SERVICE MANUAL
Contents
1. Fitting Fitting is the reverse procedure Fig 50 Removing the Seat control panel lid Fig 51 The Seat control panel electrical connector 22 Circuit breaker and fuses Circuit breaker and fuses Resetting the circuit breaker The circuit breaker also acts as a battery isolator but is usually referred to as the circuit breaker You will not normally need to change the circuit breaker as you can reset it when it has tripped It is located on the underside of the chassis above the right rear wheel see fig 52 The circuit breaker is protected from dirt and water by a rubber lip which can easily be folded back N WARNING A tripped circuit breaker often means that there is a serious electrical fault Check the cause thoroughly before you reset the circuit breaker Changing the circuit breaker 1 Switch off the main switch on the control panel 2 Put the circuit breaker to the OFF position see fig 52 3 Remove the battery cover and chassis cover see page 8 4 Disconnect the battery positive lead which is between the battery and the circuit breaker 5 Remove the circuit breaker by removing the two SCrews see fig 53 AN WARNING Note the orientation of the circuit breaker for refitting The ON OFF positions must agree with the label 6 Disconnect the cables from the circuit breaker by loosening the screws see fig 54 7 Connect the cables to the new circuit bre2. 24 FUSE for SEAL e TTE 24 TTOUDIESNOOUNG e ORE IU 25 Distribution CAPT zegin eege e RS SES TR TYF NF 26 Introduction Introduction The Service Manual is intended for technical personnel who maintain and repair electric 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 Rating plates je ei a Fd Wa E ps PS Fas H z ntm Iren Data plates Chassis Se e T Ex 2 3 nuls galln salir Fig 1 Chassis identification number Pilot Motor Controller PILOT Type D49987 2 KL Penny les gnn gt P em MADE IN ENGLAND Fig 2 Pilot Motor Controller identification number Control panel Fig 3 Control panel identification number Operating the seat lift manually If you can not move the seat up in the normal way because the battery is flat or there is a fault other than in the l
3. XL 1 9 ri c O g EI I Q Bi gt i5 Zia E Ki 5 am o Ss AAA AAA o gt JALVOJN IV ZA SOd YSLLV9 3AUvVO3N OLOW m a m 3AlllSOd JOLOVi E IAW Dv em em JANISOd 3NVYY 387 ONINO2 40 walA WOLIOE Y ONDIOO1 S Iw DO NOILO3NNOO AXIL NET ORINOD JO ASIA WOLLOE LY ON 3OC cw INV LW STINV130 NOILLO3NNOO SOLOW 26 Distribution chart 9 6 1 7 1 8 White Relay board 7131 Rear light Es 8083 L Red White Brown OG 4 D 0 Blue Ll 8517 White E To extra b relay board H x 1 Left front light 9968 ee 9 x 2 o blue White C A mn Right front light eS 9394 t 1 DO O o 6 Motor left o M2 Brake left o Brake lefti o Pilot dl Motor left o otor Controller 9393 Battery input 9 Battery input y main fuse Charge connector 602566 2 L Motor right a Brown Brake right a Yellow Brown Brake right 9 Motor righi o Blue e ES 0 11101 555 Pilot Control panel 9391 Distribution chart 27 Notes N Notes N Notes co Article no 201164 US 0
4. seat lift These gas springs are part of the tilt mechanism N WARNING vn Do not drill into the tube or gas spring and do not expose them to heat as this could cause an explosion Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 2 Remove the battery cover and chassis cover see page 8 3 Switch off the main switch on the control panel Put the circuit breaker to the OFF position see page 23 fig 52 5 Remove the bolt to detach the rear end of the spring see fig 39 2 and 40 8 Lock the pivot arm 40 2 by inserting a drift from underneath through the hole in the end of the parallel tube 6 Remove the circlip from the front attachment point see fig 39 1 and 40 3 7 Remove the parallel tube complete with the gas spring 8 Remove the socket head cap screw that locks the adjuster 40 1 and remove the tube Bolt MC6S Pivot arm Circlip SgA 16 Gas spring attachment Spring tension pin 8 x 18 Gas spring Spring tension pin 8 x 20 Bolt 8 x 16 9 Drive out the spring tension pin 40 5 and remove the gas spring attachment 40 4 10 Drive out the spring tension pin 40 7 and remove the tube Fitting Fitting is the reverse procedure oNOOR SON Fig 40 Parallel tube with gas spring Slide bearings Changing a bearing The basic procedure for changing a bearing is the same for all bearings 1 Remove the part where the beari
