Küschall CHAMPION User manual

Service Manual
KÜSCHALL CHAMPION
S

3
KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
TABLE OF CONTENTS
GENERAL...................................................................................................................... 4
Introduction 4
Spare parts and adaptations 4
Tightening Allen screws 4
Torque 5
Checks 5
Identifying and alleviating malfunctions 5
FRAME............................................................................................................................6
Changing Frame 6
SEAT ...............................................................................................................................7
Fitting seat cover to frame 7
Front seat height (SHv) 7
Rear seat height (SHh) 8
Checking the folding unit for play and adjusting 9
BACKREST.................................................................................................................. 10
Tension adjustable backrest 10
Backrest height (RH) 13
Backrest angle (RW) 14
Push handles / backrest telescopes 14
Stabilisation bar 16
FOOTRESTS ................................................................................................................17
Footplate 17
Lower leg length (UL) 17
Footrest mounted in high position 18
SIDE PARTS .................................................................................................................19
Clothes-guard assembly 19
Mud guard assembly 20
Siderest assembly and adjustment 21
Armrest assembly and adjustment 21
FRONT WHEELS........................................................................................................ 22
Replacing a front wheel 22
Replacing a front wheel fork 22
Front wheels, repositioning to the frame 23
Front wheel supporter, adjusting the steering error angle 23
Front wheel supporter, adjusting the trail angle 23
REAR WHEELS ........................................................................................................... 24
Rear wheels, repositioning 24
Wheel camber, adapter sleeves 24
Adjusting the removable axle 24
Distance sleeves 25
Adapterplate 25
BRAKES ....................................................................................................................... 26
Fitting / adjusting the parking brake 26
OPTIONS & ACCESSORIES...................................................................................... 27
Antitipper 27
Tipper aid 28
Transit wheels 28
Cane holder 29
Fitting the pelvic belt 29

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
GENERAL
Introduction
This service manual is part of the instructions and contains the tech-
nical information for servicing, configuring and repairing a küschall®
wheelchair.
WARNING!
Danger of accident and severe injuries.
If the wheelchair is improperly set it can cause
accidents and severe injuries.
▸Changes to the wheelchair may only be carried out
by the dealer.
To guarantee the required safety and reliability, all wheelchairs must
be comprehensively checked once a year.
In part, assembly and adjustment require extensive experience. For
this reason, the following assembly instructions have been split into
three categories:
Requirement Symbol
Easy – technical understanding required 
Intermediate – specialist knowledge required 
Dicult – specialist wheelchair assembly knowledge
and experience required

The required tools and their respective sizes are listed above each
instruction. The instructions include information on the torques with
which the respective screw connections must be tightened. Adhering
to the given torques requires the use of a torque spanner.
Tools Symbol
Allen key Ã2x3, 4, 5, 6
Phillips screwdriver Ò2
Straddle spanner 19
Socket spanner/ring spanner 8, 10, 14, 22
Spare parts and adaptations
All spare parts can be purchased from küschall®'s Customer Services.
An electronic spare parts catalog is available by logging onto
www.kueschall.com. Only original spare parts may be used.
Installing additional adaptations to a küschall®wheelchair requires
the prior written approval of küschall®AG.
Tightening Allen screws
Allen keys are not designed for greater forces. When tightening or
loosening an Allen screw, it is therefore advisable to apply force to
the nut to prevent the hexagon socket from being damaged.
Tightening and loosening
Turn the nut with a socket spanner (only use a straddle spanner
if there is insucient space) and merely hold the screw tight with
the Allen key.
ST
SHv
SW
SHh
RH
GL
UL
RW
GB
SB

