Permobil C400 User manual

Permobil C400
SERVICE MANUAL
Power wheelchair
US
Order no.: 205225-US-0
Permobil C400

Produced and published by Permobil AB, Sweden
Edition no.3, 2010-06
Order no.: 205225-US-0
How to contact Permobil
Head Office of the Permobil group




 ..................................................................................................... 5
 ......................................................................................... 6
 .............................................................................................................. 7
 ........................................................................................................... 8
 .................................................................................................. 10
 ................................................................................................... 12
 .............................................................................................. 13
 .................................................................................................... 14
 ................................................................................ 15
 ........................................................................................... 16
 ........................................................................................... 18
 ............................................................................. 20
 ........................................................................... 22
 ..................................................................................... 23
 .................................................................................................... 26
 .................................................................................................. 28
 .............................................................................................. 36
Adjusting the Seat Height .......................................................................... 36
Removal ..................................................................................................... 37
 ................................................................................................. 38
 .............................................................................................. 39
 .................................................................................................... 40
 ........................................................................................ 42
 .............................................................................................................. 42
Charging fuse ............................................................................................. 42
Main Fuse .................................................................................................. 43
 .............................................................................................................. 44
 .............................................................................................. 46
 ........................................................................................... 47
 ........................................................................................... 60
 ............................................................................................................... 62




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.

In the event of technical problems, you should contact your dealer, or Permobil Inc. USA at 800-736-0925.

Spare parts must be ordered through your dealer.

Contact your dealer or Permobil Inc. USA for information about the warranties for this chair.

See the information in the Owner’s Manual.





Chassis identification number.
Rnet output stage ID number
Control panel Rnet ID number





The chassis cover is mounted with two knobs at
the front edge and a knob at the back.
The seat lift cover is mounted with
four plastic plugs.


 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 36. If the seat lift does not work normally
because the batteries are discharged or the
actuator is defective, the seat can be raised/
lowered manually, see page 28.
 The seat lift cover is mounted with four
plastic plugs which can be flipped up using a
screwdriver.
 Remove the seat lift cover by lifting it
upwards/forwards.

Fit the cover in the reverse order.

 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 36. If the seat lift does not work normally
because the batteries are discharged or the
actuator is defective, the seat can be raised/
lowered manually, see page 28.
 Remove the seat lift cover, see above.
 Remove the two knobs on the front edge of
the cover, see fig.
 Unscrew the knob at the far back of the
chassis cover, see fig.
 Remove the chassis cover by lifting it
upwards/backwards.

Fit the cover in the reverse order.
If the chair is equipped with lighting, disconnect the rear-light
cabling at the connector fitted on the cabling.
m
The front fender is mounted with three screws.

 Remove the three screws, see fig.
 Remove the front fender by lifting it
upwards/forwards.

Fit the front fender in the reverse order.
If the chair is equipped with lighting, remove the chassis-
and seat lift cover. Disconnect the front-light cabling at the
connector fitted on the cabling.
m



The knobs on the chassis-
and the battery cover.
Pulling out the batteries
Circuit breaker (Off/On).


 Place the wheelchair on a level surface.
 Switch off the main power switch on the control
panel.
 On wheelchairs with Pilot+ control system,
put the circuit breaker in the “OFF” position. It
is accessed through a hole in the chassis cover;
see page 43.
 Loosen the rear end of the chassis cover a little
by unscrewing the knob that holds the cover.
 Open the battery covers by loosening the
knobs that holds the battery covers, and drop
the covers down.
 Use the battery straps to pull each battery
out just enough so you can loosen the outer
battery connection.
 Loosen the outer battery connection.
 Pull the batteries completely out and disconnect
the inner battery connections.
 Remove the batteries.
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.
m
 



Fit the outer battery connections.
Fit the inner battery connections.
The knobs on the chassis-
and the battery cover.


 Lift new batteries into the chassis using the
battery belt. Leave the battery belt on the
batteries. Place the battery with the battery
terminals facing backwards, see fig.
 Fit the inner battery connections.
 Push the batteries halfway into the chassis.
 Fit the outer battery connections.
 Push the batteries fully into the chassis.
 Close the battery covers and tighten the knobs.
 On wheelchairs with Pilot+ control system,
put the circuit breaker in the “ON” position. It is
accessed through a hole in the chassis cover;
see page 43.
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.
m



Fitting/removing front wheels.


