Küschall K-SERIES User manual

Service Manual
KÜSCHALL K-SERIES

3
KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
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
SEAT ...............................................................................................................................7
Seat width (SB) 7
Seat depth (ST) 7
Front seat height (SHv) 7
Rear seat height (SHh) 9
Seat angle (SW) 9
Tipping point adjustment 10
Suspension 10
BACKREST...................................................................................................................11
Backrest height (RH) 12
Adjusting the backrest height 12
Securing/adjusting the release cord 12
Replacing the backrest tube 13
Replacing the handle 14
Replacing foldable push handles 14
Backrest angle (RW) 15
FOOTRESTS ...............................................................................................................16
Lower leg length (UL) 16
Replacing footrests 16
Adjusting the footrest height 16
Fitting and adjusting high-mounted footrest 17
Angle-adjustable footplate, adjusting the angle 17
Fit fold-up footrest 17
SIDE PARTS .................................................................................................................18
Armrest 18
Clothes-guard/mudguard 19
FRONT WHEELS.........................................................................................................21
Replacing a front wheel 21
Replacing a front wheel fork 21
REAR WHEELS ........................................................................................................... 22
Ensuring the rear wheels are parallel 22
Adjusting the removable axle 22
Fitting and adjusting a rear wheel extension 22
Changing the wheel chamber / Fitting and adjusting an axle 23
BRAKES ....................................................................................................................... 24
Fitting / adjusting the parking brake 24
OPTIONS & ACCESSORIES...................................................................................... 25
Antitipper 25
Active antitipper 26
Transit wheels 26
Fitting the pelvic belt 27
Attaching the snap hook symbols 27

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
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 provider.
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 Ã3, 4, 5
Phillips screwdriver Ò2
Straddle spanner 10, 11, 19
Socket spanner/ring spanner 8, 10
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.
kuschall.com. Only original spare parts may be used. Installing additi-
onal 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.
RH
SHv
SHh
UL
SB
GL

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
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 instructionsregularly, 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)
Spoke unevenly tensioned Tighten excessively loose spokes
Dirty or damaged wheel bearings Clean or replace bearings
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 Use longer vertical struts
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
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
Increased forward tip
tendency Frame deformed Replace frame

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
Service Manual
FRAME
The K-Series frame is available in aluminium, titanium and carbon. Aluminium and titanium frames
come with frame angles of 75° and 90°; carbon frames come with a frame angle of 75°. Further-
more, the 75° and the 90° aluminium frames come with adduction and in a short, respective +5
version.
Frame
Front seat
height (SHv) in
mm
(with a 24”rear
wheel)*
Lower leg length
(UL) with standard-
mounted bar
Lower leg length (UL) with
standard-mounted fold-
up footrest
Seat depth
(ST)
Aluminium
75° short 450 to 470 SHv -120** to SHv -30 SHv -160** to SHv -30 375 to 450
75° standard 480 to 500 SHv -110** to SHv -30 SHv -150** to SHv -30 375 to 450
75°+5 500 to 520 SHv -110** to SHv -30 SHv -150** to SHv -30 450 to 525
90° short 450 to 470 SHv -140** to SHv -40 SHv -180** to SHv -40 375 to 450
90° standard 480 to 500 SHv -130** to SHv -40 SHv -170** to SHv -40 375 to 450
90°+5 500 to 520 SHv -130** to SHv -40 SHv -170** to SHv -40 450 to 525
75° adduction 480 to 500 SHv -110** to SHv -30 SHv -150** to SHv -30 375 to 450
90° adduction 480 to 500 SHv -130** to SHv -40 SHv -170** to SHv -40 375 to 450
Titanium
75° standard 480 to 500 SHv -110** to SHv -30 SHv -150** to SHv -30 375 to 450
90° standard 480 to 500 SHv -130** to SHv -40 SHv -170** to SHv -40 375 to 450
Carbon
75° standard 490 to 500 SHv -110** to SHv -30 SHv -150** to SHv -30 375 to 450
*With a 25”rear wheel, the SHv is 10 mm greater in each case. With a 26”rear wheel, the SHv is 20
mm greater in each case.
**With a 25”rear wheel, deduct 10 mm in each case when calculating the lower leg length. With a
26”rear wheel, deduct 20 mm in each case from the SHv (see examples in the following Table).
Examples:
Frame SHv in mm
Lower leg length
(UL) with standard-
mounted bar
Lower leg length with
standard-mounted fold-up
footrest
75° short, 25” rear wheel 460 to 480 SHv -130 to SHv -30 SHv -170 to SHv -30
75° short, 26” rear wheel 470 to 480 SHv -140 to SHv -30 SHv -180 to SHv -30
For lower leg lengths, the high-mounted footrest must be used. àChapter: Footrests, ‹Assemb-
ling and adjusting high-mounted footrests›
FRAME

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
Service Manual
SEAT
Seat width (SB)
Available seat widths: SB 340 to 480 in 20 mm steps.
Changing the seat width is very complicated and requires the replacement of numerous parts.
Seat depth (ST)
Available seat depths: ST 375 to 525 in 25 mm steps.
Changing the seat depth requires the replacement of the complete seat module including the
seat cover and the seat rail and potentially also the seat cushion.
Front seat height (SHv)
The front seat height is dependent on several factors that interact with each other. The size
of the rear wheels determines the height of the sub-structure. In addition to the size and the
positioning of the brackets on the seat module, the frame, seat depth and rear seat height
influence the seat height.
26
25
24
3'' 4'' 5''
A B C D E F
75° / 75°+5 75°short
90° / 90°+5 90°short
SEAT

