Küschall Champion 2008 User manual

Technical module
1
Copyright © 08/2008,Küschall AG
Champion ’08
Champion
Changing configurations
Table of contents
1 Adjustment possibilities 2
1.1 Seat width 2
1.2 Seat depth 2
1.3 Knee-to-heel length (UL) 2
1.4 Rear seat-to-floor height (SHh) 2
1.5 Front seat-to-floor height (SHv) 3
1.6 Tipping stability 4
1.7 Backrest height (RH) 4
2Assembly and adjustment methods 7
2.1 Footrest replacement 7
2.2 Footrest height adjustment 7
2.3 Footplate angle adjustment 8
2.4 Footrest mounted in high position 8
2.5 Front fork replacement 9
2.6 Front fork, repositioning to the front frame 9
2.7 Front wheel supporter, vertical adjustment 10
2.8 Front wheel replacement 10
2.9 Adapter plate adjustment to folding unit 11
2.10 Rear wheel to adapter plate adjustment 11
2.11 Parking brakes assembly and adjustment 12
2.12 Clothes-guard assembly 12
2.13 Mud guard assembly 13
2.14 Armrest assembly and adjustment 13
2.15 Backrest height adjustment 14
2.16 Push handle / telescopic tube replacement 15
2.17 Backrest angle adjustment 15
2.18 Stabilisation bar assembly 16
2.19 Antitipper assembly and adjustment 16
2.20 Tipper aid assembly and adjustment 17
2.21 Transit wheels assembly and adjustment 17
2.22 Cane holder assembly and adjustment 18
3 Troubleshooting 19

Technical module
2
Copyright © 08/2008,Küschall AG
Champion ’08
Please note that ad-
justments made to
the rear seat-to-floor
height changes the
seat angle.The front
seat-to-floor height
may be changed ac-
cordingly.
1 Adjustment possibilities
1.1 Seat width
To change the seat width, the folding mechanism, the seat cover, the backrest upholstery
and part of the footplate must be exchanged. 7 seat widths are available from SB34 to
SB46 (in steps of 2cm).
1.2 Seat depth
To adjust the seat depth you must exchange the frame, seat rail and seat cover.The follow-
ing seat depths are available:
Aluminium frame: ST34 to ST46
Carbon frame: ST40 to ST46
1.3 Knee-to-heel length (UL)
To adjust the knee-to-heel length you must adjust the footrest height. (Chapter 2.2)
The following adjustments are possible:
Aluminium frame UL20 – UL29 high mounted footrest
UL30 – UL50 standard footrest
Carbon frame UL30 – UL39 high mounted footrest
UL40 – UL50 standard footrest
1.4 Rear seat-to-floor height (SHh)
The following possibilities are available to adjust the rear seat height:
- Adjustment of the adapter plate to the folding unit. (Chapter 2.9)
- Replacement of the rear wheel with a larger or smaller one.
A new seat cushion is
required if you chan-
ge the seat depth or
the seat width.
Rear seat-to-floor height by position in the adapter plate
SHh 22’’ wheel 24’’ wheel 26’’ wheel
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2
3
4
5
6
7
38 2
39 3 1
40
41 4 2
42531
43642
44753
45
46 6 4
47 7 5
48 6
49 7
assumption: seat angle=6 cm

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
1.5 Front seat-to-floor height (SHv)
The following possibilities are available to adjust the front seat-to-floor height:
- Replace the front wheel with a larger or smaller one. (Chapter 2.8)
- Replace the front fork with a larger or smaller one. (Chapter 2.5)
Front seat-to-floor height per frame size, front fork and front wheel
SHv
Frame 90° (dynamic)
Leg length from 32 to 40 (short frame) Leg length from 40 to 50 (long frame)
45 4'' 3''
46 5'' 4'' 3'' 3''
47 4'' 3''
48 5'' 4'' 3''
49 5'' 4'' 3'' 4'' 3''
50 5'' 4'' 5'' 4'' 3''
51 5'' 5'' 4'' 3''
53 5'' 4'' 3''
54 5'' 4''
Front seat-to-floor height per frame size,
front fork and front wheel
SHv
Carbon Frame 87°
Leg length from 40 to 50
45 3''
46 4'' 3''
48 4'' 3''
49 5'' 4'' 3''
50 5'' 4'' 3''
51 5'' 4'' 3''
53 5'' 4''
54 5''
Front seat-to-floor height per frame size, front fork and front wheel
SHv
Frame 75° (active)
Leg length from 32 to 40 (short frame) Leg length from 40 to 50 (long frame)
45 5'' 4'' 3''
46 4'' 3''
47 5'' 4'' 3''
48 6'' 5'' 4'' 3'' 4'' 3''
49 6'' 5'' 4'' 5'' 4'' 3''
50 6'' 5'' 5'' 4'' 3''
51 6'' 5'' 4'' 3''
52 6''
53 6'' 5'' 4''
54 6'' 5''