 Switch off the main power switch on the control panel.
 Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground.
 Remove the hub cap by pulling it straight out. If necessary, carefully lever it out using a screwdriver
in the slot on the cap.
 Remove the four screws that hold the wheel in place.
The central screw must not be removed.
m
 Remove the wheel by pulling it straight out.

Assemble in the reverse order.
Tighten the four screws using a dynamometric wrench.

3
2
1
 Hub cap
 Screw, ISO 4762 M8x20 8.8 Fe/Zn 5 C1
 Rear wheels
 



Fitting a solid tire to a split rim.


The rim can be taken apart to make it possible to fit/remove solid or pneumatic tires.
 Remove the wheel in question from the wheelchair. See the previous page.
 If the tire is pneumatic, release the air.
 Rim, outer section
 Tire
 Rim, outer section
 Screw, ISO 4762 M8x30 8.8 Fe/Zn 5 C1
 
3
2
1
4
Ensure that pneumatic tires are not pressurized before the rim is taken apart, otherwise there is a risk of personal injury.
m
 Remove the six screws holding the two halves of the rim together (see illustration).
 Take the rim apart.

Assemble in the reverse order.
Tighten the six screws using a dynamometric wrench.

The recommended tire pressure for pneumatic tires is 200 kPa (2 bar). Overfilling entails a risk of explosion.
Incorrect tire pressure may result in lower stability and maneuverability. Check regularly that the tires have the correct pressure.
m



Rear wheels
Fitting of rim.
4
3
2
1
 Hubcap
 Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1 / Locking
coat DIN 267-28
 Washer, 8.5x23x3
 Rear heel
 


 Turn off the main power switch on the control
panel.
 Lift the wheelchair chassis and support it on
blocks so that the wheel is off the ground.
 Remove the hucap (1).
 Remove the screw (2) and the washer (3).
. Pull the wheel off the shaft.

 Check that the wheel shaft and rim are
undamaged. Clean as necessary to remove
dirt and rust. Replace damaged parts.
 Fit the wheel onto the axle with the use of
hand force only. Make sure the rim is fully
seated upon the axle.
 Fit the washer (3) onto the screw (2) and
secure the wheel.


Do not use a Pneumatic impact wrench.
m
The bolt must be used once only. Removed bolt is not
allowed to be refitted.
Other types of bolts or washers are not to be used.
Do not use any other type of thread lock.
m




The support wheels should always be fitted in the
upper position, see fig.

 Turn off the main power switch on the control
panel.
 Remove the bolt, see fig.
The support wheels should always be
fitted in the upper position.

 Turn off the main power switch on the control
panel.
 Fit the support wheel with screw, washer and
nut in the lower position, see fig.
Removal/fitting of the support wheel unit.
Chassis with support wheels fitted.

 Turn off the main power switch on the control
panel.
 Remove the front wheel on the side in question,
see page 10.
 Remove the three bolts that holds the support
wheel unit and the drive unit.
The support wheels should always be fitted in the upper
position.
m
Removing the support wheels entails an increased risk of
the wheelchair tipping over. Wheelchairs with support wheels
fitted as standard must not be driven when the support
wheels are removed.
m
Removing the support wheels entails an increased risk of
the wheelchair tipping over. Wheelchairs with support wheels
fitted as standard must not be driven when the support
wheels are removed.
m

Fit the support wheel unit in the reverse order.



 Switch off the main power switch on the control
panel.
 Lift up and chock up the wheelchair chassis
so that the wheel in question is free of the
ground.
 Remove the cap from the top of the link arm.
See fig.
 Remove the wheel fork. It is fitted with one
screw from above, see fig.
 
Fit the wheel fork in the reverse order.


Wheel fork
 Plastic plug
 Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1/
Locking coat DIN 267-28
 Washer, 8.5x23x3
 Bearing 6002-2RS1, 15x32x9
 Circlip DIN472, Ø32
 
1
2
3
6
5 4


Do not use a Pneumatic impact wrench.
m
The bolt must be used once only. Removed bolt is not
allowed to be refitted.
Other types of bolts or washers are not to be used.
Do not use any other type of thread lock.
m





 Switch off the main power switch on the control
panel.
 Lift up and chock up the wheelchair chassis so
that the rear wheel suspension is free of the
ground.
 Remove the rear wheel suspension. It is fitted
with a bolt with two washers, see fig.
 Pull the rear wheel suspension straight
backwards.

