Permobil Trax, Service Manual

Page 1: ...SERVICE MANUAL Trax US ...

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Page 3: ... US 0 How to contact Permobil Head Office of the Permobil group Permobil Inc USA 6961 Eastgate Blvd Lebanon TN 37090 USA Email info permobilusa com Phone 800 736 0925 Fax 800 231 3256 Permobil AB Box 120 861 23 Timrå Sverige E post info permobil se Tel 060 59 59 00 Fax 060 57 52 50 ...

Page 4: ...uckle spring mounting in the front wheel assembly 30 Manual steering moving between the right and left sides 32 Changing the steering wire adjustment front wheel adjustment Toe in 33 Power steering adjustment 35 Potentiometer front wheel assembly 36 Changing the lights indicators 37 Changing the wheel base manually Electrical wheel base adjustment 38 Bumper positions 40 Pinch protection switch 41 ...

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: ...Introduction 6 Rating plates Trax Chassis Seat lift Identity marking Chassis no Identity marking Seat lift Rear edge of battery box ...

Page 7: ...y is used on older wheelchairs Warning A drill must not be used to raise the seat There is a risk of damage to the electronics unit 1 Raise the seat lift by turning the centre bolt on the front of the seat lift counterclockwise see the figure to the right Turn counterclockwise to raise the seat lift Raising the seat lift electrically The seat lift is raised electrically using the button box on the...

Page 8: ...sconnect the contact which is connected to the jack panel Fitting 1 Place the cover on the chassis after the rear lighting cable has been connected to the jack panel NB The rear lighting cable must not be pulled over any of the drive motors There is a risk that the cable will become caught between the motor brake and the cover 2 Screw down the four screws which hold the cover in place 3 Fold the s...

Page 9: ... to the rear lights Disconnect the contact which is connected to the jack panel Fitting 1 Place the cover on the chassis after the rear lighting cable has been connected to the jack panel NB The rear lighting cable must not be pulled over any of the drive motors There is a risk that the cable will become caught between the motor brake and the cover 2 Screw down the four screws which hold the cover...

Page 10: ...tch off the power on the manoeuvring panel and then switch off the electric circuit using the battery cut out 3 Remove the cover which is held in place by four screws See page 7 4 Disconnect all battery connections the positive poles first and then the negative poles 5 Loosen the straps which hold the batteries in place Fold the front straps forwards over the front of the battery box Check that th...

Page 11: ...atteries in place with the straps Tighten the straps properly so that the clamping bow is tensioned 3 Connect the battery connections first the negative poles and then the positive poles NB The cables must be located correctly See the figure below 4 Refit the cover after the rear lighting cable has been connected to the jack panel See page 7 5 Switch on the battery cut out 6 Charge the batteries F...

Page 12: ...e If necessary install the new key and check for fit 3 Lubricate the shaft with a thin layer of copper paste Würth 0893800x Art no 1820540 Warning Other types of bolts or washers are not to be used Warning Do not use any other type of thread lock Warning Do not use any type of lubrication in the threaded hole in the axle or on the bolt If necessary you should clean these parts 4 Fit the wheel onto...

Page 13: ... out the locking lip on the toothed plate connector 3 Thread the axle nut off the wheel axle 4 Pull the wheel off the axle Fitting the front wheel 1 Fit the wheel onto the axle 2 Place the locking washer on the axle 3 The nut must not be tightened too hard The wheel must turn easily Fold the toothed plate connector s locking lip into the axle nut s recess so that it is fixed 4 Thread the plastic p...

Page 14: ...ped with a fixed seat tube the screw at the rear of the seat must be loosened so that the seat can be tipped forwards 2 Remove the cover See page 7 Press the brake release handle down to its lower position to facilitate removal 3 Loosen the two screws in the pinch protection plate 1 4 Loosen the locking nut 2 5 Screw the adjusting screw 3 all the way in 6 Loosen the wire at the magnetic brake and ...

