Permobil Chairman Basic User manual

SERVICE MANUAL
Chairman Basic
Chassinr. 400 001-
US

3
Contents
Introduction.....................................................................................................3
Technical support.........................................................................................3
Spare parts..................................................................................................3
Warranties....................................................................................................3
Maintenance................................................................................................3
Rating plates ...................................................................................................4
Chairman Basic ...........................................................................................4
Control unit ..................................................................................................4
Raising the seat lift.........................................................................................5
Covers..............................................................................................................6
Removal.......................................................................................................6
Fitting...........................................................................................................6
Changing the batteries...................................................................................7
Removal.......................................................................................................7
Fitting...........................................................................................................8
Changing the drive wheel..............................................................................9
Removal.......................................................................................................9
Fitting...........................................................................................................9
Changing the brake release wires ................................................................10
Changing the magnetic brake .......................................................................11
Removal.......................................................................................................11
Fitting...........................................................................................................12
Changing the drive motor..............................................................................14
Removal.......................................................................................................14
Fitting...........................................................................................................16
Changing the carbon-brush in the drive motor...........................................18
Removal of the carbon-brush......................................................................18
Fitting the carbon-brush...............................................................................19
Changing the seat lift.....................................................................................20
Removal.......................................................................................................20
Fitting...........................................................................................................21
Changing the seat lift motor..........................................................................22
Removal.......................................................................................................22
Fitting...........................................................................................................22
Seat lift belt .....................................................................................................23
Changing the seat lift belt............................................................................23
Changing the control unit..............................................................................24
Removal.......................................................................................................24
Fitting...........................................................................................................26
Fault codes......................................................................................................29
Wiring diagram................................................................................................30

4
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 Pemobil Inc at 800-736-0925
Spare parts
Spare parts must be ordered through your dealer.
The spare parts catalogue for the Chairman Basic chassis is PAB 1224 and is available from Permobil
Inc.
Warranties
The Warranty Manual, PAB 9533, contains information on the current warranties available from
Permobil AB. Warranties for the Swedish market are covered by a supply contract with SUB.
Equivalent contracts for other markets are available from Permobil.
Maintenance
See the information in the Instructions for Use.
Reconditioning
Reconditioning instructions are available from Permobil.
Introduction
Produced and published by Permobil AB, Sweden
Edition no. 1, Jan 1999
Order no: 201064-US-0
PAB nr: 1064:1

5
Rating plates
Chairman Basic
Control unit/
panel
Rating plates
Identity marking
Art. no.
Serial no.
Modification no.
Identity marking
Chassis no.

6
Raising the seat lift
Raising the seat lift manually
If the seat lift cannot be raised in the normal
manner because the batteries are discharged or
the adjustment device is defective, the seat can
be raised manually.
1. Remove the cushion and the seat plate.
2. Raise the seat using the seat lift crank
provided.
Raise the seat with the seat lift crank
Seat tube brace screw
Raising the seat
(Fixed seat tube)
1. Remove the cushion and the seat plate.
2. Loosen the screw for the seat tube brace.
3. Raise the seat using the seat lift crank or pull
the seat up by hand.

7
Cover
Removal
1. Raise the seat to its highest position.
2. Loosen the three plastic knobs which hold
the cover in place.
3. Remove the cover.
Fitting
1. Place the cover on the chassis.
2. Tighten the three plastic knobs which hold
the cover in place.
Cover

8
Changing the batteries
NB. Use protective goggles when working with
batteries.
Removal
1. Raise the seat to its highest position. If the
battery is defective, see Raising the seat lift
on page 6.
2. Remove the chassis cover. It is held in place
by three plastic knobs.
3. Disconnect all battery connections, the
positive poles first and then the negative
poles.
4. Lift out the batteries. Use lifting straps.
Changing the batteries

Battery connections
9
Fitting
1. If the wheelchair is fitted with acid batteries,
check that the battery fluid is at the right level.
2. Insert two new batteries. The battery poles
must be at the front.
3. Connect the battery connections, first the
negative poles and then the positive poles.
NB! The cables must be connected correctly.
4. Replace the chassis cover and set the seat
to the correct height again. Tighten the seat
tube brace.
5. Charge the batteries.
Changing the batteries
+
–+
–
Red cable - Bat +
Red cable - Bat +
Main fuse
Front
Black cable = Bat -
Black cable from main fuse
Red cable from main fuse
Rear
Black cable - Bat -

Removal tool 304103-99-0
10
Changing the drive wheel
Removal
1. Raise and block up the wheelchair's chassis
so that the wheel does not reach the
ground.
2. Loosen and remove the centre screw C, the
washer B and the rim locking washer A (see
the figure at the bottom of the page).
3. Pull the wheel off the axle. Use the removal
tool 304103-99-0 if the wheel cannot be
removed by hand.
Fitting
1. Fit the wheel onto the axle.
2. Fit the rim locking washer A, the washer B
and the centre screw C and tighten to
secure the wheel.
NB! The screw has a locking coating which is
sufficient for refitting 3-4 times. Then the screw
must be replaced with a new one.
Changing the drive wheel

