Permobil C500 User manual

SERVICE MANUAL
Permobil C500
Power wheelchair


Produced and published by Permobil AB, Sweden
Edition no.3, 2010-06
Order no.: 205227-US-0


Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Permobil AB
Box 120
861 23 Timrå
Sverige
Tel: [phone]
Fax: [phone]
E-post: [email protected]




 ..................................................................................................... 5
 ......................................................................................... 6
 .............................................................................................................. 7
 ........................................................................................................... 8
 .................................................................................................. 10
 ................................................................................................... 12
 .............................................................................................. 14
 .................................................................................................... 16
 ................................................................................ 17
 ........................................................................................... 18
 ........................................................................................... 20
 .............................................................................. 22
 ........................................................................... 24
 ..................................................................................... 25
 .................................................................................................... 28
 ........................................................................................................... 30
 .............................................................................................. 38
Adjusting the Seat Height .......................................................................... 38
Removal ..................................................................................................... 39
 ................................................................................................. 40
 .............................................................................................. 41
 .................................................................................................... 42
 ........................................................................................ 44
 .............................................................................................................. 44
Charging fuse ............................................................................................. 44
Circuit breaker .......................................................................................... 45
 .............................................................................................................. 46
 .............................................................................................. 48
 ........................................................................................... 49
 ........................................................................................... 62
 ............................................................................................................... 65




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







 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 38. 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 30.
 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.
The chassis cover is mounted with two knobs at
the front edge and one 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 38. 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 30.
 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.
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 cover 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
If the chair is equipped with lighting, disconnect the rear-light
cabling at the connector fitted on the cabling.
m

Fit the front fender in the reverse order.




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.
 Put the circuit breaker in the “OFF” position.
 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.


 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.
The knobs on the chassis-
and the battery cover.
 Fit the outer battery connections.
 Push the batteries fully into the chassis.
 Close the battery covers and tighten the knobs.
 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.
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 wheel


 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.


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
 
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



Filling Valve, rear wheel


 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 rear wheel, see page 12.
 Let the air out of the tire.
 Remove the three bolts with nuts thats holds
the inner and outer part s of the rim together,
see figure below.
 Remove the broken inner tube.
 Fit a new inner tube in the tire.
 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
 Refit the three bolts with nuts.
 Fill the tire with air, see below.

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).
 Unscrew the plastic cap on the air valve of the
tire.
 Connect the compressed air nozzle to the
air valve and adjust the tire pressure to the
prescribed level.
 Hubcap
 Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1 / Locking
coat DIN 267-28
 Washer, 8.5x23x3
 Bolt, ISO 4762 M6x40 8.8 Fe/Zn 5 C1
 Rim, Outer part.
 Inner tube, 210x65 TR-87
 Tire, 2,50x3 (210x65)
 Rim, Inner part.
 Locking nut, ISO 7040, M8 Fe/Zn 5 C1
 
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.
m
Fälg med innerslang och däck.
6789 54321




The support wheels should always be fitted in the
lower 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 lower 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.
Chassis with support wheels fitted.
The support wheels should always be fitted in the lower
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



Removal/fitting of the support wheel unit.


 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.

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.
m



 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 bolt
from above, see fig.
 
Fit the wheel fork in the reverse order. Stack
the disc springs and fit with the socket and the
screw, see fig.

Wheel fork with friction brake.
 Plastic plug
 Bolt, ISO 4017 M8x16 8.8 Fe/Zn 5 C1/
Locking coat DIN 267-28
 Socket
 Disc spring
 Bearing 6002-2RS1 (15x32x9)
 Circlip DIN 472 Ø32
 
1
2
3
65


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
Friktionsbroms





 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 three bolts with two washers and one nut
each, see fig.
 Pull the rear wheel suspension straight
backwards.

 Check that the rear wheel suspension
bushings are undamaged. Clean as necessary
to remove dirt and rust. Replace damaged
parts.
 Fit the rear wheel suspension to the chassis.
 Fit the three bolts with washers and nuts, see fig.
Tighten the bolts holding the rear wheel suspension
in place with a torque wrench.
 The rear wheel suspension is fitted with three
bolts with two washers and one nut each.
1
2
 
 Bolt, DIN 931 M12x75 8.8 FE/Zn 8 C1
 Washer, ISO 7089 12 200 HV Fe/Zn 8 C1 (13x24x2.5)
 Nut, DIN 982 M12 8 Fe/Zn 8 C1
2
3
Other types of bolts or washers are not to be used.
m
Do not use a Pneumatic impact wrench.
m





 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 below.
Shock absorber
The shock absorber is fitted with a bolt,
two washers and a nut

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.

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.
m

Before the new shock absorber is mounted, it must be adjusted to the proper value.







 

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)





 Raise the seat to the highest position. If the
chassis is equiped with fixed seat post, see
page 38. 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 30.
 Switch off the main power switch on the control
panel.
 Remove the seat lift 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 lift/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 lift/seat post.