Avantgarde CV / CS / CLT. Service Manual Otto Bock 647G690=EN

Transcription

1 Avantgarde CV / CS / CLT Service Manual... 3 Otto Bock 647G690=EN

2 2 02/2011

3 Table of contents Table of contents 1 Introduction Foreword Support Product overview Safety Explanation of warning symbols General Safety Instructions Service Work Instructions for Adjustment Required Tools and Accessories Special features of the Avantgarde CLT Maintenance Schedule Assembly A: Frame Replacement Work on the Frame Replacing the Front Frame Part Replacing the Rear Frame Part Replacing the Cross-Brace/Cross-Brace Bracket Replacing the Joint Tubes Replacing the Seat Tube Supports Retrofitting the Vertical Accessory Mount Installation / adjustment of the anti-tipper Installing the anti-tipper Adjustment of the anti-tipper Replacing the Pivot Arm Replacing Anti-Tipper Rollers Retrofitting the Transport Wheels Retrofitting the Horizontal Accessory Mount Retrofitting the Tip-Assist Retrofitting the Crutch Holder Retrofitting the Frame Pads (CS/CLT only) Assembly B: Footrest Adjusting the Foot Rests/Tube Foot Rest/Foot Plates Replacement Work on the CV Model Replacing the Foot Rest Replacing the Foot Rest Bar/Swivel Segment Replacing the Foot Plate Replacing the Pivot Bearing Replacing the Locking Device Retrofitting the Heel Strap Elevating Foot Rest with Automatic Length Adjustment Retrofitting the Elevating Foot Rest Replacing the Foot Rest Bar Replacing the Calf Pads Replacing the Retaining Plate Replacement Work on the CS/CLT Model Replacing the Foot Rest Bar Replacing the Foot Plate Replacing the Foot Plate Replacing the Tube Foot Rest /2011 3

4 Table of contents Replacing the Tube Foot Rest Mounting Assembly C: Seat Replacing the Standard/Business Seat Upholstery Replacing the Seat Upholstery, Adaptable Cleaning the Seat Upholstery Cleaning the Standard Seat Cushion Assembly D: Back/Push Handle Replacement Work on the Push Handles Replacing the Push Handles, Standard Retrofitting the Telescoping Push Handles Retrofitting the Height-Adjustable Push Handles Retrofitting the Folding Push Handles Replacing the Rubber Hand Grips Replacing the Back Upholstery Replacing the Back Upholstery, Standard Replacing the Back Upholstery, Adaptable Replacing the Back Tubes Replacing the Angle-Adjustable Back Tubes Assembly E: Side Panels Replacement Work on the Standard Side Panel/Clothing Protector Replacing the Standard Side Panel/Clothing Protector Replacing the Side Panel Mounting Replacement Work on the Desk Side Panel Replacing the Desk Side Panels Replacing the Side Panel Mounting Replacing the Seat Tube Support Replacing the Retaining Clip Replacing the Pivot Pin Replacing the Strut Replacing the Arm Rest Pad Assembly F: Caster Wheels Replacing/Changing the Installation Position of the Caster Head Adjusting the Caster Wheel Journal Angle Replacing/Changing the Installation Position of the Caster Wheels Replacing the Caster Fork Replacing the Eccentric Disc Retrofitting the Caster Fork System Frog Legs (spring-mounted) Retrofitting the Caster Wheel Adapter for High/Low Seat Heights in the Front Assembly G: Rear Wheels Adjusting the Rear Wheels/Rear Wheel Adapters Rear Wheel Adapter, Standard Replacing the Rear Wheel Adapter, Standard Installing the Fitting Shock Absorber System Retrofitting the Shock Absorber Installing the Fitting Wheelbase extension Retrofitting the Wheelbase Extension Installing the Fitting Changing the Rear Wheel Camber Maintenance Work on the Rear Wheel Replacing the Tyres Replacing the Push Rings/Adjusting the Installation Position "narrow/wide" Tensioning the Spokes/Adjusting the Out-of-Round /2011

5 Table of contents Adjusting the Quick-Release Axle Retrofitting the Tetra Axle Assembly H: Wheel Lock/Brake Adjusting the Knee Lever Wheel Lock/Drum Brake Replacing the Knee Lever Wheel Lock Replacing the Brake Block Retrofitting the Wheel Lock Lever Extension Retrofitting the Drum Brake Adjusting the Drum Brake Other Accessories Retrofitting a Lap Belt Retrofitting a Tray Appendices Technical Data /2011 5

6 Introduction 1 Introduction 1.1 Foreword Regular maintenance is important it improves safety and increases the lifespan of the product. All Mobility products should be inspected and serviced once a year. However, we recommend inspecting, readjusting, and if necessary servicing the product every 6 months if the product is used frequently, by growing children, or by patients with changing clinical pictures. Only use original spare parts for all service and maintenance work. The service and maintenance tasks described here should only be completed by trained, qualified personnel and not by the user of the device. This service and maintenance manual refers to the respective spare parts catalogues and the instructions for use of the described products. Please use these documents together. Use the maintenance schedule (checklist) as a template for making copies. Retain completed maintenance schedules and provide the customer with a copy. Instructions for Use (qualified personnel) Instructions for Use (User) Avantgarde CV/CS/CLT 647G568=* 647G689=* 1.2 Support Your national Otto Bock team will be happy to answer any technical questions. The contact addresses and telephone numbers can be found on the back of the service manual. 6 02/2011

7 Introduction 1.3 Product overview 1 Avantgarde CS Maximum load (in combination with double cross-brace): 140 kg Thanks to its closed frame geometry, the Avantgarde CS allows very rigid and sporting use /2011 Seat/seat pad Side panel Back/back upholstery Push handle Back tube Rear frame Front frame Rear wheel adapter Rear wheel with push ring Quick-release axle release button Double cross-brace Caster wheel Caster fork Foot plate Knee lever wheel lock 7