5. the cable is tensioned but does not pull the release link 3 Check the operation Operate the brake release mechanism to release the brake and check that the wheel can turn 4 Tighten the locknut 17 2 Refit the brake release mechanism 6 Refitthe covers Brake release sensor Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 Fig 17 Brake release system Switch off the main switch on the control panel Put the circuit breaker to the OFF position see page 23 fig b2 4 Remove the battery cover and chassis cover see page 8 5 Remove the brake release mechanism it is attached by two bolts see fig 16 It is easier to remove the brake release sensor with the brake release mechanism removed 6 Remove the brake release sensor it is attached by two screws see fig 18 7 Disconnect the connector in the brake release sensor cable Fitting Fig 18 The brake release sensor is attached by Fitting is the reverse procedure two screws 11 Magnetic brake Magnetic brakes Removal 1 Put the wheelchair on a flat surface 2 Raise the seat to its highest position To operate the seat lift manually see page 7 3 Switch off the main switch on the control panel 4 Put the circuit breaker to the OFF position see page 23 fig 52 5 Remove the battery cover and chassis cover see page 8 6 Disconnect the magnetic brake and drive mo
6. the cable to the anti trap mechanism before you lift the cover off completely see fig 8 Use caution when you remove the battery cover The anti trap mechanism cable is attached to the electronic unit 4 Remove the chassis cover lt is held by two screws at the front edge and two on either side see fig 9 10 Fitting Fitting is the reverse procedure N WARNING Fig 8 The battery cover is attached by two knobs at the front edge Be careful with the anti trap mechanism cable Fig 9 The chassis cover is attached by two screws at the front edge Fig 10 The chassis cover is attached by two screws on either side 9 Batteries Batteries N WARNING Use protective goggles when working on batteries Removal 1 Putthe wheelchair on a level surface 2 Raise the seat to its highest position To operate the seat lift manually see page 7 3 Switch off the main switch on the control panel 4 Put the circuit breaker to the OFF position see fig 11 5 Remove the battery cover see page 8 Use caution when you remove the battery cover The anti trap mechanism cable is attached to the electronic unit 6 Disconnect the battery leads positive terminals first see fig 12 Fig 12 Battery connections 7 Remove the spacer plate at the front of the battery compartment by pulling it straight upwards see fig 13 8 Lift out the batteries Fitting Fitting is the reve
7. 0000000000400900909000000009909000000009000000009000400000000990000000090900000000009000000000000000000009000000000990000000009909000000090000000000909009090098 D Check the battery and the connections between the battery and Pilot Motor Controller D 4 990990999009099090090990900099099090009090000900000090909009000900000909000009090009000900000090000900000090994909909000909000009090900000909900009090900000000009900909009900909009009000090099900009009090000920000090000009090009909090000090000090990000909090900900099009099 9 D D amp eoseesesc0e0000090000000000000000009000090000000900920000000000000000000000000000000900000000020009000004000000000000900090000090000090000002000900000900090900909000090000000000000000090000090009009 00909009000000090000000000000000000900092900900200202004 Check the connections to the Pilot Motor Controller If the fault persists change the Pilot Motor Controller D amp oooes06090000900900900000000900900000000000900009090900000090090000090000900009000000000000000000009000000000 0000090000900900900000000000000090000200000090099009900000090090090900000000000900000000009090009009000000900900900000000090090000090000000900090990900 Make sure the joystick isn t actuated at switch Fault in the control panel _ On change the control panel D 09000900909000000900000000000000000000900000900000090000000000000009000000000000000000009000009000000909900000000000000000000000000000000090000