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
Service Manual
SEAT
If the rear wheel, front wheel and front wheel fork are defined, the
front seat height can be adjusted by changing the position of the seat
module within the frame. There are 2 brackets available, each with 2
fixing options.
Positioning or replacing the brackets at the front for
setting the front seat height (SHv)
Diculty:  Tools: Ã4, 5
Remove the rear wheels, fold the backrest forward and place the
wheelchair on its back.
Loosen the screws and that connect the seat brace to the
seat module or the frame on both sides.
Remove the screw and place it in the bracket’s other hole.
If you require a new bracket, remove the screws and , replace
the bracket and fix it using the screws and .
Refit the rear wheels, stand the wheelchair back up and check the
position of the seat braces . They must be as perpendicular to
the ground as possible.
Tighten the screw connections and of the seat braces and 
and of the front brackets again.
Carry out the same setting on both sides.
iNote: ensure that adjusting the front seat height results in a change to the seat angle. It may be necessary to correspondingly
adjust the rear seat height (SHh) or the backrest angle.
Possible front and rear wheel combinations
Rear
wheel Frame 3'' 4'' 5''
24‘‘
75° short F E D
75° / 75°+5 / 90°short D C B
90° / 90°+5 B A --
25‘‘
75° short -- F E
75° / 75° +5 /
90°short E D C
90° / 90°+5 C B --
26‘‘ 75° / 75° +5 F E D
90° / 90°+5 D C B
iOnly select combinations listed in the Table to ensure that the frame is straight and the front wheel supports are perpendicular to
the ground.
1cm
1
3
2
4
6
5
à7 Nm
à13 Nm
à7 Nm
à7 Nm

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
Service Manual
SEAT
Rear seat height (SHh)
The seat braces can be repositioned to adjust the rear seat height.
The seat braces are available in three dierent sizes, covering seat
heights of between 380 and 490 mm.
Generally, we recommend fixing the seat braces to the lower hole on
the frame.
Adjusting the rear seat height (SHh)
Diculty:  Tools: Ã5
Remove the rear wheels, fold the backrest forward and place the
wheelchair on its back.
Loosen the screw for the front bracket on both sides.
If you can set the desired seat height using the existing seat
brace , loosen the screw and remove the screw and the
connecting bar .
If you require a new seat brace, remove the existing one and the
connecting bar and loosely fix the new seat brace to the frame
using screw .
Slide the seat brace against the rear bracket so that the required
holes overlap.
Insert the connecting bar and fix it with screw .
Carry out the same setting on both sides.
Refit the rear wheels, stand the wheelchair back up and check the
position of the seat brace . It must be as perpendicular to the
ground as possible.
Tighten the screws , and .
iNote: ensure that adjusting the rear seat height results in a change to the seat angle. It may be necessary to correspondingly adjust
the front seat height (SHv) or the backrest angle.
Seat angle (SW)
The seat angle is determined by the dierence between the rear seat
height (SHh) and the front seat height (SHv).
Rear seat height based on wheel position and wheel size
24”
wheel
25”
wheel
26”
wheel
SHh S M L S M L S M L
380 1
390 1 1
400 2 1 1
410 3 5a 2 1
420 4 5 3 5a 2
430 6 4 5 3 5a
440 7 9a 6 4 5
450 8 9 7 9a 6
460 10 8 9 7 9a
470 11 10 8 9
480 12 11 10
490 12 11
1
2
3
45
6
7
89
10
11
12
5a
6a
7a
8a 9a
10a
11a
12a
S M L
1
2
3
4
5
à7 Nm
à13 Nm
à7 Nm

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KÜSCHALL K-SERIES
© Küschall AG, Switzerland | 2014-07
Service Manual
SEAT
Tipping point adjustment
The tipping point of the wheelchair can be adjusted by changing the
horizontal position of the seat module.
Diculty:  Tools: Ã4, 5
Remove the rear wheels, fold the backrest forward and place the
wheelchair on its back.
Loosen the screws , and .
Remove the screws and and slide the seat module forwards
or backwards.
Fix the seat module with the screws and and tighten the
screws , and again.
Carry out the same setting on both sides.
There are 3 possible positions for the rear bracket and 5 possible
positions for the front bracket.
iNote: ensure that the seat brace is as vertical as possible following an adjustment.
Suspension
A suspension can be fitted for a SHh of between 380 and 460.
Fitting a suspension
Diculty:  Tools: Ã4, 5
Remove the rear wheels, fold the backrest forward and place the
wheelchair on its back.
Remove the seat module by removing the brackets at the front 
and the rear .
Removing the seat brace .
Fit the suspension housing to the frame. Here, slide the screw
with the washer through the suspension housing and place the
lubricated sleeve with the spacer elements on the screw. Slide the
screw through the frame into the axle holder stay and tighten it
firmly.
Function check:
It must be possible to rotate the suspension housing , but it must
not be loose.
Insert the suspension seat strut from above into the suspension
housing . Slide the sleeve from below over the suspension
seat strut and position it at the desired seat height. Fix it using
the screw and the washer .
Carry out the same setting on both sides.
Lubricate the springs and insert them into the suspension
housing . Insert the screws into the suspension housing until
they protrude by 25 mm.
Fix the front and rear spring brackets to the seat module
(screws a), insert the lubricated rotating sleeves band fix the
seat module to the frame (screws c) again.
Reattach the wheels and stand the wheelchair up again.
Check:
Check the front seat height. When fitting the mudguard, ensure that
it is at least 4 mm from the wheel. Check the suspension function.
1
4
2
3
5
7
7
à7 Nm
à7 Nm
à7 Nm
à7 Nm
à13 Nm
1
2
3
4
4
6
7
9
8
6
12
12
13
13
5
10
11
à7 Nm
à4 Nm
aà7 Nm
cà7 Nm