Brake release mechanism
11
Changing the brake release wires
The upper wire controls the left brake unit and the
lower wire controls the right brake unit.
Removal
1. Raise the seat lift to its highest position (use
the crank provided for chairs without a seat
lift).
2. Remove the cover. Move the brake release
lever forwards to its front position to facilitate
removal.
3. Loosen the locking nut (1).
4. Screw the adjusting screw (2) all the way in.
5. Loosen the wire at the magnetic brake and
at the brake release mechanism.
Fitting
1. Fit the wire first at the magnetic brake and
then at the release lever.
2. Adjust the length of the wire sleeve using
the adjusting screw (2) so that the wire is
tensioned but does not pull on the release
clamp.
3. Check that the brake works. Release the
brake with the release lever and check that
the wheel can turn.
4. Refit the cover.
Changing the brake release wires
12

12
Changing the magnetic brake
Removal
1. Raise the seat to its highest position.
2. Remove the chassis cover, which is held in
place by three plastic knobs.
3. Loosen the electrical connection of the
magnetic brake.
4. Detach the brake release wire from the
brake.
5. Unscrew the three screws which hold the
brake and remove the brake with the
extensible cover, brake disc and cover.
6. Note the position of the brake release arm.
Changing the magnetic brake
Electrical connection of the magnetic brake

13
Fitting
1. Check the setting of the brake. Follow the
instructions on the decal on how the two
Allen screws are adjusted.
2. Place the magnetic brake's brake disc in the
brake assembly.
3. Put on the cover.
Changing the magnetic brake

The magnetic brake's electrical connection
14
4. Insert a screw to align the parts and screw
the magnetic brake in place using all three
screws.
5. Attach the magnetic brake's electrical
connection.
6. Fit the chassis cover, see Covers, page 7.
Changing the magnetic brake

MotorMagnetic brake
Fuse holder
15
Changing the drive motor
Removal
1. Raise the seat to its highest position.
2. Remove the chassis cover.
3. Remove the positive pole from one battery.
4. Block up the appropriate side of the
wheelchair.
5. Remove the wheel. See Changing the drive
wheel, page 10.
6. Remove the two screws for the fuse holder
(left motor).
7Detach the electrical connections for the
motor and magnetic brake.
Changing the drive motor

Brake release wire
16
8. Detach the brake release wire from the
magnetic brake.
9. Remove the three screws which hold the
motor.
10. Turn the motor sideways so that the wheel
axle turns freely. Pull the motor straight
forwards.
11. Remove the spacer, which is located
between the motor and the chassis.
Changing the drive motor

Brake release wire
Spacer
17
Fitting
1. If a new motor is to be fitted, the magnetic
brake must be moved from the old motor.
See Fitting a magnetic brake, page 13.
2. Fit the spacer and lift the motor into place.
Turn it a little so that the wheel axle can turn
freely without being obstructed by the
chassis.
3. Screw the motor in place with the three
bolts.
4. Attach the brake release wire.
Changing the drive motor

Motor contactMagnetic brake contact
18
5. Attach the electrical connections for the
motor and magnetic brake.
NB. Ensure that the contacts are fully
interlocking.n
6. Fit the fuse holder with the two screws.
7. Fit the wheel. See page 10.
8. Remove the blocks.
9. Connect the battery poles.
10. Fit the chassis cover.
Changing the drive motor

Changing the carbon-brush
in the drive motor
Removal
1. Remove the drive motor. See page 15.
2. Remove the motor's cables from the
coupling box.
3. Remove the magnetic brake and the
mounting plate.
4. Mark the stator's position against both ends
with a small mark before loosening the nuts.
It is important for the function of the motor
that the parts are assembled precisely
without being moved away from the original
position.
5. Loosen two nuts and pull off the motor end.
Press the cable gland off the motor end.
6. Remove the brush holder completely.
Changing the carbon-brush in the drive motor
Marking
Do not
divide here
19

20
Fitting
1. Fit a new carbon-brush using the fitting ring
provided with the new brush holder. Ensure
that you turn the cables in the same
direction as the outgoing shaft of the gear.
2. Fit the end with two nuts.
Remember the wave washer between the
bearing and the end. Ensure that you
assemble the parts according to the marking
made earlier.
It is important for the function of the motor
that the parts are assembled precisely
without being moved away from the original
position.
3. Insert the mounting plate, cover and brake
disc. Ensure that you position the holes
correctly for fitting the brake.
Turn the brake so that the brake arm is in
the correct position. Turn the holes in the
extensible cover downwards so that any
condensation water can run out.
4. Screw the motor cables to the coupling box.
5. Fit the drive motor. See page 17.
Changing the carbon-brush in the drive motor
Marking