SERVICE MANUAL Playman/Robo
Contents
1. Fig 3 Control panel identification number Seat lift release If the seat lift cannot provide elevation in a normal manner due to discharged batteries or a broken actuator the seat can instead be lifted forward manually 1 Remove the plug located on the left side of the cover see fig 4 2 Unscrew the actuator until it is loose using a long allen key 10mm see Fig 5 Fig 6 shows the actuator s base with the cover removed NOTE Block the seat up in front before loosening the screw The seat is heavy and can fall forwards 3 Carefully lower the seat forwards NOTE Make sure that the wiring is not stretched too tightly 4 Detach the seat lift cover see page 8 5 Remount the actuator Seat lift release k te aa SA gt in Se Fig 5 Seat lift release Covers Covers Removal 1 Run the seat up to its uppermost position To manually raise the seat see page 7 2 Remove the seat lift cover by lifting it straight up It is mounted with hooked pile fabric belts Fig 7 The seat lift cover can be lifted straight up 3 Then loosen the chassis cover which is mounted using four screws See fig 8 NOTE Be careful when removing the chassis cover A chassis equipped with lights has the wiring for its rear lights fastened to the electronics Separate the wiring for the rear lights at the contact located on the wiring Fig 8 The chassis cover is mounted using four sc2. Make sure the joystick isn t actuated at switch Fault in the control panel on change the control panel Check the condition of the battery Check the connection between the battery and the control unit D 2 00000000000000000008 Distribution Chart I I al UMCT I 91 YING I E psy I I I I UMD a SIT 9 l A peg a Nl sl I BEDUG ol o I x wo o I UMO I 59 SCH 32919 a SL WIY AO FINIOWYW AO LSACT OL AOLIINNOS SNOLLYS NNWHIOD la a it i i i i sr e 19 63 24v Oulput Unswitched Power out Power in F J 3 R blink On Of J SLS 24V Llight nal JLL cc a a a ep a AA Extra speed low r P0000 9496 a D Red Brow fe 9496 aa L UL Brake release Switch 7120 E E D lt i g no 2497 3171021329 Ol xH SOLE NGO 30 MIIA SH YOLJINKOD SOIL SING AOD Pila Motor Q 934 O Q Q Q SW4 SW3 6094
3. MEMBRANSWITCH 6061 3 SW2 24V MEMBRANSWITCH ACTUATOR CONTROLLER 5954 10 N um gt N Not Ynna Ku a a FLY ASL Pn Dn JAWS Od AIL YE 3ALYOIN YOLOW On mmm JA LSOd YOLOW 3AlLYSDIN 31749 w IAILISOd 3328 37 O3INOO3O MIA POLLOS IV OSCH W ONY LW STIV13q NOILDINNOD AOLOW SCT OYINOD JO MBIA MOUDA IF 9NDOQ1 SIIY13G NOILOINNOD Adili ya 24 Distribution Chart 3 LB LZ 8 Relay board 7131 Rey A A 24 a m ram QQ Motor left MO Brake left Brake left Pilot Motor left otor Controller 9393 Battery input Battery input Motor right Brake right MI Brake right Motor right lt SES o 2 EEES Brown A iole 24 m no no a na T O 1 CH AAN rt Si V HRS w o L Brow Brown Rod Blue j ed 3 Orange Blink gt 36 ae Cable 3475 flown j Right Front Light la N i St lt gt O O O gp Right Front Blinkers PAY RIAS j Light Blink Brown o i Left Front Light Pink light 9 Red S946 Right Lights 3047 Left Lights 3047 ES 3 Left Front Blinkers AA ca UL A a a a a ta em ia _ Seat elevator stop I Tera Half speed Actuator Inhibit driving I I jara Red Black e Blas Orang Gree a ne no a no ne I I I Actuator I Control I I I I I I I I r I l I I I I I I I Blue I I I l I I I I I I I I l I I L u pn U SO U U U U U E U T U J uU uU U U T u U Ha U U U u U HOS
4. 7 2 Switch off the power using the control panel 3 Put the circuit breaker in the OFF position see page 20 4 Remove the seat lift and chassis covers see page 8 5 Lift up the SLS box which is sitting loose in its holder see fig 34 1 3 Fig 35 Electrical connections for 6 Pull the cover off the box the Power Pilot Cut away the wiring bundle tie holding the cables and loosen the electrical connections Pay attention to the placement of the contacts with an eye towards later remounting 8 Detach the circuit board from the case by loosening the two fastening screws in the middle of the card Fixings in the form of plastic clips can also occur Installation Mounting is performed in the reverse order Refer to the diagram on the cover of the SLS box for connections Fig 36 Electrical connections for the SLS Driver 18 Control panel amp Seat control panel Control panel Removal 1 Put the circuit breaker in the OFF position see page 20 2 Disconnect the control panel cable by pulling the connector at the rear of the control panel straight outwards 3 To remove the control panel remove the screws holding the common bracket for the control panel and Seat control panel see fig 37 Remove the control panel bracket by removing the two screws on the rear of the control panel see fig 38 I Fig 37 The Control panel and Installation Seat control panel bracket Installation is the
