Permobil C500 Service Manual Download

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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.

Summary of Contents for C500

Page 1: ...SERVICE MANUAL Permobil C500 Power wheelchair US ...

Page 2: ......

Page 3: ... 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 info permobilusa com Permobil AB Box 120 861 23 Timrå Sverige Tel 060 59 59 00 Fax 060 57 52 50 E post info permobil se ...

Page 4: ...s 18 Slewing brackets 20 Wheel lock release cable 22 Wheel lock release sensor 24 Magnetic wheel lock 25 Drive motor 28 Seat lift 30 Fixed seat post 38 Adjusting the Seat Height 38 Removal 39 Control panel 40 R net controller 41 ESP Module 42 ICS Master Module 44 Fuses 44 Charging fuse 44 Circuit breaker 45 Lights 46 Control System 48 Trouble shooting 49 Cabling overview 62 Index 65 ...

Page 5: ...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 wa...

Page 6: ...6 Identification plates Identification plates Chassis Chassis identification number Rnet output stage ID number Control panel Rnet ID number Rnet output stage Rnet control panel ...

Page 7: ...th 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 2 Remove the seat lift 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 upwar...

Page 8: ...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 me...

Page 9: ...ctions 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 ...

Page 10: ...lling it straight out If necessary carefully lever it out using a screwdriver in the slot on the cap 4 Remove the four screws that hold the wheel in place The central screw must not be removed m Warning 5 Remove the wheel by pulling it straight out Assembly Assemble in the reverse order Tighten the four screws using a dynamometric wrench Tightening torque 24 Nm 3 2 1 1 Hub cap 2 Screw ISO 4762 M8x...

Page 11: ...Ensure that pneumatic tires are not pressurized before the rim is taken apart otherwise there is a risk of personal injury m Warning 3 Remove the six screws holding the two halves of the rim together see illustration 4 Take the rim apart Assembly Assemble in the reverse order Tighten the six screws using a dynamometric wrench Tightening torque 22 Nm The recommended tire pressure for pneumatic tire...

Page 12: ...ged 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 24Nm Fitting of rim 4 3 2 1 1 Hubcap 2 Bolt ISO 4017 M8x16 8 8 Fe Zn 5 C1 Locking coat DIN 267 28 3 Washer 8 5x23x3 4 Rear heel Pos Description Do not use a Pneumatic i...

Page 13: ...ar 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 1 Hubcap 2 Bolt ISO 4017 M8x16 8 8 Fe Zn 5 C1 Locking coat DIN 267 28 3 Washer 8 5x23x3 4 Bolt ISO 4762 M6x40 8...

Page 14: ... 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 m NOTE Removing the support wheels entails an increased risk of the wheelchair tipping over Wheelchairs with support wheels fitted as standard...

Page 15: ...nt 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 m WARNING ...

Page 16: ... springs and fit with the socket and the screw see fig Use a torque wrench to tighten the bolt to 24Nm Wheel fork with friction brake 1 Plastic plug 2 Bolt ISO 4017 M8x16 8 8 Fe Zn 5 C1 Locking coat DIN 267 28 3 Socket 4 Disc spring 5 Bearing 6002 2RS1 15x32x9 6 Circlip DIN 472 Ø32 Pos Description 1 2 3 6 5 16 Wheel Forks 4 Do not use a Pneumatic impact wrench m NOTE The bolt must be used once onl...

Page 17: ...ndamaged 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 91Nm The rear wheel suspension is fitted with three bolts with two washers and one nut each 1 2 Pos De...

Page 18: ...h 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 Th...

Page 19: ...Return damping valve 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 ...

Page 20: ...nd 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 lift seat post see fig 7 Disconnect the wheel lock release cable 8 Remove the shock absorbers front brac...

Page 21: ... side in quesstion by loosening the knobs that holds the battery cover and drop the cover down 11 Remove the slewing bracket it is fitted with a bolt with washer For removal of the drive motor see page 28 Fitting Fit the slewing brackets in the reverse order Tighten the bolt holding the wheel fork in place with a torque wrench Use a torque wrench to tighten the bolt to 11 ft Ibs 15Nm Do not use a ...

Page 22: ... the right front fender see page 7 4 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 1 2 Wheel lock release cable attachment at the magnetic wheel lock 7 Remove the cable at the magnetic wheel lock by pulling the cable casing forward and pa...

Page 23: ... that the wheel lock release sensor see figure is actuated just before the cable pulls the release 3 Ensure that the wheel cannot be turned before the wheel lock release sensor has been actuated 4 Ensure that the wheel can be turned when the wheel lock release coupling is released with the release lever 5 Tighten the lock nut 1 6 Refit the wheel lock release mechanism and the covers Mechanism for ...

