Küschall KSL User manual

Service Manual

3© Küschall AG,Switzerland | 04/2010
Service Manual
Contents
General ......................................................................................................................... 4
Introduction 4
Spare parts 4
Tipping point of the wheelchair 4
Fastening with hexagon socket bolts 4
Visual check 5
Identifying and repairing faults 5
Frame............................................................................................................................ 6
Adjusting the frame 6
Changing the frame 6
Seat ............................................................................................................................... 7
Adjusting the seat height 7
Replacing the seat cover 7
Backrest........................................................................................................................ 8
Backrest height 8
Backrest angle 8
Replacing the Standard Light backrest cover 8
Replacing Velcro® tapes for adjustable backrests 9
Replacing push handles with Light cover 10
Replacing push handles with adjustable backrest 10
Foldable backrest, angle adjustable (optional) 11
Footrests..................................................................................................................... 12
Replacing the footrest 12
Adjusting the height of the footrest 12
Adjusting the angle of the footrest 12
Sides ........................................................................................................................... 13
Fitting the clothes guard 13
Fitting the mudguard 13
Front wheels............................................................................................................... 14
Replacing the front wheel fork 14
Replacing the front wheel 14
Cleaning the front wheel bearings 15
Rear wheels ................................................................................................................ 16
Checking the tyre pressure 16
Checking the spoke tension 16
Checking that removable axles are seated correctly 16
Adjusting the removable axles 16
Replacing the rear wheels 17
Replacing the axle 17
Ensuring the rear wheels are parallel 17
Repairing or changing an inner tube 17
Fitting tubed tyres to carbon wheels 18
Brakes .........................................................................................................................19
Checking the parking brake 19
Fitting and adjusting the parking brake 19
Options & accessories ............................................................................................... 20
Fitting an antitipper 20

4© Küschall AG,Switzerland | 04/2010
Service Manual
General
Introduction
This Service Manual contains all the technical information necessary for the
inspection, conguration or repair of a Küschall® wheelchair.
To maintain the necessary levels of safety and reliability, every wheelchair
must be thoroughly examined once a year.
Some aspects of the assembly and conguration of the wheelchair require
a high level of expertise. These assembly instructions therefore break the
various tasks down into 3 categories:
Requirement Symbol
Easy – technical understanding required 0
Medium – technical knowledge required 00
Dicult – technical knowledge and expertise in
assembling wheelchairs required
000
Spare parts
All spare parts may be obtained from the Küschall customer ser-
vice department. An electronic spare parts catalogue can be found at
www.kueschall.com.
Tipping point of the wheelchair
The tipping point of the wheelchair can only be modied by tting a new
backrest with a larger or smaller backrest angle. The seat depth can also be
adjusted by changing the hole position.
Fastening with hexagon socket bolts
Hexagon socket bolts are not designed to withstand an excessive appli-
cation of force. When tightening or undoing a hexagon socket bolt, force
should be applied to the nut wherever possible to avoid damaging the bolt.
Tightening and undoing
Turn the nut using an open-end spanner, or preferably a socket span-
ner, using the Allen key simply to stop the bolt turning.
Tightening and undoing when no nut is present
If a hexagon socket bolt is screwed directly into a thread, the bolt must be
tightened using the Allen key.
LEnsure that the Allen key is of good quality and not worn.

5© Küschall AG,Switzerland | 04/2010
Service Manual
Visual check
Part of the regular maintenance of the wheelchair includes the following
visual checks:
Test all bolt connections
Check the entire frame for cracks, especially in the vicinity of joints and
weld seams (frame, axle clamp components, backrest)
Identifying and repairing faults
Fault Possible cause Action
The wheelchair does not travel
in a straight line
Incorrect tyre pressure on one rear wheel Correct tyre pressure
One or more spokes broken Replace broken spoke(s)
Spokes tightened unevenly Tighten loose spokes
The wheelchair tips too easily Frame geometry does not meet specications Fitting an antitipper
Backrest angle too great Replace backrest with smaller backrest angle
Removable axles cannot be
inserted correctly
Removable axles dirty Clean removable axles
Removable axles misaligned Adjust removable axles
The brakes are gripping poorly
or asymmetrically Incorrect tyre pressure in one or both rear tyres Correct tyre pressure
The rolling resistance is very
high
Tyre pressure in rear tyres is too low Correct tyre pressure
Rear wheels not parallel Ensure rear wheels are parallel
The front wheels wobble when
moving fast
Too little tension in front wheel bearing block Tighten the nut on the bearing block axle slightly
Front wheel has worn smooth Change front wheel
The front wheel is sti or stuck Bearings are dirty or faulty Clean or replace the bearings

6© Küschall AG,Switzerland | 04/2010
Service Manual
Frame
Frame
Adjusting the frame
The seat width, seat depth, lower leg length and tipping point are determi-
ned by the design of the frame and cannot be changed retrospectively.
A modication of the tip behaviour can only be achieved by ordering a new,
one-o backrest. The seat depth can be adjusted by changing the hole po-
sition.
Changing the frame
Please contact the Küschall customer service department if you wish to
change the frame.