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 1.6 Tipping stability
The tipping stability is influenced by the seat angle which is given by the front and rear
seat-to-floor height. Another possibility to influence the tipping stability is to change the
position of the front and rear wheels:
- Adjust the rear wheels position to the adapter plate more to the front or more to the
rear (Chapter 2.10).
- Adjust the position of the front wheel supporter more to the front or more to the
rear (Chapter 2.6).
The chair will be more stable, the further rearwards that the rear wheels are fitted.
1.7 Backrest height (RH)
To adjust the backrest height you must adjust or replace the backrest tubes. (Chap-
ter 2.15)
Tension adjustable backrest with push handles standard
RH
push
handle
inter-
mediate
tube
Velcro straps
without stabili-
sation bar
Velcro straps
with
stabilisation bar
    
30 SS L M S
31.5 SS L M S
33 S S L S+M S
34.5 S L L S+M S
36 S L L S+M S
37.5 SL L L S
39 SL L L S
40.5 L L L L S S+L L
42 L L L S+L S S+L L
43.5 L L L S+L S S+L L
45 L L L S+L S M+L L
46.5 L L L S+L S M+L L
Tension adjustable backrest with foldable push handles
RH
teles-
copic
tube
inter-
mediate
tube
Velcro straps
without stabili-
sation bar
Velcro straps
with
stabilisation bar
  
30 SS LM S
31.5 SS LM S
33 S L L S+M S
34.5 S L L S+M S
36 S L L S+M S
37.5 S L L L not S
39 L L L L possible S
40.5 LL L L L
42 L L L S+L L
43.5 L L L S+L L
45 L L L S+L L
46.5 L L L S+L L

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
Tension adjustable backrest without push handles
RH
Teles-
copic
tube
Inter-
mediate
tube
Velcro straps
without stabi-
lisation bar
Velcro straps
with
stabilisation bar
  
30 SSLM S
31.5 SSLM S
33 L S L S+M S
34.5 L S L S+M S
36 L S L S+M S
37.5 LLLL S
39 LLLL S
40.5 L L L L S S+L L
42 L L L S+L S S+L L
43.5 L L L S+L S M+L L
45 L L L S+L S M+L L
46.5 L L L S+L S M+L L
Tension adjustable backrest with push handles, height adjustable
RH
Teles-
copic
tube
Inter-
mediate
tube
without
stabilisation
bar
with
stabilisation
bar

30 SSSM S
31.5 SSSM S
33 SLLM S
34.5 SLLM S
36 S L L S+M S
37.5 SLSL S
39 LLSL S
40.5 L L S S+L S 2S+M L
42 L L L L S 2S+M L
43.5 LLLLSS+L L
45 L L L S+L S S+L L
46.5 L L L S+L S S+L L

