Permobil C500 User manual

Permobil C500
SERVICE MANUAL
Power wheelchair
US

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]
Produced and published by Permobil AB, Sweden
Edition no.4, 2009-06
Order no.: 205210-US-0

4
Contents
Contents
Introduction ...................................................................................................... 5
Identification plates ......................................................................................... 6
Covers ............................................................................................................... 7
Batteries ........................................................................................................... 8
Front wheels ................................................................................................... 10
Rear wheels .................................................................................................... 12
Support wheels .............................................................................................. 14
Wheel forks .................................................................................................... 16
Rear wheel suspension ................................................................................. 17
Shock absorbers ............................................................................................ 18
Slewing brackets ........................................................................................... 20
Wheel lock release cable .............................................................................. 22
Wheel lock release sensor ............................................................................ 24
Magnetic wheel lock ...................................................................................... 25
Drive motor ..................................................................................................... 28
Seat elevator .................................................................................................. 30
Manual Raising/Lowering of the Seat elevator ........................................... 30
Removing the Seat elevator ....................................................................... 31
Seat elevator cable ..................................................................................... 32
Seat elevator motor .................................................................................... 32
Seat elevator drive belt ............................................................................... 33
Fixed seat post .............................................................................................. 34
Adjusting the Seat Height ........................................................................... 34
Removal ...................................................................................................... 35
Control panel .................................................................................................. 36
Seat control panel........................................................................................ 36
Pilot+ controller ............................................................................................. 37
SLS drive stage .............................................................................................. 38
Fuses .............................................................................................................. 39
Circuit breaker .......................................................................................... 39
SLS fuse ..................................................................................................... 40
Charging fuse ............................................................................................. 40
Fuse for seat/lighting .................................................................................. 41
ESP module .................................................................................................... 42
Lights .............................................................................................................. 46
Control System .............................................................................................. 48
Trouble shooting ............................................................................................ 49
Cabling overview ........................................................................................... 52
Distribution Chart .......................................................................................... 54
Index ............................................................................................................... 57

5
Introduction
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.
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
Chassis identification number.
Pilot+ controller identification number.
Control panel Pilot+ identification number.
Pilot+ controller
Control panel Pilot+

7
Covers
Covers
Removing the seat elevator cover
1. Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 34. 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 30.
2. The seat elevator cover is mounted with four
plastic plugs which can be flipped up using a
screwdriver.
3. Remove the seat elevator cover by lifting it
upwards/forwards.
Fitting
Fit the cover in the reverse order.
The chassis cover is mounted with two knobs at
the front edge and one knob at the back.
The seat elevator cover is mounted with
four plastic plugs.
Removing the chassis cover
1. Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 34. 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 30.
2. Remove the seat elevator cover, see above.
3. Remove the two knobs on the front edge of
the cover, see fig.
4. Unscrew the knob at the far back of the
chassis cover, see fig.
5. Remove the chassis cover by lifting it
upwards/backwards.
The front fender is mounted with three screws.
Removing the front fender
1. Remove the three screws, see fig.
2. Remove the front fender by lifting it
upwards/forwards.
Fitting
Fit the cover in the reverse order.
If the chair is equipped with lighting, remove the chassis- and
seat elevator cover. Disconnect the front-light cabling at the
connector fitted on the cabling.
NOTE
If the chair is equipped with lighting, disconnect the rear-light
cabling at the connector fitted on the cabling.
NOTE
Fitting
Fit the front fender in the reverse order.

8
Batteries
Batteries
The knobs on the chassis-
and the battery cover.
Pulling out the batteries
Circuit breaker (Off/On).
Removal
1. Place the wheelchair on a level surface.
2. Switch off the main power switch on the
control panel.
3. Put the circuit breaker in the “OFF” position.
4. Loosen the rear end of the chassis cover a little
by unscrewing the knob that holds the cover.
5. Open the battery covers by loosening the
knobs that holds the battery covers, and drop
the covers down.
6. Use the battery straps to pull each battery out
just enough so you can loosen the outer
battery connection.
7. Loosen the outer battery connection.
8. Pull the batteries completely out and
disconnect the inner battery connections.
9. 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.
WARNING
Off On

