Küschall KSL User manual

Service Manual

3© Küschall AG,Switzerland | 2011-12
Service Manual
Table of contents
General ......................................................................................................................... 4
Introduction 4
Spare parts 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
Adjusting the backrest height 8
Backrest angle 8
Tipping point of the wheelchair 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 14
Rear wheels ................................................................................................................ 15
Checking the tyre pressure 15
Checking the spoke tension 15
Checking that removable axles are seated correctly 15
Adjusting the removable axles 15
Replacing the rear wheels 16
Replacing the axle 16
Ensuring the rear wheels are parallel 16
Repairing or changing an inner tube 16
Fitting tubed tyres to carbon wheels 17
Brakes ......................................................................................................................... 18
Fitting / adjusting the parking brake 18
Options & accessories ............................................................................................... 19
Fitting an antitipper 19

4© Küschall AG,Switzerland | 2011-12
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 
Medium – technical knowledge required 
Dicult – technical knowledge and expertise in
assembling wheelchairs required

The required tools and their respective sizes are listed above each instruc-
tion. 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
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.
Fastening with hexagon socket bolts
Hexagon socket bolts are not designed to withstand an excessive applicati-
on of force. When tightening or undoing a hexagon socket bolt, force must
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.
iEnsure that the Allen key is of good quality
and not worn.

5© Küschall AG,Switzerland | 2011-12
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
Check that all bolts have been tightened with the torque specied in
the instructions.
Check the entire frame for cracks, especially in the vicinity of joints and
weld seams (frame, axle clamp components, backrest)
jSeveral bolts are secured with adhesive. If these are loosened, they
have to be cleaned and secured with adhesive again.
jSelf-locking nuts and screws, once loosened, have to be replaced by
new ones.
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 | 2011-12
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 position.
Changing the frame
Please contact the Küschall® customer service department if you wish to
change the frame.

7© Küschall AG,Switzerland | 2011-12
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 [mm] 450 - 510
As the seat angle is dictated by the design of the frame, the seat height rear
(SHh) also changes by 10 mm.
The following settings are possible:
iTo 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:  Tools: Ã3,4, 5 8, 10
Remove mudguard or clothes guard by loosening
bolts .
Remove bolts on both sides of the seat cover.
Remove seat cover and replace with new one.
iOwing 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 using bolts .
Ensure the rear wheels are parallel, Chap. Rear Wheels, ‹Ensuring the
rear wheels are parallel›,and tighten axle holder bolts.
Fit mudguard or clothes guard using bolts .
à7 Nm
à4 Nm
Front seat height (SHv) according to front wheel and rear
wheel
SHv [mm] possible SHh
[mm] Rear wheel Frame Front wheel
3'' 4'' 5''
450 - 500 400 - 480 24‘‘ 75° D C B
90° B A --
460 - 510 400 - 480 25‘‘ 75° E D C
90° C B --
25''
24''
3'' 4'' 5''
A B C D E
75°90°
1
2
3
1

8© Küschall AG,Switzerland | 2011-12
Service Manual
Back
Backrest
Adjusting the backrest height
Readjusting the push handle/telescopic tube
Diculty:  Tools: Ã3 8
Remove the backrest padding.
Remove the screw connection and adjust the desired height of the
push handle or the telescopic tube. Insert the screw connection 
again and tighten the nut.
Carry out the same setting on both sides.
Ret the backrest padding.
iIf the desired height cannot be achieved, you must use a dierent
telescopic tube or push handle. If the backrest height is too high, the
backrest tube can be cut o and redrilled.
Possible backrest heights:
RH [mm] 270 285 300 315 330 345 360 375 390
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°
iChanging the backrest angle also modies the tipping point of the wheelchair.
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.
Replacing the Standard Light backrest cover
Diculty:  Tools: Ã3 8 Ò2
Remove push handles, if tted, Chap. Back, ‹Replacing push handles›.
Remove bolts and, clothes guard or mudguard.
Open the Velcro® fasteneron 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.
1
à7 Nm
à7 Nm
à7 Nm
2
3
1

9© Küschall AG,Switzerland | 2011-12
Service Manual
Back
Replacing Velcro® tapes for adjustable backrests
Diculty:  Tools: Ã3,4, 5 8, 10 Ò2
The upper backrest bands can be taken straight o, the backrest must be
removed in order to access the lower ones.
Remove backrest cover.
1Remove mudguard or clothes guard.
Push the backrest band down in order to access the bolts . Remove
nuts and bolts on both sides.
Pull the push handle and end bandout of the backrest tube (if t-
ted).
Pull the upper backrest band o the backrest tube .
Remove bolts on both sides.
Remove the seat cover, the bolts on both sides and the backrest.
Replace the lower backrest band and put the backrest to one side.
iOwing 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 .
Fit the seat cover, insert and tighten bolts .
Ensure the rear wheels are parallel, Chap. Rear wheels, ‹Ensuring the
rear wheels are parallel› and tighten axle holder bolts.
Pull the upper backrest band over the backrest tube .
Ret the push handles and end band and secure using bolts .
Fit mudguard or clothes guard.
à7 Nm
à4 Nm
à7 Nm
4
1
7
2
3
6
5

10 © Küschall AG,Switzerland | 2011-12
Service Manual
Back
Replacing push handles with Light cover
Diculty:  Tools: Ã3, 4 Ò2 8
Remove boltson both sides.
Push the cover down a little to expose the bolt . Remove bolts on
both sides.
Remove mudguard or clothes guard.
Pull out push handle and replace with new one.
Insert and tighten bolt on both sides.
Fit cover to both push handles using bolt.
iIf a push handle is not going to be tted, a new Light cover that is sealed at the top can be used.
Replacing push handles with adjustable backrest
Diculty:  Tools: Ã3,4 8 Ò2
Remove backrest cover .
Remove bolts and end band.
Push the backrest band down a little to expose the bolt . Remove
nut and bolt on both sides.
Pull the push handlesfrom the backrest tubes.
Slip the end bandover the new push handles.
Fit the push handles in the desired position using the bolts . Secure
the end bandto the push handles again using the bolts .
à4 Nm
à7 Nm
à4 Nm
à7 Nm
1
2
6
2
5
4
3
1