Swirl Wheelbase and Interface Workshop Manual.doc

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1 Swirl WHEELBASE AND INTERFACE WORKSHOP MANUAL IMPORTANT Please read these instructions carefully Before attempting to maintain the Wheelbase or Interface Document No: v3 Page 1 of 34 June 2018

2 Fig 0.1 Swirl Wheelbase Front View Document No: v3 Page 2 of 34 June 2018

3 Fig 0.2 Swirl Wheelbase Rear View Document No: v3 Page 3 of 34 June 2018

4 Fig 0.3 Wheelbase Folded Document No: v3 Page 4 of 34 June 2018

5 Fig 0.4 Seat Interface Fig 0.5 Interface Fitted To Frame Document No: v3 Page 5 of 34 June 2018

6 Fig 0.7 Swirl with Snug Seat, Forward Facing Fig 0.8 Swirl with Snug Seat, Rearward Facing Document No: v3 Page 6 of 34 June 2018

7 Fig 0.9 Swirl with Modular Seat, Rearward Facing Document No: v3 Page 7 of 34 June 2018

8 CONTENTS Item Description Page 1 Your Snappi Wheelbase and Interface Workshop Manual Transit Packaging 11 3 Tools & Torque Settings 12 4 Preparing for use and operation Unfolding the frame Pin Brakes Tilt In Space The Interface Rotation mechanism 13 5 Fitting Special Seat Final Checks 15 7 Maintenance Routine maintenance Six monthly maintenance 16 8 Repairs Rear wheels Castor assembly Pin Brake Assembly The Interface Push Handle Adjustors Change the Locking Lever Cleaning Parts Lists 34 Document No: v3 Page 8 of 34 June 2018

9 1: Your Swirl Wheelbase / Interface Workshop Manual The purpose of this manual is to help you get the best from your wheelbase & interface. It does this by telling you how to complete those maintenance and repair tasks that can be carried out by a competent person. The manual also tells you when you should contact the manufacturer who is: Tendercare Ltd. PO BOX 3091, Littlehampton, BN16 2WF Tel: (01903) Fax: (01903) info@tendercareltd.com Web: IMPORTANT: This manual must be read and used in conjunction with the user manual. The Wheelbase is made of a strong and lightweight aluminium alloy, minimising weight and providing a very rugged frame. The wheelbase provides tilt in space and rotation facilities and has 2 fixed rear wheels and 2 castor wheels at the front for easy steering. The Interface provides a very lightweight, easy to operate, quick release system that can be fitted to a wide range of special seating systems. Please note the interface requires additional framework to fit to a seat, and has been designed to take 19mm (3/4 ) aluminium or mild steel tube. The interface can be quickly fitted and released from the wheelbase, which can be folded for transport. The Swirl has been successfully impact tested as a wheelbase and interface, with the Snappi, Snug and Modular seating systems. When fitting 3 rd party seating systems to the Swirl, the manufacturer of the system must carry out a risk assessment before use. These instructions apply to all sizes. Interfacing Options: Seat / Interface Version Maximum Footrest Width (mm) Max Carry Maximum Seat Width Weight (Kg)* (mm) Size IMPORTANT: Maximum width; maximum space available for seating systems being fitted into frame. *Maximum carry weight is defined as the user weight, weight of the seating system, plus any accessories / equipment which may be fitted or carried on the chassis. Warning: Never exceed the maximum stated carry weight. Frame Weight: 13.4kg Document No: v3 Page 9 of 34 June 2018

10 Swirl Wheelbase Open Dimensions (mm): A B C Swirl Wheelbase Folded Dimensions (mm): A B C All sizes and weights are given as a guide. Tendercare ltd reserves the right to amend specifications at any time as part of their product development programme. Document No: v3 Page 10 of 34 June 2018

