Permobil M300 Corpus HD User manual

SERVICE MANUAL
Permobil
M300/M400
Power Wheelchair
US

Produced and published by Permobil AB, Sweden
Version 2, 2011-06
Article no.: 205261-US-0
How to contact Permobil
Head Office of the Permobil group

4
Contents
Contents
Introduction ..................................................................................................... 5
Serial Number labels ....................................................................................... 6
Covers .............................................................................................................. 8
Batteries ......................................................................................................... 14
Drive wheels .................................................................................................. 18
Casters ........................................................................................................... 20
Shock absorbers ........................................................................................... 22
Link arms ....................................................................................................... 24
Wheel forks .................................................................................................... 26
Friction brakes ............................................................................................... 27
Drive motors .................................................................................................. 28
Magnetic brake .............................................................................................. 30
Electric seat lift .............................................................................................. 31
Fixed seat tube .............................................................................................. 34
Seat support .................................................................................................. 36
Seats ............................................................................................................... 38
Control panel ................................................................................................. 42
Power Module ................................................................................................ 44
ICS Master Module ........................................................................................ 48
Lights module ................................................................................................ 49
Fuses .............................................................................................................. 50
Lights .............................................................................................................. 52
Control system .............................................................................................. 55
Troubleshooting guide R-net ........................................................................ 56
Troubleshooting guide VR2 .......................................................................... 72
Cabling overview R-net ................................................................................ 74
Cabling overview VR2 ................................................................................... 76
Index ............................................................................................................... 78

5
Introduction
Introduction
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.
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
Serial Number labels
Serial Number labels
Chassis
Chassis ID number.
R-net Power Module ID number.
R-net Control panel ID number.
R-net Power Module
R-net control panel

7
Serial Number labels
VR2 Power Module ID number.
VR2 control panel ID number.
Serial Number labels
VR2 Power Module
VR2 control panel
VR2 Lights module ID number.
VR2 lights module

8
Covers
Removing the rear chassis cover
1. Switch off the main power switch on the
control panel.
2. If the upper chassis cover isn’t removed,
remove it’s rear knobs and lift it’s rear end to
release the rear chassis cover, raise the seat
if needed. Remove the rear chassis cover by
lifting it upwards/backwards.
Covers
Removing the front chassis cover
1. Move/fold the leg rests out.
2. Switch off the main power switch on the
control panel.
3. Remove the two knobs that hold the cover in
place (see fig.).
4. Lift the lower edge of the cover upwards/
forwards. Note that the cover is mounted
partially inside the chassis at the lower edge.
Assembly
Assemble in the reverse order.
1. Fit the cover partially inside the chassis at the
lower edge (see fig.).
2. Fit the two knobs that hold the cover in place
(see fig.).
The rear cover is fitted with the
upper chassis cover.
3. On wheelchairs equipped with lights, disconnect
the rear lights cabling (see fig.).
Assembly
Assemble in the reverse order.
1. On wheelchairs equipped with lights, reconnect
the rear lights cabling (see fig.).
2. Fit the cover partially inside the chassis at the
lower edge (see fig. above).
3. Make sure the upper cover holds the rear cover
and refit the two knobs (see fig. above).
The front cover is fitted with two knobs.
Rear lights cabling connections.
1. Left rear Indicator
2. Right rear Indicator
3. Left rear Light
4. Right rear Light
1 2
3 4

9
Covers
The upprer cover is fitted with four knobs.
Covers
Removing the upper chassis cover
The cover is fitted with four knobs (see fig.).
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. If fitted, remove the front cover. See page 8.
4. Remove the two remaining knobs holding the
cover. (see fig.).
5. Remove the cover by pulling/lifting it
backwards.
Fitting the upper chassis cover
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. Fit the rear chassis cover before the two rear
knobs on the upper chassis cover is fitted (see fig.).
4. Fit the front chassis cover before the two front
knobs on the upper chassis cover is fitted
(see fig.).
Chassis covers.

10
Covers
Removing the front link arm covers.
Both sides of the link arms have covers fitted. The
covers are fitted with four screws.
1. Switch off the main power switch on the control
panel.
2. Remove the drive wheel on the side in question
(see page 18).
3. Remove the four screws holding the covers
(see fig.).
Assembly
Assemble in the reverse order.
1. Fit the covers using the four screws (see fig.).
2. Fit the drive wheel on the side in question (see
page 18).
Covers
Front link arm covers.
Front link arm covers.
For this task the following tools are necessary:
1 Torx key TX20.