5. brake then to the release lever 2 Adjust the length of the cable sleeve using the adjusting screw 15 1 so that the cable is tensioned but does not pull the release link 3 Check the operation Operate the release lever to release the brake and check that the wheel can turn 4 Tighten the locknut 15 2 5 Refit the covers ruti WWW bam WUES Fig 15 Brake release mechanism 11 Magnetic brakes Magnetic brakes Removal 1 Raise the seat lift to its highest position see page 7 Switch off the power using the control panel 3 Put the circuit breaker in the OFF position see page 20 4 Remove the battery cover and rear cover see page 8 5 Remove the battery from the side you are working on see page 9 to facilitate removal of the magnetic brake Fig 16 Magnetic brake electrical connection 6 Disconnect the electrical connector from the magnetic brake see fig 16 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 17 Fig 17 Magnetic brake release cable 8 Unscrew the three screws that hold the brake see fig 19 Note the position of the brake release arm for refitting Remove the brake complete with the disc and cover Fig 18 Magnetic brake fixing bolts 12 Magnetic brakes Fitting 1 Use the adjusting screws to adjust the magnetic brake Set
6. count the number of flashing lights then look up the possible cause and action in the table below e D Check the battery and the connections between the battery and control unit Check the connections to the power module If the fault persists change the power module 9 2 300000000000000000008
7. the cable mounting Unhook the brake release cable from the magnetic brake see fig 27 Fig 27 Release cable for magnetic brake 15 Drive motor 8 In order to be able to take the drive motor out the chassis reinforcement on the side concerned must be detached The reinforcement is attached with two screws In order to gain access to the nut on the lower screw the plastic cover located between the reinforcements can be taken out reinforcement 9 Unscrew the three screws holding the motor 10 Turn the motor sideways so that the drive shaft moves freely Then pull the motor straight out NOTE In order to facilitate its extraction push the battery as far back as possible Installation Mounting is performed in the reverse order Fig 30 Removal of drive motor 16 Seat lift actuator The working procedure is the same for both of the seat lift s actuators NOTE However the work for the left actuator can be made easier if the seat is pushed forward manually Make sure when doing so that no cables are stretched too tightly Removal 1 Run the seat lift up to its uppermost position before releasing the seat lift see page 7 2 Detach the seat lift and chassis covers see page 7 Run the seat lift back down again 3 Switch off the power using the control panel 4 Put the circuit breaker in the OFF position see page 20 5 Cut away the wiring bundle ties fastening the wiring for t
8. A EE AAA AA an in Ee Sm am Ir 4 d I H I I I Seat elevator Red Blue Half speed I Actuator N ZOE Black i Blac I ma no nc no I mal Mex n d WA Ki Red UN L Rotate A N ontro Grey Black NE j Seat elevator C N L Brown Grey I I I I A d I d I H I I I AR AHA aa A HEPA AA AA i CG JAG ma Y En H Chorge connector rope 12V 9585 SC J LT Pilot j Control panel 9391 m m m Distribution Chart 25 Notes N Order no 201162 US 0
