Permobil X850 MiniFlex User manual

Service manual English
X850

Introduction
The Service Manual is intended for technical personnel who maintain and
repair power 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.

Text
Produced and published by Permobil AB
Edition: Edition 2, 2015-09
Order no: 205214-UK-0

Permobil X850
How to contact Permobil
Permobil Benelux BV
De Beitel 11
6466 GZ Kerkrade
Netherlands
Tel: [phone]
Fax: [phone]
Email:: [email protected]
The Permobil Group’s Head Office
Permobil AB
Box 120
861 23 Timrå
Sweden
Tel: [phone]
Fax: [phone]
E-mail: [email protected]

Permobil X850 Contents
CONTENTS
Serial Number labels .................................................................................................................................... 9
Repairs ......................................................................................................................................................... 11
Adjustments ................................................................................................................................................. 53
Troubleshooting .......................................................................................................................................... 55
Cabling Overview........................................................................................................................................ 57

Permobil X850 Serial Number labels
SERIAL NUMBER LABELS
Chassis
Figure 1. Chassis identification number.
Seat lift
Figure 2. Seat lift ID number.
9

Permobil X850 Serial Number labels
10

Permobil X850 Repairs
REPAIRS
Covers............................................................................................... 12
Batteries ........................................................................................... 16
Drive wheels .................................................................................... 18
Front wheels .................................................................................... 20
Inner tube ......................................................................................... 21
Filling tyres with air.......................................................................... 22
Shock absorbers ............................................................................. 23
Brake release cables ...................................................................... 24
Brake release switch....................................................................... 26
Magnetic brake ................................................................................ 27
Drive motor....................................................................................... 28
Fixed seat......................................................................................... 30
Electric seat lift................................................................................. 31
Seat lift motor................................................................................... 33
Electric wheelbase adjustment ..................................................... 34
Front.................................................................................................. 35
Steering knuckle suspension and bearings................................. 36
Potentiometer .................................................................................. 38
Power steering actuator ................................................................. 39
Toe-in check..................................................................................... 40
Toe-in adjustment............................................................................ 41
Bushings in wheelbase adjustment .............................................. 42
Bushing and plastic guide .............................................................. 43
Electronics (Safe Gate) .................................................................. 44
Connection box................................................................................ 45
Fuses ................................................................................................ 46
Front lights........................................................................................ 49
Front indicators................................................................................ 50
Rear lights/indicators ...................................................................... 51
11

Permobil X850 Repairs
Covers
Removing the chassis covers
Figure 3. The front cover is fixed with one knob on each
side and two guide pins at the front.
Figure 4. The rear cover is fixed with the same knob as
the front cover and two knobs at the rear.
Figure 5. Chassis covers.
1. Chassis with electric seat lift: Place the wheelchair
on a level surface. Raise the seat to the highest posi-
tion. If the seat lift does not work normally because
the batteries are discharged or the motor is defective,
see Manual raising/lowering, Page 31.
Chassis with a fixed seat: Remove the rear cover. It
is fixed with two knobs at the rear and one knob on
the left and right sides. Tip the seat forwards. See
Fixed seat, Page 30.
2. Switch off the power supply with the On/Off key on
the control panel.
3. Remove the front cover. This is fixed with two knobs
on the sides and two guide pins at the front. Lift the
cover up and forwards. Divide the cabling to the crush
protection at the contact on the cabling.
4. On a chassis with an electric seat lift, remove the rear
cover. This is fixed with the same knob as the front
cover and two knobs at the rear. Lift the cover up and
backwards.
NOTE!
If necessary, the rear cover can be removed without rais-
ing the seat.
Assembly of the chassis covers
Assembly the covers in the reverse order.
12

