Permobil C300, Service Manual

Page 1: ...SERVICE MANUAL Permobil K C300 Power wheelchair US ...

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Page 3: ... US 0 How to contact Permobil Head Office of the Permobil group Permobil Inc USA 6961 Eastgate Blvd Lebanon TN 37090 USA Phone 800 736 0925 Fax 800 231 3256 Email info permobilusa com Permobil AB Box 120 861 23 Timrå Sverige Tel 060 59 59 00 Fax 060 57 52 50 E post info permobil se ...

Page 4: ...rive motor 23 Seat elevator 24 Manual Raising Lowering of the Seat elevator 24 Removing the Seat elevator 25 Fixed seat post 26 Service Position 26 Adjusting the Seat Height 26 Removal 27 Seat tilt 28 Seat 30 Corpus 30 PS 32 CS 34 PS Junior 35 Control Panel Rnet 36 Control Panel VR2 37 Output stage Rnet 38 Output stage VR2 39 Lights module 40 ICS master module 41 Main Fuse 42 Control System 43 Tro...

Page 5: ...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 wa...

Page 6: ...6 Identification plates Identification plates Chassis Chassis identification number Rnet output stage ID number Control panel Rnet ID number Rnet output stage Rnet control panel ...

Page 7: ...7 Identification plates VR2 output stage ID number VR2 control panel ID number Identification plates VR2 output stage VR2 control panel Control panel VR2 ID number VR2 lights module ...

Page 8: ...the front See figure 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 Remove the two knobs that hold the cover at the front 4 Release the hook and loop fastener by lifting the cover straight up Then remove the cover by pulling it backwards Fitting Fit the cover in the reverse order Covers ...

Page 9: ...rds backwards Fitting Fit the cover in the reverse order Covers Removing the Front Battery Cover The cover is wedged in under the chassis cover 1 Move fold the leg rests out 2 Switch off the main power switch on the control panel 3 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...

Page 10: ...ticker on the battery cover 6 Lift pull the battery out of the chassis using the battery belt Removing 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 Remove the front battery cover See page 9 Be careful when using metal objects when working with batteries A short...

Page 11: ...traight up Rear battery removed 5 Disconnect the battery connections See also the sticker on the rear chassis cover 6 Lift pull the battery out of the chassis using the battery belt Installation 1 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 2 Connect the battery connections on the new batt...

Page 12: ...lling 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 The central screw must not be removed m Warning 5 Remove the wheel by pulling it straight out Assembly Assemble in the reverse order Tighten the four screws using a dynamometric wrench Tightening torque 24 Nm 3 2 1 1 Hub cap 2 Screw ISO 4762 M8x...

Page 13: ...Ensure that pneumatic tires are not pressurized before the rim is taken apart otherwise there is a risk of personal injury m Warning 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 Tighten the six screws using a dynamometric wrench Tightening torque 22 Nm The recommended tire pressure for pneumatic tire...

Page 14: ...the axle using just your hands Check that the wheel is fully located on the axle 3 Fit the screw 6 in the wheel fork 4 Fit the axle 5 wheel 4 washer 3 and nut 2 and tighten the wheel 5 Fit the hub cap 1 Tightening torque 24 Nm Fitting of rim 5 4 2 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 m...

Page 15: ...mewhat High 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 Removal 1 Switch off the main power switch on the control panel 2 Remove the screw See figure Support wheels may be fitted in three different posit...

Page 16: ...val 1 Switch off the main power switch on the control panel 2 Remove the chassis cover See page 8 3 Unscrew and remove the two screws that hold the support wheel damper in place See figure Fitting Fit the damper in the reverse order Support wheel damper ...

Page 17: ...t 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 Tightening torque 33 Nm Tighten the screw holding the friction plate in place with a torque wrench Tightening torque 15 Nm Lubricate the O ring with Lubricant friction brake Part no 1820405 m NOTE m NOTE 1 Plastic plug 2 Bolt ISO 10642 M8x20 10 9 Fe Zn 5...