Page 15: ...assis 4 Check that the brake works Release the brake with the release lever and check that the wheel can turn 5 Screw any pinch protection plate in the brake release mechanism in place 6 Refit the cover See page 7 NB Check that the switch for the pinch protection switches by lowering the seat lift and simultaneously pressing the switch at the front of the cover The lift should then stop Brake rele...

Page 16: ...ition 2 Remove the cover which is held in place by four screws See page 7 3 Disconnect the electrical connection of the magnetic brake See the figure to the right 4 Detach the brake release wire first from the drive assembly and then from the clamp of the magnetic brake 5 Unscrew the three screws which hold the brake and remove the brake brake disc and cover 6 Note the position of the brake releas...

Page 17: ...e brake Follow the instructions on the decal on how the two Allen screws are adjusted 2 Place the magnetic brake s brake disc in the brake assembly 3 Put on the cover Changing the magnetic brake Brake setting Magnetic brake Magnetic brake ...

Page 18: ...ctrical connection 4 Insert a screw to align the parts and screw the magnetic brake in place on the motor using the three screws 5 Connect the magnetic brake s electrical connection to the jack panel 6 Fit the chassis cover See Covers page 7 Magnetic brake ...

Page 19: ...ng panel s OFF button 0 before switching the power off on the main fuse battery cut out 4 Remove the cover See page 7 5 Block up the appropriate side of the wheelchair 6 Remove the rear wheel See Changing the drive wheel page 10 7 Detach the electrical connections from the interference suppression card Detach the electrical connections for the magnetic brake See the centre figure to the right 8 Un...

Page 20: ...d with electrical extension it must be extended to its outermost position Remove the rear extension adjustment device from the mounting Then press the front wheel assembly in approximately 10 cm Fold the adjustment device motor electrical extension away from the drive assembly in order to be able to remove the drive assembly 11 Loosen the three screws of the drive assembly 12 Lift the drive assemb...

Page 21: ...etic brake on page 12 2 Lift the motor into place on the chassis 3 Screw the motor in place with the three screws Changing the drive motor Brake release wire 4 First attach the brake release wire to the magnetic brake s clamp and fix the brake cable to the mounting on the motor See the figure to the right Fit the motor Lift the motor in ...

Page 22: ...ectronics are fixed with three screws See 2 in the figure to the right 7 Connect the magnetic brake Screw the electrical connections in place on the interference suppression cards 8 Fit the rear wheel See Changing the drive wheel page 10 9 Refit the cover See page 7 10 Switch on the main fuse battery cut out Battery cut out Rear wheel assembly Magnetic brake connection Interference suppression car...

Page 23: ...from the drive assembly The interference suppression card is held in place by two screws Changing the carbon brush in the drive motor Cable connections in the drive motor 4 Remove the brush holder by pressing the cable terminal clockwise with your thumb See the figure to the right NB Change only one brush holder at a time Brush holder 5 Tip the brush holder forwards carefully Removing a brush hold...

Page 24: ...that the cable which is located in the brush holder is not stretched and does not get into the motor Loosen the cable connection Change the brush holder Fitting Takes place in reverse order see above 1 Screw the cable connection onto the brush holder 2 Press the brush holder into the drive assembly 3 Screw the two cables from the interference suppression card to the brush holders 4 Screw the inter...

Page 25: ...he seat lift motor Seat lift motor mounting Seat lift motor connection The seat lift motor must not be operated before the motor has been properly screwed to the seat lift See the figure at the top right There is a risk of material damage Fitting 1 Press the motor shaft into the seat lift s screws 2 Tighten the two screws which fix the motor in place on the rear of the seat lift See the figure to ...

Page 26: ...o the right Cable attachment Seat lift mounting Seat mounting 4 Unscrew the two screws under the seat mounting Lift the seat off the chassis Detach the cables from the battery poles and remove the batteries See page 8 5 Disconnect the seat lift motor s cables from the jack panel Unscrew the two screws on the seat lift motor and remove it See page 21 6 Unscrew the screw and locking nut at the very ...