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2 Assembly and adjustment methods
2.1 Footrest replacement
Remove the bolt set attaching the telescope tube to the frame on both sides
of wheelchair.
Remove the footrest .
Slide the bridging sleeve onto the telescope tube of the new footrest .
Slide the footrest into the wheelchair frame and position the bridging sleeve 
accurately.
Re-assemble the bolt set and tighten.
Function Control:
Check that the footrest is firmly attached but that it can fold easily.
2.2 Footrest height adjustment
Remove the 2 bolts from the frame above the footrest.
Extend the footrest telescope to the required length, then insert the bolts into the
closest holes.
Tighten the locking bolts firmly.
Function Control:
Check that the footrest is firmly attached but that it can fold easily.
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Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 2.3 Footplate angle adjustment
Slightly loosen the bolted footplate connection which fixes the telescopic tube 
in the footplate fixture below the footplate.
Adjust the angle as required.
Retighten the bolts .
Function Control:
Make sure that the footplate folds easily.
2.4 Footrest mounted in high position
Remove the footrest from the frame.
Detatch the telescopic tube and footplate fixture from the footrest by removing
the screw .
Attach the mounting bracket to the frame using the screws and nuts.
Attach the footrest at the desired height on the mounting brackets with the
screws and the conical spacers .
Fit caps to the ends of the frames.
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Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2.5 Front fork replacement
Remove the ball bearing cover cap .
Remove the nut and washer .
Dismantle the front fork .
Check the ball bearing blocks and
replace if necessary.
Attach the new front fork with the
nut and washer and tighten.
Perform function control (see below)
Attach the ball bearing cover cap 
again.
Function Control:
Tip the wheelchair 90° backwards, so that the
chair is lying on the backrest and rear wheels.
Turn the fork upwards (position A) and let it tip
downwards.
The fork is positioned correctly when it turns
slightly over the lowest point and stays there
(position B).
The fork hasn’t been tightened sufficiently if it
turns back into the lowest position (position C).
If tightened wrongly, there is a possibility for the
front wheels to start fluttering at high speeds.
2.6 Front fork, repositioning to the front frame
The front forks can be mounted in 3 different positions on the front frame:
Remove screws .
Place the front wheel supporter in the required position on the frame then
replace the screws .
Check that the axis of the bearing block is perpendicular to the floor. Adjust if
necessary.
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4
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2
1
5
A
B
C
2
3
1

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 2.7 Front wheel supporter, vertical adjustment
Remove screw and slightly loosen screw .
Place a spirit level against the bearing block and turn the disc with an allen key so
that the bearing block is perpendicular to the floor.
Replace the screw , then tighten both screws and .
2.8 Front wheel replacement
Remove the screws and the front wheel axle .
Remove the front wheel and attach a new front wheel.
or
Place the front wheel in its new position.
(2 bushings must be slid onto the axle with a Starec wheel, Skater wheel, 3’’ Sport
wheel or 5’’ Softroll wheel.The bushings are already attached in the smooth running
wheel, sports wheels and pneumatic wheels.)
Guide the front wheel axle through the fork and the wheel (and the
bushing ).Tighten the screws .
90˚
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1
3
3
1
1
2
4
4
1
1
2

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2.9 Adapter plate adjustment to folding unit
Remove the 4 bolts from the adapter plate .
Adjust the adapter plate to the required height on the scissor axle .Tighten the
bolts firmly again.
Repeat the procedure on the other side of the wheelchair.
Function Control: Check that the rear seat height is correct.
Note that a rear seat height adjustment changes the seat angle.If necessary the
backrest angle can be adjusted accordingly.
Changing the rear seat height also changes the angle of the front wheel supporters.
These have to be re-adjusted to 90° to the floor. (chapter 2.7)
2.10 Rear wheel to adapter plate adjustment
There are 2 different adapter plates available covering 4 possible rear wheel positions. If
necessary replace the adapter plate.
Remove the nut from the adapter sleeve .
Insert the adapter sleeve in the required hole of the adapter plate .
Tighten the nut again firmly (torque 30Nm).
Make sure to do the
same adjustment
on both sides of the
wheelchair.
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1
3
1
2
3
1
4321

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 2.11 Parking brakes assembly and adjustment
Attach parking brake holder with bolt to frame, tighten slightly.
Slide brake into the holder and adjust to correct position in relation to the rear
wheel.
The distance between the rear wheel and the brakepole should measure 25mm.The
brakepole shouldn’t press more than 4mm into the rear wheel when the brake is locked.
Tighten bolt .
2.12 Clothes-guard assembly
Attach the seat module fixation piece to the seat module with the screws .
Align the clothes guard to the rear wheel and note the best hole on the clothes
guard to fix it to the backrest hinge.
Remove backrest hinge screw then re-assemble together with the clothes
guard .
Function control: Fold and unfold the backrest (this must be done easily). Make sure
the clothes-guards are positioned slightly higher than the rear wheels. Check that the
clothes-guards flip up easily.
The function of the
parking brakes is only
ensured if sufficient
air is in the tires.
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1
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1
2
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4