Page 24: ...e page 7 4 Remove the wheel lock release mechanism see page 22 5 Remove the wheel lock release sensor It is attached with two screws see fig 6 Disconnect the electrical connection of the wheel lock release sensor it s positioned on the wheel lock release sensors cabling Fitting Fit the Wheel lock release sensor in the reverse order Wheel lock release sensor 1 Locking nut DIN 985 M3 6 Fe Zn 5 C1 2 ...

Page 25: ...ned on the inside of the chassis on each side of the seat lift seat post 6 Pull the cable casing forward out through the slot in the cable holder and detach the wheel lock release cable from the magnetic wheel lock see fig 7 Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground 8 Loosen the shock absorbers front end Follow the instructions on page 18 until...

Page 26: ...nstructions on the back of the magnetic wheel lock see fig 2 Fit the wheel lock disk in the magnetic wheel lock 3 Fit the cover Wheel lock adjustment is made using the two adjusting screws Magnetic wheel lock wheel lock disk cover and rubber seal disassembled Magnetic wheel lock wheel lock disk and cover assembled ...

Page 27: ...ith the motor s cable bracket Now fit the magnetic wheel lock using the three screws 5 Refit the shock absorbers front end see page 18 Magnetic wheel lock electrical connection Align the parts with one another using one of the attachment screws Fit the rubber seal Fit the wheel lock release cable 7 Fit the wheel lock release cable see figure 44 8 Fit the covers see page 7 6 Connect the magnetic wh...

Page 28: ...ront fender on the side in question see page 7 5 Lift up and chock up the wheelchair chassis so that the wheel in question is free of the ground 6 Remove the wheel in question see page 10 7 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 8 Pull the drive motor s ...

Page 29: ...29 Drive motor Drive motor 9 Remove the drive motor It is attached with three screws see fig Fitting Fit the drive motor in the reverse order Drive motor with gear Drive motor mounting screws ...

Page 30: ... ally 1 Switch off the main power switch on the control panel 2 Remove the cushion from the seat by lifting it straight up 3 Remove the seat plate s See the illustration Drills must not be used in connection with manual operation of the seat lift There is a risk of damage to materials m Warning 4 Raise lower the seat using the seat lift crank supplied The seat plates for the PS seat are held in pl...

Page 31: ...the seat Seat lift s upper attachment screws 6 Remove the Seat lift It is attached with four screws see fig The upper attachment screws are accessible from the the battery boxes Open the battery covers and pull each battery out just enough to get access to the screws through the holes in the chassis Seat lift s lower attachment screws The seat is heavy Two people should therefore lift it Be carefu...

Page 32: ...34 7 Remove the four screws which secure the seat lift Fitting 1 Identify the holes for fitting the seat lift on the chassis see the figure Older chassis models may not have the two lower holes The chassis must then be adapted see page 35 2 Identify the holes on the seat lift for the relevant configuration see page 33 3 Fit the lower fixing screws and appropriate washers see page 33 When fitting a...

Page 33: ...s C400 500 STD C400 500 VS C400 500 LOWRIDER Wheelchair chassis Wheelchair chassis Wheelchair chassis When fitting a seat lift to an older adapted chassis without fixed nuts on the lower holes use the nuts and washers supplied in the same way as on the upper fixing screws m NB ...

Page 34: ...bling to the ICS General Module see figure below Connection 1 Connect the seat lift cabling to the ICS General Module see figure below 2 Fit the ICS General Module to the chassis using the appropriate screw see figure Connection of the seat lift to the ICS General Module Connected to the ICS Master Module Connected to the seat lift The ICS General Module is fitted with one screw ...

Page 35: ...lder chassis An older chassis may have been designed for a different seat lift model To fit the new type of seat lift the chassis needs to have two new holes see figure below On an older chassis two new holes need to be drilled to fit the seat lift ...

Page 36: ...crew each Note the positions of the sensors for subsequent fitting see figure Fitting Fit in the reverse order Seat lift motor s connection contacts Positions of the sensors on the seat lift The motor is held in place by three screws Sensor fitted on the seat lift Seat lift motor Removal 1 Disconnect the seat lift cabling from the motor Note the positions of the cables see figure 2 Remove the moto...

Page 37: ...tment 1 First fit the belt on the seat lift screw s cogwheel and then on the motor shaft s cogwheel 2 Adjust the belt tension by moving the motor shaft sideways The belt is correctly tensioned when it can be pressed in 4 5 mm see figure below 3 Tighten the two screws that hold the seat lift motor s shaft see figure below 4 Check the belt tension Adjust as required as described in 2 3 above The sea...