Page 27: ... seat lift motor to the jack panel 6 Lift the batteries back onto the chassis Attach the battery connections first the negative poles and then the positive poles See page 9 7 Lift the seat and seat plate onto the seat lift Screw the two screws in place under the seat mounting See the figure to the right Tighten the screws properly 8 Connect the seat s cable connection to the jack panel Tie the cab...

Page 28: ...her way from the front wheel assembly s insert in the chassis 6 Press in new bushes The innermost bush is pressed in to the edge of the recess for the stop lug The outer bush should be flush with the front edge of the tube 7 Fit the front wheel assembly back on the chassis Apply loctite 628 to the threads of the four screws and screw the stop lug in place 8 Mount the length adjustment at the rear ...

Page 29: ...ssis and fit the plastic plug on the steering link 9 Attach the steering wire to the steering link 6 Press out the inner sleeve which is located in the bearing 7 Press out the sliding bearing which is located in the swing arm 8 Press in a new bearing NB Be very careful that the edge of the sliding bearing is not damaged during fitting If the edge is damaged it is more difficult to fit the inner sl...

Page 30: ...t wheel See page 10 Steering knuckle spring mounting Front mudguard Remove the articulated strut and plastic plug Loosen the steering mounting 4 Remove the articulated strut Remove the locking pin and pull apart the articulated strut or loosen the screw in the steering mounting 5 Remove the plastic plug using a screw driver 6 Loosen the M8 screw and lift up the steering mounting Plastic plug Artic...

Page 31: ...ding bush and knuckle spring as required Press out the steering knuckle spring Changing the knuckle spring Screw the ball bearing back 9 Refit the steering mounting Press the articulated strut in place on the ball and fix it with the locking pin Refit the sliding bush with the ball bearing 10 Press the M8 screw down hard so that it threads Tighten the screw close against the end of the steering kn...

Page 32: ...e joystick mounting from the chassis Place any screw in the hole so that the swing arm does not fall down 10 Unscrew the cover protection from the expander bar It is mounted with three screws Turn the cover protection and move the potentiometer and front light cables to the other side of the bar Screw the cover protection in place on the other side of the expander bar 11 Screw the steering wire s ...

Page 33: ... in place in the front wheel assembly s steering plate Fix the steering wire in the mounting at the very rear of the foot plate 11 Fix the cable between the batteries as shown in the figure to the right NB Do not tie the steering wire together with the brake wires and the pinch protection cables 12 Fix the cable in the cable holder in the rear wheel assembly Only the steering wire is to be fixed i...

Page 34: ... articulated struts on both sides half a turn Check the measurement between the centre lines of the front wheels The distance between the centre lines of the front of the front tyres must be 2 4 mm less than the distance between the rear of the front tyres See the top right figure 6 Screw the articulated struts in place in the steering plate NB The articulated struts must be in place when the meas...

Page 35: ...ng nuts at both ball joints of the steering wire and thread the ball joints in or out Adjustment must take place both in the front wheel assembly and at the power steering NB The wire must engage with the ball joint with at least 4 threads to ensure that the connection holds Tighten the locking nuts after adjustment and check that the steering wire s ball joint passes the end positions of the powe...

Page 36: ...ometer off the axle 8 Remove the axle which is held in place with two screws Fitting 1 Fit the axle on the steering mechanism using the two screws 2 Lubricate the O ring with grease Adjust the bevel on the axle journal so that it corresponds with the potentiometer Press the potentiometer carefully into place on the axle Screw the potentiometer in place in the holes provided under the front wheel a...

Page 37: ...own towards the foot plate 2 Unscrew and remove the protective plate on the inside of the front mudguard Pull out the clamp which fixes the indicator to the mudguard 3 Pull the indicator housing away from the insert 4 Pull out the bulb 5 Press in a new bulb 6 Press the indicator housing into the insert Pull the rubber protector over the contact 7 Place the indicator in the mudguard Press the clamp...

Page 38: ...i Justerstång It is possible to set seven different lengths When the wheelchair is transported hole G in the adjustment bar always matches hole G in the chassis i e the shortest length See the example to the right The lengths below indicate the c c dimensions between the front and rear wheels Other lengths are A to A 1015 mm B to B 980 mm C to C 945 mm D to D 910 mm E to E 885 mm F to F 850 mm G t...