9
Batteries
Fit the outer battery connections.
Fit the inner battery connections.
Batteries
Fitting
1. 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.
2. Fit the inner battery connections.
3. Push the batteries halfway into the chassis.
The knobs on the chassis-
and the battery cover.
4. Fit the outer battery connections.
5. Push the batteries fully into the chassis.
6. Close the battery covers and tighten the knobs.
7. Put the circuit breaker in the “ON” position. It is
accessed through a hole in the chassis cover;
see figure.
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.
WARNING

10
Front wheels
Puller 304103-99-0.
64321
Fitting of rim.
5
Front wheels
Removal
1. Turn off the main power switch on the control
panel.
2. Lift the wheelchair chassis and support it on
blocks so that the wheel is off the ground.
3. Remove the hubcap (1), bolt (2) and the three
washers (3 and 4); see figure.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight; see figure.
Fitting
1. Check that the wheel shaft and rim are
undamaged. Clean as necessary to remove
dirt and rust. Replace damaged parts.
2. Check that the key is firmly attached and
undamaged; fit a new key if necessary.
3. Lubricate the shaft with a thin layer of copper
paste (Würth 0893800x, Art. no.: 1820540).
Do not use any type of lubrication in the threaded hole in the
axle or on the bolt.
WARNING
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.
The washer (4) should be placed with the most flat side
inwards.
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.
Hitting too hard with a rubber mallet could cause damage to
the gear.
5. Mount the three washers (3) and 4) onto the
bolt (2) and secure the wheel. Use a torque
wrench to tighten the bolt to 24 ft-Ibs (33Nm).
Install the hub cap (1). See Fig. 13.
NOTE
NOTE
WARNING
1Hubcap
2Bolt, ISO 4762 M8x25 10.9 Fe/Zn 5 C2 / Locking
coat DIN 267-28
3Shim washer DIN 988 8 A2 (DB 8x14x0.5 Stainless)
4Washer, 8 HB 305 Fe/Zn 5 C2 (TBRSB 8,4x26x5)
5Front wheel
6Key DIN 6885A 6x6x22
Pos. Description

11
Front wheels
Filling with air
Check at regular intervals that the wheelchair's tires
have the prescribed tire pressure. An incorrect tire
pressure can cause deterioration in stability and
manueverability, plus extremely low air pressure can
give rise to abnormal wear as well as shorter driving
distances. So check regularly to see that the tires
are maintained at a pressure of 29 psi (200 kPa).
1. Unscrew the plastic cap on the air valve of
the tire.
2. Connect the compressed air nozzle to the air
valve and adjust the tire pressure to the
prescribed level.
The recommended air pressure for front/rear tires is 29 psi
(200 kPa). Overfilling causes a risk of explosion. Incorrect tire
pressure can involve a deterioration of stability and
manueverability, so check regularly that the tire contains the
prescribed air pressure.
WARNING
Force the tire off the rim.
Filling Valve, front wheel
Front wheels
Replacement of inner tube
1. Turn off the main power switch on the control
panel.
2. Put the wheelchair up on blocks so that the
wheel is free and then let the air out of it.
3. Force the tire off the rim.
4. Remove the broken inner tube
5. Fit a new inner tube.
6. Refit the tire.
7. Fill the tire with air, see below.
Rim, innertube and tire.

12
Rear wheels
Rear wheel
Rear wheels
Removal
1. Turn off the main power switch on the control
panel.
2. Lift the wheelchair chassis and support it on
blocks so that the wheel is off the ground.
3. Remove the hucap (1).
4. Remove the screw (2) and the washer (3).
5. Pull the wheel off the shaft.
Fitting
1. Check that the wheel shaft and rim are
undamaged. Clean as necessary to remove
dirt and rust. Replace damaged parts.
2. Fit the wheel onto the axle with the use of
hand force only. Make sure the rim is fully
seated upon the axle.
3. Fit the washer (3) onto the screw (2) and
secure the wheel.
Use a torque wrench to tighten the bolt to 17.7 ft-
Ibs (24 Nm).
Fitting of rim.
4
3
2
1
1Hubcap
2Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1 / Locking
coat DIN 267-28
3Washer, 8.5x23x3
4Rear heel
Pos. Description
Do not use a Pneumatic impact wrench.
NOTE
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.
WARNING