Page 18: ...absorber on the chassis with screws and washers 2 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 3 Fit the chassis cover See page 8 4 Lower the seat to its normal height Adjustment The shock absorber s spring force should be adjusted to the correct value see figure The spring force can be adjusted for various user weig...

Page 19: ... 2 Switch off the main power switch on the control panel 3 Remove the chassis cover 4 Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground 5 Remove the front wheel see page 12 6 Remove the lower shock absorber bracket See page 16 7 Remove the link arm it is fitted with screw and washer For removal of wheel forks and wheels see the respective chapters Fitt...

Page 20: ...e the chassis cover See page 7 4 Remove the wheel lock release sensor see page 20 Before inserting the plastic rail make sure the wheel lock release sensor is removed m NOTE 1 Insert the plastic rail on the right side of the chassis 2 Check that the rail is correctly located by the wheel lock release sensor See figure 3 Push the rail in further so that its end emerges on the left side of the chass...

Page 21: ...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 2 Switch off the main power switch on the control panel 3 Remove the chassis cover See page 8 4 Disconnect the electrical connection of the magnetic wheel lock See figure 5 Unscrew and remove the three screws that hold the wheel lock i...

Page 22: ...an be raised lowered manually See page 22 2 Switch off the main power switch on the control panel 3 Remove the chassis cover See page 8 4 Disconnect the electrical connection of the wheel lock release sensor it s positioned on the top of the front battery 5 Remove the wheel lock release sensor It is fitted with two screws See figure 6 Remove the plate fitted on the wheel lock sensor It is fitted w...

Page 23: ...move the front wheel on the relevant side See page 12 6 Disconnect the electrical connection for the drive motor and the magnetic wheel lock The connections are positioned on the inside of the chassis on each side of the seat lift seat post 7 Run the connection cables out through the chassis cable duct See figure 8 Remove the four screws that hold the drive motor s gear and the support wheel brack...

Page 24: ...ered manu ally 1 Switch off the main power switch on the control panel 2 Remove the cushion from the seat by lifting it straight up 3 Remove the seat plate s See the illustration Drills must not be used in connection with manual operation of the seat lift There is a risk of damage to materials m Warning 4 Raise lower the seat using the seat lift crank supplied The seat plates for the PS seat are h...

Page 25: ...efore lift it when removing or fitting it Be careful with the cabling m NB 5 Remove the seat lift by unscrewing the four screws See the illustration below 6 VR2 Divide the seat lift cabling at the contact on the cabling R net Remove the ICS general module which is held in place in the chassis to the right of the seat lift by means of Velcro Then disconnect the seat lift cabling from the ICS genera...

Page 26: ...mended that the wheelchair s control system be programmed so that the parameter for maximum forward speed is set to 75 This particularly applies if the user s weight exceeds 100 kg For more information concerning programming of the control system see page 41 Turn the seat so that the height adjustment screw ends up in the groove in the outer tube Height adjustment screw in standard position If the...

Page 27: ...ten the screw that locks the fixed height position of the seat tube The seat is heavy Two people should therefore lift it Be careful with the cabling m NB 5 Remove the seat tube by unscrewing the four screws See the illustration 6 Lift the seat tube straight up out of the chassis Assembly Assemble in the reverse order Removing the fixed seat tube 1 Raise the seat to the service position see previo...

Page 28: ...ul with the cabling m NB 5 On a chassis with a VR2 control system disconnect the seat angle cabling at the contact on the output stage see illustration below Cut the cable ties holding the cabling in place noting the position of the cable ties for subsequent fitting 6 Remove the seat angle by unscrewing the four screws See the illustration 7 Lift the seat angle away from the seat tube seat lift Th...

Page 29: ...29 Seat angle mechanism 1 Used on seats with seat depth extension 2 Used on standard seats 3 Not used on this chassis The seat angle mechanism fitted in the standard holes 1 2 3 Seat angle mechanism ...

