Permobil Trax Service Manual
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Permobil Trax Service Manual

Power wheelchairs
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SERVICE MANUAL
Trax
US

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Summary of Contents for Permobil Trax

  • Page 1 SERVICE MANUAL Trax...
  • Page 3 800-231-3256 Email: info@permobilusa.com Head Office of the Permobil group Permobil AB Box 120 861 23 Timrå Sverige Tel: 060-59 59 00 Fax: 060-57 52 50 E-post: info@permobil.se Produced and published by Permobil AB, Sweden Edition no.3, 2010-02 Order no.: 201096-US-0...

  • Page 4: Table Of Contents

    Contents Contents Introduction .........................5 Technical support ......................5 Spare parts........................5 Warranties ........................5 Maintenance........................5 Rating plates........................6 Raising the seat lift ......................7 Covers ..........................8 Changing the batteries .......................10 Removal ...........................10 Fitting ..........................11 Changing the drive wheel ....................12 Changing the brake release wires..................14 Changing/adjusting the magnetic brake................16 Changing the drive motor ....................19 Removal ...........................19 Fitting ..........................21...

  • Page 5: Introduction

    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.

  • Page 6: Rating Plates

    Introduction Rating plates Rear edge of Trax battery box Chassis Identity marking Chassis no. Seat lift Identity marking Seat lift...

  • Page 7: Raising The Seat Lift

    Rating plates Raising the seat lift manually If the seat lift cannot be raised in the normal manner because the batteries are discharged or the adjustment device is defective, the seat can be raised manually with a 13 mm open-end spanner. NB.
  • Page 8 Raising the seat lift Cover (with fixed seat tube) Removal Loosen the rear Allen screws and tip the seat forwards, see the figure to the right. Unscrew the four screws which hold the cover in place. Lift off the cover. NB.

  • Page 9: Covers

    Covers Cover (with seat lift) Removal Raise the seat to its highest position. If the battery is discharged, see page 6. Unscrew the four screws which hold the cover in place. Lift off the cover. NB. Be careful with the cable which goes to the rear lights.

  • Page 10: Changing The Batteries

    Changing the batteries Changing the batteries NB. Use protective goggles when working with batteries. WARNING! First switch off the power on the manoeuvring panel before switching the power off on the main Front fuse. Clamping Removal Place the wheelchair on a level base. Battery connection, front Raise the seat to its highest position.

  • Page 11: Fitting

    Changing the batteries Fitting Insert two new gel batteries. The battery poles must face out from the centre. Fix the batteries in place with the straps. Tighten the straps properly so that the clamping bow is tensioned. Connect the battery connections, first the negative poles and then the positive poles. NB.

  • Page 12: Changing The Drive Wheel

    Changing the drive wheel Changing the drive wheel Removing the rear wheel 1. Raise and block up the wheelchair's chassis so that the wheel does not reach the ground. Thread the plastic plug out of the centre hole. 2. Loosen and remove the centre screw C, the Nordlock washer B and the rim locking washer A.

  • Page 13: Removing The Front Wheel

    Changing the front wheel Removing the front wheel 1. Raise and block up the wheelchair's chassis so that the wheel does not reach the ground. Remove the plastic plug from the centre hole. 2. Fold out the locking lip on the toothed plate connector.

  • Page 14: Changing The Brake Release Wires

    Changing the brake release wires Changing the brake release wires The right wire controls the left brake unit and the left wire controls the right brake unit. Removal 1. Raise the seat lift to its highest position. If the chair is equipped with a fixed seat tube, the screw at the rear of the seat must be loosened so that the seat can be tipped forwards.
  • Page 15 Changing the brake release wires Fitting 1. Fit the wire first at the magnetic brake and then at the release lever. 2. Adjust the length of the wire sleeve using the adjusting screw (3) so that the wire is tensioned but does not pull on the release clamp.

  • Page 16: Changing/Adjusting The Magnetic Brake

    Changing the magnetic brake Changing/adjusting the magnetic brake Removal Raise the seat to its highest position. Remove the cover, which is held in place by four screws. See page 7. Disconnect the electrical connection of the magnetic brake. See the figure to the right. Electrical connection of the magnetic brake Detach the brake release wire first from the drive assembly and then from the clamp of...
  • Page 17 Changing the magnetic brake Fitting Check the setting of the brake. Follow the instructions on the decal on how the two Allen screws are adjusted. Brake setting Place the magnetic brake's brake disc in the brake assembly. Magnetic brake Put on the cover. Magnetic brake...
  • Page 18 Changing the magnetic brake Insert a screw to align the parts and screw the magnetic brake in place on the motor using the three screws. Magnetic brake Connect the magnetic brake's electrical connection to the jack panel. Fit the chassis cover. See "Covers", page 7.