13
Rear wheels
Filling Valve, rear wheel
Rear wheel with air
Replacement of inner tube
1. Turn off the main power switch on the control
panel.
2. Lift the wheelchair chassis and support it on
blocks so that the wheel is off the ground.
3. Remove the rear wheel, see page 12.
4. Let the air out of the tire.
5. Remove the five bolts with nuts thats holds
the inner and outer part s of the rim together,
see figure below.
6. Remove the broken inner tube.
7. Fit a new inner tube in the tire.
8. Refit the rim parts, fit the outer part with the
innertubes valve throu the hole, see fig.
Assemble the rim with the tire, making sure the
tube doesn’t get trapped between the two
halves of the rim
9. Refit the five bolts with nuts.
10. Fill the tire with air, see below.
Filling with air
Check at regular intervals that the wheelchair's tires
have the prescribed tire pressure. An incorrect tire
pressure can cause deterioration in stability and
manueverability, plus extremely low air pressure can
give rise to abnormal wear as well as shorter driving
distances. So check regularly to see that the tires
are maintained at a pressure of 29 psi (200 kPa).
1. Unscrew the plastic cap on the air valve of
the tire.
2. Connect the compressed air nozzle to the air
valve and adjust the tire pressure to the
prescribed level.
Rim with innertube and tire.
1Hubcap
2Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1 / Locking
coat DIN 267-28
3Washer, 8.5x23x3
4Bolt, ISO 4762 M6x40 8.8 Fe/Zn 5 C1
5Rim, Outer part.
6Inner tube, 210x65 TR-87
7Tire, 2,50x3 (210x65)
8Rim, Inner part.
9Locking nut, ISO 7040, M8 Fe/Zn 5 C1
Pos. Description
6789 54321
The recommended air pressure for front/rear tires is 29 psi
(200 kPa). Overfilling causes a risk of explosion. Incorrect tire
pressure can involve a deterioration of stability and
manueverability, so check regularly that the tire contains the
prescribed air pressure.
If the wheel bolt is removed for tire service, replace it with a
new, unused part from Permobil and tighten the bolt to the
recommended torque. Also, inspect the drive axle and wheel
rim for any damage. Damage to either part can cause the
wheel bolt to loosen or fracture. Permobil recommends that
wheel bolts be used only one time.
WARNING

14
Support wheels
Support Wheels
The support wheels should always be fitted in the
lower position, see fig.
Removing the support wheels
1. Turn off the main power switch on the control
panel.
2. Remove the bolt, see fig.
The support wheels should always be
fitted in the lower position.
Fitting
1. Turn off the main power switch on the control
panel.
2. Fit the support wheel with screw, washer and
nut in the lower position, see fig.
Chassis with support wheels fitted.
The support wheels should always be fitted in the lower
position.
NOTE
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.
WARNING

15
Support wheels
Removal/fitting of the support wheel unit.
Support Wheels
Removing the support wheel unit
1. Turn off the main power switch on the control
panel.
2. Remove the front wheel on the side in question,
see page 10.
3. Remove the three bolts that holds the support
wheel unit and the drive unit.
Fitting
Fit the support wheel unit in the reverse order.
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.
WARNING

Wheel Forks
Removal
1. Switch off the main power switch 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. Remove the cap from the top of the link arm.
See fig.
4. Remove the wheel fork. It is fitted with one
bolt from above, see fig.
Fitting
Fit the wheel fork in the reverse order.
Fit the O-ring on the friction plate. See figure
Use a torque wrench to tighten the bolt to 17.7
ft-Ibs (24Nm).
Wheel fork with friction brake.
1Plastic plug
2Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1/
Locking coat DIN 267-28
3O-ring, Ø24,2x3 EPDM
4Friction plate
5Bearing 6002-2RS1 (15x32x9)
6Circlip DIN 472 Ø32
Lubricant friction brake, Momentum, PRO AA 2/0,025
Pos. Description
1
2
3
6 5
16
Wheel Forks
Fit the O-ring In the groove of the friction plate.
4
Lubricate the O-ring with Lubricant friction brake,
Part. no: 1820405
No other type of lubricant than that stated here may be used.
NOTE
Do not use a Pneumatic impact wrench.
NOTE
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.
WARNING

