Permobil Corpus 3G Service Manual Download Page 15 | Manualshive

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16

Repairs

Replacing a UniTrack rail

UniTrack rails are available in five different lengths

that are used depending on the seat depth

selected. See the table on 43.

Removal

1.

Remove the two screws that hold the rail in

place. See the illustration.

Mounting

1.

Mount the UniTrack rail using two screws.

See the illustration. Use a torque wrench to

tighten the screws.

Tightening torque 9.8 Nm.

The UniTrack rail is held in place by two screws.

Repairs

Replacing a UniTrack rail

For this task the following tools are necessary:

1 Allen key 5 mm

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Summary of Contents for Corpus 3G

Page 1: ...SERVICE MANUAL Corpus 3G Seat system for electric wheelchair US ...

Page 2: ......

Page 3: ...Replacing a UniTrack rail 16 Replacing seat plates 17 Replacing backrest plates 18 Replacing the armrest height adjustment mechanism 20 Replacing the manual legrest adjustment unit 24 Replacing the manual backrest adjustment unit 25 Replacing the legrest actuator 26 Replacing the backrest actuator 27 Replacing the seat angle mechanism 28 Replacing the fixed seat mounting plate 32 Replacing the ada...

Page 4: ...5 5 ...

Page 5: ... need adjusting See 37 1 Remove the seat cushion by lifting it straight up It is attached by means of Velcro on the rear of the cushion 2 Remove the seat plates which are held in place by two screws at the back edge and two quick mount clamps at the front See the illustration First remove the screws then use your hand to carefully push the seat plate from below to release the quick mount clamps at...

Page 6: ...with which the seat depth is adjusted are marked with the settings for each potential position The scale is marked with millimeters on one side and inches on the other 6 Secure it at the required setting by remounting the five screws Seat depth Back rest position Leg rest position M300 M400 Other Models M300 M400 Other Models 370 mm 15 N A 100 mm 4 N A 0 395 mm 16 100 mm 4 75 mm 3 25 mm 1 0 420 mm...

Page 7: ... millimeters on one side and inches on the other 9 Secure it at the required setting by remounting the five screws The position of the rear section of the Seat frame Back rest Position is fixed by five screws marked with the letter L Seat depth Back rest position Leg rest position M300 M400 Other Models M300 M400 Other Models 370 mm 15 N A 100 mm 4 N A 0 395 mm 16 100 mm 4 75 mm 3 25 mm 1 0 420 mm...

Page 8: ...tion 12 Fit a cushion of a suitable length width for this setting See the table on 43 Secure the cushion in place using the Velcro on the back of the cushion The UniTrack rails are fixed in place with two screws each The seat plates are held in place by two screws at the back edge and two quick mount clamps at the front The seat s mounting position on the seat lift fixed seat column may need to be...

Page 9: ...nit See the illustration below 4 Adjust the seat width by moving the right or left section of the seat frame to the required position The rails with which the seat width is adjusted are marked with the settings for each potential position The scale is marked with millimeters and inches 5 Secure it at the required setting by replacing the four screws 7 Remount the seat plates using two screws at th...

Page 10: ...ing the backrest locking mechanism in place See the illustration 4 Adjust the height of the backrest by sliding the upper section upwards downwards to the required position The upper backrest plate is marked with the settings for each potential position The scale is marked with millimeters and inches 5 Lift up the upper section of the backrest enough that the locking mechanism can be mounted with ...

Page 11: ...position using the adjustment screw on the rear of the backrest See the illustration below 3 Secure the armrest at the preferred height by tightening the four screws on the rear of the backrest See the illustration below For this task the following tools are necessary 1 Allen key 5 mm 1 Undo the four screws holding the armrest at its current height See the illustration below Adjustment Adjusting t...

Page 12: ...is adjustment is only performed in special cases It may have negative effects on the movement of the armrest when raising lowering the backrest 1 Adjust the armrest height by turning the adjustment bars C See the illustration 2 The angle of the armrest is secured using a screw B Move the screw from a fixed position A to a flexible position B See the illustration below 3 Adjust the armrest to the r...

