Permobil C300S User manual

SERVICEMANUAL

Permobil

K/C300/C300s

Power Wheelchair







 ..................................................................................................... 5

 ....................................................................................... 6

 .............................................................................................................. 8

 ......................................................................................................... 10

 .................................................................................................. 12

................................................................................................... 14

 .............................................................................................. 16

 .................................................................................. 17

 .................................................................................................... 18

 ........................................................................................... 19

 ........................................................................................... 20

 ........................................................................................ 21

Plastic rail .................................................................................................... 21

Magnetic wheel lock ................................................................................... 22

Wheel Lock Release Sensor ...................................................................... 23

 .................................................................................................. 24

 .................................................................................................. 26

Manual Raising/Lowering of the Seat elevator .......................................... 26

Removing the Seat elevator ....................................................................... 27

Fitting the Seat elevator .............................................................................. 28

 .............................................................................................. 29

Service Position ......................................................................................... 29

Adjusting the Seat Height .......................................................................... 29

Removal ...................................................................................................... 30

 .................................................................................................. 31

 ............................................................................................................... 33

Corpus 3G ................................................................................................... 33

 ......................................................................................... 35

 ......................................................................................... 36

 .......................................................................................... 37

 .......................................................................................... 38

 ................................................................................................ 39

 ................................................................................................................. 40

 ......................................................................................... 41

 .............................................................................................................. 42

...................................................................................... 44

 .............................................................................................. 47

 ................................................................................... 48

 .................................................................................... 63

 ................................................................................... 66

 ................................................................................... 68

 ............................................................................................................... 70





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 Permobil BV.

Always state the seats serial number when contacting Permobil to ensure that the correct information

is provided.



Spare parts and accessories must be ordered through Permobil BV.



Batteries and charger are supplied with a one-year warranty



See the information in the Owner’s Manual.







Identification plate on chassis.

Identification plate on Rnet output stage.

Identification plate on Rnet control panel.









Identification plate on VR2 output stage

Identification plate on VR2 control panel.







Identification plate on VR2 lights module.









 Switch off the main power switch on the

control panel.

 If the upper chassis cover isn’t removed,

remove it’s fastening 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..





 Move/fold the leg rests out.

 Switch off the main power switch on the

control panel.

 Remove the two knobs that hold the cover in

place (see fig.).

 Lift the lower edge of the cover upwards/

forwards. Note that the cover is mounted

partially inside the chassis at the lower edge.



Assemble in the reverse order.

 Fit the cover partially inside the chassis at the

lower edge (see fig.).

 Fit the two knobs that hold the cover in place

(see fig.).

The rear cover is fitted with the

upper chassis cover.

 On wheelchairs equipped with lights, disconnect

the rear lights cabling (see fig.).



Assemble in the reverse order.

 On wheelchairs equipped with lights, reconnect

the rear lights cabling (see fig.).

 Fit the cover partially inside the chassis at the

lower edge (see fig. above).

 Make sure the upper cover holds the rear cover

and refit the two knobs (see fig. above).

The front and upper chassis cover

is fitted with two knobs.

Lights and indicator cabling connections.

1. Front Light

2. Indicator

3. Rear Light

1

2 3

Left

1

3 2

Right





The upprer cover is fitted with four knobs.





The cover is fitted with two knobs (see fig.).

 Move/fold the leg rests out and, if necessary,

raise the seat.

 Switch off the main power switch on the control

panel.

 If fitted, remove the front cover. See page 8.

 Remove the cover by pulling/lifting it

backwards.



 Move/fold the leg rests out and, if necessary,

raise the seat.

 Switch off the main power switch on the control

panel.

 Fit the rear chassis cover before the upper

chassis cover is fitted (see page 8).

 Fit the front and upper chassis cover with the

two knobs (see fig. below.).

Chassis covers.





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 front

chassis cover.

 Refit the battery cover. See page 8.



 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 8.

 Disconnect the battery connections. See fig.

See also the sticker on the front chassis cover.

 Lift/pull the battery out of the chassis using the

battery belt.

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.

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

 Disconnect the battery connections. See also

the sticker on the upper 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. See also the sticker on the upper

chassis cover.

 Refit the output stage’s mounting plate and the

chassis covers.





Fitting/removing the Drive 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 (1) by pulling it straight out. If necessary, carefully lever it out using a

screwdriver in the slot on the cap.

 Remove the four screws (2) that hold the wheel in place.