8 Introduction 2 Avantgarde CV Maximum load (in combination with double cross-brace): 140 kg Thanks to its frame geometry, the Avantgarde CV offers precise leg guidance with the possibility of swinging away and removing the foot rests. When the foot rests are removed, the upright frame front section allows the wheelchair to be manoeuvred close to objects Seat/seat pad Side panel Back/back upholstery Push handle Back tube Rear frame Front frame Rear wheel adapter Rear wheel with push ring Quick-release axle release button Double cross-brace Caster wheel Caster fork Foot plate (foot rest removable) Knee lever wheel lock 02/2011

9 Safety 3 Avantgarde CLT Maximum load (in combination with double cross-brace): 100 kg The Avantgarde CLT is the weight-optimised sports version for particularly active users. In the version CLT "welded", subsequent modification of the wheel position and back height was sacrificed in favour of saving additional weight Seat/seat pad Side panel Back/back upholstery Back tube Push handle Rear frame Front frame Rear wheel attachment device (here welded) Rear wheel with push ring Quick-release axle release button Double cross-brace Caster wheel Caster fork Foot rest Knee lever wheel lock 2 Safety 2.1 Explanation of warning symbols WARNING Warnings regarding possible risks of severe accident or injury. CAUTION Warnings regarding possible risks of accident or injury. NOTICE 02/2011 Warnings regarding possible technical damage. 9

10 2.2 General Safety Instructions INFORMATION Read the service manual before starting work. Familiarise yourself with the product's functions before use. If you are not familiar with the product, read the service manual before performing the inspection. If a service manual is not available, request it from the manufacturer (see the overview of all Otto Bock branches "Otto Bock Worldwide"). You can also download documents from our home page at or CAUTION Wearing unsuitable work clothing Risk of pinching, crushing, being pulled in Wear suitable work clothing and, for example, gloves and protective eyewear as necessary when working on the product. CAUTION Use of unsuitable tools Risk of pinching/crushing or damage to the product. When completing the tasks, only use tools that are suitable for the conditions at the place of work and for which safety and the protection of health are assured with proper use. NOTICE Tipping or falling of the product Risk of damage to the product When you work on the product, secure it so that it cannot tip over or fall down. Use a clamping fixture to secure the product whenever you work on it at a workbench. NOTICE Re-use of self-locking nuts Unintended loosening of the screw connections Always replace self-locking nuts with new self-locking nuts after disassembly. INFORMATION Many screw connections utilise screws and nuts equipped with thread lock. If you loosen screw connections, be sure to replace the respective nut or screw with one having a new thread lock. If new screws or nuts with thread lock are not available, apply a medium-strength liquid thread locker (such as Loctite 241 or Euro Lock A24.20) to the existing screws. INFORMATION Clean and disinfect the wheelchair before commencing service work. Observe the applicable care instructions and product-specific inspection instructions in the instructions for use. 3 Service Work 3.1 Instructions for Adjustment The following section describes the replacement and retrofitting of standard and option parts on the CV / CS / CLT wheelchairs /2011

11 All instructions concerning the adjustment of the parts installed are included in the Instructions for Use (qualified personnel) order number 647G Required Tools and Accessories The following tools are required in order to perform the service work: Reversible ratchet handle wrench and sockets (sizes: 8 24) Torque wrench (measurement range: 5 50 Nm) Wrench (size: 8 24)* Allen wrench (size: 2.5 6)** Screwdriver (blade width: 2.5/3.5/5 mm) Phillips head screwdriver (size: 2) Hammer (approx. 300 g); plastic hammer Pliers: cutting pliers, combination pliers, snap ring pliers Pin punch, ø 3/4/5/6 mm Drill/twist drill ø 3.2/5/5.2/6 mm Stanley knife with sickle hooked blade and standard blade Tyre mounting levers and inner tube repair kit* Workbench and vice with plastic jaws and rubber insert Measurement equipment: rule, spirit level Liquid thread locker, "medium" and "strong" * Included in the tool set 481C08=ST010 ** Size 3 6 included in the tool set 481C08=ST Special features of the Avantgarde CLT Lightweight construction was strictly applied in the design of the Avantgarde CLT ultra-light active wheelchair. This necessitates the greatest possible care during adjustment. In particular the tightening torques for the bolts of high-strength aluminium alloy must be strictly observed (see table). Bolt diameter (mm) Maximum torque for aluminium bolts (Nm) Before re-assembly and re-use of the aluminium bolts, inspect the threads for damage. We recommend that new aluminium bolts are used at each (re-)assembly. Use a liquid bolt locking compound on the aluminium bolts (e.g. Loctite 241 ). 3.4 Maintenance Schedule Maintenance schedule Type of wheelchair: Customer: Item Area Inspection (checklist) Service Work SN: A B 1. Function/setting 2. Inspected for damage/deformation 3. Screw connections (depending on equipment) inspected Frame Frame x x Frame accessories Foot rests Foot rest accessories Anti-tipper x x Crutch holder x x Tip-assist x x Crutch holder x x Frame pad Folding mechanism x x Lower leg length setting x x Angle adjustment x x Plastic plate x x Lateral heel blocks x x x 02/