11 2: Transit Packaging The Swirl wheelbase and interface are delivered together in a cardboard carton. This measures 740mm wide x 650mm deep x 510mm high and weighs approximately 16.5Kg. WARNING: The transit carton is quite bulky so moving and unpacking must be done with care. Observe all lifting and handling regulations. Stand the carton upright making sure it is supported and cannot fall over. Open the carton and remove any packages or packing materials, which could obstruct the removal of the wheelbase. Remove the wheelbase. The carton should contain the following items: Item Component QTY. Yes No 1 Swirl Wheelbase 1 2 Interface (if ordered) 1 3 User Manual 1 IMPORTANT: The interface will be supplied fitted to the frame. These can easily be separated by releasing the interface catch once the frame has been removed from its packaging. Please refer to section 4.4 of the user manual for more information on working with the interface. If any items are damaged or missing, then please contact Tendercare, preferably by at info@tendercareltd.com or alternatively please call us on (01903) within 36 hours of delivery. After unpacking and checking that you have all the components and that they are in good condition dispose of the packaging at your local recycling centre. Alternatively retain and reuse. Document No: v3 Page 11 of 34 June 2018

12 3: Tools and Torque Settings The following tools are required to dismantle, reassemble and repair the Wheelbase / Interface: Spanners and sockets: Hexagon Keys: Torque Wrench: 10mm, 13mm and 19mm 4mm, 5mm and 6mm Range 0 to 50 Nm 4: Preparing for use and operation Torque Settings If Not Specified Spanner Size (mm) Torque (Nm) WARNING: When opening or folding the wheelbase, ensure that you hold the frame so that you avoid any danger of catching your fingers in moving parts. The following pre-delivery procedures should be carried out to check that the wheelbase and interface has not suffered damage during transit and that all features operate satisfactorily. Refer to the user manual for detailed instructions on performing each action. 4.1 Unfolding the Frame Unfold and assemble the frame: Follow the instructions in section 4.1 of the user manual Checks: Make sure all joints move freely Make sure the frame lock bar latches correctly Ensure the handles move freely and lock securely Check that the push handle adjustors work Ensure that all fixings are secure and that the frame has not been bent or otherwise damaged during transit. 4.2 Brakes Test the brakes: Follow the instructions in section 4.2 of the user manual Checks: Make sure the brakes work correctly Check that the fixing bolts are secure WARNING: The break mechanism is spring loaded so care must be taken when operating it. Document No: v3 Page 12 of 34 June 2018

13 4.3 Tilt in Space Test the tilt in space mechanism: manual. Follow the instructions on section 4.3 of the user Checks: Make sure that the tilt lever is free to move. Check that the centre section tilts correctly and locks throughout its adjustment range. Check that the 4 bolts that mount the centre section into the frame are secure. IMPORTANT: Always ensure any harness provided for the child is used and correctly adjusted before reclining or returning the seat to a more upright position. Always support the seat when tilting, as the gas springs can be quick to operate. If the seat is not supported, is may move swiftly and could cause the occupant distress. 4.4 The Interface Test the operation of the interface: Follow the instructions on section 4.4 of the user manual to attach and remove the interface. Checks: 1. Make sure that the interface frame has not been bent or damaged during transit 2. Check that the spring clips move freely and snap back to their closed position when the lever is released 3. Make sure the interface latches down and locks securely to the frame 4. Check that the secondary latch mechanism functions correctly 5. Check that the interface releases correctly and that there is not excessive friction on the lever when releasing it from the frame IMPORTANT: The interface is spring loaded, so ensure your fingers are clear of the clips before fitting. 4.5 Rotation System Test the operation of the rotation mechanism: Follow the instructions on section 4.5 of the user manual switching from forward to rearward facing. Checks: 1. Make sure the handles release easily and are free to move when lowered 2. Ensure the rotation release catch lifts easily and fully releases 3. Ensure the mid-section is free throughout the full rotation 4. Check that the rotation locks securely once the mid-section has been rotated 180 degrees. Document No: v3 Page 13 of 34 June 2018