11
Covers
Removing the rear link arm covers.
Both sides of the link arms have covers fitted. The
covers are fitted with four screws.
1. Switch off the main power switch on the control
panel.
2. Remove the chassis rear cover. See page 8.
3. Remove the four screws holding the covers
(see fig.).
Assembly
Assemble in the reverse order.
1. Fit the covers using the four screws (see fig.).
2. Fit the chassis rear cover. See page 8.
Covers
Rear link arm covers.
Rear link arm covers.
For this task the following tools are necessary:
1 Torx key TX20.

12
Covers
Covers
Removing the drive motor covers
The drive motor covers are fitted with two screws
each. The associated brake release covers are
fitted with one screw each.
1. On wheelchairs equipped with lights and
indicators, remove the front and upper chassis
cover. (See page 8-9).
2. Remove the drive motor cover, it is attached
with two screws (see fig.).
The drive motor cover is fitted with two screws.
The brake release cover is fitted
with one screw.
The connector on the front indicator cabling.
3. Remove the brake release cover, it is attached
with one screw (see fig.).
4. On wheelchairs equipped with lights and
indicators, separate the indicators’ cabling at
the contact on the cabling. This is positioned
on the inside of the chassis, next to the seat
lift.
For this task the following tools are necessary:
1 Allen key 3 mm.
1 Allen key 2,5 mm.

13
Covers
Covers
Fitting the drive motor covers
1. On wheelchairs equipped with lights and
indicators, connect the indicators cabling at the
contact on the cabling. This is positioned on the
inside of the chassis, next to the seat lift.
2. Install the brake release cover using the screw
(see fig.).
3. Replace the Drive motor cover with the two
screws as per diagram.
4. On wheelchairs equipped with lights and
indicators, refit the front and upper chassis
cover. (See page 8-9).
The connector on the front indicator cabling.
The brake release cover is fitted
with one screw.
The drive motor cover is fitted with two screws.
For this task the following tools are necessary:
1 Allen key 3 mm.
1 Allen key 2,5 mm.

14
Batteries
Batteries
Front battery connections.
Replacing 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. Switch the main fuse to OFF (see fig.).
5. Remove the two knobs that hold the cover in
place (see fig.).
6. Lift the lower edge of the cover upwards/
forwards. Note that the cover is mounted
partially inside the chassis at the lower edge.
The front cover is fitted with two knobs.
Observe care in the use of metallic objects when working
with batteries. A short-circuit can easily cause an explosion.
Always use protective gloves and protective eye-glasses.
The batteries are heavy and must be handled with care.
Used or broken drive batteries should be taken care of in an
environmentally correct manner in accordance with locally
applicable recycling directions.
m WARNING!
For this task the following tools are necessary:
1 Wrench 10 mm.
Off On
Main fuse/battery isolator (On/Off).

15
Batteries
Batteries
7. On Permobil M300, the batteries are secured
with battery locks. Remove these by pushing
them downwards/towards the center of the
chassis (see fig.).
Front battery connections.
Fit the cover partially inside the
chassis at the lower edge.
8. Disconnect the battery connections (see fig.).
See also the sticker on the inside of the front
chassis cover.
9. Lift/pull the battery out of the chassis using the
battery belt.
10. Lift a new battery into the chassis using the
battery belt. Leave the battery belt on the
battery. Position the battery with the battery
terminals at the front.
11. Refit the battery connections to the new
battery (see fig.). See also the sticker on the
inside of the front chassis cover.
12. On Permobil M300, refit the battery locks by
pushing them downwards and at the same
time into the intended recess in the chassis
(see fig. above).
13. Fit the cover partially inside the chassis at the
lower edge, then secure it with the two knobs.
(see fig.).
On Permobil M300, the batteries are
secured with battery locks.
Observe care in the use of metallic objects when working
with batteries. A short-circuit can easily cause an explosion.
Always use protective gloves and protective eye-glasses.
The batteries are heavy and must be handled with care.
Used or broken drive batteries should be taken care of in an
environmentally correct manner in accordance with locally
applicable recycling directions.
m WARNING!

16
Batteries
Batteries
Observe care in the use of metallic objects when working
with batteries. A short-circuit can easily cause an explosion.
Always use protective gloves and protective eye-glasses.
The batteries are heavy and must be handled with care.
Used or broken drive batteries should be taken care of in an
environmentally correct manner in accordance with locally
applicable recycling directions.
m WARNING!
Remove the electronics by pulling the lockig handles on the
left and right handside of the chassis outwards.
For this task the following tools are necessary:
1 Wrench 10 mm.
Off On
Main fuse/battery isolator (On/Off).
Replacing the rear battery
1. Place the wheelchair on a level surface.
2. Raise the seat; electric seat lift to the highest
position; fixed seat tube to the service position.
See page 34. If the electric seat lift does
not work normally because the batteries
are discharged or the adjustment device is
defective, the seat can be raised/lowered
manually. See page 31.
3. Switch off the main power switch on the control
panel
4. Switch the main fuse to OFF (see fig. above).
5. Remove the chassis covers. See page 8-9.
6. Remove the electronics by pulling the locking
handles on the left and right handside of the
chassis outwards (see fig. below). Disengage
the tabs before pulling assembly back.
7. If the wheelchair is equipped with seat support,
remove it. See page 36.