3

2

1

 Hub cap

 Screw, ISO 4762 M8x20 8.8 Fe/Zn 5 C1

 Wheel

 

m

 Remove the wheel by pulling it straight out.



Assemble in the reverse order.

 Fit the wheel with the four screws (2). Tighten the four screws using a torque wrench.



 Align the hubcap on the rim and fit it by pushing it straight in.

The central screw must not be removed.

m 



1 Allen key 6 mm.





Fitting a 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

 Inner tube

 Tire

 Rim, outer section

 Screw, ISO 4762 M8x30 8.8 Fe/Zn

 

4

2

15

 Remove the six screws holding the two halves of the rim together (see illustration).

 Take the rim apart.



Assemble in the reverse order.

 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.



 On wheels with pneumatic tires, fill the tire to recommended tire pressure, 200 kPa (2 bar).

 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 

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 



1 Allen key 6 mm.









 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 (4) (see fig. below).

 Remove the screw (3) and washer (2) (see fig. below).

. Remove the wheel (1) by pulling it of the axle (see fig. below).



Assemble in the reverse order.

 Check that the axle and rim is 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 washer (2) on to the screw (3).

 Fit the screw (3) and washer (2) on to the axle. Tighten the screw with a torque wrench.



 Fit the hubcap (4).

4321

 Wheel

 Washer, 8,5x23x3

 Screw, ISO 4762 M8x16 10.9 Fe/Zn

 Hub cap

 

No type of screw and washer other than those stated here

may be used.

m 

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 



1 Allen key 6 mm.



Fitting a tire on the split rim.





The rim can be taken apart to make it possible to

fit/remove solid tires.

 Remove the wheel in question from the

wheelchair. See the previous page.

 Remove the three screws holding the two

halves of the rim together (see illustration).

 Take the rim apart.

 Locking nut, ISO 7040 M6 8 FE/n

 Rim, inner section

 Tire, Solid 200x50

 Rim, outer section

 Screw, ISO 4762 M6x30 8.8 Fe/Zn

 

4

21 5

3



1 Allen key 5 mm.



Assemble in the reverse order.

 Fit the two rim halves (2&4) together with tire (3).

 Tighten the three screws using a torque wrench.



 Fit the wheel on to the wheelchair. See previous page.







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.

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.



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.

 Remove the rear wheel on the side in question. See the illustration above.

 Remove the two screws (2) that hold the support wheel bracket in place at the rear (see illustration).

At the same time, lift the support wheel carefully to make it easier to remove the screws. Please note

that the spring in the top edge of the bracket now comes loose.

 Remove the screw (1) that holds the support wheel bracket in place at the front (see illustration).

 

Assemble in the reverse order. Begin with the front screw (1) and associated spacer and washer. Then

replace the spring before fitting the two remaining screws (2) with associated spacers and washers. Lift

the support wheel carefully to make it easier to fit the two rear screws.

Attaching the support wheel.



1

2







 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.

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.



Wheel fork with friction brake.

Fit the O-ring In the groove of the friction plate.

 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

10

11

7 6

No other type of lubricant than that stated here may be used.

m 

Lubricate the O-ring with Lubricant friction brake,

Part. no: 1820405

m 

Do not use an impact wrench for the tightening torque.

m 









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 29. 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 26.

 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

Shock Absorbers fitted in standard position.

 



0 - 100 Kg.

Above 100 Kg. (standard)

48 mm.

46 mm.





12

Adjustment of shock absorber spring.

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 29. 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 26.

 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 drive wheel, see page 12.

 Remove the lower shock absorber bracket.

See page 19.

 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 





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 29. 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 26.

 Switch off the main power switch on the control

panel.

 Remove the chassis cover. See page 8.

 Remove the wheel lock release sensor, see

page 23.

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.

 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 23.

 Refit the chassis cover. See page 8.

 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 

Before inserting the plastic rail, make sure the wheel lock

release sensor is removed.

m 





The electrical connections of the wheel locks are

positioned on the inside of the chassis, on

each side of the seat lift/seat post.

The magnetic wheel lock is

fitted with three screws

Magnetic wheel lock.





 Raise the seat; seat elevator to the highest

position; fixed seat tube to the service position.

See page 26. 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 24.

 Switch off the main power switch on the control

panel.

 Remove the chassis cover. See page 8.

 Disconnect the electrical connection of the

magnetic wheel lock. See figure.

 Unscrew and remove the three screws that

hold the wheel lock in place. See figure.



Fit the magnetic wheel lock in the reverse order.

Fit the magnetic wheel lock with the release arm

facing upwards.

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