14 5: Fitting a Special Seat The interface is designed to bolt onto the base of a special seating system using the 4 base fixing points. The interface should always be fitted with a suitable framework and includes 4 tube mounting brackets that fit 19mm or ¾ aluminium or mild steel tube. We recommend using ¾ x 10 SWG (or 19 x 3mm metric) aluminium tube in grade 6063 T6 for the frame mounting. Alternatively 16 SWG (1.6mm) mild steel tubing can be used. Due to the wide range of different special seating systems, Tendercare do not supply fixing brackets for these items. Please refer to the special seat manufacturers instructions. An example set up using the interface is shown below: Fig Document No: v3 Page 14 of 34 June 2018

15 IMPORTANT: The Swirl has been successfully impact tested as a wheelbase and interface with the Snappi seating system. When fitting third party seating systems to the Swirl, the manufacturer of the system must carry out a risk assessment before use. When fitting a third party seat stability may be affected. A test is necessary to confirm that the static stability is satisfactory. A stability test to meet the requirements of EN.ISO7176 must be completed by the commissioning wheelchair service. This test must be passed before handover of the system. 6: Final checks 1. Check that the special seat is firmly attached to the interface and framework. 2. Check that all harnesses are secure and adjusted properly. 3. Check that the interface is located and locked correctly in the wheelbase. 7: Maintenance Should a problem be found when carrying out the regular checks, it should be immediately reported to the issuing authority or Tendercare Ltd. 7.1 Routine maintenance The user s family can easily carry out the following tasks. No tools are required. 1. Always wipe the wheelbase and seat frame dry. Never put them away damp. 2. Check all nuts, bolts, and hand wheels are tight (daily) 3. Check operation of the brake, folding, rotation and reclining mechanisms (weekly). 4. Clean frame when necessary (we suggest at least once a week). 5. If your pushchair is fitted with pneumatic tyres, regularly check the condition of the tyre. Ensure tyres are inflated to 36 psi (if too low use a suitable hand or foot pump, do not use an air-line or mechanical inflator, and do not over inflate the tyre). In the event of a puncture, you will need to purchase a set of tyre levers and a puncture repair kit form a reputable bicycle shop. Always follow the instructions given in the puncture repair kit. If you find any faults refer to your issuing authority or Tendercare Ltd. Document No: v3 Page 15 of 34 June 2018

16 7.2 Six-monthly maintenance Only someone who is a competent tradesman or repairer should carry out this work. If a major fault is found stop using the wheelbase until it has been corrected. 1. Fold and open the wheelbase. Check that all movements through the folding range are free. Examine frame for any damage. 2. Check operation of the wheelbase tilt in space mechanism. 3. Examine nuts, bolts, pivots and frame plugs for tightness and general condition. 4. Examine brake assembly for wear, damage and correct operation. 5. Examine tyres for sharp objects, cuts or splits. 6. Examine castor and wheel bearings for excessive wear. 7. Check castors and rear wheels for free rotation, security and accumulation of fluff and grit. Remove any fluff and grit with a dry lint free cloth. 8. Check the Interface fits securely into the frame, and that it is not worn or damaged. 9. Check the interface clips to ensure they can rotate freely and that the springs return the clips to the closed position when released. 10. Check the handle folding mechanism for wear, damage and correct operation. 11. Check the rotation mechanism, ensure it locks securely and rotates freely when released. For all other repairs refer to your issuing authority or Tendercare Ltd. Document No: v3 Page 16 of 34 June 2018

17 8: Repairs Only an authorised repairer should carry out the following repairs. 1. Repairs: For all repairs contact your issuing authority 2. Major repairs: For all major repairs e.g. bent or damaged frame, the wheelbase / interface should be returned to the factory. Contact Tendercare ltd, customer services on , or to info@tendercareltd.com 3. Factory replacement components should be used in all repairs. These are available from Tendercare. Please refer to the parts lists at the end of this manual (section 10) for details of replacement parts. Important points when performing a repair: 1. Do not reuse Nylock nuts, always replace with a new nut 2. Always use Loctite thread locking compound grade 241 or 243 on all threads when reassembling any part of the system. 3. Always use the recommended component parts available from Tendercare Ltd. 4. Do not attempt to correct bent framework or perform any modifications to welded parts. If any main framework sections are bent or damaged please return the product to the factory. Document No: v3 Page 17 of 34 June 2018