8. 00900000000000000000000000000000000009000000090000009000000000000000000000000000000000009000009200000900 e H Check the condition of the battery Check the connection between the battery and the control unit D D amp ooso0e0060000900900000900090900090000000900000009000900900000000090000000009000090000000090000000000000002000000 0000000009009009000000009000000090000252000000900909000000009009000000000000000000090000000900090090000009000900000000090000000000000000000090990900 Distribution chart 9969 9968 o o D 9968 Black CL LI Power out d Power in Red Black F BUS o On Off J cd ATY 30 31000 ADUSAOT OL 4OLD3NNO2 SNOIY ONT WOOD gt N 4 Ke 12 3 EE Le I 1 0 lo I 9 I I O I I I I a I la 10 lg fs Z lo l E iS 2 SR I I I J 9394 Green Low SW 9972 Blue Brake release Switch nc b Blue Seat Elevator T ONON OL LTX 2O_DINKOD O M3 SNId 2OLD3NNOD SNO IV OINnWIOD Q O o O S S D On H o doe O gt I i 72222 I l I I xt 2 el 3 N 351 x xi d 2 Zim lt i Lt o e E zi SCH l x Lo I RA A o 3 Md A n ST Qz I w 31 O 2 A El c Zi Ez Oi 9 O co 3 Q e gt gi d gt 5 Oi
9. SERVICE MANUAL Koala permobil How to contact Permobil Permobil Inc 300 Duke Drive Lebanon TN 37090 PH 800 736 0925 FAX 800 231 3256 info 9 permobil com Head Office of the Permobil group Permobil AB Box 120 861 23 Timr Sweden Tel 46 60 59 59 00 Fax 46 60 57 52 50 E mail info permobil com Produced and published by Permobil AB Sweden Edition no 5 2006 01 Article no 201164 US 0 Contents Contents DE OC d e EE 5 Helle ici tele e EE 5 NU NN em 5 UE e EI EE 5 Maintenance src Ernte TE FF NA 5 Data Plates SY NF RF RR FF FN NN 6 AMA sio A DOG O a 6 Pilot Motor Controller GG GYG RG CL LC YY YF yd 6 BONO Dame ne ee UNT 6 Operating the seat elevator manually ccccccococccnconccccnnonnnnnncnnnnns 7 ON O E E Eed de 8 SSES 9 Drive WHBB S cio in 10 Brake release cables anno LYFR Y FF Y Y nennen 11 Brake release eensor uu LG HH LL GL GL CGG FFR GG FRY Y nennen 11 Magnetic brakes nenne nnnnn nenn nennen nenn nenne nenne nennen 12 Drive motore uu LG GG LG GG GL RG nun A RG e emere remesas 13 Seat elevator uu LL LL GL LL FF FF Lu 18 A E 18 Sa o a Y FR NF FN FFF A 19 olde DEAN CN 19 Pilot Motor Controller uu A Rmi 20 SLS drive stage seat function board 00 21 Control Danel un eI HN RO de ose en 22 Seat control panel Ye Oe NF FFR RE EYN NEF FFRED 22 Circuit breaker and fuses uu LI LL FF Wd 23 Circuit DFOAKOF ca ae TWRF HYNN 23 Charge TUSE A A o o EE NR
10. aker Put the circuit breaker to the OFF position AN WARNING Check that the cables are fully secure 8 Attach the new circuit breaker with the two screws see fig 53 AN WARNING Check the orientation of the circuit breaker The ON OFF positions must agree with the label 9 Connect the battery positive lead 10 Fit the battery cover and chassis cover see page 8 11 Put the circuit breaker to the ON position see fig 52 Fig 52 Circuit breaker 63A Off On Fig 53 Circuit breaker 63A 23 Fig 54 Circuit breaker electrical connections Circuit breaker and fuses Changing the charge fuse The charge fuse is on the underside of the chassis above the right rear wheel beside the circuit breaker see fig 55 Switch off the circuit breaker and the charger if in use before you change the charge fuse The circuit breaker must be in the ON position during charging Changing the seat lights fuse There are two fuses in the SLS driver stage F1 unswitched and F2 switched These protect two free outlets which are located beside the SLS driver stage One of the outlets unswitched supplies power irrespective of whether the chair is switched on or off The other outlet switched supplies power only when the chair is switched on Fuse F2 protects the seat and lights 1 Remove the seat lift cover and chassis cover see page 8 2 Pull the lid off