Page 30: ...ws holding the seat in place See the illustration 7 Lift the seat off The seat plate is held in place with two screws Assembly Assemble in the reverse order The seat is held in place with four screws The seat is heavy Two people should therefore lift it Be careful with the cabling m NB Front mounting screw of the adjustment device Removal from chassis with seat angle 1 Remove the upper and rear ch...

Page 31: ...he general modules which are fixed at the front of the back rest see illustration 5 Remove the crush protection devices on the left and right sides which are fixed in place with two screws each see illustration below 6 Remove the seat which is held in place with two screws on the left and right sides see illustration below Make a note of which holes the screws are fixed in for subsequent fitting A...

Page 32: ...Remove the cushion from the seat 4 Remove the seat plates which are held in place with four screws see illustration Assembly Assemble in the reverse order The seat is held in place with four screws 5 Remove the control panel See page 36 Cut off the cable ties holding the cabling in place on the seat noting the position of the cable ties for subsequent fitting 6 Unscrew and remove the four screws h...

Page 33: ...ng the position of the cable ties for subsequent fitting Front mounting screw of the adjustment device The crush protection devices on the left and right sides are held in place with two screws The seat is held in place with two screws on the left and right sides 3 Remove the crush protection devices on the left and right sides which are fixed in place with two screws each see illustration Assembl...

Page 34: ...at is fitted with four screws The Legrest unit is fitted with four screws with washers and nuts Because the seat is heavy it should be lifted by two persons Be careful with the cabling m NOTE Fitting Fit the seat in the reverse order Always use the front holes on the seat when fitting it on the leg rest unit m NOTE Use the center holes on the leg rest unit when fitting it on the seat lift fixed se...

Page 35: ...ocated at the rear of the underside of the seat See the figure below 5 Unscrew and remove the four screws underneath the seat that hold the seat in place See the figure 6 Lift off the seat Fitting Fit the seat in the reverse order The seat is held in place with four screws In the figure the seat is viewed from below The seat can be fitted on the seat lift in two different positions A B A B A B A B...

Page 36: ...positions of the cable ties for subsequent fitting 3 Divide the control panel cabling at the contact on the cabling 4 Remove the control panel 1 It is held in place with two screws see illustration These two screws also hold the bracket for the ICS control panel 2 if there is one fitted see illustration Assembly Assemble in the reverse order The control panel is held in place with two screws 1 2 ...

Page 37: ...lace with two screws underneath see illustration Assembly Assemble in the reverse order Control panel VR2 Removal 1 Remove the upper and rear chassis cover See page 8 2 Remove the cable ties holding the control panel cabling in place Note the positions of the cable ties for subsequent fitting 3 Disconnect the control panel cabling from the output stage see illustration 3 ...

Page 38: ... the output stage by unscrewing its two mounting screws See fig Fitting Assemble in reverse order Older models of C300 have output stages of type PM80 while later models have output stages of type PM90 When renewing output stages on older models PM80 may be replaced by PM90 Note the location of the cable connections see photo above Battery Inhibit External charging socket Output stage cable connec...

Page 39: ...ote their positions see illustration below 4 Remove the output stage by unscrewing its two mounting screws See the figure On a chassis fitted with lights remove the lights module See page 40 Assembly Assemble in the reverse order The output stage is fitted with two screws Kabelaansluitingen powermodule VR2 Motor 1 Links Motor 2 Rechts Accu Inhibit Extern laadcontact Stelmechanisme Bedieningspaneel...

Page 40: ... the main power switch on the control panel 2 Remove the upper and rear chassis covers See pages 8 9 3 Disconnect the electrical connections from the lights module Note their positions for subsequent fitting 4 Remove the lights module It is fitted with Velcro at the rear Assembly Assemble in the reverse order ...

Page 41: ... 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 26 2 Switch off the main power switch on the control panel 3 Remove the chassis cover See page 8 4 Pull the master module straight up out of its holder see illustration 5 Pull the cover off 6 Cut off the cable ties that hold the cables and detach ...