Page 39: ...ear of the adjustment device 8 Block up the wheelchair under the battery box so that the wheels are approximately 5 cm clear of the ground 9 Detach the bumper mountings on both sides NB When the wheelchair is blocked up under the battery box the lower frame moves down which makes it easier to change the extension motor 10 Disconnect the connections on the extension motor 11 Tip the motor so that i...

Page 40: ... NB Positions 5 7 raise the centre of gravity and must be avoided for adults Screw the first bumper in place in the new position 2 Loosen the upper screw on the second bumper Move the bumper to the position equivalent to that of the first bumper and screw it in place NB When the bumpers are to be moved from positions 1 4 to positions 5 7 both bumpers must be moved at the same time Block the wheelc...

Page 41: ...ection in place with two screws Straighten the pinch protection before screwing it in place NB Check that the pinch protection s switch roll is placed on top of the brake release plate before it is screwed in place Tighten the screws until they meet the base Tighten the screws but not too hard 2 Lay the cable between the batteries and back towards the jack panel Tie the cable to the brake release ...

Page 42: ...tomatically return to its original position when it has been pressed down 4 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 the seat plate Loosen the four screws which hold the plastic seat 5 Remove the two screws from the top of the seat plate with which the spring plate is mounted 6 Turn the spring...

Page 43: ...the swivel stop Screw in place again in the new holes Check when mounting that the drive is on the correct side of the swivel stop 4 Refit the seat and connect the cable to the rear of the back NB The seat swivel direction must be changed in Mini Config New holes 5 Changes in Mini Config Start Mini Config Hold down the LIGHTS and MAX SPEED buttons when the chair is started with the ON button Set t...

Page 44: ... chassis and front wheel assembly Connection in jack panel Fitting 1 Lay the cable behind the expander bar and in under the seat lift back to the jack panel 2 Place the cable in the cable holder on the jack panel and connect the contact as shown on the decal on the chassis 3 Connect the contacts in the front wheel assembly one contact for each front light and pull the cable down to the potentiomet...

Page 45: ... charging socket 1 Screw the jack panel in place with two screws on the chassis See page 43 This does not apply if the charging socket is being moved 2 Screw the charging socket in place in the side mounting on the chassis with two screws Do not tighten the screws too hard 3 Lay the cable from the charging socket and down to the jack panel See the figure to the right Fix the charging cable to the ...

Page 46: ...aying Electronics removed Fitting the electronics 1 Screw the wide contact SUB D in place and connect the panel cable to the electronics Connect the charging cable s 2 pin contact to the lower left part of the electronics 2 Place the electronics in the chassis 3 Fit the electronics on the chassis Screw the electronics in place with three screws on the rear of the chassis 4 Fit the protective cover...

Page 47: ...s mounting on the chassis Jack panel Contacts in the jack panel Fitting the jack panel 1 Screw the jack panel in place with two screws 2 Screw the charging socket to the chassis It is fixed to the chassis with two screws Do not tighten the screws too hard NB If the chair is equipped with electrical extension the contacts on the rear of the jack panel must be connected to the adjustment device moto...

Page 48: ...nel 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 See the figures to the right 1 Change the blown fuse Charging Adjustment device Lights indicators Invest...

Page 49: ...t Fitting 1 Connect and fix the cables by tightening the screws under the main fuse Tighten the screws well 2 Place the main fuse in the mounting Fix the main fuse in the mounting plate by pressing in the locking spike on the top of the main fuse 3 Place the mounting plate with the main fuse on the chassis 4 Screw the main fuse in place with the two screws located on the top of the rubber cover 5 ...

Page 50: ...d tubes of the side bows Fix the upper bow with the two star handles See the bottom figure to the right Ensure that the upper bow can easily be removed from the side bows 5 Then tighten all the bow s screws Removal 1 Loosen the star handles and lift off the upper bow 2 Unscrew the side bows rear 2 M8x16 screws and plain washers 3 Loosen the front screws of the side bow Each mounting is held in pla...