9. NB 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 Detach the seat lift and chassis covers see page 8 2 Switch off the power using the control panel 3 Put the circuit breaker in the OFF position see fig 41 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 42 NB Note the orientation of the circuit breaker The ON OFF positions must agree with the label 6 Disconnect the cables from the circuit breaker by loosening the screws see fig 43 7 Connect the cables to the new circuit breaker Put the circuit breaker in the OFF position NB Check that the cables are fully secure 8 Attach the new circuit breaker with the two screws see fig 42 NB Check the orientation of the circuit breaker The ON OFF positions must agree with the label 9 Reconnect the battery positive lead 10 Mount the seat lift and chassis covers see page 8 11 Put the circuit breaker in the ON position see fig 46 Fig 41 Circuit breaker Battery isolator Fig 42 Circuit breaker mounts Fig 43 Circuit breaker electrical connections 20 Changing the charge fuse The charge fuse is on the underside of the chassis over the right rear wheel next to th
10. SERVICE MANUAL Chairman Playman Robo Cus gt How to contact Permobil Permobil Inc USA 6961 Eastgate Blvd Lebanon TN 37090 USA Phone 800 736 0925 Fax 800 231 3256 Email info permobilusa com Head Office of the Permobil group Permobil AB Box 120 861 23 Timra Sweden Tel 46 60 59 59 OO Fax 46 60 57 52 50 E mail info permobil se Produced and published by Permobil AB Sweden Edition no 3 2006 01 Article no 201162 US 0 Contents Contents EY CC ON cocina saca losa sce cette AP AN 5 Helle Ee e EEN 5 ec ar u u etic o AA 5 E PE O ae 5 MANT N AMI CE uuu u u lu uu u AA AANGAL akka qanqawanuqawwaqqkuqqawaanakuqqan ha 5 Identification Plates nono no nono nn nnnnnnnnnn 6 E EE 6 Pilot output stage haare en 6 ergeet EE 6 Operating the seat lift manually 7 NS aa 8 Ent AA AA 9 a HO 10 Brake release cables aa 11 Magnetic brakes munu wa nenne nenne nnnnennnnn nenne nnnne nennen 12 Drive MAA a GA AA AD PAO ee ran ran AA ee 15 Seat lift achuator 2 cece ccc ccc ccc cccceccccececcccecuceccucecaucecsuuauceeauaesecseaeeetsueeuereeass 17 Pilot Power Module ccc ccc cc cccccccececcacccecuaccccueaeaeeseneaeueeneaeaeeeeananeneneas 18 SLS drive Stage nee an 18 Control Panel nee ee 19 SEAL CONTE ON Panel un ee ee 19 Circuit breaker and fuses cece ccccccece
11. both screws flush with back surface of the brake then turn the screws downwards 1 1 4 turns see fig 18 Fig 19 Adjusting the magnetic brake using the two adjusting screws 2 Fit the brake disc into the magnetic brake Fig 20 Magnetic brake brake disc and cover removed 3 Fit the cover Fig 21 Magnetic brake brake disc and cover fitted 13 Magnetic brakes 4 Insert a bolt to align the parts Note the position of the brake release arm fit the brake so that it is aligned with the motor s cable mounting Secure the magnetic brake using the three bolts Fig 22 Align the parts with one another using one of the fixing bolts 5 Connect the magnetic brake electrical connector see fig 23 6 Install the brake release cable see fig 24 7 Install the batteries see page 9 8 Install the covers see page 8 Fig 24 Magnetic brake release cable 14 Drive motor Drive motor Removal 1 Raise the seat to its highest position see page 7 Switch off the power using the control panel 3 Put the circuit breaker in the OFF position see fig 25 Remove all covers see page 8 5 Remove the wheel see page 10 Fig 25 Main fuse Battery isolator 6 Disconnect the electrical connectors to the motor and magnetic brake see fig 26 Fig 26 Electrical connections for magnetic brake 7 Pull the cable sleeve forwards and take the cable out through the slot in
12. cecececececcceceucauneacacausceceeeneneneaeneneanes 20 Circuit Preak p AA 20 NTS TSG ee 21 Fuse for seat lights surreal AA NAA BAGA 21 Brake release sensor nennen nen nnnnnn nam nn nn en nn nn nn nenne nennen 22 Seat electronics 22 2 2 0 ccc cccccccceccececcececceccececcecuececaucueaeseeaeceeaeceeaecaenecaesecaeseeaeears 22 Trouble Shooting nennen nnennnnnnnennnnnnnennne nn 23 Distribution Chart ais 25 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 serial 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 Identification Plates Identification Plates Chassis Pilot Power Module Control panel Y Fig 1 Chassis identification number kel ce Dinge PILOT Des 712 e sag a eee ADE DA Pb AH E Fig 2 Pilot output stage identification number