12 SN: 1. Function/setting 2. Inspected for damage/deformation 3. Screw connections (depending on equipment) inspected B Foot rest accessories Heel strap x x C D E F G H Seat Back / push handles Side panels Cross-brace x x Seat upholstery x x Seat cushion Back upholstery Back tubes x x Angle adjustment x x Push handles x x Height setting x x Swivel mechanism x x Removability Side panel accessories Arm rest padded, swing-away x x Tray x x Caster wheel Rear wheel Rear wheel accessories Wheel locks / brakes Wheel lock accessories Accessories Tyres (wear) x x Air pressure x x Caster wheel journal angle x x Screw connections on the frame x x Swivelling of the caster forks x x Running behaviour of the wheels x x Swivelling of the caster forks x x Tyres (wear) x x Running behaviour of the wheels x x Spokes / push rings x x Quick-release axles x x Wheel camber x x Rear wheel attachment device x x Drum brake x x Hub brake x x One-arm drive x x Wheelbase extension x x Spoke protectors x x Shock absorber x x Braking function x x Swing-away mechanism x x Wheel lock lever extension x x Tray x x Lap belt x x x x x Do the wheelchair settings match the user's requirements? The maintenance service was performed by: on: 3.5 Assembly A: Frame Replacement Work on the Frame Replacing the Front Frame Part 1) Remove the rear wheels and flip up the foot plates. 2) Remove the side panels (see Page 33). 3) Slightly fold the wheelchair. 4) Unscrew and remove the caster wheel assembly from the lower frame tube (see Fig. 4). The lower frame tube is detached from the rear part of the frame. 5) Lay the wheelchair on its back and unscrew the upper frame tube (see Fig. 5) /2011

13 6) Remove the front part of the frame upward (see Fig. 6). 7) Remove all parts (knee lever brake, supports) installed on the frame. 8) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23 Nm Replacing the Rear Frame Part 1) Remove the rear wheels and flip up the foot plates. 2) Remove the side panels (see Page 33). 3) Unscrew the rear wheel adapter and remove (see Page 41). 4) Slightly fold the wheelchair. 5) Remove the seat pad (see Fig. 8) 6) Open the back upholstery hook-and-loop fasteners and remove the back upholstery (see Fig. 9). 7) Remove the rear part of the frame rearward (see Fig. 10). 8) Remove all parts (back tubes, supports) installed on the frame. 9) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23 Nm. 02/

14 Replacing the Cross-Brace/Cross-Brace Bracket INFORMATION The frame components are no longer connected when the crossbrace is removed. Carefully lay the frame components on the work surface one after another. 1) Remove both front parts of the frame (see Page 12). 2) Unscrew the cross-brace centre screw and remove (see Fig. 11). 3) Remove the cross-brace bracket retaining clip (see Fig. 12). 4) Remove the end caps (see Fig. 13). 5) Remove the cross-brace upward (see Fig. 14) and replace. 6) To reassemble, perform these steps in reverse order. Tighten the centre screw to the point that folding without jamming is possible /2011

15 Replacing the Joint Tubes 1) Remove the front part of the frame (see Page 12). 2) Unscrew the rear wheel adapter and remove (see Page 12). 3) Remove the cross-brace (see Page 14). 4) Remove/replace the joint tubes (see Fig. 15). 5) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23 Nm Replacing the Seat Tube Supports 1) Slightly fold the wheelchair (see Fig. 16). 2) Unscrew the seat tube supports Allen head screws, wrench size 3 (the support with side panel attachment device as well if necessary) (see Fig. 17). 3) Remove/replace the supports. 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screws to 4 Nm. 02/

16 Retrofitting the Vertical Accessory Mount INFORMATION The vertical accessory mount and the frame accessories cannot be installed on the welded Avantgarde CLT. The vertical accessory mount is required for the installation of the anti-tipper and the transport wheels (see Fig. 18, item 1). The vertical accessory mount can be installed in two positions. 1) Remove the rear reflector from the rear frame (see Fig. 19). 2) Hold the vertical accessory mount against the inside of the frame tube with the rounded side towards the frame tube (see Fig. 20). 3) Bolt on the accessory mount: Insert a screw with washer from the outside through the frame tube (see Fig. 21, item 1). Thread a nut from above into the profile of the vertical accessory mount (see Fig. 21, item 2). Hold the nut (see Fig. 21, item 3) and tighten the screw from the outside to 7 Nm /2011

17 Installation / adjustment of the anti-tipper CAUTION Incorrect fitting of anti-tipper / missing anti-tipper Risk of tipping of the user to the rear Check correct installation and adjustment of the anti-tipper: Depending on the adjustment of the chassis, the wheelchair centre of gravity and the experience of the user, an anti-tipper may be necessary. CAUTION Anti-tipper not intended Risk of tipping of the user to the rear On the Avantgarde CLT with fixed welded fitting, installation of an anti-tipper is not intended. Therefore examine the user intensively for suitability (adequate physiological capabilities) before supplying the user with this version. This wheelchair version is intended only for experienced users with sporting ambitions who, thanks to their physiological capabilities, are able to handle the wheelchair proficiently Installing the anti-tipper The anti-tipper can be installed at 5 positions on the vertical accessory mount (see Fig. 22, item 1). 1) Push the anti-tipper tube from below into the vertical accessory mount. 2) Tighten the anti-tipper tubes in the vertical accessory mount with the Allen head bolt to 7 Nm (see Fig. 22, item 2) /