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2.13 Mud guard assembly
If replacing a clothes guard with a mudguard, first remove the clothes guard and the
bracket attached to the seat module.
Remove the rear wheels.
Attach the bracket to the seat module with the screws and remount the rear
wheels.
Slightly loosen the three screws on the adjustment plate and move it along the
mounting bracket until the mudguard is in position.Tighten the screws .
Function control:Take care that the distance between rear wheel and mud-guard is
equable (approx. 5mm).
2.14 Armrest assembly and adjustment
Remove the rear wheels.
Attach the bracket to the seat module with the screws .
Remount the rear wheels.
Slightly loosen the three screws on the height adjustment bracket then move the
armrest to the desired height (with the height adjustment bracket touching the
seat module bracket ).Tighten the screws .
Make sure to do the
same adjustment
on both sides of the
wheelchair.
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3
1
2
1
2
4
3

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 2.15 Backrest height adjustment
Lightly upholstered back
Push the backrest band so that the backrest tube is revealed.
Remove the backrest bolt . Adjust the backrest tube to the required height then
insert the bolt into the closest hole and tighten it again.
Reposition the backrest band correctly.
Tension adjustable back
Remove the backrest cover .
Slide the backrest straps either up or down to locate the fixing bolt . Remove nut
and bolt.
Adjust the push handle or the telescopic tube to the required height then fix it with
nut and bolt again.
Repeat on the other side, than re-assemble the backrest cover again.
Function Control: Check that nothing impedes the backrest when folding or unfolding.
Make sure that the push handles are attached tightly to the tubes.
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2
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2

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2.16 Push handle / telescopic tube replacement
Remove the backrest cover .
Remove the screws holding the uppermost backrest band to the push
handles (or telescopic tubes).
Slide the backrest straps either up or down to locate the fixing bolt . Remove
nut and bolt.
Remove push handles (or telescopic tubes) and uppermost backrest band . Slide
new push handle through backrest band and fix it on the backrest with bolt . Fix
the upmost backrest band with screw .
2.17 Backrest angle adjustment
Leave the backrest in a closed position (backrest lying on seat).
Remove the lower bolt from the side supporter .
Move the backrest to the required position.
Insert the bolt into the closest hole and tighten it again.
Repeat the procedure on the other side of the wheelchair.
Function control:The backrest must fold easily and the ratchet bolt must sit tightly
against the side supporter.
Make sure to do the
same adjustment
on both sides of the
wheelchair.
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1

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08 2.18 Stabilisation bar assembly
With a back height RH40.5 or larger it is possible to assemble a stabilisation bar to in-
crease the rigidity of the backrest handles.
Remove backrest cover .
Remove push handles and 10cm backrest band (or end band, if no push
handles are assembled).
Assemble a 5cm backrest band or end band to the push handles .
Attach the clamps together with the RH socket and the LH socket to the
push handles below the top backrest band .
Replace the push handle/backrest band/socket assembly.
Press pin and slide the stabilisation bar into the RH socket , then swing the
stabilisation bar upwards, press pin and click the stabilisation bar into the LH
socket .
2.19 Antitipper assembly and adjustment
Remove the nut from the adapter sleeve .
Mount the antitipper to the adapter plate with the anchor sleeve inserted
into any adjacent hole.
Tighten the nut and the screw for the anchor sleeve .
The height of the antitipper can be adjusted by pressing the spring pin , then
sliding the inner part of the antitipper to the required position until the spring pin
locates in the correct hole.
Function control:The antitipper should measure a distance of 4–6cm from the ground
and should swing under the chair without any difficulty.
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Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
2.20 Tipper aid assembly and adjustment
Attach the mounting block onto the wheelchair using the 2 bolts .
Attach the horizontal adaptation support to the mounting block using the 2
bolts .
Note that if a cane holder is mounted on the other side of the wheelchair, then an
additional mounting block is needed to lower the tipper aid to prevent them clashing
together when the wheelchair is folded.
Slide the tipper aid into the horizontal adaptation support and fasten it with
the spring clip .
Function Control:The tipper aid should not touch the floor if the wheelchair is tipped
backwards.
If the tipper aid touches the floor remove it and change the position of the spring
clip .This is done by removing the tube end cap then pushing the spring clip 
one hole further into the tube using a screwdriver.
2.21 Transit wheels assembly and adjustment
Attach the vertical adaptation support to the chair with the 4 bolts .
Place the transit wheel against the vertical adapter support . and attach it with
the 2 bolts .
Repeat for other side.
Adjust transit wheels to the correct height with the spring clip .
It's not possible to
attach tipper aid
and cane holder to
the same side of the
wheelchair.
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4
1
5
2
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1
2
3
4
1
5