13. e circuit breaker see fig 49 Switch off the main circuit breaker and the charger if in use before you Change the charge fuse NB The circuit breaker must be in the ON position during charging Changing the seat lights fuse There are two fuses in the SLS drive stage F1 24V unswitched and F2 24V switched These protect two outlets located to the left of the SLS drive stage next to the charge socket One of the outlets 24V unswitched supplies power regardless of whether the chair is switched on or off The other outlet 24V switched supplies power only when the chair is switched on The seat and lights are normally connected to this outlet 1 Detach the seat lift and chassis covers see page 8 Switch off the power using the control panel Set the main fuse to the OFF position see page 20 4 Lift up the SLS box which is sitting loose in its holder see fig 45 Pull the cover off the SLS box Replace broken fuses see Fig 46 Put the cover back on the box o ND O Put the SLS box back into its place on the chassis 9 Remount the covers 10 Put the circuit breaker in the ON position see page 20 Circuit breaker and fuses 21 Fig 46 F1 24V unswitched 15A F2 24V switched 15A Seat Lights Brake release sensor amp Actuator control board Brake release sensor Removal 1 Detach the seat lift and chassis covers see page 8 2 Switch off the power using t
14. he actuator 6 Loosen the wiring connections to the actuator s motor see fig 31 Note the placement of the cables with an eye towards their future remounting 7 Unscrew and remove the two screws holding the actuator see fig 32 8 Unscrew and remove the screw holding the clamping ring for the limit switch rod Open the clamping ring and detach it from the actuator see fig 33 1 9 Loosen the screws holding the limit switch kit see fig 33 2 3 10 Draw the actuator out Installation Mounting is performed in the reverse order Seat lift actuator Fig 32 The actuator s base 17 Fig 33 Limit switch kit fastening points Pilot Power Module amp SLS Driver Pilot Power Module Removal 1 Raise the seat to its highest position see page 7 2 Switch off the power using the control panel 3 Put the circuit breaker in the OFF position see page 20 4 Remove the seat lift and chassis covers see page 8 5 Loosen the two screws used to mount the power module see fig 34 2 6 Lift the power module up ANG 7 Loosen the electrical connections to the POWET Fig 34 SLS driver sits loosely in its holder module Pay attention to the placement of the Power Pilot fastened with two screws contacts with an eye towards later remounting see fig 35 Fitting Mounting is performed in the reverse order SLS Drive stage Removal 1 Raise the seat to its highest position see page
15. he control panel 3 Set the main fuse to the OFF position see page 20 4 Detach the brake release sensor s base by loosening the two screws see fig 47 5 Separate the connector in the connection cable Installation Installation is the reverse procedure Seat electronics Actuator Control Board Removal 1 Detach the seat lift and chassis covers see page 8 2 Switch off the power using the control panel 3 Set the main fuse to the OFF position see page 20 4 Detach the case and the actuator control board by unscrewing and removing the two screws see fig 48 Fig 48 Detachment of Actuator control board 5 Loosen all cable connections sitting on the card Take careful note of the placement of the cables with an eye towards their future remounting Installation Installation is performed in the reverse order Fig 49 Detached Actuator control board 22 Trouble Shooting Trouble Shooting 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 quickly 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 If the fault is still there