18 Adjustment of the anti-tipper Height adjustment of the anti-tipper 1) Unscrew the mounting screw of the anti-tipper tube from the accessory mount (see Fig. 22, item 2). 2) Move the anti-tipper tube in the vertical accessory mount. 3) Bolt down the anti-tipper tube. The distance between the anti-tipper rollers and the ground must be 5 cm maximum (see Fig. 23). Angle adjustment of the pivot arm 1) Remove the pivot arm mounting screw from the anti-tipper tube (see Fig. 24, item 1). 2) Move the pivot arm to a new position (3 setting possibilities: (see Fig. 24, item 2). The distance between the antitipper rollers and the ground must be 5 cm maximum. 3) Bolt down the pivot arm. Longitudinal adjustment of the pivot arm 1) Press the button on the pivot arm (see Fig. 25). 2) Adjust the length of the pivot arm. In doing so, the rocker's outer arm should protrude beyond the largest diameter of the tyre (see Fig. 26). 3) Allow the button to engage Replacing the Pivot Arm 1) Unscrew the screwed tube connection to the pivot arm (see Fig. 27) through the service opening (see Fig. 28). 2) Remove and replace the pivot arm. 3) To reassemble, perform these steps in reverse order. Tighten the pivot arm screw connection to 4 Nm /2011

19 Replacing Anti-Tipper Rollers The replacement is made without tools by pulling out the plug-in tube Retrofitting the Transport Wheels CAUTION Incorrect adjustment of the transport wheels Risk of falling, tipping of the user Align the transport wheels to the rear while installing. Verify that the transport wheels have been set to the same height before using them. 1) Press the transport wheel latch pin in (see Fig. 29). 2) Insert the transport wheel true to side into the vertical accessory mount. 3) Adjust the height of the transport wheels (see Fig. 30). Adjust the height so that the transport wheels are approx. 2 cm above the ground when the rear wheel is installed cm Retrofitting the Horizontal Accessory Mount The horizontal accessory mount is required for the installation of the tip-assist and the crutch holder (see Fig. 31). Screw the mounting screws (above/inside) into the holes on the frame to 8 Nm (see Fig. 32). 02/

20 Retrofitting the Tip-Assist 1) Unscrew the mounting screw on the accessory mount clamp (see Fig. 33). 2) Insert the tip-assist true to side (see Fig. 34). 3) Tighten the clamp's mounting screw to 8 Nm Retrofitting the Crutch Holder Set the crutch holder onto the tip-assist and screw it in place Retrofitting the Frame Pads (CS/CLT only) 1) Position the frame pad on the front frame (see Fig. 37). 2) Close the frame pad hook-and-loop fastener (see Fig. 38) /2011

21 Assembly B: Footrest Adjusting the Foot Rests/Tube Foot Rest/Foot Plates All instructions concerning the adjustment of the foot rests are included in the Instructions for Use (qualified personnel) order number 647G Replacement Work on the CV Model Replacing the Foot Rest 1) Open the calf strap or pull it off the retaining lug on the swivel segment. 2) Push the swivel handle of the foot rest to the rear. 3) Swing the foot rest outwards and to the side by 90 (see Fig. 39). 4) Remove the foot rest upward and replace (see Fig. 40). 5) To reassemble, perform these steps in reverse order Replacing the Foot Rest Bar/Swivel Segment 1) Remove the foot rest. 2) Unscrew/remove the size 4 Allen head screw on the swivel segment (see Fig. 41). 3) Remove the foot rest bar from the swivel segment. Replace the foot rest bar/swivel segment if necessary. 4) Push the foot rest bar at least 60 mm into the swivel segment (see Fig. 42). 5) Tighten the Allen head screw on the foot rest bar to 10 Nm. 02/

22 Replacing the Foot Plate 1) Remove the foot rest. 2) Unscrew the size 4 Allen head screws on the angle adjustment (see Fig. 43). 3) Replace the foot plate. 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screw to 10 Nm Replacing the Pivot Bearing 1) Remove the foot rest. 2) Unscrew the size 4 Allen head screw at the centre of the pivot bearing (see Fig. 44). 3) Remove/replace the pivot bearing. 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screw to 5 Nm /2011

23 Replacing the Locking Device 1) Remove the foot rest. 2) Unscrew the size 4 Allen head screw on the locking device (see Fig. 45). 3) Remove/replace the locking device. 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screw to 5 Nm Retrofitting the Heel Strap 1) Remove the foot rest. 2) Unscrew the Phillips head screw on the heel strap holder (see Fig. 46). 3) Remove/replace the heel strap holder and the heel strap. 4) To reassemble, perform these steps in reverse order Elevating Foot Rest with Automatic Length Adjustment Retrofitting the Elevating Foot Rest 1) Remove the foot rest. 2) Tighten the retaining bolt with shell and size 4 Allen head screw on the frame (see Fig. 47). 3) Insert the elevating foot rest with automatic length adjustment into the frame. In doing so, keep the foot rest swung outward by 90 (see Fig. 48). 4) Swing the elevating foot rest inward and press down Replacing the Foot Rest Bar 1) Remove the Allen head screw from the foot rest bar (see Fig. 49). 2) Select one of the 3 threaded bores. INFORMATION Depending on the setting it may be necessary to add or remove one or more spacer sleeves. 02/

24 3) Insert the Allen head screw. 4) Tighten the Allen head screw to 8 Nm Replacing the Calf Pads 1) Unscrew the calf pad with retaining plate from the foot rest (see Fig. 50). 2) Unscrew the calf pad from the retaining plate (see Fig. 51). 3) Install the new calf pad with retaining plate on the foot rest. The slots and the alternative holes can be used to adjust the position and angle Replacing the Retaining Plate 1) Unscrew the size 10 Allen head screw. 2) Replace and install the retaining plate /2011