18 8.1: Rear Wheels Replace if damaged or worn. To change the rear wheel: Fig Remove the wheel cap using a small screwdriver (see fig left) Using a 19mm spanner, undo the axle bolt and remove the wheel from the frame (see fig below) Fig Place the M12 bolt through the rear wheel and into the threaded hole in the frame. Tighten to 35Nm with a torque wrench Finally push fit the wheel cap over the bolt head. Document No: v3 Page 18 of 34 June 2018

19 8.2: Front Castors Replace if damaged or worn. To change the front castor: Fig Remove the wheel by unscrewing the M8 socket cap bolt using a 5mm hexagon key (see Fig 8.2.1, left). Next remove the castor housing and front tie down by undoing the main M12 bolt using a 19mm spanner as shown in Fig (below). Fig To fit the new castor, first ensure the wheel is removed from its housing. Place the M12 front castor bolt through the castor housing and the tie down bracket, making sure to keep the loop of the tie down bracket facing the front of the frame. Apply some Loctite to the thread on the M12 bolt (see fig below). Fig Tighten the M12 bolt to 35Nm with a torque wrench. This should secure the castor hosing and front tie down bracket. Screw the new wheel into the castor housing using a 5mm hexagon key and tighten firmly (no other tool is required to fit the wheel as the castor housing includes a captured nylock nut). Document No: v3 Page 19 of 34 June 2018

20 8.3: Pin Brake Assembly Replace the brake bar if it is bent or damaged. The springs, actuators and guide bushes can also be replaced if warn. IMPORTANT The brake system uses two compression springs. Care must be taken when working on the brake mechanism. The following instructions are the recommended method to safely dismantle the brake assembly. If you are not confident to work on this assembly please return your frame to the Tendercare factory. To remove the pin brake. First set to the brake to the ON position (for instructions how to do this please refer to the user manual). Then, remove the rear wheels (see section 8.1). Fig As the brake is set to on the ends of the lock pins will be accessible. Use a pair of grips to pull one of the pins out against the spring to reveal the 2mm assembly hole in the brake pin (see Fig 8.3.2, left). Fig Push a 2mm pin through the assembly hole (pins will be provided with replacement brake parts). This will hold the brake pins in the fully extended position. Fig Document No: v3 Page 20 of 34 June 2018

21 Using a hex key and spanner / socket remove the 6 socket button bolts that secure the brake actuator to the actuator caps as shown (see Fig 8.3.4, left). Fig With all the bolts removed, slide the brake actuator caps towards the middle of the frame and remove them as shown (see fig 8.3.5, right). Fig Fig Left: The brake bar with the actuator caps removed. Fig You will now be able to remove the brake bar assembly from the frame. Fig Document No: v3 Page 21 of 34 June 2018

22 Undo the 2 M4 screws securing the brake actuators to the brake bar using a hex key as shown (see fig 8.3.8, left). Fig Fig Right: The brake bar removed from the actuators. Fig To remove the lock pins, springs and guide bushes: First place a block of wood on the inside of the frame as shown in fig (this is to provide a stop for the brake pin when the spring is released). Fig With the block of wood held in place, pull out the 2mm pin to release the brake pin. With the pressure of the spring safely released, now push the brake pin, spring and guide bush out of the mounting on the frame. Fig Document No: v3 Page 22 of 34 June 2018