Page 13: ... both wide and low the adjustment bar for the left armrest angle can touch the rear actuator bracket for the backrest angle If this is the case turn the adjustment bar bracket Turn the bracket 180 so the adjustment bar is closer to the center of the seat For this task the following tools are necessary 1 Combination wrench 10 mm 1 Remove the lower bracket of the adjustment bar which is secured with...

Page 14: ...sition 3 Secure it at the required setting by retightening the screw The trunk support height is fixed using one screw For this task the following tools are necessary 1 Allen key 5 mm Adjusting the thigh support The position of the thigh support can be adjusted forwards or backwards to give the user optimal comfort Slide the thigh support forwards or backwards to the desired position The position ...

Page 15: ...moval 1 Remove the two screws that hold the rail in place See the illustration Mounting 1 Mount the UniTrack rail using two screws See the illustration Use a torque wrench to tighten the screws Tightening torque 9 8 Nm The UniTrack rail is held in place by two screws Repairs Replacing a UniTrack rail For this task the following tools are necessary 1 Allen key 5 mm ...

Page 16: ...use your hand to carefully push the seat plate from below to release the quick mount clamps at the front Mounting 1 Mount the seat plates by first mounting them with the quick mount clamps at the front and then the screws at the back Fit the quick mount clamps by pushing them straight into the holes 2 Fit the seat cushion by pressing it against the seat plate in the desired position to ensure good...

Page 17: ...to its most upright position Remove the upper section of the backrest by carefully opening the locking mechanism catch outwards while also pulling the upper section of the backrest straight up See the illustration The upper section of the backrest is secured with a locking mechanism 3 Remove the knob securing the position of the lower backrest plate See the illustration The lower backrest plate is...

Page 18: ...section of the cushion is fastened to the seat plate by means of Velcro The upper section of the backrest is secured with a locking mechanism 2 Secure the position of the plate by fitting the knob See the illustration The lower backrest plate is secured by means of a knob Mounting 1 Mount the lower backrest plate by lining up the four keyholes on the locking devices and then sliding the plate stra...

Page 19: ...bove the contact block 2 The BUS contacts are mounted on the contact block 4 Remove the four screws that hold the armrests in place See the illustration Then carefully move the armrests downwards or backwards 5 Remove the joint for the backrest slide function which is held in place by one screw See the illustration The armrests are held in place by four screws The joint for the backrest slide func...

Page 20: ...e groove on the backrest profile See the illustration at bottom right The end cover of the backrest profile is secured using one screw on the left side and one on the right 6 Remove the backrest profile which is secured using two screws on the left and right See the illustration Remove by undoing the screws and pulling the backrest profile straight up The backrest profile is secured using two scre...

Page 21: ...d using one screw on the left side and one on the right Mounting 1 Push the threaded rod into the backrest profile and at the same time screw on the driver 1 See the illustration below 2 Apply threadlocker Loctite 2701 to the ends of the threaded rod and fit the two end pieces 2 3 onto the threaded rod See the illustration below 3 Mount the adjustment bar brackets which are each held in place by t...

Page 22: ...oint for the backrest slide function using the screw supplied See the illustration Tighten the screw using a torque wrench Tightening torque 9 8 Nm 8 Mount the BUS contacts on the contact block and mount the cabling for the ICS switchbox at the contact on the cabling See the illustration at bottom left 9 Remount the plastic cover on the back of the backrest using the two screws supplied See the il...

Page 23: ...tools are necessary 1 Allen key 5 mm 1 Allen key 8 mm Mounting 1 Fit the rear fixing screw M6x12 and washer for the manual adjustment unit See the illustration below Tighten the screw using a torque wrench Tightening torque 9 8 Nm 2 Fit the front fixing screw M10x60 spacer and washer for the manual adjustment unit See the illustration below Tighten the screw using a torque wrench Tightening torque...