  • Page 19: Changing The Drive Motor

    Changing the drive motor Changing the drive motor Removal The right and left motors are fitted and removed in the same way. Therefore, the procedure is described only for the left motor. When changing the left drive motor, it is necessary, however, to loosen the extension motor.
  • Page 20 Changing the drive motor 10. Unscrew the sheet metal mounting where the jack panel is mounted. Tip up the Bracket to electronics and the jack panel so that the jack there is room to remove the left drive panel. assembly. See the figure to the right. Electrical extension: If the wheelchair is equipped with electrical extension, it must be extended...

  • Page 21: Fitting

    Changing the drive motor Fitting When a new drive motor is to be fitted, the magneticbrake must be moved over from the old drive assembly. See "Fitting the magnetic brake" on page 12. Lift the motor into place on the chassis. Lift the motor in Screw the motor in place with the three screws.
  • Page 22 Changing the drive motor Fitting the drive motor, cont. Screw the jack panel in place with two screws. See (1) in the figure to the right. Screw the electronics in place from the outside of the chassis. The electronics are fixed with three screws.

  • Page 23: Changing The Carbon-Brush In The Drive Motor

    Changing the carbon-brush in the drive motor Innehåll Changing the carbon-brush in the drive motor Removal Remove the cover. See page 7. Unscrew the two cables which are connected to the drive motor. See the figure to the right. Unscrew the interference suppression card from the drive assembly.

  • Page 24: Fitting The Carbon-Brush

    Changing the carbon-brush in the drive motor Unscrew the cable connection from the brush holder. Make sure that the screw does not get into the motor. If it does, the motor has to be changed. Change only one brush holder at a time. Ensure that the cable which is located in the brush holder is not stretched.

  • Page 25: Changing The Seat Lift Motor

    Changing the seat lift motor Changing the seat lift motor Cable connection Removal Raise the seat lift and remove the cover. See page 7. Disconnect the seat lift motor's cables from the jack panel. Unscrew the two screws which hold the motor at the very rear of the seat lift.

  • Page 26: Changing The Seat Lift

    Changing the seat lift Changing the seat lift Removal Raise the seat lift and switch off the electric circuit on the manoeuvring panel and then the battery cut-out. See page 15. Remove the cover. See page 7. Disconnect the seat's cable connection from the jack panel.

  • Page 27: Fitting

    Changing the seat lift Fitting Place the seat lift in the mounting on the chassis. Screw the seat lift in place at the bottom of the mounting using screws, washers, ball bearings and locking nuts. Mounting the seat lift Screw the seat lift in place in the rear mounting with screws and locking nuts.

  • Page 28: Changing The Bush In The Front/Rear Wheel Assembly

    Changing the bush Changing the bush in the front/rear wheel assembly Steering wire mounting Changing the bush in the rear wheel assembly Switch off the electric circuit on the manoeuvring panel and then on the battery cut-out. See page 15. Remove the foot plate. See page 32. Contacts Detach the steering wire mounting from the front wheel assembly.
  • Page 29 Changing the bush Press out the inner sleeve which is located in the bearing. Press out the sliding bearing which is located in the Swing arm swing arm. Press in a new bearing. NB! Be very careful that the edge of the sliding bearing is not damaged during fitting.

  • Page 30: Steering Knuckle Spring Mounting In The Front Wheel Assembly

    Steering knuckle spring mounting Steering knuckle spring mounting Changing the steering knuckle spring suspension or steering knuckle bearing and O-ring Block up the front wheel assembly. Remove the front mudguard. See page Remove the front wheel. See page 10. Front mudguard Remove the articulated strut.
  • Page 31 Steering knuckle spring mounting Lift up and turn the steering mounting. Press out the spring using a screwdriver. NB. Be careful with the two O-rings and sliding bush which are located in the end position. If the bearings and O-rings need changing, press out the sliding bearing, remove the O-rings and fit new ones.