25 3.6.3 Replacement Work on the CS/CLT Model Replacing the Foot Rest Bar 1) Unscrew/remove the size 5 Allen head screw on the inside of the front frame (see Fig. 53). 2) Remove and replace the foot rest bar (see Fig. 54). 3) The foot rest bar must be pushed at least 60 mm into the swivel segment. 4) Tighten the screws to 8 Nm Replacing the Foot Plate 1) Unscrew the size 5 Allen head screw at the under foot rest bar (see Fig. 55). 2) Remove the foot plate (see Fig. 56). 3) To reassemble, perform these steps in reverse order. Tighten the Allen head screw to 10 Nm Replacing the Foot Plate The instructions for the CV model apply (see Page 22) Replacing the Tube Foot Rest 1) Flip up the tube foot rest. 2) Release and flip up the lateral cover for the angle adjustment (see Fig. 57, item 1). 3) Unscrew the size 5 Allen head screw (see Fig. 57, item 2). 4) Remove/replace the tube foot rest from the lateral mounting (see Fig. 58). 5) Position the tube foot rest in place and tighten the Allen head screw to 10 Nm. 6) Set the width of the tube foot rest by adjusting the screw (see Fig. 59). 7) Flip down the tube foot rest and close the lateral cover for the angle adjustment. 02/

26 Replacing the Tube Foot Rest Mounting 1) Unscrew the size 3 Allen head screw on the tube foot rest mounting (see Fig. 60). 2) Remove/replace the tube foot rest mounting. 3) Tighten the Allen head screw on the tube foot rest mounting to the point that flipping up and down without clearance is possible. 3.7 Assembly C: Seat Replacing the Standard/Business Seat Upholstery 1) Slightly fold the wheelchair and remove the seat cushion. 2) Remove the protective cap (see Fig. 61). 3) Remove/replace the seat upholstery from the cross-brace (see Fig. 62). 4) If necessary, tighten the seat upholstery with the aid of the hook-and-loop connector on the bottom of the seat upholstery (see Fig. 63). 5) Push the new seat upholstery onto the cross-brace. 6) Push on the protective cap. 7) Unfold the wheelchair. In doing so, the cross-brace must seat fully in the support guides /2011

27 Replacing the Seat Upholstery, Adaptable 1) Slightly fold the wheelchair and remove the seat cushion. 2) Remove the seat pad. 3) Remove the protective cap (see Fig. 64). 4) Remove the seat upholstery from the cross-brace (see Fig. 65). 5) Remove/replace the upholstery bar (see Fig. 66). 6) Replace the seat upholstery. 7) To reassemble, perform these steps in reverse order. 8) If necessary, adjust the seat upholstery with the aid of the upholstery strap hook-and-loop connector (see Fig. 67) /

28 Cleaning the Seat Upholstery 1) Remove the seat upholstery. 2) Clean the seat upholstery with regular mild household detergent. 3) Reinstall the seat upholstery Cleaning the Standard Seat Cushion 1) Open the zipper and remove the foam core. 2) Clean the seat cushion according to the attached care label Assembly D: Back/Push Handle Replacement Work on the Push Handles All push handles are installed on the upper end of the back tubes Replacing the Push Handles, Standard 1) Unscrew/remove both size 5 Allen head screws on the back tube (see Fig. 70). 2) Remove/replace the push handle off the back tube (see Fig. 71). 3) To reassemble, perform these steps in reverse order /2011

29 Retrofitting the Telescoping Push Handles 1) Remove the old push handle. 2) Insert the telescoping push handle into the back tube (see Fig. 72). 3) In the upper hole screw the clamping lever onto the clamping lever slide block (see Fig. 73) Retrofitting the Height-Adjustable Push Handles 1) Remove the old push handle. 2) Push the height-adjustable push handle onto the back tube. 3) Insert the installation adapter into the back tube (see Fig. 74). 4) Bolt the installation adapter together with the push handle (see Fig. 75) /

30 Retrofitting the Folding Push Handles 1) Remove the old push handle. 2) Remove the back pad. 3) For adaptable back upholstery: Open/remove the uppermost strap. 4) Insert the folding push handle into the back tube and bolt down the 2 size 5 Allen head screws (see Fig. 76). 5) For adaptable back upholstery: Mount the uppermost strap on the push handle and secure with hook-and-loop fastener (see Fig. 77). 6) Put the back pad back on Replacing the Rubber Hand Grips 1) Carefully cut the old rubber hand grip open (see Fig. 78). 2) Remove the old rubber hand grip and material residue from the back tube. 3) Clean the tube end with solvent. 4) Open the two-component adhesive package. Follow the instructions provided by the adhesive manufacturer. 5) Use a spatula to apply half of the adhesive to the inside of each of the rubber hand grip. Spread evenly around the grip opening up to a depth of approx. 4 5 cm. 6) Turn the handles while pushing them onto the tube ends. 7) Allow the adhesive to harden for approx. 24 h before handing the wheelchair over to the user Replacing the Back Upholstery Replacing the Back Upholstery, Standard 1) Remove the push handles. 2) Remove the side panels (see Page 33ff; desk side panel example: see Fig. 79) /2011

31 3) Remove/replace the back upholstery (see Fig. 80). 4) To reassemble, perform these steps in reverse order Replacing the Back Upholstery, Adaptable 1) Remove the push handles. 2) Remove the side panels. 3) Remove the back pad. 4) Open the uppermost strap and remove/replace (see Fig. 81). 5) Remove/replace other straps (see Fig. 82). 6) To reassemble, perform these steps in reverse order Replacing the Back Tubes 1) Remove the push handles. 2) Remove the side panels. 3) Remove the back upholstery. 4) Remove the lower mounting screw(s) (depending on the version) from the rear frame (see Fig. 83). 5) Remove the mounting screw for the side panel mounting (see Fig. 84). 6) Remove the rear reflector and frame accessories from the rear frame (see Fig. 85). 7) Remove/replace the back tube (see Fig. 86). 8) To reassemble, perform these steps in reverse order. Tighten the screw connection evenly with 7 Nm. 02/