Page 24: ...crew has been removed the backrest can be angled forward to rest on the seat cushion For this task the following tools are necessary 1 Allen key 5 mm 1 Allen key 8 mm Mounting 1 Mount the front fixing screw M6x12 and washer for the manual adjustment unit See the illustration below Tighten the screw using a torque wrench Tightening torque 9 8 Nm 2 Fit the rear fixing screw M10x60 spacer washers and...

Page 25: ... using a torque wrench Tightening torque 9 8 Nm 2 Fit the front fixing screw M10x60 spacer and washer for the actuator See the illustration below Tighten the screw using a torque wrench Tightening torque 35 Nm For this task the following tools are necessary 1 Allen key 5 mm 1 Allen key 8 mm The actuator cabling is connected to the contact block on the right side of the seat Repairs Replacing the l...

Page 26: ...angled forward to rest on the seat cushion Mounting 1 Fit the front fixing screw M6x12 and washer for the actuator Tighten the screw using a torque wrench Tightening torque 9 8 Nm For this task the following tools are necessary 1 Allen key 5 mm 1 Allen key 8 mm 2 Fit the rear fixing screw M10x60 spacer washerand nut for the actuator Tighten the screw using a torque wrench Tightening torque 35 Nm 4...

Page 27: ... by two screws at the back edge and two quick mount clamps at the front The seat is held in place by six screws 5 Remove the six screws that hold the seat in place Have someone help you by holding the seat while you remove the screws and then helping you lift the seat and lay it next to the chassis Be careful with the seat cabling The connector is on the cabling at the front right corner of the se...

Page 28: ...nt positions depending on the chassis the seat is mounted on and the depth of the seat Note the position the seat angle mechanism is mounted in for future reference Lift the seat angle mechanism off the seat lift seat column The seat angle mechanism is held in place by four screws Position 1 Position 2 Position 3 Repairs Replacing the seat angle mechanism ...

Page 29: ...unting positions for standard model wheelchairs accessories such as height adjustable footplates or a respirator shelf may affect the mounting position Contact Permobil in case of doubt The seat angle mechanism is held in place by four screws Position 1 Position 2 Position 3 Repairs Replacing the seat angle mechanism Mounting position Seat depth C300 C300S C350 M300 M400 C400 C500 C500S 370 mm 15 ...

Page 30: ...right corner of the seat angle mechanism next to the rest of the cabling 3 Connect the cabling for the seat angle mechanism to the wheelchair s ICS Master Module If the cabling for the ICS Master Module is already there connect it to the contact that is at the front right corner of the seat angle mechanism next to the other cabling See the illustration When mounting new cabling for the ICS Master ...

Page 31: ...lease the quick mount clamps at the front For this task the following tools are necessary 1 Allen key 5 mm 1 Allen key 8 mm The seat plates are held in place by two screws at the back edge and two quick mount clamps at the front The seat is held in place by six screws 4 Remove the six screws that hold the seat in place Have someone help you by holding the seat while you remove the screws and then ...

Page 32: ... positions depending on the chassis the seat is mounted on and the depth of the seat Note the position the seat mounting plate is mounted in for future reference Lift the seat mounting plate off the seat lift seat column The seat mounting plate is held in place by four screws Position 1 Position 2 Position 3 Repairs Replacing the fixed seat mounting plate ...

Page 33: ...ing positions for standard model wheelchairs accessories such as height adjustable footplates or a respirator shelf may affect the mounting position Contact Permobil in case of doubt The seat mounting plate is held in place by four screws Position 1 Position 2 Position 3 Repairs Replacing the fixed seat mounting plate Mounting position Seat depth C300 C300S C350 M300 M400 C400 C500 C500S 370 mm 15...

Page 34: ...t plates are held in place by two screws at the back edge and two quick mount clamps at the front 3 Mount the seat plates by first mounting them with the quick mount clamps at the front and then the screws at the back Fit the quick mount clamps by pushing them straight into the holes Repairs Replacing the fixed seat mounting plate The seat is heavy This work should therefore always be performed by...