11. ead diameter is no less than 1 5 inches 38 mm to ensure that the rim is fully seated upon the motor Key DIN 6885A 6x6x16 Key DIN 6885A 6x6x22 Hubcap NB Hitting too hard with a rubber mallet could cause damage to the gear 5 Mount the three washers 1 and 2 onto the bolt 3 and secure the wheel Use a torgue Fig 15 Wheel attachment wrench to tighten the bolt to 24 ft Ibs 33Nm Install the hub cap 6 See Fig 14 NB The washer 1 should be placed with the most flat side inwards NB The bolt must be used once only Removed bolt is not allowed to be refitted AN WARNING Warning Other types of bolts or washers are not to be used AN WARNING Warning Do not use any other type of thread lock 10 Brake release cables Brake release cables Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 2 Remove the battery cover and chassis cover see page 8 3 Remove the brake release mechanism it is attached by two bolts see fig 16 4 Slacken the locknut see fig 17 2 5 Screw the adjusting screw fully in see fig 17 1 6 Detach the cable at the magnetic brake and brake release mechanism Fitting 1 Attach the cable to the brake release mechanism then to the magnetic brake Fig 16 The brake release mechanism is attached by two bolts 2 Adjust the length of the cable sleeve using the adjusting screw 17 1 so that
12. ged and the existing seat function board is moved to the new box Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 2 Switch off the main switch on the control panel 3 Put the circuit breaker to the OFF position see page 23 fig 52 4 Remove the seat lift cover and chassis cover see page 8 5 Pull the lid off the box that contains the SLS driver stage and actuator control board see fig 45 6 Remove the box that contains the SLS driver stage and actuator control board it is attached by two screws from underneath see fig 46 Seat function board 7 Remove the electrical connectors from the actuator control board note their locations for refitting 8 Remove the board from the box it is attached by four plastic clips see fig 47 SLS driver stage 9 Cut off the tie that holds the cable 10 Disconnect the electrical connectors from the SLS driver stage note their locations for refitting Fitting Fitting is the reverse procedure SLS driver stage 4 Actuator control board er Fig 45 The box containing the SLS driver stage and the actuator control board is mounted on the left side of the chassis and the actuator control board is attached by two screws from underneath Fig 47 The actuator control board is attached by four plastic clips Control panel Control panel Removal 1 Switch off the main power switch on the cont
13. ift mechanism you can raise the seat by using a cable part number 308515 00 0 1 Disconnect the connector in the lift mechanism cable You can get to it from underneath beside the rear fixing of the lift mechanism see fig 4 2 Connect the cable to the lift mechanism and a battery or other voltage source not exceeding 24 VDC An ordinary 12V car battery is sufficient to operate the seat lift on a temporary basis If you do not have a cable for emergency operation or the lift mechanism is faulty you can raise the seat manually 1 Remove the cushion from the seat 2 Remove the seat plate it is attached by three bolts see fig 5 3 Remove the front from the lift mechanism see fig 6 fixing The seat is heavy Exercise caution when the bolt is removed 4 Lift the seat manually to its highest position lock the seat in the upper position using the safety stop See fig 7 NE A Fig 6 Lift mechanism front fixing Operating the seat lift manually Fig 4 Connecting the cable for emergency operation Fig 5 The seat plate is attached by three bolts Fig 7 Seat lift safety stop Covers Covers Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 2 Unscrew the two knobs that hold the front edge of the battery cover see fig 8 3 Lift the battery cover at the front edge and move it backwards Disconnect the connector in
14. ng is to be changed 2 Deform the bearing by driving a drift through the hole in the bearing seat see fig 41 Pull out the deformed bearing using pliers 3 Clean the bearing seat and press or carefully drive in the new bearing Turn the bearing so that the slot is aligned with the hole used when deforming the bearing in order to make the next bearing change easier Fig 41 Hole for deforming the bearing 4 Refit the part with the new bearing 19 Pilot Motor Controller Pilot Motor Controller Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 Switch off the main switch on the control panel 3 Put the circuit breaker to the OFF position see page 23 fig 52 4 Remove the seat lift cover and chassis cover see page 8 5 Lift the Pilot Motor Controller out of its holder see fig 42 43 Fig 42 The Pilot Motor Controller sits in its holder without any fixings 6 Disconnect the electrical connectors from the output stage note their locations for refitting see fig 44 Fitting Fitting is the reverse procedure Fig 44 Electrical connectors for the Pilot Motor Controller 20 SLS driver stage amp Actuator control board The SLS driver stage and seat function board are mounted in the same box When changing the seat function board a new board is fitted into the existing box When changing the SLS driver stage the entire box is chan
