Küschall R33 User manual

Service Manual

3© Küschall AG,Schweiz | 2011-12
Service Manual
Inhaltsverzeichnis
General ......................................................................................................................... 4
Introduction 4
Spare parts and adaptations 4
Fastening with hexagon socket bolts 4
Torque 5
Checks 5
Identifying and repairing faults 5
Seat ............................................................................................................................... 6
Seat width (SB) 6
Seat depth (ST) 6
Rear seat-to-floor height (SHh) 6
Rear seat height adjustment – Low impact system 6
Rear seat height adjustment – without Low impact system 7
Tipping point adjustment 8
Front seat-to-floor height (SHv) 10
Seat angle (SW) 10
Backrest...................................................................................................................... 11
Replacing the backrest tube 12
Backrest angle (RW) 12
Adjusting the backrest height 13
Replacing the handle 14
Replacing foldable push handles 14
Footrests .................................................................................................................... 15
Lower leg length (UL) 15
Replacing footrests 15
Adjusting the footrest height 15
Fitting and adjusting high-mounted footrest 16
Angle-adjustable footplate, adjusting the angle 16
Side parts ................................................................................................................... 17
Clothes-guard/mudguard 17
Siderests 19
Front wheels............................................................................................................... 20
Replacing a front wheel 20
Replacing a front wheel fork 20
Rear wheels ................................................................................................................ 21
Control of rear wheel parallelism 21
Rear wheel axle replacement 22
Brakes ......................................................................................................................... 23
Parking brakes assembly and adjustment 23
Options & accessories ............................................................................................... 24
Antitipper assembly and adjustment 24

4© Küschall AG,Schweiz | 2011-12
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 
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.
Tool Symbol
Allen key Ã3, 4, 5, 8
Phillips screwdriver Ò2
Open-end spanner 8, 10, 11, 19
Socket spanner/Box spanner 8, 10
Spare parts and adaptations
All spare parts may be obtained from the Küschall® customer service de-
partment. An electronic spare parts catalogue can be found at
www.kueschall.com. Only original spare parts may be used. The written
authorisation of Küschall® AG must be obtained before installing additional
adaptations on a Küschall® wheelchair.
Fastening with hexagon socket bolts
Hexagon socket bolts are not designed to withstand an excessive applica-
tion 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 a socket spanner (only use an open-end spanner if
there is insucient space), 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.
GL
SB
GB

5© Küschall AG,Schweiz | 2011-12
Service Manual
Torque
All bolts must be tightened with the torque specied in the following instructions.
Checks
Visual check
Check the entire frame for cracks, especially in the vicinity of joints and weld seams.
Check of the bolts
Check that all bolts have been tightened with the torque specied in the instructions.
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
Front wheel bearings are dirty or
damaged Clean or replace the bearings
The wheelchair tips too
easily
Backrest angle too large Reduce backrest angle
Wrong seat position Change seat position
The brakes are gripping
poorly or asymmetrically
Incorrect tyre pressure in one or both
rear tyres Correct tyre pressure
Brake setting incorrect Correct brake setting
The rolling resistance is very
high
Tyre pressure in rear tyres is too low Correct tyre pressure
Rear wheels are not parallel Make rear wheels parallel
Front wheel axles are restrained by dirt
or hair Clean front wheel axles
Bearings are dirty or faulty Replace the bearings
The front wheels wobble
when moving fast
Too little tension on the clevis pin
housing
Tighten the nut on the castor fork
slightly
Front wheel is worn at Replace front wheel
The front wheel is sti or
stuck Bearings are dirty or faulty Replace the bearings