Page 35: ...dge and two quick mount clamps at the front Adapter plate standard C400 C500 The seat angle mechanism or seat mounting plate is held in place by four screws 2 Remove the four screws that hold the seat angle mechanism or seat mounting plate in place Either of these can be mounted in three different positions depending on the seat depth setting as well as which chassis it is mounted on Note the posi...

Page 36: ...quick mount clamps at the front and then the screws at the back Fit the quick mount clamps by pushing them straight into the holes The seat plates are held in place by two screws at the back edge and two quick mount clamps at the front The mounting position for the seat mounting plate seat angle mechanism depends on the chassis model and the seat depth setting The table shows mounting positions fo...

Page 37: ...ch on the control panel 2 Remove the legrest s top cover by carefully pulling it straight out See the illustration 3 Remove the front ends of the UniTrack rails See the illustration 4 Remove the front bracket of the manual adjustment unit actuator See the illustration below Start with the lock nut and the washer on the inside of the bracket then remove the screw and washer 5 Remove the legrest whi...

Page 38: ...screw and washer Tighten the screw using a torque wrench Tightening torque 47 Nm Then fit the lock nut and washer on the inside of the bracket 3 Mount the front ends of the UniTrack rails See the illustration Remove the front ends of the UniTrack rails Mount the legrest s top cover by carefully pressing its bracket into place on the legrest s fixing screws spacers 4 Mount the legrest s top cover b...

Page 39: ...se and can be carefully placed on the floor 4 Remove the two screws holding the strap bracket on the back of the legrest in place See the illustration 5 Pull the strap out of the legrest mechanism Mounting 1 Pull the strap through the bracket on the back of the legrest Measure to make sure that the strap extends 85 mm under the bracket Secure the strap by tightening the two screws on the bracket S...

Page 40: ... See the illustration above 5 Remove the slide bushing in the lower section of the legrest and at the same time use a suitable tool to press in the locking tabs on the bushing located in the hole immediately below the top edge of the legrest See the illustration Mounting 1 Fit the slide bushing in the lower section of the legrest making sure the locking tabs on the bushing are securely fixed in th...

Page 41: ...Mount the footplate friction brake by sliding the parts onto the shaft Make sure that the metal butt is positioned in the intended hole in the footplate See the illustration to the right 3 Fit the screw that holds the footplate in place See the illustration below Tighten the screw using a torque wrench Tightening torque 33 Nm For this task the following tools are necessary 1 Allen key 5 mm The fri...

Page 42: ...0 mm 620 670 mm 645 mm 670 mm 460 mm Low height not adjustable 460 mm 480 mm 545 mm 545 595 mm 570 mm 595 mm 620 mm 620 670 mm 645 mm 670 mm Seat depth mm Seat width mm Cushion Length Cushion Width Seat plate Length UniTrack rail Length 370 420 470 520 420 mm Sitsbredd 370 mm 370 mm 395 420 470 520 420 mm Sitsbredd 420 mm 420 420 470 520 420 mm Sitsbredd 420 mm 445 420 470 520 420 mm Sitsbredd 470...

Page 43: ...44 A B C D E F 1 2 3 4 Repairs Cabling overview ...

Page 44: ...45 45 Cabling overview A B C D E F 5 6 7 8 Repairs Cabling overview ...

Page 45: ... Cabling overview 44 D Disposal 5 F Footplate 42 H Headrest 19 I Introduction 5 L Legrest 38 Legrest slide bushings 41 Legrest strap 42 M Maintenance 5 Manual backrest adjustment 25 Manual legrest adjustment 24 P Product approval 5 S Seat depth 6 Seat mounting plate 32 Seat plates 17 Seat width 10 Service 5 Spare parts 5 T Technical support 5 Thigh support 15 Trunk support 15 U UniTrack rails 16 W...

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