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
Tightening and loosening if there is no nut
If an Allen screw is directly screwed into a screw thread, the screw must be tightened
using an Allen key.
iEnsure that the Allen key is of good quality and not worn.
Torque
All screw connections must be tightened with the torques specified in the following
instructions.
Checks
Visual check
Check the entire frame for cracks, especially the areas around joints and welded
seams.
Checking the screw connections
Check all bolts with the torques specified in the instructions regularly, and adjust if
required.
CAUTION! Several screw connections have been secured with safety seals. If these are opened,
they must be secured again using new safety seals.
High-power and low power adhesives are available. For torque entries notice shall be
made whether an adhesive and which adhesive needs to be used.
Identifying and alleviating malfunctions
Malfunction Possible cause Measure
The wheelchair will not
move in a straight line
Incorrect tire pressure in a rear wheel Correct tire pressure
One or more spokes broken Replace defective spoke(s)
Spokes unevenly tensioned Tighten excessively loose spokes
Dirty or damaged wheel bearings Clean or replace bearings
Bearing block of castor fork is not vertical Align bearing block vertically
Front wheels not set to the same height
Position the front wheels in such a way
that they touch the ground at the same
time
Rear wheels not parallel or axes not aligned Adjust the prestress load on the scissor
mechanism and/or the trail
The wheelchair tips
backwards too easily
Rear wheels have been fitted too far forward Fit rear wheels further back
Backrest angle too great Reduce backrest angle
Seat angle too great
Mount the adapter plate lower on the
side profile
Mount the smaller castor fork
The brakes engage poorly
or asymmetrically
Incorrect tire pressure in one or both rear wheels Correct tire pressure
Brake setting incorrect Correct brake setting
Roll resistance is too great
Insucient tire pressure in the rear wheels Correct tire pressure
Rear wheels are not parallel Ensure that the rear wheels are parallel
(4° wheel camber)
The front wheels wobble
when moving fast
Insucient tension in the front wheel bearings block Lightly tighten the nut in the bearings
block axle
Front wheel is worn flat Replace front wheel
The front wheel is sti or
stuck Dirty or damaged bearings Clean or replace the bearings
The wheelchair is very
dicult to unfold The backrestcover is too tight Loosen the backrestbands a little
Handling seems imprecise The scissor mechanism is not closed properly If required, remove dirt from scissor
mechanism
The scissor mechanism is misaligned Realign the scissor mechanism

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
FRAME
FRAME
The Champion 08 frame is available in aluminium, titan or carbon.
Aluminium or titan frames are available with frame angles of 75° and
90°, carbon frames with a frame angle of 87°
Changing Frame
Fitting frame tubes
Fit both frame tubes into the side supportersusing bolts and
tighten lightly.
When assembling the titan frames, make sure an aluminium
spacer sleeve is placed between frame tube and side
supporter.
Drilling frame mounting holes
Diculty:  Tools: drill, drill bit: ∅5,9 mm
Before drilling the frame mounting holes, fit and adjust the
following components:
- Front wheels, Chapter Front wheels;
Front wheels, repositioning to the frame
Front wheel supporter, adjusting the steering
error angle
Front wheel supporter, adjusting the trail angle
- Footrests, Chapter Footrests;
Footrest, height adjustment
- Adapter sleeves, Distance sleeves, Adapterplates,
Chapter Rear Wheels;
Adjustment of rear wheel parallelism
Adapterplate, adjustment to folding unit or
assembly of new adpterplate
Adapterplate spacer assembly
- Seat cover, Chapter Seat;
Fitting seat cover to frame
iMake sure that all settings on the wheelchair are correct.
To guarantee that the wheelchair runs straight, make sure that
the frame is parallel and in plumb.
Drill the frame mounting holes carefully on both sides through
the side supporters and the seat cover from the inside out to ∅
5.9 mm.
Attaching the side supporters, frame tubes and seat cover
iThe purpose of the threaded connection through the frame
mounting holes is to provide additional fixing. The frame is thus
easier to guide and is better secured. Any misalignment of the
toe angle of the front wheels is counteracted.
Attach the side supporters, frame tubes, seat cover and optionally,
the holders for the mudguard or siderests using bolts through the
frame mounting holes on both sides and tighten.
2
1
5
5
6
à7 Nm
4
3

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
SEAT
SEAT
Fitting seat cover to frame
Fit seat cover to side supports on both sides using bolts .
Front seat height (SHv)
The following possibilities are available to adjust the front seat height (SHv):
- Replace the front wheel with a larger or smaller one,
Chap. Front wheels; Replacing a front wheel.
- Replace the front fork with a larger or smaller one,
Chap. Front wheels; Replacing a front wheel fork.
iAdjusting the front seat height changes the seat angle. It may be necessary to adjust the rear seat height correspondingly.
iIn the case of a 4° wheel camber, it must be ensured that the rear wheels are parallel after changing the front seat height.
If required, they must be readjusted,
Chap. Rear wheels; Adjustment of rear wheel parallelism.
Front seat height (SHv) per frame size, front fork and front wheel
SHv
[mm]
Aluminium / Titan frame 75° (active)
(short frame) (long frame)
450 5'' 4'' 3'' 3''
460 5'' 4'' 3'' 4'' 3''
470 5'' 4'' 3'' 4'' 3''
480 6'' 5'' 4'' 3'' 4'' 3''
490 6'' 5'' 4'' 5'' 4'' 3''
500 6'' 5'' 5'' 4'' 3''
510 6'' 6'' 5'' 4'' 3''
520 6'' 6'' 5'' 4''
530 6'' 5'' 4''
540 6'' 5''
1
1
à7 Nm