  • Page 32: Manual Steering (Moving Between The Right And Left Sides)

    Manual steering Manual steering (moving between the right/left) Steering on right or left side Remove the cover. See page 7. Remove the foot plate. See page 32. Remove the protective plate under the front wheel assembly. See page 32. NB! For manual steering it is necessary for the steering wire to be mounted on the same side in the front wheel assembly as the joystick is mounted.

  • Page 33: Changing The Steering Wire (Adjustment) - Front Wheel Adjustment (Toe-In)

    Changing the steering wire, front wheel adjustment Changing the steering wire, front wheel adjustment Changing the steering wire Remove the cover. See page 7. Remove the foot plate. See page 32. Remove the protective plate under the front wheel assembly. See page 32. Loosen the steering wire's ball joint, which is located at the very front in the steering plate of the front wheel assembly.
  • Page 34 Adjustment of Toe-in Adjustment of Toe-in Adjustment An important part of the steering system is the adjustment of toe-in. NB. Toe-in must be 2-4 mm measured at the centre line of the tyre. 2-4 mm shorter Toe-in check distance Check that the steering triangle is in the than at the position "straight ahead".

  • Page 35: Power Steering (Adjustment)

    Power steering (adjustment) Power steering (adjustment) Locking clamp Adjustment of power steering Remove the locking clamp and loosen the ball joint furthest out on the steering wire from the steering arm. Power steering Turn the front wheels fully to the right so that the steering wire is in its outermost position.

  • Page 36: Potentiometer, Front Wheel Assembly

    Power steering (adjustment) Changing the potentiometer, front wheel assembly Removal Unscrew and remove the foot plate if required. It is mounted with 8 screws. See the figure to the right. Block up the front wheel assembly or tip the wheelchair onto its side. NB.

  • Page 37: Changing The Lights/Indicators

    Changing the lights/indicators Changing the lights/indicators Changing the front lights Detach the front mudguard from the front wheel assembly. It is held by three screws. Fold it down. Unscrew and remove the protective plate on the inside of the front mudguard. Loosen the insert from the front mudguard.

  • Page 38: Changing The Wheel Base (Manually)/Electrical Wheel Base Adjustment

    Changing the manual wheel base Changing the manual wheel base When delivered, the wheelchair is always transported at its shortest possible length. When it has been unpacked, it must be adjusted to the correct length. On wheelchairs which are equipped with manual extension, the length is adjusted on the adjustment bar in the rear wheel assembly.
  • Page 39 Electric wheel base adjustment Electric wheel base adjustment Removal Move the foot plate in. If the adjustment device motor for extension is defective, the adjustment device must be detached from the front wheel assembly and the rear wheel assembly. See the figures to the right.

  • Page 40: Bumper Positions

    Changing the bumper positions Bumper positions Adjusting the bumper positions WARNING! WARNING! Move only one bumper at a time. There is a risk of personal injury. Loosen the upper screw first on one bumper. Move to the desired position. Position 1, see the positions in the figure to the right, tolerates a person with a high weight.

  • Page 41: Pinch Protection Switch

    Changing the pinch protection switch Changing the pinch protection switch Removing the pinch protection switch Raise the seat lift. See page 6. Remove the cover. See page 7. Remove the pinch protection by loosening the two screws. See the figure to the right. Cut off the two cable ties which fix the cable between the batteries.

  • Page 42: Changing The Seat Swivel Direction (Manually/Electrically)

    The lever must automatically return to its original position when it has been pressed down. NB. On chairs which are equipped with a Trax seat, it is necessary to remove the plastic Lever shell in order to be able to reach the screws screws on the top of the seat plate.
  • Page 43 Centre screw NB. On chairs which are equipped with a Trax seat, it is necessary to remove the plastic shell in order to be able to reach the screws on the top of Swivel stop decal the seat plate.

  • Page 44: Changing The Cable Of The Lights Potentiometer

    Changing the cable of the lights and potentiometer Changing the cable of the lights/ potentiometer Cable of lights, potentiometer Removal Raise the seat lift and remove the cover. See page 7. Remove the foot plate and disconnect the cable from the potentiometer. See page 32. Disconnect the cable's contacts which go to the front lights, one contact for each front light.

  • Page 45: Changing/Moving The Charging Socket

    Changing/moving the charging socket Changing/moving the charging socket Removing the charging socket Remove the cover. See page 7. Unscrew the guard cap for the charging socket. This applies when moving the charging socket Guard cap from the right to the left side, for example. When the charging socket is moved, the cover cap must also be unscrewed from the cover and moved to the cut-out on the other side.

