SERVICE MANUAL
Chairman
US
Produced and published by Permobil AB, Sweden
Edition no. 2, 2006-01
Article no.: 201166-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, Sweden
Tel: +46 60 59 59 00. Fax: +46 60 57 52 50
E-mail: info@permobil.se
Contents
4
Contents
Introduction.................................................................................................. 5
Technical support...................................................................................... 5
Spare parts ............................................................................................... 5
Warranties ................................................................................................ 5
Maintenance ............................................................................................. 5
Identification plates ..................................................................................... 6
Chassis..................................................................................................... 6
Pilot+ output stage.................................................................................... 6
Control panel ............................................................................................ 6
Operating the seat elevator manually ....................................................... 7
Covers........................................................................................................... 8
Batteries ....................................................................................................... 9
Drive wheels............................................................................................... 10
Brake release cables ................................................................................. 11
Magnetic brakes......................................................................................... 12
Drive motors............................................................................................... 15
Seat lift........................................................................................................ 16
Seat lift cables ........................................................................................... 18
Seat lift motor ............................................................................................ 19
Seat lift drive belt....................................................................................... 20
Changing the seat lift drive belt.............................................................. 20
Adjusting the belt tension ....................................................................... 20
Pilot+ output stage .................................................................................... 21
SLS drive stage.......................................................................................... 21
Control panel.............................................................................................. 22
Seat control panel ..................................................................................... 22
Circuit breaker and fuses ......................................................................... 23
Circuit breaker ........................................................................................ 23
Charge fuse ............................................................................................ 23
Fuse for seat/lights ................................................................................. 24
Brake release sensor ................................................................................ 24
Troubleshooting......................................................................................... 25
Distribution chart....................................................................................... 27
5
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.
Introduction
6
Identification plates
Fig. 1. Chassis identification number
Fig. 2. Pilot+ output stage identification number.
Fig. 3. Control panel identification number.
Identification plates
Chassis
Pilot+ output stage
Control panel
7
Fig. 4. Use the seat elevator crank to
raise the seat.
Operating the seat elevator manually
Fig. 5. Fixed seat post.
1
2
Operating the seat elevator
manually
Electric seat elevator
If the seat elevator will not move normally because
the battery is flat or the adjusting mechanism is
broken.
1. Remove the cushion and plastic plug from
the seat.
2. Raise/lower the seat using the seat elevator
crank supplied, see fig. 4.
Fixed seat post
1. Remove the cover and plastic plug from
the seat.
2. Loosen the seat tube clamp screw (5:2).
3. Crank up the seat using the seat elevator
crank supplied, see fig. 4.
4. Lower the seat and turn it so that the locating
screw (5:1) seats in its groove.
5. Tighten the seat tube clamp screw.
Torque: 11 ft.Ib.
Warning! Using a drilling machine during the
manual operation of the seat lift is not allowed.
There is a risk of material damage.
Fig. 7. The front cover is attached by two
screws at the front edge.
Fig. 6. Chassis cover attachment points.
8
Covers
Removal
1. Raise the seat to its highest position.
2. First remove the rear battery cover, which is
fitted with two handles on each side.
Disassembly is facilitated if the brake release
lever is moved to the forward position.
3. Remove the rear cover, it is attached by five
screws. Unscrew the rubber pads on the seat
support. Disconnect the rear light cable at the
connector in the cable.
4. Remove the seat lift cover, which is fitted with
two plastic plugs on the upper side of
the chassis.
5. Remove the front battery cover, which is
secured by two screws on the upper side of
the chassis.
6. Remove the front cover, it is attached by two
screws on the front edge.
Fitting
Fitting is the reverse procedure.
Covers
A
B
D
E
A. Front cover
B. Seat elevator cover
C. Front battery cover
D. Rear battery cover
E. Rear cover
C
9
Batteries
Batteries
NB! Use protective goggles when working on
batteries.
Removal
1. Put the wheelchair on a level surface.
2. Raise the seat. To raise the seat manually,
see page 7.
3. Put the circuit breaker in the “OFF” position,
see fig. 8.
4. Remove the battery covers and rear cover,
see page 8.
NB! Take care when removing the rear cover; the
rear light cable is attached to the electronic unit.
5. Disconnect the battery leads, positive
terminals first.
6. To make access to the battery easier, you can
also disconnect the electrical connections for
the drive motor, magnetic brake, lights and
brake release sensor. Make a careful note of
the location of the cables for reconnection.
7. Lift out the batteries.
Fitting
1. Lift the batteries into position, with the poles
at the back, see fig. 9.
2. Attach the electrical connections for the drive
motor, magnetic brake, lights and brake
release sender, if you disconnected
them earlier.
3. Reconnect the battery leads, negative first.
4. Refit the covers.
5. Put the circuit breaker in the “ON” position,
see fig. 8.
