Permobil Chairman Playman User manual

SERVICE MANUAL
US
Chairman
Playman/Robo

Produced and published by Permobil AB, Sweden
Edition no.3, 2006-01
Article no.: 201162-US-0
How to contact Permobil
Head Office of the Permobil group
Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Permobil AB
Box 120, 861 23 Timrå, Sweden
Tel: [phone]. Fax: [phone]
E-mail: [email protected]

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 lift manually .................................................................... 7
Covers.............................................................................................................. 8
Batteries........................................................................................................... 9
Drive wheels.................................................................................................... 10
Brake release cables ...................................................................................... 11
Magnetic brakes.............................................................................................. 12
Drive motors.................................................................................................... 15
Seat lift actuator.............................................................................................. 17
Pilot+ Power Module ...................................................................................... 18
SLS drive stage............................................................................................... 18
Control panel................................................................................................... 19
Seat control panel........................................................................................... 19
Circuit breaker and fuses .............................................................................. 20
Circuit breaker ............................................................................................. 20
Charge fuse ................................................................................................. 21
Fuse for seat/lights ...................................................................................... 21
Brake release sensor...................................................................................... 22
Seat electronics .............................................................................................. 22
Trouble Shooting ............................................................................................ 23
Distribution Chart ........................................................................................... 25

5
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.

6
Identification Plates
Identification Plates
Chassis
Pilot+ Power Module
Control panel
Fig. 1. Chassis identification number
Fig. 2. Pilot+ output stage identification number.
Fig. 3. Control panel identification number.

7
Seat lift release
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.
Fig. 4. Seat lift release.
Fig. 5. Seat lift release.
Fig. 6. Seat lift release.

8
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.
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.
4. Remove the two front covers. Each is
mounted with two screws, see fig. 9.
Fitting
Mounting is performed in the reverse order.
Covers
Fig. 7. The seat lift cover can be lifted straight up.
Fig. 8. The chassis cover is mounted
using four screws.
Fig. 9. Each of the front covers is mounted
using two screws.

9
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 lift’s 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 thereafter 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. 12. Battery connections.
Fig. 10. Main fuse/Battery isolator.
On Off
Fig. 11. Seat lift lock nut.

10
Drive wheels
5
4
3
2
1
Fig. 14. Wheel attachment.
1. Front wheel
2. Washer, TBRSB 8.4x26x5
3. Washer, Nordlock M8x16.6, glued.
4. Bolt, Eslock MC6S M8x35
5. Hubcap
Fig. 13 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 (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 (Würth 0893800x, Art. no.: 1820540).
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. 14.
Use a torque wrench to tighten the bolt to
18 ft-Ibs. Install the hub cap (6), see Fig. 14.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.