32 Replacing the Angle-Adjustable Back Tubes CAUTION Missing anti-tipper Risk of tipping of the user to the rear When using the 30 backrest angle with short wheelbase, two anti-tippers (one on each side) and with long wheelbase at least one anti-tipper must be fitted and activated. Check that the anti-tipper is securely attached. 1) Remove the old back tube (see previous section). 2) Insert the angle-adjustable back tube into the rear part of the frame (see Fig. 87). 3) Install the mounting for the side panel. 4) Tighten all mounting screws on the rear frame to 7 Nm. 5) Finally, adjust the angle on both back tubes in the same way (see Fig. 88) /2011

33 Assembly E: Side Panels Replacement Work on the Standard Side Panel/Clothing Protector Replacing the Standard Side Panel/Clothing Protector 1) Remove the rear wheel. 2) At the back tube unscrew the size 5 Allen head screw from the side panel (see Fig. 89). 3) Unscrew the mounting screw on the adjustment disc and remove the cover of the adjustment disc (see Fig. 90). 4) Remove/replace the side panel Installing/adjusting the side panels Fine adjustment of the side panels to the rear wheel position is required during installation: 1) If necessary, slightly loosen the slide block on the bottom of the frame (see Fig. 91). 2) Connect the side panel mounting on the back tube to the side panel do not tighten (see Fig. 89). 3) Push on the rear wheel to determine the position. 4) Adjust the position: Front: Find the position of the adjustment disc relative to the mounting point (see Fig. 92). Rear: Adjust the angle (see Fig. 93). Slide block: If necessary, adjust the depth position (see Fig. 94, item 2). 5) Push the cover onto the adjustment disc (see Fig. 94, item 1). The marks on the disc help to find the position. 6) Securely retighten all the screws. 7) Push on the rear wheel and ensure that it can rotate freely. After adjustment of both side panels, both rear wheels must rotate freely without scraping noises. 02/

34 Replacing the Side Panel Mounting 1) Remove the size 5 Allen head screw on the adjustment disc (see Fig. 94, item 1). 2) Unscrew the size 4 Allen head screw on the slide block (see Fig. 91). 3) Remove/replace the side panel mounting (see Fig. 96). 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screws Replacement Work on the Desk Side Panel Replacing the Desk Side Panels 1) Remove/replace the desk side panel. 2) Insert the desk side panel in the side panel mounting and fold downward /2011

35 Replacing the Side Panel Mounting 1) Remove the desk side panel (see Fig. 99). 2) Unscrew the size 3 Allen head screw (see Fig. 100). 3) Remove/replace the side panel mounting. 4) To reassemble, perform these steps in reverse order. Tighten the Allen head screw to 5 Nm Replacing the Seat Tube Support For the replacement see Page Replacing the Retaining Clip 1) Remove the desk side panel. 2) Unscrew the size 5 Allen head screw on the retaining clip (see Fig. 101). 3) Replace/position/bolt down the retaining clip /

36 Replacing the Pivot Pin 1) Remove the side panel. 2) Unscrew the 2 Phillips head screws on the pivot pin (see Fig. 102). 3) Remove/replace/bolt down the pivot pin Replacing the Strut 1) Remove the desk side panel. 2) Release the strut lock. 3) Remove/replace the strut (see Fig. 103; remove the arm rest pad if necessary). 4) Re-insert the strut into the desk side panel Replacing the Arm Rest Pad 1) Unscrew the 3 Phillips head screws on the bottom of the arm rest pad (see Fig. 104). 2) Remove/replace the arm rest pad (see Fig. 105). 3) If necessary, remove/replace/position the arm rest pad longitudinal adjustment (see Fig. 106). 4) To reassemble, perform these steps in reverse order. Tighten all screws Assembly F: Caster Wheels Replacing/Changing the Installation Position of the Caster Head The wheelbase can be changed by changing the installation position of the caster head. 1) Unscrew/remove the caster head mounting on the frame (2x size 6 Allen head screws) (see Fig. 107). 2) Remove/replace the caster head adapter and the caster head (see Fig. 108). 3) To reassemble, perform these steps in reverse order. Tighten the screw connection evenly with 23 Nm /2011

37 Adjusting the Caster Wheel Journal Angle The threaded axle in the caster wheel adapter should be perpendicular to the ground to ensure optimum rolling behaviour of the wheelchair. The caster wheel adapter permits a continuous adjustment of this angle. 1) Remove the protective cap. 2) Slightly loosen the Allen head screw on the eccentric (see Fig. 109). 3) Slightly loosen the Allen head screws on the inside of the frame (see Fig. 110). 4) Position the spirit level (see Fig. 111, item 1). 5) Adjust the caster angle to 90 with a wide flat screwdriver. The spirit level must be in the centre position to do so (see Fig. 111, item 2). 6) Tighten the Allen head screw on the eccentric to 8 Nm (CLT: 5.5 Nm) (see Fig. 112). 7) Tighten the Allen head screws on the inside of the frame to 23 Nm (CLT: 13 Nm). The threaded axle on both caster wheel adapters must be positioned vertically /

38 Replacing/Changing the Installation Position of the Caster Wheels INFORMATION Observe the seat height table in the "Technical Data". INFORMATION Replace the caster wheels if cracks are visible in the material or if the material is damaged. 1) Unscrew the screw connection of the threaded axle (see Fig. 113). 2) Remove the threaded axle/spacers (see Fig. 114). 3) Remove/replace the caster wheel. 4) Insert the threaded axle with the 1st spacer bush (see Fig. 115, item 1). 5) Install the caster wheel. 6) Push on the 2nd spacer bush (see Fig. 116, item 1). 7) Tighten the threaded axle to 8 Nm. Once changed, the left and right caster wheel must have the same vertical position in the caster wheel fork /2011