17
Batteries
Batteries
8. On Permobil M300, the batteries are secured with battery locks. Remove these by pushing them
downwards/towards the center of the chassis (see fig.).
9. Disconnect the battery connections (see fig.). See also the sticker on the inside of the rear
chassis cover.
10. Lift/pull the battery out of the chassis using the battery belt.
Battery connections and battery locks of the rear battery.
10. Lift a new battery into the chassis using the battery belt. Leave the battery belt on the battery.
Position the battery with the battery terminals at the rear.
11. Refit the battery connections to the new battery. See also the sticker on the inside of the rear
chassis cover.
12. On Permobil M300, refit the battery locks by pushing them downwards and at the same time into the
intended recess in the chassis (see fig. above).
13. If the wheelchair is equipped with seat support, refit it. See page 36.
14. Refit the chassis covers. See page 8-9.
Observe care in the use of metallic objects when working with batteries. A short-circuit can easily cause an explosion. Always use
protective gloves and protective eye-glasses.
The batteries are heavy and must be handled with care.
Used or broken drive batteries should be taken care of in an environmentally correct manner in accordance with locally applicable
recycling directions.
m WARNING!

18
Drive wheels
Fitting/removing the Drive wheels.
Drive 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 in question is free of the ground.
3. Remove the hub cap by pulling it straight out. If necessary, carefully lever it out using a screwdriver
in the slot on the cap.
4. Remove the four screws that hold the wheel in place.
3
2
1
1 Hub cap
2 Screw, ISO 4762 M8x20 8.8 Fe/Zn 5 C1
3 Drive wheel
Pos. Description
5. Remove the wheel by pulling it straight out.
Assembly
Assemble in the reverse order.
1. Fit the wheel with the four screws (2). Tighten the four screws using a torque wrench.
Tightening torque 17.7 ft-Ibs (24Nm)
2. Align the hubcap on the rim and fit it by pushing it straight in.
The central screw must not be removed.
m WARNING!
For this task the following tools are necessary:
1 Allen key 6 mm.

19
Drive wheels
Fitting a tire to a split rim.
Drive wheels
Taking the rim apart
The rim can be taken apart to make it possible to fit/remove solid or pneumatic tires.
1. Remove the wheel in question from the wheelchair. See the previous page.
2. If the tire is pneumatic, release the air.
1 Rim, outer section
2 Inner tube
3 Tire
4 Rim, outer section
5 Screw, ISO 4762 M8x30 8.8 Fe/Zn
Pos. Description
4
2
15
3. Remove the six screws holding the two halves of the rim together (see illustration).
4. Take the rim apart.
Assembly
Assemble in the reverse order.
1. Fit the two rim halves (1&4) together with tire (3) and if pneumatic tire is used, it’s inner tube (2).
Tighten the six screws using a torque wrench.
Tightening torque: 16.2 ft-Ibs (22Nm)
2. On wheels with pneumatic tires, fill the tire to recommended tire pressure, 29 psi (200 kPa).
3. Fit the wheel on to the wheelchair. See previous page.
3
Ensure that pneumatic tires are not pressurized before the rim is taken apart, otherwise there is a risk of personal injury.
m WARNING!
The recommended tire pressure for pneumatic tires is 29 psi (200 kPa). 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 WARNING!
For this task the following tools are necessary:
1 Allen key 6 mm.

20
Casters
Casters
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 hub cap (4) (see fig. below).
4. Remove the screw (3) and washer (2) (see fig. below).
5. Remove the wheel (1) by pulling it of the axle (see fig. below).
Assembly
Assemble in the reverse order.
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 washer (2) on to the screw (3).
4. Fit the screw (3) and washer (2) on to the axle. Tighten the screw with a torque wrench.
Tightening torque: 24 ft-Ibs (33Nm)
5. Fit the hubcap (4).
Attaching/removing the casters.
4321
1 Wheel
2 Washer, 8,5x23x3
3 Screw, ISO 4762 M8x16 10.9 Fe/Zn
4 Hub cap
Pos. Description
No type of screw and washer other than those stated here
may be used.
m WARNING!
The screw must only be used once. Once removed, the screw
must therefore never be refitted. Do not use an impact wrench
for the tightening torque.
m CAUTION!
For this task the following tools are necessary:
1 Allen key 6 mm.