6. Lower the seat. For manual lowering,
see page 7.
Fig. 9. Battery connections
Fig. 8. Circuit breaker/Battery isolator.
ON
OFF
10
Drive wheels
5
4
3
2
1
Fig. 11. Wheel attachment.
1. Front wheel
2. Washer, TBRSB 8.4x26x5
3. Washer, Nordlock M8x16.6, glued.
4. Bolt, Eslock MC6S M8x35
5. Hubcap
Fig. 10 Puller 304103-99-0.
Warning! Other types of bolts or washers are not
to be used..
Warning! Do not use any other type of thread lock.
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
diameter 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. 11.
Use a torque wrench to tighten the bolt to
18 ft-Ibs. Install the hub cap (6), see Fig. 11.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.
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. 11.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight, see fig. 10.
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 (Würth 0893800x, Art. no.: 1820540).
11
Brake release cables
Fig. 12. Brake release mechanism.
1
2
Brake release cables
The upper cable controls the left brake unit and the lower cable controls the right brake unit.
Removal
1. Make sure the brakes are engaged.
2. Raise the seat elevator to its highest position.
3. Remove the battery and seat elevator covers, see page 8.
4. Slacken the locknut, see fig. 12:2.
5. Screw the adjusting screw fully in, see fig. 12:1.
6. Detach the cable at the magnetic brake and brake release mechanism.
Fitting
1. Attach the cable to the magnetic brake, then to the release lever.
2. Adjust the length of the cable sleeve using the adjusting screw (12:1), so that the cable is tensioned
but does not pull the brake release arm.
3. Check the operation. Operate the release lever to release the brake and check that the wheel can turn.
4. Tighten the locknut (12:2).
5. Refit the covers.
12
Fig. 14. Magnetic brake release cable.
Magnetic brakes
Removal
1. Raise the seat elevator to its highest position.
2. Switch off the main switch on the control panel.
3. Put the circuit breaker in the “OFF” position,
see page 23.
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.
6. Disconnect the electrical connector from the
magnetic brake, see fig. 13.
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. 14.
8. Unscrew the three screws that hold the brake,
see fig. 15. Note the position of the brake
release arm for refitting. Remove the brake,
complete with the disc and cover.
Magnetic brakes
Fig. 13. Magnetic brake electrical connection.
Fig. 15. Magnetic brake fixing bolts.
13
Fitting
1. Fitting new brakes, use the adjusting screws to
adjust the magnetic brake, as described in the
instructions on the back of the magnetic
brake, see fig. 16.
2. Fit the brake disc into the magnetic brake.
3. Fit the cover.
Magnetic brakes
Fig. 16. Adjusting the magnetic brake
using the two adjusting screws.
Fig. 17. Magnetic brake, brake disc
and cover removed.
Fig. 18. Magnetic brake, brake disc
and cover fitted.
14
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 motor’s cable mounting. Secure the
magnetic brake using the three bolts.
5. Connect the magnetic brake electrical
connector, see fig. 20.
6. Fit the brake release cable, see fig. 21.
7. Fit the batteries, see page 9.
8. Fit the covers, see page 8.
9. Put the circuit breaker in the “ON” position,
see page 23.
Magnetic brakes
Fig. 20. Magnetic brake electrical connector.
Fig. 19. Align the parts with one another using
one of the fixing bolts.
Fig. 21. Magnetic brake release cable.
15
Drive motor
Removal
1. Raise the seat to its highest position.
2. Switch the main power breaker off.
3. Put the circuit breaker in the “OFF” position,
see fig. 22.
4. Remove the battery cover and front cover,
see page 8.
5. Remove the battery on the side concerned,
see page 9, to facilitate removal of the motor.
6. Raise the relevant side of the chair on blocks.
7. Remove the wheel, see page 10.
8. Disconnect the electrical connectors to the
motor and magnetic brake, see fig. 23.
9. 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. 24.
Fig. 23. Magnetic brake and drive motor
electrical connectors.
Drive motor
Fig. 24. Magnetic brake release cable.
Fig. 22. Circuit breaker/Battery isolator.
On
Off
16
10. Remove the three bolts holding the motor.
11. Turn the motor sideways to free the wheel shaft.
Pull the motor straight forwards.
Fitting
Fitting is the reverse procedure.
Seat lift
Removal
1. Raise the seat using the accompanying seat
lift crank, see page 7. Raise the seat until it will
not go any higher while you crank, i.e. the seat
lift is “not engaging”.
2. Switch off the main power switch on the
control panel.
3. Set the main fuse to the “OFF” position,
see page 23.
4. Detach the seat lift and chassis covers,
see page 8.
5. Clip off the wiring bundle tie mounted on the
cabling between the seat and the chassis.