16. r the positive terminals 3 Mount the electrical connections for the drive motor magnetic brake lights and brake release sensor if they have been disconnected earlier 4 Carefully elevate the seat upwards again mount the base and retighten the lock nut 5 Mount the covers again 6 Switch the main fuse to the ON position see fig 10 Batteries Fig 10 Main fuse Battery isolator Fig 12 Battery connections 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 5 bolt 4 and washers 2 and 3 see fig 14 4 Pull the wheel off the shaft Use puller 304103 99 0 if the wheel is tight see fig 13 Fitting 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 2 Check that the key fits solidly in the keyway of the axle If necessary install the new key and check for fit 3 Lubricate the shaft with a thin layer of copper paste Wurth 0893800x Art no 1820540 AN WARNING Warning Do not use any type of lubrication in the threaded hole in the axle or on the bolt If necessary you should clean these parts 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 head diame
17. reverse procedure Seat control panel Removal 1 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 39 2 You can now lift the circuit board and cable out of the box 3 Disconnect the cable from the circuit board by pulling the connector straight upwards see fig 40 4 To remove the seat control panel remove the screws holding the common bracket for the seat control panel and Seat control panel see fig 37 Remove the seat control panel bracket by Fig 38 The Control panel and removing the two screws on the underside of Seat control panel fixings the box see fig 38 Note the position of the bracket for refitting Installation Installation is the reverse procedure gt Fig 39 Removing the Seat control panel lid Fig 40 The Seat control panel electrical connector 19 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 over the right rear wheel see fig 41 The circuit breaker is protected from dirt and water by a rubber lip which can easily be folded back
18. rews 4 Remove the two front covers Each is mounted with two screws see fig 9 Fitting Mounting is performed in the reverse order Fig 9 Each of the front covers is mounted using two screws Batteries NOTE Wear safety goggles when working with batteries Removal 1 Detach the seat lift cover and chassis cover see page 8 NOTE Be careful when removing the chassis cover A chassis equipped with lights has the wiring for its rear lights fastened to the electronics Separate the wiring for the rear lights at the contact located on the wiring 2 Switch off the power using the control panel 3 Set the main fuse to the OFF position see fig 10 4 Block the front edge of the seat up loosen the seat lifts base by loosening the lock nut see fig 11 Take note of the design of the base with an eye towards the future remounting Carefully lower the seat forward 5 Loosen the battery connections The positive terminals first and thereafter the negative terminals 6 In order to gain access to the battery more easily the electrical connections for the drive motor magnetic brake lights and brake release sensor can be loosened Note the placement of the cables with an eye towards future remounting 7 Lift the batteries out Install 1 Seat your two new batteries The battery terminals must be located towards the rear 2 Mount the battery connections first the negative terminals and thereafte
19. ter is no less than 1 5 inches 38 mm to ensure that the rim is fully seated upon the motor NB Hitting too hard with a rubber mallet could cause damage to the gear 5 Put the washers 2 and 3 onto the bolt 4 and tighten the wheel see fig 14 Use a torque wrench to tighten the bolt to 18 ft lbs Install the hub cap 6 see Fig 14 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 Fig 13 Puller 304103 99 0 Ta SC ee E SSN J N N Na Gu Zoe EE Es Ka oss E ast A _ A a a 1222262226 ANNO ow as Front wheel Washer TBRSB 8 4x26x5 Washer Nordlock M8x16 6 glued Bolt Eslock MC6S M8x35 Hubcap Fig 14 Wheel attachment Brake release cables Brake release cables The upper cable controls the right brake unit and the lower cable controls the left brake unit Removal Raise the seat lift to its highest position see page 7 Remove the battery and seat lift covers see page 8 Loosen the locknut see fig 15 2 Screw the adjusting screw fully in see fig 15 1 oP N gt Detach the cable at the magnetic brake and brake release mechanism Fitting 1 Attach the cable to the magnetic
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