Page 38: ...he seat using the seat lift crank supplied 4 Screw the height adjustment screw in place in the desired height position 5 Lower the seat using the seat lift crank supplied Turn the seat so that the height adjustment screw ends up in its groove See figure Adjusting the Seat Height using the seat lift crank The length of the fixed seat post can be adjusted to five different fixed positions 1 2 After ...

Page 39: ... seat tube is attached with four screws The Seat Post s lower attachment screws The Seat Post s upper attachment screws Because the seat is heavy it should be lifted by two persons Be careful with the cabling m NOTE 6 Remove the fixed seat tube It is attached with four screws see fig The upper attachment screws are accessible from the the battery boxes Open the battery covers and pull each battery...

Page 40: ...positions of the cable ties for subsequent fitting 3 Divide the control panel cabling at the contact on the cabling 4 Remove the control panel 1 It is held in place with two screws see illustration These two screws also hold the bracket for the ICS control panel 2 if there is one fitted see illustration Assembly Assemble in the reverse order The control panel is held in place with two screws 1 2 ...

Page 41: ... and the chassis cover see page 7 5 Lift the R net controller out of its holder see fig 6 Disconnect the electrical connections to the R net controller being attentive to their placement see figure Fitting Assemble in reverse order Older models of C500 have output stages of type PM80 while later models have output stages of type PM90 When renewing output stages on older models PM80 may be replaced...

Page 42: ...e main power switch on the control panel 3 Remove the seat lift cover and chassis cover see page 7 4 The ESP module is fitted at the very front of the chassis Remove the cable from the ESP module by pulling it straight out see figure Disconnecting the cable from the ESP module 5 Remove the ESP module s bracket which is held in place by two screws see figure The ESP module s bracket is held in plac...

Page 43: ...ur screws see figure Connecting the cable to the ESP module 2 Fit the ESP module and its bracket using the two screws see figure The ESP module s bracket is held in place by two screws The ESP module is held in place by four screws 3 Attach the cable to the ESP module by pressing it straight in see figure 4 Refit the seat lift cover and chassis cover see page 7 ...

Page 44: ...efective the seat can be raised lowered manually see page 30 2 Switch off the main power switch on the control panel 3 Put the circuit breaker in the OFF position It is accessed through a hole in the chassis cover see page 45 4 Remove the seat lift cover and the chassis cover see page 7 5 Lift the ICS Master module out of its holder see fig 6 Remove the lid from the ICS Master Module 7 Clip the ca...

Page 45: ...he two screws see fig Circuit breaker replacement 1 Remove the seat lift cover and the chassis cover see page 7 2 Put the circuit breaker in the OFF position It is accessed through a hole in the chassis cover see fig 3 Disconnect the minus cable from the left battery 4 Disconnect the plus cable from the right battery 9 Mount the new circuit breaker with the two screws see fig A tripped circuit bre...

Page 46: ... 45 3 Remove the seat lift cover chassis cover and the front fender on the side in question see page 7 4 Disconnect the electrical connection of the front light in question it s positioned on the front light cabling on the inside of the chassis 5 Clip the cable ties that hold the cable 6 Remove the Cable pass through on the front fender in question 7 Remove the front light in question It is attach...

Page 47: ...e chassis cover see page 45 3 Remove the seat lift cover and the chassis cover see page 7 4 Disconnect the electrical connection of the rear light in question it s positioned on the rear lights cabling on the inside of the chassis 5 Remove the rear light in question It is attached with two screws see fig Fitting Fit the rear lights in the reverse order The rear lights are attached with two screws ...

Page 48: ...he wheelchair s other settings and equipment The control system can also be programmed in order to make adjustments needed for a specific user Standard parameter files can be downloaded from Permobil s website www permobil se For more information on programming adjustment of the Rnet control system and obtaining parameter files see the technical user manual for programming R net Art no 205222 SE 0...

Page 49: ...heelchair cannot be Battery charger connected Stop charging and disconnect driven the charging cable from the wheelchair s charging socket Brake release activated Reset the brake release The wheelchair is locked Unlock the wheelchair See user manual An exclamation mark on the Electronics fault See pages 50 61 control panel display is flashing rapidly and the wheelchair will not run The wheelchair ...

Page 50: ...omewhere in the wheelchair s electric al system NB If the fault is in a module that is not currently being used it will still be possible to drive the wheelchair but the diagnostic screen is displayed occasionally Switch off the wheelchair and leave it off for a few minutes Then restart the wheelchair If the fault persists you must switch off the wheelchair and get in touch with your service conta...