6. Loosen the seat lift motor's cable connection,
pay attention to the placement of the cables
for purposes of later remounting, see page 21.
7. Lift out the seat, place it on its side next to the
chassis, see Fig. 27.
NB! The seat is heavy, hence there should be two
people to do this. Be careful with the cabling
8. Unscrew and remove the two screws on the
seat lift's upper fastener, see fig. 27:1.
9. Remove the two screws on the seat lift's lower
fastener, see fig. 27:2.
Drive motor
Fig. 25. Drive motor mounting bolts.
Fig. 26. Removing a drive motor.
Fig. 27. Lift out the seat.
2
1
17
Seat lift
Fig. 31. Seat without seat tilt, the upper part of
the seat lift is mounted with four screws.
Fig. 28. The seat plate is mounted with two screws.
10. Detach the seat lift by drawing it straight up.
11. Clip off the wiring bundle tie holding together the
seat lift cabling, follow the cabling to its end, and
loosen the contact at the SLS Drive, as well as
the conductor joint located beside the SLS Drive,
prior to detaching the SLS Drive, see page 24.
The upper part of the seat lift is mounted on the
seat and can be detached as described in the
following.
12. Unscrew and remove the two screws holding
the seat plate, see fig. 28.
13. If the seat is equipped with seat tilt, unfasten
the actuator’s front bracket, see fig. 29. Draw
the seat tilt mechanism apart, see fig. 30.
14. Unscrew and remove the four screws holding
the seat lift, see fig. 30 and 31.
Fitting
Fitting is the reverse procedure.
Fig. 29. Unfasten the front bracket on
the seat tilt actuator.
Fig. 30. Seat with seat tilt, the upper part of the
seat lift is mounted with four screws.
18
Seat lift cable
Seat lift cable
Removing
1. Remove the seat lift; follow the instructions on
page 18.
2. Remove the seat lift sensors. Note the position
of the sensors for refitting, see fig. 32-33.
Fitting
Fitting is the reverse procedure.
NB! After fitting, check that the arm of the Lever
switch can move freely.
Fig. 33. Attachment of the
sensors to the seat lift.
1. Screw
2. Lever switch plate
3. Lever switch
4. Insulating plate
5. Seat lift
6. Plate
7. Nut
Fig. 32. Attachment of the
sensors to the seat lift.
42321 567
Seat lift motor
19
Seat lift motor
Removing
1. Remove the seat lift, see page 17.
2. Disconnect the seat lift cable at the motor;
note the position of the connectors,
see fig. 34.
3. Remove the seat lift motor by taking out the
three bolts that hold it, see fig. 34.
Fitting
Fitting is performed in reverse order.
Blue
Blue
Red
Green
Fig. 35. The motor is attached
by three bolts.
Fig. 34. Note the connector colors.
20
Seat lift drive belt
Seat lift drive belt
Removing
1. Remove the seat lift, see page 18.
2. Loosen the two bolts holding the shaft to the
seat lift motor. Push the shaft sideways to
slacken the drive belt.
3. Remove the belt from the motor shaft, then
from the toothed wheel on the seat lift screw.
4. Fit the new belt using the reverse procedure.
5. Adjust the belt tension as described below.
6. Fit the seat lift, see page 18.
Adjusting the belt tension
1. Loosen the two bolts near the belt, see fig. 36.
2. Adjust the belt tension by moving the motor
shaft sideways.
3. Tighten the two screws.
4. Check the belt tension. The belt is correctly
tensioned when it can be pressed in 4 - 5 mm,
see fig. 37.
Fig. 37. The drive belt tension can be adjusted
after the two bolts have been loosened.
Fig. 36. The seat lift shaft is
attached by two bolts.
21
Pilot+ output stage & SLS Drive stage
Pilot+ output stage
Removal
1. Raise the seat to its highest position, see page 7.
2. Put the circuit breaker in the “OFF” position,
see page 23.
3. Remove the battery cover and rear cover,
see page 8.
4. Loosen the knob that holds the cover plate
over the electronics, see fig. 38.
5. Lift up the output stage.
6. Disconnect the electrical connectors from the
output stage, note their locations, see fig. 39.
Fitting
Fitting is the reverse procedure.
Fig. 38. The Pilot+ output stage and SLS drive
stage are under a cover plate.
Fig. 39. Electrical connectors for the
Pilot+ output stage.
SLS Drive stage
Removal
1. Raise the seat to its highest position, see page 7.
2. Put the circuit breaker in the “OFF” position,
see page 23.
3. Remove the battery cover and rear cover,
see page 8.
4. Loosen the knob that holds the cover plate
over the electronics, see fig. 38.
5. Lift up the drive stage.
6. Pull the cover off the drive stage.
7. Cut off the ties holding the cables and
disconnect the electrical connectors, note their
locations for refitting.
