, see page 8. (Removal will be easier if the brake release lever is in the
forward position.)
4. Remove the batteries, see page 9.
5. Lift off the seat, stand it at the side, next to the chassis, see fig. 31.
NB! The seat is heavy, so two people should lift it. Be careful with the cables.
6. Loosen the clamp that holds the two safety senders, see fig. 33:1.
7. Loosen the lower seat elevator mounting bolts, see fig. 31:2.
8. Remove the upper mounting bolts, see fig. 31:1.
9. Remove the seat elevator by pulling it straight upwards.
10. Remove the tie holding the seat elevator cable. Follow the cable to the end. Disconnect the
connector for the SLS drive stage, and the connector located next to the SLS drive stage.
For removal of the SLS drive stage, see page 21.
11. Remove the upper part of the seat elevator from the seat by unscrewing the four screws, see fig. 32.
The mounting for the two senders and a locating plate are attached by the same screws, note their
position for refitting.
Fitting
Fitting is the reverse procedure.
Seat elevator
Fig. 32. The attachment of the
seat elevator to the seat.
2
1

19
Seat elevator cables & Seat elevator motor
Seat elevator cables
Removal
1. Remove the seat elevator, follow points 1-10 on the previous page.
2. Remove the seat elevator senders. Note the position of the senders for refitting, see figs. 33:2-34.
Fitting
Fitting is the reverse procedure.
Fig. 36. The motor is attached by three bolts.Fig. 35. Seat elevator motor
electrical connections.
Blue
Green
Fig. 33. Seat elevator senders.
1
2
Fig. 34. Attachment of the senders
to the seat elevator.
42321 567
Seat elevator motor
Removal
1. Remove the seat elevator, see page 18.
2. Disconnect the seat elevator cable at the motor; note the position of the cable for refitting.
3. Remove the three mounting bolts, see fig. 36.
Fitting
Fitting is the reverse procedure.
1. Screw
2. Microswitch plate
3. Switch
4. Insulating plate
5. Seat elevator
6. Plate
7. Nut

20
Seat elevator drive belt
Seat elevator drive belt
Changing the seat elevator drive
belt
1. Remove the seat elevator, see page 18.
2. Loosen the two bolts holding the shaft to the
seat elevator motor, see fig. 37. Push the shaft
sideways to slacken the drive belt.
3. Remove the belt from the motor shaft then from
the toothed wheel on the seat elevator screw.
4. Fit the new belt using the reverse procedure.
5. Adjust the belt tension by moving the motor
shaft sideways, see the description below.
6. Fit the seat elevator, see page 18.
Adjusting the belt tension
1. Loosen the two bolts near the belt, see fig. 37.
2. Adjust the belt tension by moving the motor
shaft sideways.
3. Tighten the two screws.
4. Check the belt tension. The belt is correctly
tensioned when it can be pressed in 0.15”-0.20”,
see fig. 38.
Fig. 38. The drive belt tension can be adjusted after the
two bolts have been loosened.
Fig. 37. The seat elevator shaft is attached
by two bolts.