 Check that the axle and the rear wheel
suspension bushings are undamaged. Clean
as necessary to remove dirt and rust. Replace
damaged parts.
 Lubricate the shaft with a thin coating of
grease (Lubetec Redguard, art. no.1190) or oil.
Rear wheel suspension.
 Fit the rear wheel suspension onto the axle
using hand force only.
 Fit the two washers on the bolt and secure the
rear wheel suspension.


Do not use any type of lubrication in the threaded hole or on
the bolt. Clean as necessary.
m
 
 Bolt, ISO 4017 M10x25 8.8 Fe/Zn 8 C1/
Locking coat DIN 267-28
 Washer, 10 Fe/Zn 8 C1 (SRKB 11x35x3)
Do not use a Pneumatic impact wrench.
m
The bolt must be used once only. Removed bolt is not
allowed to be refitted.
Other types of bolts or washers are not to be used.
Do not use any other type of thread lock.
m
1 2





 Switch off the main power switch on the control
panel.
 Remove the front fender on the side in
question, see page 7.
 Lift up and chock up the wheelchair chassis
so that the wheel in question is free of the
ground.
 Loosen the shock absorbers front end. It is
fitted with a bolt, two washers and a nut, see fig.
 Loosen the shock absorbers rear end. It is
fitted with a bolt, two washers and a nut, see fig.
 
Fit the shock absorber in the reverse order. Adjust
the shock absorbers spring force before fitting,
see page 17.
Shock absorber
The shock absorber is fitted with a bolt,
two washers and a nut.




 
Before the new shock absorber is mounted, it must be adjusted to the proper value.
The spring force can be set to suit different user weights using the adjustment nut. Increase the
dimension fo a harder suspension, decrease the dimension for a softer suspension, see fig.



 

0 - 110 Ibs
110 - 155 Ibs
155 - 200 Ibs
200 - 265 Ibs
265 - 300 Ibs
1 inch (25 mm.)
1 1/32 inch (26 mm.)
1 1/16 inch (27 mm.)
1 1/8 inch (29 mm.)
1 1/4 inch (32 mm.)





 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 36. If the seat elevator does not work
normally because the batteries are discharged
or the actuator is defective, the seat can be
raised/lowered manually, see page 28.
 Switch off the main power switch on the control
panel.
 Remove the seat elevator cover, chassis cover
and the front fender on the side in question,
see page 7.
 Lift up and chock up the wheelchair chassis
so that the wheel in question is free of the
ground.
 Remove the front wheel, see page 10.
 Disconnect the electrical connection for the
drive motor and the magnetic wheel lock. The
connections are positioned on the inside of the
chassis, on each side of the seat elevator/seat
post, see fig.
 Disconnect the wheel lock release cable
 Remove the shock absorbers front bracket,
see fig
The electrical connection for the drive
motor and the magnetic wheel lock.
The shock absorbers front bracket.
The electrical connections of the drive
motors and the wheel locks are positioned
on the inside of the chassis, on each side of
the seat elevator/seat post.



The slewing bracket is fitted with
a screw and washer.
Removal/fitting of slewing brackets.

 Remove the slewing bracket, it is fitted with
screw and washer.
For removal of the drive motor, see page 26.
 
Fit the slewing brackets in the reverse order. 
Tighten the bolt holding the wheel fork in place
with a torque wrench.


Do not use a Pneumatic impact wrench.
m





 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 36. If the seat elevator does not work
normally because the batteries are discharged
or the actuator is defective, the seat can be
raised/lowered manually, see page 28.
 Switch off the main power switch on the control
panel.
 Remove the seat elevator cover, chassis
cover and the right front fender, see page 7.
 Remove the wheel lock release mechanism. It
is attached with two screws; see fig.
Adjustment of wheel lock release cable.
Lock nut (1) Adjusting screw (2).
The wheel lock release mechanism
is attached with two screws.
 
Wheel lock release cable attachment
at the magnetic wheel lock.
 Remove the cable at the magnetic wheel
lock by pulling the cable casing forward and
passing the cable through the slot in the cable
holder. Detach the wheel lock release cable
from the magnetic wheel lock.
 Remove the cable from the release lever.
 Remove the lock nut (1).
 Screw in the adjusting screw (2) fully.