17
Rear wheel suspension
Rear wheel suspension
Removal
1. Switch off the main power switch on the control
panel.
2. Lift up and chock up the wheelchair chassis
so that the rear wheel suspension is free of
the ground.
3. Remove the rear wheel suspension. It is fitted
with three bolts with two washers and one nut
each, see fig.
4. Pull the rear wheel suspension straight
backwards.
Fitting
1. Check that the rear wheel suspension
bushings are undamaged. Clean as necessary
to remove dirt and rust. Replace damaged
parts.
2. Fit the rear wheel suspension to the chassis.
3. Fit the three bolts with washers and nuts, see fig.
Tighten the bolts holding the rear wheel
suspension in place with a torque wrench.
Use a torque wrench to tighten the bolt to
67 ft-Ibs (91Nm).
The rear wheel suspension is fitted with three
bolts with two washers and one nut each.
1
2
1Bolt, DIN 931 M12x75 8.8 FE/Zn 8 C1
2Washer, ISO 7089 12 200 HV Fe/Zn 8 C1 (13x24x2.5)
3Nut, DIN 982 M12 8 Fe/Zn 8 C1
Pos. Description
2
3
Other types of bolts or washers are not to be used.
WARNING
Do not use a Pneumatic impact wrench.
NOTE

18
Shock Absorbers
Shock Absorbers
Removal
1. Switch off the main power switch on the control
panel.
2. Remove the front fender on the side in
question, see page 7.
3. Lift up and chock up the wheelchair chassis so
that the wheel in question is free of the ground.
4. Loosen the shock absorbers front end. It is
fitted with a bolt, two washers and a nut, see fig.
5. Loosen the shock absorbers rear end. It is
fitted with a bolt, two washers and a nut, see fig.
Fitting
Fit the shock absorber in the reverse order. Adjust
the shock absorbers spring force before fitting,
see below.
Shock absorber
The shock absorber is fitted with a bolt,
two washers and a nut
The spring force
The spring force can be set to suit different user weights using the adjustment nut. Increase the
dimension for a harder suspension, decrease the dimension for a softer suspension, see fig.
Return damping valve
To get standard setting, screw the return damping valve fully clockwise by hand. Then screw the valve
fully counterclockwise, counting the ”clicks”. Then screw the valve halfway clockwise i.e. halve the
number of ”clicks”.
Screw the valve clockwise (open the valve) for softer damping, or counterclockwise (close the valve) to
have harder damping .
On early models of the chassis, DNM shock absorbers are fitted. Make sure using the right settings for the right shock absorber.
NOTE
Adjusting
Before the new shock absorber is mounted, it must be adjusted to the proper value.

19
Shock Absorbers
Adjustment nutSetting
Setting
Return damping valve
Adjusting the DNM Shock Absorber
Return damping valve
Adjustment nut Setting
Stop spring
Make sure the stop spring is in the right position.
NOTE
Adjusting the KS 291 Shock Absorber
User weights Setting
Adjustment of shock absorber spring
0 - 110 Ibs
110 -155 Ibs
155 -200 Ibs
200 -265 Ibs
265 -310 Ibs
5/8 inch (16 mm)
21/32 inch (17 mm)
3/4 inch (19 mm)
13/16 inch (21 mm)
15/16 inch (24 mm)
User weights Setting
Adjustment of shock absorber spring
0 - 110 Ib.
110 - 155 Ib.
155 - 200 Ib.
200 - 264 Ib.
0 - 3/32 inch
3/32 - 5/32 inch
5/32 - 1/4 inch
1/4 - 3/8 inch

20
Slewing brackets
Slewing brackets
Removal
1. Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 34. 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 30.
2. Switch off the main power switch on the control
panel.
3. Remove the seat elevator cover, chassis cover
and the front fender on the side in question,
see page 7.
4. Lift up and chock up the wheelchair chassis so
that the wheel in question is free of the ground.
5. Remove the front wheel, see page 10.
6. 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.
7. Disconnect the wheel lock release cable
8. 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.