Permobil Trax User manual

SERVICE MANUAL
Trax
US

Produced and published by Permobil AB, Sweden
Edition no.3, 2010-02
Order no.: 201096-US-0
How to contact Permobil
Head Office of the Permobil group
Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Email: [email protected]
Phone: [phone]
Fax: [phone]
Permobil AB
Box 120
861 23 Timrå
Sverige
E-post: [email protected]
Tel: [phone]
Fax: [phone]

Contents
4
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
Changing the carbon-brush in the drive motor ...............................................................23
Removal of the carbon-brush...........................................................................................23
Fitting the carbon-brush ...................................................................................................24
Changing the seat lift motor ..............................................................................................25
Changing the seat lift .........................................................................................................26
Removal ...........................................................................................................................26
Fitting ...............................................................................................................................27
Changing the bush in the front/rear wheel assembly .....................................................28
Steering knuckle 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
Changing the seat swivel direction (manually/electrically) ............................................42
Changing the cable of the lights potentiometer ..............................................................43
Changing/moving the charging socket.............................................................................45
Changing the electronics (Safe Gate) ...............................................................................46
Changing the jack panel.....................................................................................................47
Changing the fuses in the electronics and jack panel....................................................48
"Battery cut-out" main fuse ...............................................................................................49
Accessories (bows, luggage basket/box, crutch holder, rear-view mirror) ..................50
Cable laying .........................................................................................................................56
Wiring diagram ....................................................................................................................58

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.

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

7
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. An Allen key 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 manoeuvring panel, see
the Instructions for Use.
WARNING!

Raising the seat lift
8
Cover (with fixed seat tube)
Removal
1. Loosen the rear Allen screws and tip the
seat forwards, see the figure to the right.
2. Unscrew the four screws which hold the
cover in place.
3. Lift off the cover.
NB. Be careful with the cable which goes
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 in place.
3. Fold the seat down and refit the rear
Allen screw. Tighten the screw properly.
Rear Allen screw

9
Cover (with seat lift)
Removal
1. Raise the seat to its highest position.
If the battery is discharged, see page 6.
2. Unscrew the four screws which hold the
cover in place.
3. Lift off the cover.
NB. Be careful with the cable which goes
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 in place.
Covers
Cover screws

Changing the batteries
10
Changing the batteries
NB. Use protective goggles when working with
batteries.
Removal
1. Place the wheelchair on a level base.
Raise the seat to its highest position.
If the battery is completely discharged, it is
possible to crank the seat lift up using the
hexagon head bolt or Allen screw.
The screw is located at the front under the
seat. See "Raising the seat lift" on page 6.
If the chair has a fixed seat bracket/tube,
loosen the rear screw, see page 7, and the
seat can be tipped forwards.
2. Switch 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 the clamping bow remains in
position when the strap is loosened. See
the top figure.
Lift out the batteries. Use the batteries
handles.
Battery connection, rear poles
Front
Battery connection, front
Front
First switch off the power on the manoeuvring
panel before switching the power off on the main
fuse.
Clamping
bow
WARNING!

11
Changing the batteries
Battery connections
+
+
–
–
Green cable - Batt. +
Red cable - Batt. +
Front
Black cable - Batt. -
Green cable - Batt. -
Fitting
1. Insert two new gel batteries. The battery poles must face out from the centre.
2. Fix the batteries 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.
Front
Clamping
bow

Changing the drive wheel
12
Removal tool 304103-99-0
Fastening the rear 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. See the figures to the right.
3. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight.
Fitting
1. Check the axle and rim for any damage. If
necessary, you should clean these parts of dirt
and rust. If any parts are damaged, they
should be replaced.
2. Check that the key fits solidly in the keyway of
the axle. 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 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.
NB! Hitting too hard with a rubber mallet could
cause damage to the gear.
5. Fit the rim locking washer A, the Nordlock
washer B and the centre screw C and tighten
to secure the wheel. Fit the hubcap.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.

13
Changing the front wheel
Release the axle nut
Thread off the axle nut
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.
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 plug back into the centre of
the wheel rim.

Changing the brake release wires
14
Brake release mechanism
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.
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 at the brake release handle.
2 3
1
Magnetic brake
Release clamp

Changing the brake release wires
15
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.
3. Mount the brake release mechanism on the chassis.
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 release handle Fastening the wire at the brake
Release clamp
Pinch protection
plate
Brake release
handle

Changing the magnetic brake
16
Changing/adjusting the
magnetic brake
Electrical connection of the magnetic brake
Brake release wire attachment
Remove the brake
Removal
1. Raise the seat to its highest position.
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 release arm.

17
Fitting
1. Check the setting of the 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

Changing the magnetic brake
18
The magnetic brake's electrical 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

19
Changing the drive motor
Removal
NB.
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.
1. If the wheelchair is equipped with
electrical extension, it must be extended
to its outermost position. This applies
only when the left motor is to be changed.
2. Raise the seat to its highest position.
3. First switch the power off on the
manoeuvring 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. Unscrew the electronics, which are held
in place by three screws. See page 42.
9. then from the clamp of the magnetic
brake. See the figure to the right.
Changing the drive motor
Main fuse/battery cut-out
Brake release wire
Cable connections (left motor)
Magnetic brake
connection
Interference
suppression card

Changing the drive motor
20
Left motor
10. Unscrew the sheet metal mounting where
the jack panel is mounted. Tip up the
electronics and the jack panel so that
there is room to remove the left drive
assembly. See the figure to the right.
Electrical extension:
If the wheelchair is equipped 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 assembly out of the chassis.
Loosen the motor
Lift out the motor
Bracket to
the jack
panel.