Page 42: ...e front battery 8 Refit the front battery cover See page 9 Replacing the Main Fuse Holder 1 Switch off the main power switch on the control panel 2 Remove the front battery cover See page 9 3 Unscrew and disassemble the fuse holder 4 Detach the cables from the fuse holder by unscrewing the screws See figure 5 Connect the cables to the new holder 6 Fit the fuse and screw the holder together Main Fu...

Page 43: ... information on programming the VR2 control system and obtaining parameter files see the technical user manual for programming Pilot VSI VR2 Art no 205009 SE 0 For more information on programming adjustment of the Rnet control system and obtaining parameter files see the technical user manual for programming R net Art no 205222 SE 0 If the seat is raised above the standard position for wheelchairs...

Page 44: ...lchair cannot be Battery charger connected Stop charging and disconnect driven the charging cable from the wheelchair s charging socket Brake release activated Reset the brake release The wheelchair is locked Unlock the wheelchair See user manual An exclamation mark on the Electronics fault See pages 45 58 control panel display is flashing rapidly and the wheelchair will not run The wheelchair can...

Page 45: ...where in the wheelchair s electric al system NB If the fault is in a module that is not currently being used it will still be possible to drive the wheelchair but the diagnostic screen is displayed occasionally Switch off the wheelchair and leave it off for a few minutes Then restart the wheelchair If the fault persists you must switch off the wheelchair and get in touch with your service contact ...

Page 46: ... protection circuit has been triggered PM Low Battery 2C00 Error code Identified module Error message PM 0506 Controller Fault 2 1 4 Example The screen example shown below displays the following information Identified module Power module error Error message Low Battery Error code 2C00 This means that the battery needs charging or that the battery has not been connected properly Check the battery c...

Page 47: ...programming directly in the system On Board Programming OBP Contact Permobil or your repair engineer for more information on OBP Go to OBP mode Select System from the menu Select Diagnostics from the menu The diagnostics screen will now appear showing the connected modules and version history See the illustration below If a module has experienced no errors the message No Entries will be displayed ...

Page 48: ... Error Go to section 3 5 M2 Motor Error Go to section 3 5 Inhibit Active Go to section 3 6 Jstick Cal Error Go to section 3 7 Latched Timeout Go to section 3 8 Brake Lamp Short Go to section 3 9 Left Lamp Short Go to section 3 10 Right Lamp Short Go to section 3 10 L Ind Lamp Short Go to section 3 11 R Ind Lamp Short Go to section 3 11 L Ind Lamp Failed Go to section 3 12 R Ind Lamp Failed Go to s...

Page 49: ...r a poor connection between the control system and the batteries Check the batteries and their connection to the control system If the error persists after the batteries and connections have been checked the power module may be defective Read more in section 5 3 4 Brake Error This occurs when the control system detects a problem in the solenoid brakes or the connections to them 1505 M1 Brake Error...

Page 50: ...uit in the brake lamp electrical circuit Read more about connectors in section 2 3 Check the brake lamps their cables and the connections to the control system 3 10 Lamp Short This occurs when the control system detects a short circuit in the electrical circuit of one of the lamps 7205 Short circuit left hand lamp 7209 Short circuit right hand lamp Check the lamps their cables and the connections ...

Page 51: ...om PGDT and cycle the voltage If this has dealt with the error Connect one third party module at a time and cycle the voltage each time If the error recurs after one of the voltage cycles the last module to be connected must be defective If the error persists after the checks listed above the power module may be defective Read more in section 5 3 18 PM Memory Error This is a specific error in the ...

Page 52: ...ettings Check all parameter settings and then reprogram the control system with the help of R net s PC programmers Make a note of the current parameter settings and then reset the control system to the standard settings Reprogram the required settings in small groups and cycle the voltage after each group to see if the error recurs If the error persists after the checks listed above the power unit...

