Küschall CHAMPION User manual

Service Manual

3© Küschall AG,Switzerland | 2012-01
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) 9
Folding unit 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
Distance sleeves 25
Adapterplate 25
Brakes ......................................................................................................................... 26
Fitting / adjusting the parking brake 26
Options & accessories ............................................................................................... 27
Antitipper 27
Tipper aid 28
Transit wheels 29
Cane holder 30

4© Küschall AG,Switzerland | 2012-01
Service Manual
General
Introduction
This service manual is part of the instructions and contains the technical
information for servicing, conguring and repairing a Küschall® wheelchair.
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 instruc-
tion.
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 loo-
sening 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.
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.
ST
SHv
SW
SHh
RH
GL
UL
RW
GB
SB

5© Küschall AG,Switzerland | 2012-01
Service Manual
Torque
All screw connections must be tightened with the torques specied in the following
instructions. Adhering to the given torques requires the use of a torque spanner.
Checks
Visual check
Check the entire frame for cracks, especially the areas around joints and welded seams.
Checking the screw connections
Check all screw connections with the torques specied in the instructions.
jSeveral screw connections have been secured with safety seals. If these are opened, they must be secured again using new safety seals.
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 tted 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
prole
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 at 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

6© Küschall AG,Switzerland | 2012-01
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.
jWhen 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, t 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 xing. 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
à13 Nm
4
3

7© Küschall AG,Switzerland | 2012-01
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

8© Küschall AG,Switzerland | 2012-01
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''

9© Küschall AG,Switzerland | 2012-01
Service Manual
Seat
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 adapter-
plate›.
- Replacement of the rear wheel with a larger or smaller one.
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
420 531
430 642
440 753
450 6 4
460 6 4
470 7 5
480 6
490 7
Assumption: Seat angle=60 mm
Folding unit
Setting the scissor mechanism
jBoth scissor levers must be fully on top of each other. It is important
that there is no play. The scissor mechanism must open and close
easily.
Diculty:  Tools: Ã6 14
If the scissor mechanism is loose or if there is play in the scissor levers:
Loosen the counternut .
Tighten the screw and then loosen it by a quarter turn.
Tighten the counter nut . Hold the screw tightly whilst tightening.
If the scissor mechanism is too sti:
Loosen both counter nut and screw slightly.
Tighten the counter nut 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 approp-
riate.
2
11
3
3
à7 Nm

10 © Küschall AG,Switzerland | 2012-01
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