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
SEAT
Front seat height (SHv) per frame size, front fork and front wheel
SHv
[mm]
Aluminium / Titan frame 90° (dynamic)
(short frame) (long frame)
450 4'' 3''
460 5'' 4'' 3'' 3''
470 5'' 4'' 3'' 4'' 3''
480 5'' 4'' 3'' 4'' 3''
490 5'' 4'' 3'' 4'' 3''
500 5'' 4'' 5'' 4'' 3''
510 5'' 5'' 4'' 3''
520 5'' 4'' 3''
530 5'' 4'' 3''
540 5'' 4''
Front seat height (SHv) per frame size, front
fork and front wheel
SHv
[mm]
Carbon frame 87°
UL 400 – 500
450 3''
460 4'' 3''
480 4'' 3''
490 5'' 4'' 3''
500 5'' 4'' 3''
510 5'' 4'' 3''
520 5'' 4''
530 5'' 4''
540 5''
Rear seat height (SHh)
The following possibilities are available to adjust the rear seat height
(SHh):
- Adjustment of the adapter plate to the folding unit, Chap. Rear
wheels; Adapterplate, adjustment to folding unit or assembly of new
adapterplate.
- Replacement of the rear wheel with a larger or smaller one.

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
SEAT
iIn the case of a 4° wheel camber, it must be ensured that the rear wheels are parallel after changing the rear seat height, If required,
they must be readjusted,
Chap. Rear wheels; Adjustment of rear wheel parallelism.
Rear seat height (SHh) by position in the adapter plate and rear wheel size
SHh
[mm] 22’’ wheel 24’’ wheel 26’’ wheel
1
2
3
4
5
6
7
390 3 1
400 4 2
410 4 2
420 5 3 1
430 6 4 2
440 7 5 3
450 6 4
460 6 4
470 7 5
480 6
490 7
Assumption: Seat angle = 60 mm
Checking the folding unit for play and adju-
sting
The bolt of the scissor mechanism must be checked regularly for play
and tightened, if necessary.
Both scissor levers must lie full on top of one another. The scissor levers must not have any play.
The scissor mechanism must open and close easily.
Diculty:  Tools: Ã614
Check the bolt for play.
If the scissor mechanism is too easy to move or the scissor levers
have play:
Loosen the bolt and remove.
Check the bolt and and replace, if necessary.
WARNING! Danger of severe injury to the user as a result of using the wrong bolt.
When replacing the bolt , ensure that only original parts (spare
part kit 1540893) are used.
Insert bolt with washer through the scissor lever and screw
onto the nut ensuring there is no play.
iTo obtain a play-free bolt connection, tighten bolt firmly and
then loosen by a quarter turn.
Hold bolt firmly with an Allen key and tighten counternut .
If the scissor mechanism is too dicult to move:
Loosen counternut and bolt slightly.
Tighten counternut again.
Check:
Always ensure that the screws are tightened in such a way that
they are seated on the scissor mechanism when it is open. Please
note that the screws are secured with adhesive and this must be
replaced as appropriate.
ᆰ
ᆱ
ᆲ
ᆳ
à13 Nm

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2013-12
Service Manual
BACKREST
BACKREST
Tension adjustable backrest
Tension adjustable backrest with foldable push handles
RH
[mm]
teles-
copic
tube
Inter-
mediate
tube
Velcro straps
without
stabili-sation
bar
Velcro
straps with
stabilisation
bar

S
M
L
   
300 S S L M S
315 S S L M S
330 S L L S+M S
345 S L L S+M M
360 S L L S+M M
375 S L L L not M
390 L L L L possible M
405 L L L L L
420 L L L S+L L
435 L L L S+L L
450 L L L S+L L
465 L L L S+L L
Tension adjustable backrest with push handles standard
RH
[mm]
Push-
handle
Inter-
mediate
tube
Velcro straps
without stabili-
sation bar
Velcro
straps with
stabilisation
bar

S=5cm
L=10cm
S
M
L
     
300 S S L M S
315 S S L M S
330 S S L S+M not S
345 S L L S+M possible M
360 S L L S+M M
375 S L L L M
390 S L L L M
405 L L L L S S+L L
420 L L L S+L S S+L L
435 L L L S+L S S+L L
450 L L L S+L S M+L L
465 L L L S+L S M+L L