Permobil Koala Manuel utilisateur

SERVICE MANUAL

Koala

Produced and published by Permobil AB, Sweden

Edition no.5, 2006-01

Article no.: 201164-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: [email protected]

Permobil AB

Box 120, 861 23 Timrå, Sweden

Tel: +46 60 59 59 00. Fax: +46 60 57 52 50

E-mail: [email protected]

Contents

Introduction.................................................................................................. 5

Technical support...................................................................................... 5

Spare parts ............................................................................................... 5

Warranties ................................................................................................ 5

Maintenance ............................................................................................. 5

Data Plates ................................................................................................... 6

Chassis..................................................................................................... 6

Pilot Motor Controller................................................................................ 6

Control panel ............................................................................................ 6

Operating the seat elevator manually ....................................................... 7

Covers........................................................................................................... 8

Batteries ....................................................................................................... 9

Drive wheels............................................................................................... 10

Brake release cables ................................................................................. 11

Brake release sensor................................................................................. 11

Magnetic brakes......................................................................................... 12

Drive motors............................................................................................... 13

Seat elevator .............................................................................................. 18

Actuators ................................................................................................. 18

Gas springs ........................................................................................... 19

Slide bearings ........................................................................................ 19

Pilot Motor Controller................................................................................ 20

SLS drive stage & seat function board ................................................... 21

Control panel.............................................................................................. 22

Seat control panel ..................................................................................... 22

Circuit breaker and fuses ......................................................................... 23

Circuit breaker ........................................................................................ 23

Charge fuse ............................................................................................ 24

Fuse for seat/lights ................................................................................. 24

Troubleshooting......................................................................................... 25

Distribution chart....................................................................................... 26

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.

Data plates

Chassis

Rating plates

Control panel

Pilot Motor Controller

Fig. 1. Chassis identification number

Fig. 2. Pilot Motor Controller identification

number.

Fig. 3. Control panel identification number.

Operating the seat lift manually

Fig. 4. Connecting the cable for

emergency operation.

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 lift 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 fixing from the lift

mechanism, see fig. 6.

4. Lift the seat manually to its highest position,

lock the seat in the upper position using the

safety stop. See fig. 7.

Fig. 5. The seat plate is attached by three bolts.

Fig. 6. Lift mechanism front fixing. Fig. 7. Seat lift safety stop.

The seat is heavy. Exercise caution when the

bolt is removed.

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 the cable to the anti-trap mechanism before

you lift the cover off completely, see fig. 8.

4. Remove the chassis cover. It is held by two

screws at the front edge and two on either

side, see fig. 9-10.

Fitting

Fitting is the reverse procedure.

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

Use caution when you remove the battery

cover. The anti-trap mechanism cable is

attached to the electronic unit.

Batteries

Removal

1. Put the 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.

6. Disconnect the battery leads, positive

terminals first, see fig. 12.

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 reverse procedure.

Off

Fig. 11. Circuit breaker/Battery isolator.

Fig. 12. Battery connections.

Fig. 13. Remove the spacer plate from the battery

compartment by pulling it straight upwards.

Use caution when you remove the battery

cover. The anti-trap mechanism cable is

attached to the electronic unit.

Use protective goggles when working on

batteries.

Drive wheels

Fig. 14. Puller 304103-99-0.

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

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 (4 or

5) and check for fit.

3. Lubricate the shaft with a thin layer of copper

paste (Würth 0893800x, Art. no.: 1820540).

Fig. 15. Wheel attachment.

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. Mount the three washers (1) and (2) onto the

bolt (3) and secure the wheel. Use a torque

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.

1. Washer, 8 HB 305 Fe/Zn 5 C2 (TBRSB 8,4x26x5)

2. Shim washer DIN 988 8 A2 (DB 8x14x0.5 Rostfri)

3. Bolt, ISO 4762 M8x25 10.9 Fe/Zn 5 C2 /

Locking coat DIN 267-28

4. Key DIN 6885A 6x6x16

5. Key DIN 6885A 6x6x22

6. Hubcap

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