39 Replacing the Caster Fork 1) Loosen/remove the size 19 hex nut inside the caster fork. 2) Remove the caster fork from the threaded bolt (caster axle) and replace (see Fig. 117). 3) Set the caster fork onto the threaded bolt. 4) Retighten the hex nut with 25 Nm Replacing the Eccentric Disc 1) Unscrew/remove the Allen head screw on the eccentric (see Fig. 118). 2) Remove/replace the eccentric disc. 3) To reassemble, perform these steps in reverse order. Tighten the screw connection to 6 Nm Retrofitting the Caster Fork System Frog Legs (spring-mounted) 1) Unscrew/remove the caster head mounting on the frame (2x size 6 Allen head screws) (see Page 36). 2) Remove the caster head adapter and the caster head. 3) Install the frog legs installation unit (caster head, frog legs caster fork: see Fig. 119) on the frame using 2 size 6 Allen head screws. In doing so, install the longer screw in the rear in travel direction. 4) Tighten the Allen head screws to 6 Nm. 5) Finally, adjust the caster wheel journal angle (see Fig. 120; see Page 37). 02/

40 Retrofitting the Caster Wheel Adapter for High/Low Seat Heights in the Front 1) Unscrew/remove the caster head mounting on the frame (2x size 6 Allen head screws) (see Fig. 107). 2) Remove the caster head adapter and the caster head (see Fig. 108). 3) Position the new caster head adapter on the frame: Position A: for low seat heights (see Fig. 121) Position B: for high seat heights (see Fig. 122) 4) Bolt down the caster head adapter to 23 Nm (see Fig. 123). 5) Install the caster head (see Fig. 124) and adjust the caster wheel journal angle (see Page 37) /2011

41 3.11 Assembly G: Rear Wheels Adjusting the Rear Wheels/Rear Wheel Adapters INFORMATION If the rear wheel size is changed, then the knee lever wheel lock must be readjusted as well (see section "Adjusting the wheel lock"). INFORMATION Changing the rear wheel position also changes the angle between the caster axles and the ground. Also replace/change the installation position of the caster wheels if necessary (see section "Replacing and changing the installation position of the caster wheels"). All instructions concerning the adjustment of the rear wheels/real wheel adapters are included in the Instructions for Use (qualified personnel) order number 647G Rear Wheel Adapter, Standard Replacing the Rear Wheel Adapter, Standard The rear wheel adapter, standard, can be installed horizontally in 7 positions. The rear wheel adapter is marked for installation true to side as follows: > L = Install in travel direction on the left side of the frame > R = Install in travel direction on the right side of the frame 1) Unscrew and remove the Allen head screws with lock rings on the frame (see Fig. 125, item 1). 2) Remove/replace the rear wheel adapter. 3) Move the rear wheel adapter from inside into the desired position (see Fig. 126). 4) In order to be able to install the rear wheel adapter even more forward (for very active settings): remove the rear wheel adapter (see Fig. 127), turn the rear wheel adapter on its own axle 180 (see Fig. 128), before installation exchange the left rear wheel adapter for the right. 5) Insert the lock rings and tighten the Allen head screws to 7 Nm. Once changed, the left and right rear wheel adapter must have the same horizontal position on the frame /

42 Installing the Fitting The rear wheel can be installed at 12 height positions in the rear wheel adapter. 1) Slightly loosen the nuts on both sides of the fitting (see Fig. 129, see Fig. 130). 2) Pull the camber washers apart until the fitting can be moved (see Fig. 131). 3) Move the fitting together with the nuts and camber washers into the desired position. 4) Pay attention to the following when installing the fitting (see Fig. 131): Position the camber washer teeth offset from one another. Position the camber washer groove as parallel and upright as possible. 5) Insert the spirit level holder into the groove (see Fig. 132, item 1). 6) Insert the spirit level and align the camber washers upright (see Fig. 132, item 2). 7) Tighten the nuts on both sides of the fitting to 50 Nm. Once changed, the left and right fitting must have the same vertical position in the rear wheel adapter /2011

43 Shock Absorber System Retrofitting the Shock Absorber The shock absorber system is clamped to the frame and is continuously adjustable as a result. 1) Remove the rear wheel adapter, standard (see Page 41). 2) Pre-install the upper shell on the shock absorber (see Fig. 133): To do so, insert the 2 size 10 hex nuts into the shell's profile. Bolt on the size 5 Allen head screws do not tighten. 3) Guide the shock absorber true to side at the proper clearance onto the frame from outside (see Fig. 134): The elastomer is situated above. The fitting position is as required toward the front or rear. 4) Pre-install the lower shell (see Fig. 135). 5) Adjust the shock absorber depth. Use the bores in the frame for orientation (see Fig. 136, item 1). 6) Tighten the clamping screws to 8 Nm (see Fig. 136, item 2). Once changed, the left and right shock absorber must have the same horizontal position on the frame /

44 Installing the Fitting The rear wheel can be installed at 3 height positions on the shock absorber. 1) Loosen the nuts on both sides of the fitting (see Fig. 137, item 1). 2) Remove and change the installation position of the fitting. 3) Before installing the fitting, position the camber washers offset from one another (for 0 wheel camber; see Fig. 137, item 2). 4) Tighten the nuts to 50 Nm. Once changed, the left and right fitting must have the same vertical position on the shock absorber Wheelbase extension Retrofitting the Wheelbase Extension 1) Remove the rear wheel adapter, standard (see Page 41). 2) Move the wheelbase extension from below via the frame into position (see Fig. 138). 3) Tighten the upper Allen head screw on the wheelbase extension arm from inside to 6 Nm (see Fig. 139). 4) Install the centre screw (see Fig. 140): Guide the Allen head screw through the centre bore on the wheelbase extension arm. Insert the spacer to prevent incisions. Tighten the centre screw with the aid of the hex nut to 23 Nm. 5) Bolt down the wheelbase extension on the top rear part of the frame with size 4 Allen head screw, washer and size 10 hex nut (see Fig. 141). Torque = 23 Nm. 6) Bolt down the wheelbase extension on the bottom rear part of the frame with size 4 Allen head screw, washer and size 10 cap nut (see Fig. 142). Torque = 23 Nm. 7) Finally, push the protective caps onto the hex nuts (see Fig. 143) /2011

