Permobil Koala User manual
SERVICE MANUAL
Koala
US
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
4
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
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
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.
6
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.
7
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.
8
Covers
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.
9
Batteries
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.
On
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.
10
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
6
3
2
1
4
5
2
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3
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