Technical module
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Copyright © 08/2008,Küschall AG
Champion ’08
It's not possible to
attach tipper aid
and cane holder
to the same side of
the wheelchair.
2.22 Cane holder assembly and adjustment
Attach the mounting block onto the wheelchair using the 2 bolts .
Attach the horizontal adaptation support to the mounting block using the 2
bolts .
Note that if a tipper aid is mounted on the other side of the wheelchair, then an
additional mounting block is needed to lower the cane holder to prevent them clashing
together when the wheelchair is folded.
Slide the cane holder into the horizontal adaptation support and fasten it with
the spring clip .
Remove the screw from the backrest cover then replace it together with the
strap .
Function control:The cane holder should not touch the floor when the wheelchair is
tipped backwards.
If the cane holder touches the floor remove it and change the position of the spring
clip .This is done by removing the tube end cap then pushing the spring clip 
one hole further into the tube using a screwdriver.
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Technical module
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Copyright © 08/2008,Küschall AG
Wheelchairs general 3 Troubleshooting
Defect Possible cause Remedy
Wheelchair does not roll
straight
Wrong air pressure in the rear or
front wheels
Correct air pressure
Bearing blocks are not in a vertical
position 1)
Adjust bearing blocks to vertical position
Rear wheels do not run parallel Correct the parallelism of the rear wheels
Front wheels not adjusted to same
height 1)
Position front wheels so that they both
touch the floor
One or more spokes are broken Replace defective spoke(s)
Spokes are not equally tightened Tighten the loose-fitting spokes
Seat height adjustments are not
identical on both sides 1)
Check and correct all seat adjustments
Front wheel bearings are dirty or
damaged
Clean or replace bearing(s)
Wheelchair tips too easily Rear wheels are mounted too far to
the front
Shift wheels backward
Seat angle is too large Increase rear seat height
Select smaller front forks / wheels
Move front wheel supporters upwards 1)
Backrest angle is too large Reduce backrest angle
Poor or asymmetric brake
grip
Wrong air pressure in one or both
rear wheels
Correct air pressure
Wrong adjustment of the brake
position
Adjust brake to exert correct pressure
on tyre
Rolling resistance is high Rear wheels are off track Adjust parallelism of rear wheels
Tension on front fork axles is too
high
Loosen nut on bearing block axles
slightly
Ball bearings are defect Check all bearings and replace defect
one(s)
Front wheel axles are restrained by
dirt or hair
Clean axles
Wrong air pressure in the rear or
front wheels
Correct air pressure
Bearing blocks are not vertical 1) Adjust bearing blocks to vertical position
Backrest does not fold
easily
Clothes-guard fixations are too tight
2)
Slightly loosen fixations on both sides
Clothes-guard is not flipped in 1) Flip in clothes-guard
Front wheels vibrate
when driving fast
Tension of front fork axle in the
bearing blocks is too low
Tighten nut on bearing block axles
slightly
Rear wheels are not
removable
Axle holder is too tight 1) slightly loosen rear bolt on the axle
holder 1)
1) Fusion only
2) K-Series only