45 Installing the Fitting For the installation of the fitting see the section entitled "Shock Absorber System > Installing the Fitting" Changing the Rear Wheel Camber Instructions for adjusting/changing the rear wheel camber are included in the Instructions for Use (qualified personnel) order number 647G Maintenance Work on the Rear Wheel Replacing the Tyres All instructions concerning the replacement of tyre, tube and rim band are included in the Instructions for Use (user) order number 647G Replacing the Push Rings/Adjusting the Installation Position "narrow/wide" 1) Completely remove the tyre. 2) Unscrew/remove the push ring screws from the rim (see Fig. 144). 02/

46 3) Tightly bolt the push rings onto the rim in narrow or wide installation position. 4) Completely reinstall the tyre Tensioning the Spokes/Adjusting the Out-of-Round Tensioning the spokes 1) Completely remove the tyre (see Fig. 145). 2) Check the spokes' tension by shaking/moving the spokes. 3) If necessary, carefully adjust the tension of the spokes with spoke tensioner. 4) Completely reinstall the tyre. Adjusting the out-of-round Adjusting the out-of-round to 1 mm maximum requires special instruments and technical knowledge. The adjustment should be performed in a bicycle specialist workshop Adjusting the Quick-Release Axle The quick-release axle (see Fig. 146) should be adjusted so that it engages properly and so that the wheel has no play on the axle. 1) Hold the tip of the quick-release axle with a wrench (size 11). 2) Adjust the play by turning the nut on the end of the quick-release axle (size 19; see Fig. 146, item 1) in or out Retrofitting the Tetra Axle 1) Remove the quick-release axle with rear wheel. 2) Exchange quick-release axle for tetra axle. 3) Insert rear wheel with tetra axle into the fitting /2011

47 Assembly H: Wheel Lock/Brake Adjusting the Knee Lever Wheel Lock/Drum Brake All instructions concerning the adjustment of the wheel lock/brake are included in the Instructions for Use (qualified personnel) order number 647G Replacing the Knee Lever Wheel Lock CAUTION Inadequate braking function of the knee lever wheel lock Risk of accidents, falling Check the air pressure of the rear wheels and the correct setting of the knee lever wheel lock. The correct air pressure is printed on the sidewall of the tyre. For rear wheels, the minimum air pressure is 7 bar. Use only original rear wheels with a tested out-of-round of 1 mm maximum. 1) Unscrew/remove the Allen head screws in the slide block on the bottom of the frame (see Fig. 149). 2) Carefully remove/replace the knee lever wheel lock from the slide block (see Fig. 150). 3) Position the knee lever wheel lock in place on the slide block and bolt down do not tighten. 4) Adjust the knee lever wheel lock. The clearance between the tyres and the brake block when the wheel lock is not actuated must be max. 5 mm (see Fig. 151). 5) Tighten the Allen head screws to 6 Nm. After adjustment, the left and right knee lever wheel lock must have the same braking effect /

48 5 mm Replacing the Brake Block 1) Unscrew the Allen head screw on the brake block (see Fig. 152). 2) Remove/replace the brake block. 3) Tighten the screw connection with 6 Nm Retrofitting the Wheel Lock Lever Extension 1) Remove the wheel lock handle from the knee lever wheel lock (see Fig. 153). Cut open if necessary. 2) Slip the wheel lock lever extension on true to side (see Fig. 154) Retrofitting the Drum Brake In order to use rear wheels equipped with a drum brake, the standard fitting must be replaced with a mounting plate with fitting, and brake handles and Bowden cables must be installed on the wheelchair. Installing the mounting plate with fitting 1) Remove the standard fitting (quick-release axle housing) from the rear wheel adapter (see Page 45). 2) Install the rotation prevention. 3) Pre-install the mounting plate with fitting on the rear wheel adapter do not tighten. 4) Insert the supplied spacer bushing between the mounting plate and the rotation prevention. 5) Connect the mounting plate and rotation prevention. 6) Install the mounting plate tightly on the fitting. Secure the hex nuts (size 24) with high-strength thread locker (Loctite 601). The proper tightening torque of the screw connection on the fitting is 50 Nm on each side /2011

49 Installing the brake handles / Bowden cables 1) Install the brake handles on the back tubes (Phillips head screws; Retrofitting the Drum Brake [], similar to figure). 2) Route the Bowden cables from the brake handles to the brake drums. Make sure to prevent that scraping noises can develop. 3) Connect the Bowden cables to the brake drums. 4) Install the rear wheels and readjust the Bowden cables if necessary. 5) The maximum braking force should be attained within the first third of the brake lever travel Adjusting the Drum Brake The braking force can be adjusted via the adjusting nut (see Fig. 157, item 1). Turning the adjusting screw out: the braking force is increased. Turning the adjusting screw in: the braking force is decreased. 1) Turn the adjusting screw out until friction noise can be heard when the wheel is turned. 2) Turn the adjusting screw in until the friction noise disappears. Then the wheel should turn freely. 3) Secure the adjusting screw by tightening the lock nut (see Fig. 157, item 2). INFORMATION Note that the drum brake shows sufficient braking force only when the manual brake lever is locked in the 2nd ratchet position. INFORMATION Ensure that the braking force of both rear wheels is adjusted equally /