Page 53: ...ve Read more in section 5 3 23 Gone to Sleep energy saving mode This occurs when the system has not been used for a period that exceeds the Sleep Timer parameter used for setting the energy saving mode Each time this occurs it is registered in the system log 3 24 Charging This occurs when the control system detects that a charger has been connected to either inhibit contact 1 or inhibit contact 3 ...

Page 54: ... securely installed Do not over tighten the mounting screws m Warning The tests described are minimum recommendations It is the responsibility of the repair engineer s to perform other tests on the basis of the original error source and the wheelchair model The necessary information on other tests is available in the wheelchair service manual Permobil cannot be held responsible for losses of any k...

Page 55: ...ecking that it runs smoothly and is easy to maneuver Repeat the test with the speed control set to the highest possible value 4 4 Gradient test Run the wheelchair forwards up its steepest permitted gradient Release the joystick when the wheelchair is on the upward slope and check that the wheelchair stops and that the brakes function as they should without the front wheels lifting from the ground ...

Page 56: ... end stop tracking that is in the seat and light module ISM 4 7 Test of inhibit signal Connect a suitable battery charger or equivalent inhibit connecting device in the charging contact on the joystick module and check that the wheelchair is prevented from running If inhibit contacts 2 3 4 and 5 are used for inhibiting or speed restriction an appropriate test should be performed in order to check ...

Page 57: ...re in the wheelchair s electric al system NB If the fault is in a module that is not currently being used it may still be possible to drive the wheelchair but the diagnostic screen is displayed occasionally Switch off the wheelchair and leave it off for a few minutes Then restart the wheelchair If the fault persists you must switch off the wheelchair and get in touch with your service contact Writ...

Page 58: ...de Identified module Error message PM 0506 Controller Fault Repair of defective units Apart from specific OEM approved spare parts contact Permobil for further information on these there are no replaceable parts in the Rnet control system Consequently defective units must be sent to Permobil or a Permobil approved repairer for repair m NB If any part is replaced without Permobil s approval the whe...

Page 59: ...driven the charging cable from the wheelchair s charging socket Brake release activated Reset the brake release The wheelchair is locked Unlock the wheelchair See user manual The battery voltage indicator Electronics fault See pages 60 61 on the control panel is flashing rapidly and the wheelchair will not run The wheelchair stops while The cable connection to the Insert the cable in the control b...

Page 60: ...mediately Flashing fast 1 10 lamps A fault has been detected in the wheelchair s electronics and the wheelchair cannot be driven Switch off the wheelchair Check that all visible cables and the cable to the control panel are connected correctly Switch the wheelchair on again If the fault persists count the number of flashing lamps and check for a possible cause and remedy in the table on the adjoin...

Page 61: ...the battery charger 7 Lamps Joystick error Check that the joystick has not been moved when the wheelchair is started 8 Lamps Control system error Check the contacts to the output stage 9 Lamps Failure in brake circuit Check the contacts to the magnetic brake 10 Lamps High battery voltage Check the battery and the contacts between the battery and the control unit 7 5 Lamps Communication error A com...

Page 62: ...62 Cabling overview A B C D E F 1 2 3 4 ...

Page 63: ...63 Cabling overview Cabling overview R net A B C D E F 5 6 7 8 ...

Page 64: ...64 Cabling overview A B C D E F 1 2 3 4 ...

Page 65: ...65 Cabling overview Cabling overview VR2 A B C D E F 5 6 7 8 ...

Page 66: ...ront wheels 12 Fuses 42 I ICS module 41 Identification plates 6 Introduction 5 L Lights module 40 M Magnetic wheel lock 20 O Output stage Rnet 38 Output stage VR2 39 P PS seat 32 PS Junior seat 35 R Rear wheels 14 S Seat elevator 24 Seat tilt 28 Shock absorbers 18 Slewing brackets 19 Support wheels 15 Support wheels dampers 16 T Trouble shooting Rnet 44 Trouble shooting VR2 59 W Wheel forks 17 Whe...

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Page 68: ...Order no 205221 US 0 ...