6© Küschall AG,Schweiz | 2011-12
Service Manual
Seat
Seat
Seat width (SB)
Available seat widths: SB 340 to SB 440, in 20 mm steps.
Once it has been set the seat width cannot be modied easily. It requires replacing the seat module,
possibly the centerpart, the backrest, axle and possibly the footrest. This modication is not descri-
bed in the service manual.
Seat depth (ST)
Available seat depths: ST 375 to ST 475 in 25 mm steps.
Adjusting the seat depth requires replacing the entire seat module including seat upholstery and
rail, as well as the seat cushion.
Rear seat-to-oor height (SHh)
Available rear seat heights: SHh 400 to SHh 490 in 10 mm steps.
To adjust the rear seat height it is necessary to change the rear suspension conguration of the
spring (or xed connection piece) and distance rings,
Chap. Seat; ‹Rear seat height adjustment with/without„Low-Impact-System“›.
The following congurations are possible:
Rear seat height adjustment – Low impact system
4
5
7
1
7
6
2 2
1
3
3
Rear seat-to-oor height by rear wheel size
with ‹low impact
system›
without ‹low impact
system›
SHh 24‘‘ wheel 25‘‘ wheel 24‘‘ wheel 25‘‘ wheel
400 — — S1 —
410 — — S2 S1
420 — — S3 / M1 S2
430 1 — M2 S3 / M1
440 2 1 M3 / L1 M2
450 3 2 L2 M3 / L1
460 4 3 L3 / XL1 L2
470 5 4 XL2 L3 / XL1
480 — 5 XL3 XL2
490 — — — XL3
à7 Nm

7© Küschall AG,Schweiz | 2011-12
Service Manual
Seat
Diculty:  Tool: Ã5, 8
Loosen the bolts and remove bolt .
Lift up the seat module and remove the spring , elastomer and distance rings 
(if tted).
Insert spring , elastomer and distance rings according to the required rear seat
height, Table ‹Rear seat-to-oor height by rear wheel size (SHh)›.
Turn the clamp on the seat module against the spring unit, until all parts t
together.
Fasten the spring unit with the bolt (with adhesive). Make certain to use the correct
bolt length, Table ‹Rear seat-to-oor height by rear wheel size (SHh)›.
Tighten the bolts .
Rear seat height adjustment – without Low impact system
Diculty:  Tool: Ã5, 8
Loosen the bolts and remove bolt and rings (if tted).
Lift up the seat module and remove the seat-to-frame connection and the
distance rings (if tted).
Insert seat-to-frame connection , with or without the distance rings , according
to the requested rear seat height, Table ‹Rear seat-to-oor height by rear wheel size
(SHh)›.
Turn the clamp on the seat module against the seat-to-frame connection, until all
parts t together. Fasten the seat-to-frame connection with the
bolt (with adhesive). Slide 1 or 2 rings onto the bolt if necessary,
Table ‹Rear seat-to-oor height by rear wheel size (SHh)›.
Tighten the bolts .
2
3
7
7
1
6
5
2
3
1
4
4
à7 Nm

8© Küschall AG,Schweiz | 2011-12
Service Manual
Seat
Tipping point adjustment
The tipping point of the wheelchair can be adjusted by changing the horizon-
tal position of the seat module.
Making it easier to tip the wheelchair
Diculty:  Tool: Ã4, 5
Loosen bolts .
Remove bolts (=4 bolts that connect the rear brace and the seat
module ).
Move the rear brace forward and use the bolts to secure it in the
required position.
Remove bolts (=4 bolts that connect the front brace and the seat
module ).
Move the front brace forward and use the bolts to secure it in the
required position.
Retighten the bolts .
Making it more dicult to tip the wheelchair
Diculty:  Tool: Ã4, 5
Loosen bolts .
Remove bolts (=4 bolts that connect the front brace and the seat
module ).
Move the front brace backwards and use the bolts to secure it in the
required position.
Remove bolts (=4 bolts that connect the rear brace and the seat
module ).
Move the rear brace backwards and use the bolts to secure it in the
required position.
Retighten the bolts .
iAdditional positions can be set by turning the front brace . In this case,
the fastening elements must be moved.
jWhen tightening the fastening elements , it must be ensured that the slots in the fastening elements are parallel to one another and that the
distance of both fastening elements from the centre part is identical.
1
2
3
4
5
6
7
à7 Nm
à7 Nm
à7 Nm
à13 Nm

9© Küschall AG,Schweiz | 2011-12
Service Manual
Seat
1
1
2
2
3
3
4
4
5
Seat position and tipping point
Seat position
(1=rearmost,
6=frontmost
seat position)
Dimension x
(the larger the
value of x, the
easier it is to tip
the wheelchair)
Front brace
(1=frontmost,
4=rearmost position
of brace at seat
module)
Rear brace
(1=frontmost,
5=rearmost position
of brace at seat
module)
Bracket distance
(=distance
between brackets
of front brace)
Brace distance
(=distance between
rear brace and front
brace)
1 154 1 1 small 190
2 131 2 2 small 190
3 108 3 3 small 190
4 85 4 4 small 190
3 108 1 3 large 236
4 85 2 4 large 236
5 62 3 5 large 236
6 39 4 5 large 213