Page 51: ... is fitted on the right side without a joystick the extension sleeve does not have to be used NB If a bow is fitted on the wheelchair the crutch holder cannot be fitted with this mounting Other information The Velcro tape for holding the crutches is reversible This means that the crutches can always be released easily regardless of whether they are fitted on the right or left side Also see Assembl...

Page 52: ...rew and remove the four screws which hold the cover Lift off the cover and remove the mounting NB Be careful of the cable which goes to the rear lights Disconnect the contact which is connected to the jack panel 5 Drill up the two other newly drilled holes for the mounting in the cover with a 5 5 mm bit 6 Screw the mounting to the cover with M5x16 screws and 5 3x12x1 washers in the top holes on th...

Page 53: ... box to the mounting NB The lower part of the luggage box can be turned through 180 on the mounting sleeve so that the lock faces the seat i e forwards M6x25 Fitting the mounting plate Luggage basket Mounting plate Mounting sleeve M5x10 1 Proceed as described in points 1 9 on the previous page 2 Place the mounting sleeve on the mounting and fix it with the two quick action locks Screw the luggage ...

Page 54: ...ositive and negative poles 2 The green cable is laid down to the main fuse battery cut out Motor 1 Cable laying from the drive assembly and electronics 2 The cable trunk to the batteries and right motor is laid over the electronics and through the hole on the fuse cover See the arrow to the right Jack panel 1 Connection of contacts to the jack panel 2 Look at the decal to see where the contacts ar...

Page 55: ...wire seen from the rear Laying the power steering cable seen from the side Cable laying in the front wheel assembly seen from the side Steering wire 1 Fixing the power steering cable to the chassis Front wheel assembly 1 Position of the cable for the front lights in the front wheel assembly Power steering cable Steering wire Power steering cable Steering wire ...

Page 56: ...ng behind the seat seen from the rear Trax seat 1 Fix the cable at the very front of the panel holder tube 2 Then tie it at the base of the arm rest tube 3 Lay the cable in a loop under the arm rest and tie it to the panel holder tube 4 Check that the arm rest can be tipped up without the cable being stretched or damaged Trax seat 1 Connect the panel cable to the bus socket 2 Lay the cable in a lo...

Page 57: ...57 Notes ...

Page 58: ... PCB FUSE ACTUATOR UL 0 56 Grey UL 0 56 Red UL 0 56 Red UL 0 56 Red UL 0 56 Red UL 0 56 Red UL 0 56 Red 2 UL 0 56 Blue UL 0 56 Grey 23 25 24 UL 0 56 Red UL 0 56 Red UL 0 56 Red UL 0 56 Red 17 18 19 20 21 22 UL 0 56 Black FKUX 0 25 White UL 0 56 Yellow UL 0 56 Violette UL 0 56 White UL 0 56 Grey UL 0 56 Blue 11 13 12 14 15 9 7 8 FKUX 0 25 Blue FKUX 0 25 Blue 6 4 5 10 FKUX 0 25 Grey FKUX 0 25 Brown ...

Page 59: ...wn Rk 4 0 Black Rk 1 5 Red Rk 4 0 Red Rk 4 0 White Rk 4 0 Yellow Rk 4 0 Red Rk 1 5 Grey Rk 4 0 Grey Rk 4 0 Grey Rk 4 0 Grey Rk 4 0 M M M M M JOYSTICK M M EMI 8738 Right rear light LIGHT INDICATOR COMMON INDICATOR Right front light Speed Max 1 2 3 Key 1 2 K7 K6 K5 K8 K1 K2 K4 K3 SW2 SW4 SW1 SW3 CABLE UPPER 8424 K8 K7 SW4 K6 K5 K2 K1 K4 K3 SW1 SW3 SW2 MEMBRANSWITCH 6468 CABLE UPPER 8424 3 6 5 4 1 2 ...

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Page 64: ...Order no 201096 US 0 ...