Permobil X850 Repairs
Removing the footplate
Figure 6. The foot plate’s cover is held in place with 10
screws.
The foot plate is fitted with ten screws, three on the right
and left sides and four on the top of the foot plate. See
fig. 6.
1. Unscrew and remove the ten screws that hold the foot
plate in place. See fig. 6.
Assembly of the footplate
Assemble the chassis cover in the reverse order.
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Permobil X850 Repairs
Removing the front mudguard
Figure 7. The front mudguard is held in place with 4
screws.
The front mudguards are held in place with four screws
each.
1. Unscrew and remove the four screws that hold the
front mudguard in place. See fig. 7.
2. Lift the mudguard up.
To divide the light cabling, remove the foot plate. See Re-
moving the footplate. Then divide the cabling at the con-
tact on the cabling.
For removal of the lights, see Front lights, Page 49.
Assembly of the front mudguard
Assemble the front mudguard in the reverse order.
Removing the front’s bottom plate
Figure 8. The front’s bottom plate is held in place with
eight screws.
The front’s bottom plate is held in place with six screws.
1. Unscrew and remove the eight screws that hold the
bottom plate in place. See 8.
Assembly of the front’s bottom plate
Assemble the front’s bottom plate in the reverse order.
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Permobil X850 Repairs
Removing the crush protection
Figure 9. The crush protection cover is held in place on
the chassis’ front cover with two screws.
Figure 10. Crush protection with cover and sensor.
The crush protection is held in place with two screws.
1. Place the wheelchair on a level surface. Raise the
seat to the highest position. If the seat lift does not
work normally because the batteries are discharged
or the motor is defective, see Manual raising/lower-
ing, Page 31.
2. Switch off the power supply using the ON/OFF key on
the control panel and switch the automatic main fuse
to Off.
3. Remove the front chassis cover. This is fixed with two
knobs on the sides and two guide pins at the front. Lift
the cover up and forwards. Divide the cabling to the
crush protection at the contact on the cabling. See
Removing the chassis covers, Page 12.
4. Unscrew and remove the two screws that hold the
crush protection in place. See fig. 9.
5. Lift the crush protection up and forwards.
6. Remove the crush protection switch. This is held in
place with a nut. See fig. 10.
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Permobil X850 Repairs
Batteries
Figure 11. Main fuse/battery isolator (On/Off)
Figure 12. The batteries’ fixing bars and connections.
LWARNING!
Be careful when using metal objects when working
with batteries. A short-circuit can easily cause an
explosion. Always use safety gloves and safety
goggles.
Removal
1. Place the wheelchair on a level surface.
2. Switch off the power supply using the ON/OFF key on
the control panel and switch the automatic main fuse
to Off. It is accessible via a recess on the chassis.
See fig. 11.
NOTE!
Ensure that the power supply is switched off using
the ON/OFF key on the control panel before the auto-
matic main fuse is switched to Off.
3. Remove the chassis covers. See Removing the chas-
sis covers, Page 12.
4. Disconnect the battery connections. See fig. 12.
5. Loosen the four knobs that hold the batteries’ fixing
bars. See fig. 12.
6. Turn the battery bars backwards. Lift out the
batteries.
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Permobil X850 Repairs
Assembly
1. Lift two new batteries into place. The battery poles
must face out from the centre of the chassis.
LWARNING!
Be careful when using metal objects when working
with batteries. A short-circuit can easily cause an
explosion. Always use safety gloves and safety
goggles.
2. Fix the batteries in place with the two battery bars,
which are held in place with the four knobs. See fig.
12
3. Connect the battery connections. See fig. 12
4. Refit the chassis covers. See Assembly of the chas-
sis covers, Page 12.
5. Switch the automatic main fuse to ON. It is accessible
via a recess on the chassis. See fig. 11.
17

Permobil X850 Repairs
Drive wheels
Removal
Figure 13. Removing tool 304103-99-0.
1. Switch off the power supply with the On/Off key on
the control panel.
2. Lift up and chock up the wheelchair chassis so that
the wheel in question is free of the ground.
3. Loosen and remove the hub cap 1, the screw 2 and
the washers 3, 4 and 5. See the illustration.
4. Pull the wheel off the axle. Use the removing tool
304103-99-0 if the wheel is hard to remove. See the
illustration.
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Permobil X850 Repairs
Assembly
Figure 14. Drive wheel.
1. Check that the axle and rim are not damaged. If nec-
essary, clean to remove dirt and rust. Replace dam-
aged parts.
2. Check that the parallel key is properly located and is
not damaged. Fit a new parallel key if necessary.
3. Lubricate the axle with a thin layer of copper paste
(Würth 0893800x, Art. no.: 1820540).
LWARNING!
The threads on the screw and in the screw hole
must not be lubricated. Clean the threads if
necessary.
4. Fit the wheel on the axle using just your hands. Check
that the wheel is fully located on the axle. If neces-
sary, use a rubber mallet carefully.
5. Fit the four washers 3, 4 and 5 on the screw 2 and
tighten the wheel. Fit the hub cap 1. See fig. 14.
Tightening torque: 33 Nm.
LWARNING!
Screws must only be used once. Once removed,
screws must therefore never be refitted.
No type of screw and washer other than those
stated here may be used.
No other type of lock coating or lock liquid may be
used.
Do not use an impact wrench for the tightening
torque.
Item Description
1. Hub cap
2. Screw, ISO 4762 M8x35 10.9 Fe/Zn 5 C2 / Locking coat
DIN 267-28
3. Shim washer DIN 988 8 A2 (DB 8x14x0.5 stainless)
4. Washer, 8 Fe/Zn 5 C1 (TBRSB 8.4x26x5)
5. Washer, PA6 (8.4x15x1.5 type F)
6. Wheel
7. Parallel key DIN 6885A 6x6x36
19

Permobil X850 Repairs
Front wheels
Removal
1. Switch off the power supply with the On/Off key on the control panel.
2. Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground.
LCAUTION!
The wheelchair must not be lifted by the seat or seat lift as this can damage the wheelchair and its components.
3. Remove the hub cap 4.
4. Fold out the locking lip on the locking washer.
5. Unscrew and remove the locking nut from the axle.
6. Pull the wheel off the axle. Use the removing tool 304103-99-0 with the appropriate adapter if the wheel is hard to
remove.
Assembly
1. Check that the axle and rim are not damaged. If necessary, clean to remove dirt and rust. Replace damaged parts.
2. Fit the wheel (1) on the axle.
3. Fit the locking washer and locking nut onto the axle. Rotate the wheel clockwise while tightening the nut until the
wheel rotates a little less freely. Loosen the nut until the wheel rotates freely again and then fold back the appropri-
ate wing on the locking washer to lock the nut into position.
4. Refit the hub cap.
Item Description
1. Wheel
2. Locking washer, ISO 2982 12 (MB1 12x25x1)
3. Locking nut, ISO 2982 M12 (KM1)
4. Hub cap
Figure 15. Fitting the front wheel.
20