7© Küschall AG,Switzerland | 04/2010
Service Manual
Seat
Seat
Adjusting the seat height
The seat height can only be adjusted by tting a larger or smaller rear wheel
and at the same time using a larger or smaller front wheel fork.
Possible front seat heights: SHv [cm] 50 51
As the seat angle is dictated by the design of the frame, the seat height rear
(SHh) also changes by 1cm.
The following settings are possible:
LTo ensure that the frame is straight and the axles of the front wheel forks are perpendicular to the ground, choose one of the
combinations listed in the table.
Replacing the seat cover
Diculty: 000 Tool: W8, Z3, Z4, Z5
Remove mudguard or clothes guard c.
Remove bolts don both sides of the seat cover.
Remove seat cover eand replace with new one.
LOwing to the tension inherent in the design of the frame, it may not be possible to t the seat cover. In this case the axle holders must be
undone.
Undo axle holders
Fit new seat cover eusing bolts d.
Ensure the rear wheels are parallel (see section entitled «Rear wheels»)
and tighten axle holder bolts.
Fit mudguard or clothes guard c.
Front seat height (SHv) according to front wheel
and rear wheel
SHv possible SHh Rear
wheel Frame Front wheel
3'' 4'' 5''
50 38 - 47 24‘‘ 75° D C B
90° B A --
51 39 - 47 25‘‘ 75° E D C
90° C B --
25''
24''
3'' 4'' 5''
A B C D E
75°90°
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2
3

8© Küschall AG,Switzerland | 04/2010
Service Manual
Back
Backrest
Backrest height
The backrest module must be replaced if you want to alter the backrest
height.
Possible backrest heights:
RH [cm] 27 28.5 30 31.5 33 34.5 36 37.5 39
Backrest angle
If you want to change the backrest angle, then the complete backrest will
have to be replaced.
Possible backrest angles:
RW 74° 78° 82° 86° 90°
LChanging the backrest angle also modies the tipping point of the wheelchair.
Replacing the Standard Light backrest cover
Diculty: 0 Tool:
W8,Z3, X
Remove push handles, if tted (Replacing the push handles)
Remove bolts dande, clothes guard or mudguard.
Open the Velcro® fastenercon both sides.
Pull the backrest cover up and o and slip the new backrest cover over
the backrest tubes.
Close the Velcro® fasteners again on both sides.
Fit mudguard or clothes guard.
Fit push handles, if required.
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3
1

9© Küschall AG,Switzerland | 04/2010
Service Manual
Back
Replacing Velcro® tapes for adjustable backrests
Diculty:000 Tool
W8, W10, Z3, Z4, Z5, X
The upper backrest bands can be taken straight o, the backrest must be
removed in order to access the lower ones.
Remove backrest cover.
Remove mudguard or clothes guard.
Push the backrest band down in order to access the bolts c. Remove
nuts and bolts on both sides.
Pull the push handle and end banddout of the backrest tube (if t-
ted).
Pull the upper backrest band eo the backrest tube f.
Remove bolts gon both sides.
Remove the seat cover, the bolts hon both sides and the backrest.
Replace the lower backrest band iand put the backrest to one side.
LOwing to the tension inherent in the design of the frame, it may be extremely dicult to reposition the backrest in the frame. In this case
the axle holders must also be undone.
Undo axle holders
Insert the new backrest and secure using bolts h.
Fit the seat cover, insert and tighten bolts g.
Ensure the rear wheels are parallel (see section entitled «Rear wheels»)
and tighten axle holder bolts.
Pull the upper backrest band eover the backrest tube f.
Ret the push handles and end band and secure using bolts c.
Fit mudguard or clothes guard.
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3
6
5

10 © Küschall AG,Switzerland | 04/2010
Service Manual
Back
Replacing push handles with Light cover
Diculty: 00 Tool:
Z3, Z4, X
Remove boltscon both sides.
Push the cover down a little to expose the bolt d. Remove bolt on both
sides.
Remove mudguard or clothes guard.
Pull out push handle and replace with new one.
Insert and tighten bolt don both sides.
Fit cover to both push handles using boltc.
LIf a push handle is not going to be tted, a new Light cover that is sealed at the top must be used.
Replacing push handles with adjustable backrest
Diculty: 00 Tool:
W8, Z3, Z4, X
Remove backrest cover c.
Remove bolts eand end bandd.
Push the backrest band fdown a little to expose the bolt h. Remove
nut and bolt on both sides.
Pull push handlegout of the backrest tube.
Slip end banddover the new push handle and secure in the desired
position using bolt h. Secure end banddwith bolt e.
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