23 To re-assemble the pin brake assembly: Place the wheelbase with the front frame down onto a flat surface as shown (see fig , left). This provides easier access to the brake mounting points. Fig Slide the guide bush, spring and brake pin into the mounting point as shown (see fig , right). Fig Ensure you have a pair of grips and the 2mm pin available. Push the brake pin into the frame against the spring as shown (see fig , left). Fig Pull the brake pin out of the frame with the grips to expose the assembly hole. Push the 2mm pin through the hole to lock the pin in place. Repeat this for both sides, and then follow the reverse of the dismantling instructions to assemble the rest of the brake assembly. Fig Document No: v3 Page 23 of 34 June 2018

24 8.4: The Interface Replace the interface clips (see Fig 0.4) if they are damaged or bent; replace the springs if they are stretched or overly soft in operation. IMPORTANT The interface uses 2 strong torsion springs that are under load. Care must be taken when working on the interface clip mechanism. The following instructions are the recommended method for dismantling the assembly to safely release the tension on the springs. If you are not confident to work on this assembly please return your frame to the Tendercare factory. To dismantle the interface: Remove the front screws from the mounting using a 4mm hexagon key as shown (right). Loosen the rear screws but DO NOT remove them as the tension on the 2 torsion springs must be released before removing the clip mechanism from the interface frame. Fig Fig To release the tension on the springs: Rotate the clips forward and lift the frame so that it pivots on the 2 loosened rear screws. Keep lifting until the 2 spring arms are released from the interface frame cross bar, as shown (left) Fig Once the springs have been released, remove the 2 rear screws units a 4mm hexagon key. The interface clip assembly can then be easily taken apart by sliding off the 2 mounting blocks, springs and washers. Take note of the position of the 2 chamfers of the mounting blocks as these MUST be put back in the correct orientation or the interface mechanism will not function properly. Document No: v3 Page 24 of 34 June 2018

25 Also take careful note of the orientation of the springs- the springs are handed and must be re-fitted correctly or there will not be sufficient tension on the mechanism to close the clips. To reassemble the interface follow the reverse of these instructions and test as detailed in section 4.4 of this manual. Document No: v3 Page 25 of 34 June 2018

26 8.5: Replace Push Handle Adjustors Replace if damaged. Fig First Drill off the 8 x pop rivets securing the old adjustor with a 5mm drill, then separate the adjustors from the frame and push handle. Upend the frame and remove the rivet ends from inside the tube. Take the new adjustor and tap onto the frame using a mallet until the holes in the adjustor line up with the hole in the frame. Ensure that the adjustor is positioned so that the round body is facing down and that the release button is to the outside of the frame. Fig Fig Note the fit of the adjustor is very tight, if it is not possible to get the hole to fully line up it may be necessary to clear the holes using a 5mm drill bit. Secure the new adjustors onto the frame with 4 x 4.8mm x 14mm black pop rivets. Next fit the push handle into the top of the adjustors (ensuring that both adjustors are set at the same angle), tap down with the mallet and secure with a further 4 x 4.8 x 14mm black pop rivets. Fig Document No: v3 Page 26 of 34 June 2018

27 Fig Left: The new push handle adjustor fitted to the frame. Document No: v3 Page 27 of 34 June 2018

28 8.6 Change the locking lever Replace the locking lever if it has become excessively worn or damaged during use. Disassembly: Remove the small self tapping screw from the main frame cross tube as shown (Fig 8.6.1, right). Fig Next remove the 4 x M8 bolts holding the handle bush into the main frame as shown (see Fig 8.6.2, left). Note that 2 of the M8 bolts are positioned on the underside of the frame. Fig Slide the mounting bush out of the framethis part is a tight fit so may be difficult to remove; rotating the bush slightly whilst sliding out may make this easer. Fig Document No: v3 Page 28 of 34 June 2018

29 Use a 13mm socket or spanner to remove the M8 locknut from the end of the mounting bush as shown (see Fig 8.6.4, left). Fig Fig 8.6.5, right: The assembly with the locknut removed. Fig Remove the main threaded rod from the mounting bush using a large flat blade screwdriver. Fig Take note of the position of each of the components as shown in Fig From left to right: M8 Lock Nut, Main Mounting Bush, Compressions Spring (push handle- not shown), M8 Penny Washer, Lock Handle, Pivot Pin, Main Pin. The mounting bush is installed using a little grease, so we recommend using a cloth / paper towel to help grip the bush better whilst unscrewing the pin (see Fig 8.6.6, left). Fig Document No: v3 Page 29 of 34 June 2018

