Permobil K300 User manual

SERVICE MANUAL
Permobil K/C300
Power wheelchair


Produced and published by Permobil AB, Sweden
Edition no.2, 2010-06
Order no.: 205221-US-0


Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Permobil AB
Box 120
861 23 Timrå
Sverige
Tel: [phone]
Fax: [phone]
E-post: [email protected]




 ....................................................................................................... 5
 .......................................................................................... 6
 ............................................................................................................... 8
 .......................................................................................................... 10
 ................................................................................................... 12
 .................................................................................................... 14
 ............................................................................................... 15
............................................................................... 16
 ..................................................................................................... 17
 ............................................................................................ 18
 ............................................................................................ 19
 ........................................................................................ 20
Plastic rail ................................................................................................... 20
Magnetic wheel lock ................................................................................... 21
Wheel Lock Release Sensor ...................................................................... 22
 ..................................................................................................... 23
 ................................................................................................... 24
Manual Raising/Lowering of the Seat elevator .......................................... 24
Removing the Seat elevator ....................................................................... 25
 ............................................................................................... 26
Service Position ......................................................................................... 26
Adjusting the Seat Height .......................................................................... 26
Removal ..................................................................................................... 27
 ........................................................................................................... 28
 ................................................................................................................. 30
Corpus ........................................................................................................ 30
PS ............................................................................................................... 32
CS .............................................................................................................. 34
PS Junior .................................................................................................... 35
 ......................................................................................... 36
 .......................................................................................... 37
 ......................................................................................... 38
 .......................................................................................... 39
 ................................................................................................ 40
 ........................................................................................ 41
 ........................................................................................................ 42
 ............................................................................................... 43
 ................................................................................... 44
 .................................................................................... 59
 .................................................................................. 62
 ................................................................................... 64
 ............................................................................................................... 66




The Service Manual is intended for technical personnel who maintain and repair 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. Always state the
chassis number when contacting Permobil to ensure that the correct information is provided.

In the event of technical problems, you should contact your dealer, or Permobil Inc. USA at 800-736-0925.

Spare parts must be ordered through your dealer.

Contact your dealer or Permobil Inc. USA for information about the warranties for this chair.

See the information in the Owner’s Manual.





Chassis identification number.
Rnet output stage ID number
Control panel Rnet ID number





VR2 output stage ID number
VR2 control panel ID number



Control panel VR2 ID number




Fixing points of the front cover.


The cover is mounted with hook and loop fastener
at the rear and with two knobs at the front. See
figure.
 Move/fold the leg rests out and, if necessary,
raise the seat.
 Switch off the main power switch on the control
panel.
 Remove the two knobs that hold the cover at
the front.
 Release the hook and loop fastener by lifting
the cover straight up. Then remove the cover
by pulling it backwards.

Fit the cover in the reverse order.
Covers.



Lift the chassis cover a little at the front so that
the front battery cover comes free.

The cover is fitted with two guide lips.
 Switch off the main power switch on the control
panel.
 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.

Fit the cover in the reverse order.


The cover is wedged in under the chassis cover.
 Move/fold the leg rests out.
 Switch off the main power switch on the control
panel.
 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.

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.




Lift/pull the battery out of the chassis.
Battery connections.
Front battery removed.

 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.
 Connect the battery connections on the new
battery. See also the sticker on the battery
cover.
 Refit the battery cover. See page 9.
 Disconnect the battery connections. See also
the sticker on the battery cover.
 Lift/pull the battery out of the chassis using the
battery belt.

 Place the wheelchair on a level surface.
 Move/fold the leg rests out, and if possible,
raise the seat lift
 Switch off the main power switch on the
control panel.
 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.
m
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.
m





 Place the wheelchair on a level surface.
 Switch off the main power switch on the
control panel.
 Remove the upper and rear chassis covers.
See pages 8-9.
 Remove the output stage’s mounting plate by
lifting it straight up and then turning it so that
the output stage’s cabling faces downwards.
See Figure.
Battery connections.
Remove the output stage’s mounting plate by
lifting it straight up.
Rear battery removed.
 Disconnect the battery connections. See also
the sticker on the rear chassis cover.
 Lift/pull the battery out of the chassis using the
battery belt.

 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.
 Connect the battery connections on the new
battery.
 Refit the output stage’s mounting plate and the
chassis covers.
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.
m



Fitting/removing front wheels.


 Switch off the main power switch on the control panel.
 Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground.
 Remove the hub cap by pulling it straight out. If necessary, carefully lever it out using a screwdriver
in the slot on the cap.
 Remove the four screws that hold the wheel in place.
The central screw must not be removed.
m
 Remove the wheel by pulling it straight out.

Assemble in the reverse order.
Tighten the four screws using a dynamometric wrench.

3
2
1
 Hub cap
 Screw, ISO 4762 M8x20 8.8 Fe/Zn 5 C1
 Rear wheels
 



Fitting a solid tire to a split rim.


The rim can be taken apart to make it possible to fit/remove solid or pneumatic tires.
 Remove the wheel in question from the wheelchair. See the previous page.
 If the tire is pneumatic, release the air.
 Rim, outer section
 Tire
 Rim, outer section
 Screw, ISO 4762 M8x30 8.8 Fe/Zn 5 C1
 
3
2
1
4
Ensure that pneumatic tires are not pressurized before the rim is taken apart, otherwise there is a risk of personal injury.
m
 Remove the six screws holding the two halves of the rim together (see illustration).
 Take the rim apart.

Assemble in the reverse order.
Tighten the six screws using a dynamometric wrench.