10 © Küschall AG,Schweiz | 2011-12
Service Manual
Seat
Front seat-to-oor height (SHv)
The front seat height is variable between SHv 460 and SHv 510 (±10 mm).
The front seat height is dependent on several factors that interact with each
other. In addition to the size of the rear wheels, the frame, seat depth and rear
seat height inuence the seat height.
The following combinations of front and rear wheels are possible:
Front and rear wheel combination
Rear wheel Frame
Front wheel
3'' 4'' 5''
24’’ 75° D C B
90° B A —
25’’ 75° E D C
90° C B —
iOnly choose wheel and axle combinations specied in the table to ensure that the frame is straight and the axis of the front wheel fork is
perpendicular to the ground.
To achieve the desired front seat height, there are three frames of
dierent heights available (long, medium, short):
Seat angle (SW)
The seat angle is determined by the dierence between the rear seat height
(SHh) and the front seat height (SHv).
25
24
3'' 4'' 5''
A B C D E F
75°
90°
Frame SHv
24’’ 25’’
long 500 510
medium 480 490
short 460 470

11 © Küschall AG,Schweiz | 2011-12
Service Manual
Backrest
Backrest
The adjustable back is tted with velcro bands and a cover. Apart from the
adjustable back there is the light cover, which is produced individually for
each backrest height (RH) and seat width (SB).
A 1-band strap is placed beneath the stabilizing bar if there is a clothes-
guard, and a 2-bands strap if there is a mudguard.
Backrest height (RH) to pushhandles, telescopic
tubes and bands
RH
without pushhandles 
bands above
stabilizing bar
top
band
telescopic tube
bended 
270 1-band 
endband, 10 cm 
S
285 1-band S
300 1-band S
315 1-band S
330 2-bands S
345 2-bands S
360 2-bands S
375 2-bands+1-band M
390 2-bands+1-band M
405 2-bands+1-band M
420 2-bands+1-band M
435 4-bands L
450 4-bands L
465 4-bands L
Backrest height (RH) to cover, backrest tube, pushhandles and bands
RH cover backrest
tube
standard pushhandles 
foldable pushhandles 
pushhandle 
telescopic tube
straight 
bands above
stabilizing bar
top
band
270 S S S 1-band 
10 cm backrestband, 2 parts 
285 S S S 1-band 
300 S S S 1-band 
315 S L S 1-band 
330 S L S 2-bands 
345 M L S 2-bands 
360 M L S 2-bands 
375 M L S 2-bands+1-band
390 M L L 2-bands+1-band
405 M L L 2-bands+1-band
420 L L L 2-bands+1-band
435 L L L 4-bands 
450 L L L 4-bands 
465 L L L 4-bands 
5
6
9
1
2
3
10
8
8
7
7

12 © Küschall AG,Schweiz | 2011-12
Service Manual
Backrest
Replacing the backrest tube
Diculty:  Tools: Ã3,4 8, 10
Remove the backrest padding.
Slide the backrest bands upwards or downwards to gain access to the
screws . Remove the screws and nuts on both sides.
Remove the push handles or the telescopic tubes and remove the
upper Velcro® bands.
Remove the screws on the backrest joint.
Remove the lower Velcro® bands and the sleeve with the adjustment
screwfrom the backrest tube and t both to the new backrest
tube.
Fit the backrest tube to the backrest joint with the screws . Here, rst
t the lower screw followed by the upper screw.
Fit the upper Velcro® bands and the push handles or the telescopic
tubes again and x them with screws and nuts.
Carry out the same setting on both sides.
Ret the backrest padding.
jThe excentre plates must be adjusted identically on both sides of the
wheelchair, ‹Adjusting the backrest angle›.
Check:
Check the settings of the adjustment screws on both sides. The screw
head must only lightly touch the seat module when the backrest is in the
upright position. If necessary, readjust the length by releasing the counter
nut and tightening or loosening the adjustment screw. Then retighten the
counter nut .
jIncorrectly adjusted adjustment screws result in damage to the
backrest joint’s mechanism, ‹Adjusting the backrest joint›.
Backrest angle (RW)
The angle of the backrest can be changed by repositioning the excentre
plate in the backrest joint plate.
The following angles (measured from the seat) can be set:
1
2
4
3
à7 Nm
à7 Nm
à7 Nm
5
6
86°
90°
78°
82°
82°
74°
74° 78° 82° 86° 90°
86°
90°
78°
82°
82°
74°
86°
90°
78°
82°
82°
74°
86°
90°
78°
82°
82°
74°
86°
90°
78°
82°
82°
74°