8. Take the circuit board out of the box by
removing the plastic clip fixings. There could
be two fixing screws in the center of the board.
Fitting
Fitting is the reverse procedure.
Fig. 40. Electrical connectors for the
SLS drive stage.
22
Control panel
Control panel
Removal
1. Put the circuit breaker in the “OFF” position,
see page 23.
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. 38.
Remove the control panel bracket by removing
the two screws on the rear of the control panel,
see fig. 42.
Fitting
Fitting is the 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, 43
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. 44.
4. To remove the control panel, remove the screws
holding the common bracket for the control
panel and Seat control panel, see fig. 41.
Remove the Seat control panel bracket by
removing the two screws on the underside of the
box, see fig. 42. Note the position of the bracket
for refitting.
Fitting
Fitting is the reverse procedure.
Fig. 41. The Control panel and
Seat control panel bracket.
Fig. 44. The Seat control panel
electrical connector.
Fig. 42. The Control panel and
Seat control panel fixings.
Fig. 43. Removing the Seat control panel lid.
Circuit breaker and fuses
23
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. 45. The circuit breaker is
protected from dirt and water by a rubber lip, which
can easily be folded back.
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. Remove the battery cover and rear cover,
see page 8.
2. Put the circuit breaker in the “OFF” position,
see fig. 45.
3 Disconnect the battery positive lead, which is
between the battery and the circuit breaker.
4. Remove the circuit breaker by removing the
two screws, see fig. 46.
NB! Note the orientation of the circuit breaker.
The ON/OFF positions must agree with the label.
5. Disconnect the cables from the circuit breaker
by loosening the screws, see fig. 47.
6. Connect the cables to the new circuit breaker.
Put the circuit breaker in the “OFF” position.
NB! Check that the cables are fully secure.
7. Attach the new circuit breaker with the two
screws, see fig. 46.
NB! Check the orientation of the circuit breaker.
The ON/OFF positions must agree with the label.
8. Reconnect the battery positive lead.
9. Fit the battery cover and the rear cover,
see page 8.
10. Put the circuit breaker in the “ON” position,
see fig. 45.
Fig. 46. Circuit breaker fixings.
Fig. 47. Circuit breaker electrical connections.
Fig. 45. Circuit breaker/Battery isolator.
On
Off
24
Fuses
Fig. 48. Charge fuse
Changing the charge fuse
The charge fuse is on the underside of the
chassis, over the right rear wheel, next to the
circuit breaker, see fig. 48. Switch off the main
power 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
irrespective 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. Switch off the main switch on the controlpanel.
2. Put the circuit breaker in the “OFF” position,
see page 23.
3. Remove the battery cover and rear cover,
see page 8.
4. Loosen the knob that holds the cover plate
over the electronics, lift up the SLS drive
stage, see page. 21.
5. Pull the lid off the SLS drive stage.
6. Change the blown fuse.
7. Put the lid back on the box.
8. Put the SLS drive stage back in place in
the chassis.
9. Refit the cover plate.
10. Refit the covers, see page 8.
11. Put the circuit breaker in the “ON” position,
see page 23.
Brake release sensor
Removal
1. Put the circuit breaker in the “OFF” position,
see page 23.
2. Remove the battery cover and seat elevator
cover, see page 8.
3. Remove the brake release sensor by
removing the two screws, see fig. 50.
4. Separate the connector in the connection cable.
Fitting
Fitting is the reverse procedure.
F1
F2
Fig. 49. F1 = 24V unswitched 15A.
F2 = 24V switched 15A Seat/Lights.
Fig. 50. Brake release sensor.
25
Troubleshooting
Troubleshooting
Battery voltage indicator
The battery voltage indicator shows the status of the wheelchair.
Permanently on
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, count the number of flashing lights, then look up the possible cause and
action in the table below..
High battery voltage
Break in the brake circuit
Fault in the electronics
Fault in the control panel
Short circuit, right drive motor
Open circuit, right drive motor
Short circuit, left drive motor
Open circuit, left drive motor
Low battery voltage
Check the battery and the connections
between the battery and control Inuit.
Check the connections to the magnetic brake.
Check the connections to the output stage.
If the fault persists, change the output stage.
Make sure the joystick isn’t actuated at switchon, change the control panel.
Check the motor connections and cable.
Check the connection to the right drive
motor. Check whether the drive motor
brushes are worn.
Check the motor connections and cable.
Check the connection to the left drive motor.
Check the condition of the battery. Check the
connection between the battery and the control unit.
CAUSE
ACTION
5
6
7
10
9
8
4
3
2
1
LEDs
Distribution Chart
26
A
B
C
D
E
F
1234
27
Distribution Chart
Distribution chart
A
B
C
D
E
F
5678
Notes
28
Notes
29
Notes
30
Article no.: 201166-US-0
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