  • Page 46: Changing The Electronics (Safe Gate)

    Changing the electronics Changing the electronics (Safe Gate) Removing the electronics Raise the seat lift or tip the seat forwards. See pages 6-7. First switch off the power on the manoeuvring panel and then switch off the electric circuit with the battery cut-out. Remove the cover.

  • Page 47: Changing The Jack Panel

    Changing the jack panel Changing the jack panel Removing the jack panel First switch off the power on the manoeuvring panel and then switch off the electric circuit with the battery cut-out. Remove the cover. See page 7. Disconnect the connections from the batteries positive (+) and negative (-) poles.

  • Page 48: Changing The Fuses In The Electronics And Jack Panel

    Changing the fuses Changing the fuses for charging, adjustment device, lights/indicators The fuses for charging (20 A), the adjustment device (15 A) and lights/indicators (7.5 A) are located in the base of the rear wheel assembly (jack panel). They are easily accessible from the rear of the wheelchair between the bumpers.

  • Page 49: Battery Cut-Out" Main Fuse

    Changing the main fuse Changing the main fuse/battery cut-out Removal First switch off the power on the manoeuvring panel and then switch off the electric circuit with the main fuse. Remove the cover. See page 7. Disconnect the positive pole connections of the main fuse.

  • Page 50: Accessories (Bows, Luggage Basket/Box, Crutch Holder, Rear-View Mirror)

    Fitting accessories Fitting accessories Fitting bows Fitting Remove the centre screw which holds the electronics. Fit the rear mounting with 3 M5x12 M6x40 and plain washers. See the figure to the right. Fix the side bows on the pins in the rear mounting.
  • Page 51 Fitting accessories Fitting the crutch holder Screw the mounting in place in the holes on the right or left side of the chassis. Use 3 M5x12 and plain 5.3x10x1.0 washers. Screwed to NB. An extension sleeve must be used the rear when the crutch holder is fitted on the power mudguard steering side in order to place it away from...
  • Page 52 Fitting accessories Fitting the luggage box/basket Fitting Remove the rear cover screws. Remove the oval Permobil decal. This does not apply to the recessed decal. Press the mounting down against the cover so that it touches the cover. Then screw the mounting in place in the two lowest holes.
  • Page 53 Fitting accessories Screw the lower part of the luggage box to M6x25 the mounting sleeve. See the figure to the right. For standard fitting, the lock is turned out from the wheelchair. Use five M6x25 screws and washers and locking nuts. 10.
  • Page 54 Cable laying Cable laying, chassis Batteries Cable laying to the positive (+) and negative (-) poles. The green cable is laid down to the main fuse/battery cut-out. Cable laying at the batteries (seen from the front) Motor Cable laying from the drive assembly and electronics.
  • Page 55 Cable laying Cable laying, chassis Steering wire Power steering Laying of the power steering cable. cable Place the cable along the side of the Steering wire chassis. Laying of the steering wire (seen from the rear) Steering wire Fixing the power steering cable to the Steering wire chassis.

  • Page 56: Cable Laying

    Cable laying Cable laying on seats CII/Trax arm rest Under the arm rest, the cable must be laid in a loop before it is tied. See the figure to the right. Check that the arm rest can be tipped up without the cable being stretched or damaged.
  • Page 57 Notes...

  • Page 58: Wiring Diagram

    Distribution Chart CABLE LOWER 8490 + 24V UL 0.56 Red Left brake UL 0.56 Black + 24V UL 0.56 Red Seat stop sensor FKUX 0.25 White SAFEGAT FRONT LIGHT CABLE 8257 UL 0.56 Red + 24V 8250 Orange Yellow UL 0.56 Yellow Front light UL 0.56 Grey Green...

  • Page 59: Distribution Chart

    Distribution Chart CONTROL PANEL8630/ SERVO 8700 JOYSTICK SAFEGATE JUNC BOX M3S-BUS 8772 8632/8704/6837 7986 8250 Grey Seat driver olette Servo driver Blue Seat/sevo - J1 J2 J3 J4 Black Left brake 6 Red + 24V 6 Red + 24V ellow Left light White CABLE UPPER 8424...
  • Page 64 Order no.: 201096-US-0...

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