15. ove the front battery see page 9 8 Raise the relevant side of the chair using the Permojack or raise the chair on blocks 9 Remove the drive wheel on the relevant side the wheelchair see page 10 10 Remove the three bolts holding the motor Fitting Fitting is the reverse procedure When fitting a new motor use the cable mounting from the old motor 17 Drive motor Fig 34 Removing the drive motor Seat lift Seat lift Actuators Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 2 Switch off the main switch on the control panel 3 Put the circuit breaker to the OFF position see page 23 fig 52 4 Remove the battery cover and chassis cover see page 8 5 Remove the seat cushion and seat plate see fig 35 6 Remove the seat lift actuators front fixing bolt see fig 36 The seat is heavy Exercise caution when the bolt is removed 7 Lift the seat manually to its highest position Ensure that the safety stop is in place see fig 37 8 Disconnect the connector in the seat lift actuator cable 9 Remove the seat lift actuator rear fixing bolt see fig 38 Fitting Fitting is the reverse procedure E Le Ze En mn e kel 1 KH ie RR Mn Gr et a bereet Bag e a Fig 37 Seat lift safety stop 18 Seat lift Gas springs There are gas springs built into the parallel tubes at the sides of the
16. rol panel 2 Put the circuit breaker in the OFF position see page 23 fig 52 3 Disconnect the control panel cable by pulling the connector at the rear of the control panel straight backwards 4 To remove the control panel remove the screws holding the common bracket for the control panel and Seat control panel see fig 48 Remove the control panel bracket by removing the two screws on the rear of the control panel see fig 49 Fitting Fig 48 The Control panel and Seat control panel bracket Fitting is the reverse procedure Seat control panel Removal 1 Switch off the main power switch on the control panel 2 Put the circuit breaker in the OFF position see page 23 fig 52 3 Remove the cover of the Seat control panel by pulling it straight upwards If the lid is stuck you can carefully use a screwdriver to pry between the lid and the lower part of the end of the box see fig 50 4 You can now lift the circuit board and cable out of the box 5 Disconnect the cable from the circuit board by pulling the connector straight upwards see fig 51 6 To remove the control panel remove the screws holding the common bracket for the control panel and Fig 49 The Control panel and Seat control panel see fig 48 Remove the Seat Seat control panel fixings control panel bracket by removing the two screws on the underside of the box see fig 49 Note the position of the bracket for refitting
17. rse procedure Fig 13 Remove the spacer plate from the battery compartment by pulling it straight upwards Drive wheels Drive wheels Removal 1 Switch off the main switch 2 Lift up the chair and support it on blocks so that the wheels are off the ground 3 Undo and remove the hubcap 6 bolt 3 and the three washers 1 and 2 see fig 15 4 Pull the wheel off the shaft Use puller 304103 99 0 if the wheel is tight see fig 14 Fitting Fig 14 Puller 304103 99 0 1 Check the axle and rim for any damage If necessary you should clean these parts of dirt and rust If any parts are damaged they should be replaced lt M 2 Check that the key fits solidly in the keyway of the axle If necessary install the new key 4 or 5 and check for fit 3 Lubricate the shaft with a thin layer of copper paste Wurth 0893800x Art no 1820540 III SS SSS L SS SN N S VU a Y S Ya zz Sd AN WARNING Warning Do not use any type of lubrication in the mwn threaded hole in the axle or on the bolt ZZ i Washer 8 HB 305 Fe Zn 5 C2 TBRSB 8 4x26x5 Shim washer DIN 988 8 A2 DB 8x14x0 5 Rosttri Bolt ISO 4762 M8x25 10 9 Fe Zn 5 C2 Locking coat DIN 267 28 If necessary you should clean these parts f A 4 Fit the wheel onto the axle The use of hand force only is preferred but if need be carefully use a rubber mallet whose h