The recommended tire pressure for pneumatic tires is 200 kPa (2 bar). Overfilling entails a risk of explosion.
Incorrect tire pressure may result in lower stability and maneuverability. Check regularly that the tires have the correct pressure.
m



Rear Wheel.


 Switch off the main power switch on the control
panel.
 Lift up and chock up the wheelchair chassis
so that the wheel to be removed is free of the
ground.
 Remove the hub cap 1.
 Remove the nut 2. Apply pressure to the screw
6 using an Allen key.
. Remove the washer 3, wheel 4, axle 5 and
screw 6.

 Check that the axle and rim are not damaged.
If necessary, clean to remove dirt and rust.
Replace damaged parts.
 Fit the wheel on the axle using just your hands.
Check that the wheel is fully located on the
axle.
 Fit the screw 6 in the wheel fork.
 Fit the axle 5, wheel 4, washer 3 and nut 2,
and tighten the wheel.
 Fit the hub cap 1.

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.
m
m
m 63
 Hubcap
 Locking nut, ISO 7040 M6 8 Fe/Zn 5 Cl
 Washer, ISO 2768-c, 8,5x23x3
 Rear Wheel
 Axel, ISO 2768-m Ø15
 Bolt, ISO 10642, M8x70, 10.9 Fe/Zn 5 C1
 




Support wheels may be fitted in three different
positions; low, medium and high. These fitting
positions are marked L, M and H.

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.

With the support wheels fitted in the medium
position, the wheelchair inclines slightly more
before the support wheels meet the ground, but
the accessibility of the wheelchair is increased
somewhat.

The support wheels are fitted as standard in the
high position. This position produces the best
accessibility, but it also means that the wheelchair
may incline more before the support wheels meet
the ground, which the user may find unpleasant.

 Switch off the main power switch on the control
panel.
 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.
m

 Switch off the main power switch on the control
panel.
 Fit the wheel with the screw, washer and nut in
the desired position. See figure.








 Switch off the main power switch on the control
panel.
 Remove the chassis cover. See page 8.
 Unscrew and remove the two screws that hold
the support wheel damper in place. See figure.
 
Fit the damper in the reverse order.
Support wheel damper.



Wheel fork with friction brake.


 Switch off the main power switch on the control
panel.
 Lift up and chock up the wheelchair chassis so
that the wheel in question is free of the ground.
 Remove the cap from the top of the link arm.
See figure.
 Remove the friction plate. It is fitted with one
screw from above. See figure.
 Remove the wheel fork. It is fitted with a nut
from above. See figure.
 
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.
Fit the O-ring In the groove of the friction plate.
Tighten the nut holding the wheel fork in place with
a torque wrench.

Tighten the screw holding the friction plate in place
with a torque wrench.

Lubricate the O-ring with Lubricant friction brake,
Part. no: 1820405
m
m
 Plastic plug
 Bolt, ISO 10642 M8x20 10.9 Fe/Zn 5 C1/
Locking coat DIN 267-28
 O-ring Ø24.2x3 EPDM
 Friction plate ISO 2768-m Fe/Zn 12C1
 Nut, DIN 934 M14x1.5 8Fe/Zn 8C1
 Bearing, 6002-2RS1 (15x32x9)
 Circlip, DIN 472 Ø32
 Spacer, ISO 2768-m Fe/Zn 12C1 (Ø20 h9)
 Spacer, ISO 2768-m Fe/Zn 12C1
 Bolt, ISO 2768-m Stainless
Lubricant friction brake, Momentum, PRO AA 2/0,025
 
1
2
3
4
5
8
9
10
11
7 6




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).

 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.
 Switch off the main power switch on the control
panel.
 Remove the chassis cover. See page 8.
 Lift up and chock up the wheelchair chassis
so that the wheel in question is free of the
ground.
 Unscrew and remove the two screws that hold
the shock absorber in place. See figure.

 Fit the shock absorber on the chassis with
screws and washers.
 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.
 Fit the chassis cover. See page 8.
 Lower the seat to its normal height.
 
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.

 

0 - 220 Ib.
Above 220 Ib. (Standard)
1 29/32 inch (48 mm)
1 13/16 inch (46 mm)


Do not have any load in the wheelchair when adjusting.
m
Never adjust the spring to a setting less then 46 mm.
m



Slewing bracket attachment.
Removal/fitting of slewing brackets.


 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.
 Switch off the main power switch on the
control panel.
 Remove the chassis cover.
 Lift up and chock up the wheelchair chassis
so that the wheel in question is free of the
ground.
 Remove the front wheel, see page 12.
 Remove the lower shock absorber bracket.
See page 16.
 Remove the link arm, it is fitted with screw and
washer.
For removal of wheel forks and wheels, see the
respective chapters.
 
Fit the link arm in the reverse order.
Tighten the screw holding the link arm in place
with a torque wrench.

Do not use a Pneumatic impact wrench.
m



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

The wheel lock release consists of a plastic rail, a
wheel lock release sensor and a magnetic wheel
lock on each drive motor.

 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.
 Switch off the main power switch on the control
panel.
 Remove the chassis cover. See page 7.
 Remove the wheel lock release sensor, see
page 20.
Before inserting the plastic rail, make sure the wheel lock
release sensor is removed.
m
 Insert the plastic rail on the right side of the
chassis.
 Check that the rail is correctly located by the
wheel lock release sensor. See figure.
 Push the rail in further so that its end emerges
on the left side of the chassis.
 If the wheel lock release arm is moved
backwards on the left magnetic wheel lock,
the plastic rail can be moved into place.
 Refit the wheel lock release sencor, see
page 20.
 Refit the chassis cover. See page 7.
 Lower the seat to its normal height.
 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.

Before removing the plastic rail, make sure the wheel lock
release sensor is removed.
m