Page 51: ...hich protection circuit has been triggered PM Low Battery 2C00 Error code Identified module Error message PM 0506 Controller Fault 2 1 4 Example The screen example shown below displays the following information Identified module Power module error Error message Low Battery Error code 2C00 This means that the battery needs charging or that the battery has not been connected properly Check the batte...

Page 52: ... of programming directly in the system On Board Programming OBP Contact Permobil or your repair engineer for more information on OBP Go to OBP mode Select System from the menu Select Diagnostics from the menu The diagnostics screen will now appear showing the connected modules and version history See the illustration below If a module has experienced no errors the message No Entries will be displa...

Page 53: ...otor Error Go to section 3 5 M2 Motor Error Go to section 3 5 Inhibit Active Go to section 3 6 Jstick Cal Error Go to section 3 7 Latched Timeout Go to section 3 8 Brake Lamp Short Go to section 3 9 Left Lamp Short Go to section 3 10 Right Lamp Short Go to section 3 10 L Ind Lamp Short Go to section 3 11 R Ind Lamp Short Go to section 3 11 L Ind Lamp Failed Go to section 3 12 R Ind Lamp Failed Go ...

Page 54: ...d or a poor connection between the control system and the batteries Check the batteries and their connection to the control system If the error persists after the batteries and connections have been checked the power module may be defective Read more in section 5 3 4 Brake Error This occurs when the control system detects a problem in the solenoid brakes or the connections to them 1505 M1 Brake Er...

Page 55: ...ircuit in the brake lamp electrical circuit Read more about connectors in section 2 3 Check the brake lamps their cables and the connections to the control system 3 10 Lamp Short This occurs when the control system detects a short circuit in the electrical circuit of one of the lamps 7205 Short circuit left hand lamp 7209 Short circuit right hand lamp Check the lamps their cables and the connectio...

Page 56: ... from PGDT and cycle the voltage If this has dealt with the error Connect one third party module at a time and cycle the voltage each time If the error recurs after one of the voltage cycles the last module to be connected must be defective If the error persists after the checks listed above the power module may be defective Read more in section 5 3 18 PM Memory Error This is a specific error in t...

Page 57: ...m settings Check all parameter settings and then reprogram the control system with the help of R net s PC programmers Make a note of the current parameter settings and then reset the control system to the standard settings Reprogram the required settings in small groups and cycle the voltage after each group to see if the error recurs If the error persists after the checks listed above the power u...

Page 58: ...ective Read more in section 5 3 23 Gone to Sleep energy saving mode This occurs when the system has not been used for a period that exceeds the Sleep Timer parameter used for setting the energy saving mode Each time this occurs it is registered in the system log 3 24 Charging This occurs when the control system detects that a charger has been connected to either inhibit contact 1 or inhibit contac...

Page 59: ... are securely installed Do not over tighten the mounting screws m Warning The tests described are minimum recommendations It is the responsibility of the repair engineer s to perform other tests on the basis of the original error source and the wheelchair model The necessary information on other tests is available in the wheelchair service manual Permobil cannot be held responsible for losses of a...

Page 60: ...e checking that it runs smoothly and is easy to maneuver Repeat the test with the speed control set to the highest possible value 4 4 Gradient test Run the wheelchair forwards up its steepest permitted gradient Release the joystick when the wheelchair is on the upward slope and check that the wheelchair stops and that the brakes function as they should without the front wheels lifting from the gro...

Page 61: ...atic end stop tracking that is in the seat and light module ISM 4 7 Test of inhibit signal Connect a suitable battery charger or equivalent inhibit connecting device in the charging contact on the joystick module and check that the wheelchair is prevented from running If inhibit contacts 2 3 4 and 5 are used for inhibiting or speed restriction an appropriate test should be performed in order to ch...

Page 62: ...62 Cabling overview A B C D E F 1 2 3 4 ...

Page 63: ...63 Innehåll Cabling overview Cabling overview A B C D E F 5 6 7 8 ...

Page 64: ...64 Notes ...

Page 65: ...38 Front wheels 10 Fuses 44 I ICS Master Module 44 Identification plates 6 Introduction 5 L Lights 46 M Magnetic wheel lock 25 R Rear wheels 12 Rear wheel suspension 17 R net controller 41 S Seat lift 30 Shock absorbers 18 Slewing brackets 20 Support wheels 14 T Trouble shooting 49 W Wheel forks 16 Wheel lock release cable 22 Wheel lock release sensor 24 ...

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Page 68: ...Order no 205227 US 0 Permobil C500 ...

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