18. the box that houses the SLS driver stage see fig 56 3 Change the blown fuse see fig 57 4 Put the lid back on the box 5 Refit the covers see page 8 N WARNING c c Ei FI Fig 56 The box containing the SLS driver stage and the actuator control board is mounted on the left side of the chassis GOOD SKY CAR SH 124D AQ 12VDC 30A Fig 57 F1 24V unswitched 15A F2 24V switched 15A Seat Lights 24 Troubleshooting Troubleshooting Battery voltage indicator The battery voltage indicator shows the status of the wheelchair Steady Display Everything is working correctly Flashing slowly The batteries need to be charged Flashing guickly Fault signal A fault has occurred and the wheelchair can not be driven Fault signals The number of flashing lights indicates the fault Note the number of flashing lights Switch off the chair Switch the chair back on lf the fault is still there count the number of flashing lights then look up the possible cause and action in the table below 009090909900999990909099090900990000990909009909000909900009099900090990909009090000009000090909090009909000990990000009909009909000090009090909009090000992099000099099000990990000999900900099009909090909000990000990000090990900900909000090900000909000090909009009990000990000099990 D D D 000000990090000099090900000000090900000000900000000900000000909099000000009900000000900000
19. tor electrical connectors see fig 19 7 Pull the cable sleeve forwards and take the cable out through the slot in the cable mounting Unhook the brake release cable from the magnetic brake see fig 20 8 Raise the relevant side of the chair using the Permojack or raise the chair on blocks 9 Remove the drive wheel on the relevant side see page 10 10 Remove the three bolts that hold the drive motor see fig 21 Fig 19 The magnetic brake and drive motor electrical connectors Fig 20 Remove the brake release cable Fig 21 Drive motor fixing bolts Magnetic brake 11 Lift up the rear end of the drive motor to make it easier to remove the magnetic brake see fig 22 Fig 22 Lifting up the rear end of the motor makes the magnetic brake more accessible 12 Remove the three bolts that hold the brake see fig 23 Note the position of the brake release arm and rubber seal for refitting Remove the brake complete with the disc and cover Fig 23 Magnetic brake fixing bolts 13 Magnetic brake Fitting 1 Use the adjusting screws to adjust the magnetic brake Set both screws flush with back surface of the brake then turn the screws downwards 1 8 turn see fig 24 2 Fitthe brake disc into the magnetic brake 3 Fitthe cover 4 Insert a bolt 26 1 to align the parts Fig 24 Use the two adjusting screws to adjust the brake Fig 25 Magnetic brake brake disc co
20. ver and rubber seal removed 14 Fig 26 Use a bolt 1 to align the parts Magnetic brake 5 Fit the rubber seal with the drainage hole at the bottom Note the position of the brake release arm fit the brake so that the brake release arm is aligned with motor cable mounting Secure the magnetic brake using the three bolts 6 Refit the drive motor see fig 21 on page 12 7 Refit the drive wheel see page 10 Fig 27 Use one of the bolts to align the parts with one another Fit the rubber seal 8 Fit the brake release cable see fig 28 Fig 28 Fit the brake release cable 9 Connect the magnetic brake and drive motor electrical connectors see fig 29 10 Fit the battery cover and chassis cover see page 8 Fig 29 Magnetic brake and drive motor electrical connectors 15 Drive motor Drive motor Removal 1 Raise the seat to its highest position To operate the seat lift manually see page 7 Switch off the main switch on the control panel 3 Put the circuit breaker to the OFF position see fig 30 4 Remove the battery cover and chassis cover see page 8 5 Disconnect the drive motor and magnetic brake electrical connectors see fig 31 6 Pull the cable sleeve forwards and take the cable out through the slot in the cable mounting Unhook the brake release cable from the magnetic brake see fig 32 Fig 32 Disconnect the brake release cable 16 7 Rem
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