30 Re-Assembly: Place the pivot pin into the locking lever as shown (see Fig 8.6.8, left). Fig Slide the main pin through the hole in the pivot pin, such that the slotted head in the main pin sits in the middle of the locking lever as shown (see Fig 8.6.9, right). Fig Slide the M8 penny washer onto the end of the main pin as shown in Fig Fig Place the compression spring into the recess in the end of the mounting bush as shown (see Fig , right). Note that it may make assembly easier to apply a small amount of glue onto the end of the spring to help hold it in place during assembly. Be careful not to get any glue inside the threads of the main bush. Fig Document No: v3 Page 30 of 34 June 2018

31 Assemble the two assembles together with the push handle- the locking bush / spring go into the inside, with the pin / lock handle assemble fed through the push handle from the right hand side as shown in Fig Fig Screw the main pin through the mounting bush until the excess thread protrudes out the far end of the mounting bush as shown (see Fig , right). Fig Thread the M8 locknut onto the end of the protruding thread as shown (Fig , left). Fig Next set the tension on the locking lever against the bush: - Set the lever into the locked position - Use a flat blade screwdriver and turn the slotted pin clockwise until there is no play between the main bush and push handle. - Test that the lever still opens after the adjusment (if it is loose turn the slotted pin half a turn clockwise, if it is difficult to open then loosen the adjustment pin by turning anticlockwise half a turn and test again). Fig Document No: v3 Page 31 of 34 June 2018

32 Screw the locknut up and lock off firmly against the main bush to prevent the slotted pin turning, as shown in Fig Position the main bush so that the two small holes next to the push handle are to the top. Fig Fig Slide the main bush back into the frame, making sure the M8 threaded and the small hole for the self-tapping screw line up with the corresponding holes in the frame as shown (see Fig , left). Note that if fitting the bush back into the frame proves difficult, applying a little grease to the bush may help. Apply Loctite 243 thread locking compound to the 4 x M8 threads in the main bush as shown (see Fig , right). Fig Screw in the 4 x M8 bolts into the bush as shown (see Fig , left). Fig Document No: v3 Page 32 of 34 June 2018

33 Screw the self-tapping screw into the small hole on the end of the frame tube as shown (see Fig , right). Once re-assembled, adjust the tension on the locking lever as detailed below. Fig Adjusting the locking lever: If the locking lever is only slightly worn it can be adjusted as follows (please refer to the above replacement instructions for more detials): - Remove the self-tapping screw and 4 x M8 bolts from the main frame - Slide the main bush out of the frame - Loosen the M8 lock nut on the back of the main bush - Set the lever into the locked position - Use a flat blade screwdriver and turn the slotted pin clockwise until there is no play between the main bush and push handle (see Fig , right). - Test that the lever still opens after the adjusment (if it is loose turn the slotted pin half a turn clockwise, if it is difficult to open then loosen the adjustment pin by turning anticlockwise half a turn and test again). Fig Lock off the M8 lock nut against the main bush - Re-assemble the bush back into the frame. Document No: v3 Page 33 of 34 June 2018

34 9: Cleaning 1. To clean the wheelbase or interface, wipe with a damp cloth and dry thoroughly. 2. For more stubborn stains wipe with a damp cloth and warm water in which a little mild soap has been dissolved. Dry thoroughly. 3. Never use furniture polish or any spirit to clean the frame. 10: Parts Lists Please refer to the appropriate parts list and exploded diagram for the part of the system you are interested in. The pages available that apply to this manual are; Swirl Chassis Parts List and Snappi Interface parts list. Document No: v3 Page 34 of 34 June 2018

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