13 © Küschall AG,Schweiz | 2011-12
Service Manual
Backrest
Adjusting the backrest angle
Diculty:  Tools: Ã3, 10
Fold down the backrest and release the counter nut of the adjustment
screw and screw it in completely.
Remove the screw on the excentre plate . Remove the excentre
plate and reinsert it in the desired position.
j
The excentre plates must be set identically on both sides of the
wheelchair.
Reinsert the screw and tighten it.
Fold the backrest up until the stop bolts engage and unscrew the
adjustment screw until it touches the frame and the backrest joint
no longer moves.
Tighten the counter nut .
Adjusting the backrest joint
Diculty:  Tools: 10
Put the backrest up and let the pin engage.
Press the backrest forwards to ensure the joint cannot move.
Unscrew the screw until it touches the spigot of the seat frame.
Screw the screw back in by between a ¼ and a ½ turn and counter with
the counter nut .
Correctly adjust the backrest joint on both sides.
Function check:
Sit in the wheelchair and lean back so that the backrest is strained. Upon
pulling the release cord , the pin must be easily removed on both
sides and must fully glide back in upon letting go of the release cord.
Adjusting the backrest height
Readjusting the push handle/telescopic tube
Diculty:  Tools: Ã38
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.
1
4
2
3
1
5
4
à4 Nm
à7 Nm
4
3
3
5
2
1
à7 Nm
1
à7 Nm

14 © Küschall AG,Schweiz | 2011-12
Service Manual
Backrest
Replacing the handle
An adhesive (e.g. hair spray) is used in these instructions. When applied to
the handle, this substance works as a lubricant and as an adhesive once dry.
jAfter drying, the adhesive used must be able to resist a pull-o force of 750 N. If in doubt, contact Küschall® AG.
Diculty: 
Remove the old handle.
Remove any residue (residual adhesive, grease, dust) from the push
handle tube.
Apply a thin layer of hair spray all over the surface of the push handle
tube onto which the handle is to be slid.
Apply a thin layer of hair spray to the inside of the handle.
Slide the new handle onto the push handle tube.
Move the handle into the correct position (grooves facing upwards).
i
If a long handle has been tted and this is to be replaced with a short
one, the push handle tube must be shortened by 35 mm. The push
handle tube must be replaced when switching from a short to a long
handle.
Replacing foldable push handles
Diculty:  Tools: Ã4
Remove the old foldable push handle and the old threaded sleeve.
Slide the new threaded sleeve onto the telescopic tube .
jFor safety reasons, it is important that a new threaded sleeve is used and that the old sleeve is not left in, and reused for, the telescopic
tube.
Slide the new foldable push handle onto the telescopic tube .
Fix the foldable push handle with the screw .
i
The telescopic tube must be replaced if a foldable push handle has
not been tted and a foldable push handle is to be newly tted.
3
4
1
2
à7 Nm

15 © Küschall AG,Schweiz | 2011-12
Service Manual
Footrests
Footrests
The footrest must be selected in accordance with the seat width. A stan-
dard footrest and an angle-adjustable footrest are available. Furthermore,
there is the possibility of a high-mounted footrest.
Lower leg length (UL)
To change the lower leg length, the footrest can be xed at a higher or
lower position. Table, Chap. Frame. The shortest lower leg lengths can be
achieved using the high-mounted footrest. ‹Fitting and adjusting high-
mounted footrest›
Replacing footrests
Diculty:  Tools: Ã48
Remove the screw connections on both sides.
Remove the footrest and replace it with a new one.
Tighten the screw connections on both sides.
Carry out the same setting on both sides.
Adjusting the footrest height
Diculty:  Tools: Ã48
The height of the footrest can be adjusted in 10 mm steps.
Remove the screw connections on both sides.
Slide the footplate to the desired height.
Tighten the screw connections on both sides.
Carry out the same setting on both sides.
iIf the desired lower leg length cannot be achieved, a high-mounted
footrest must be used ‹Fitting and adjusting a high-mounted
footrest›
1
à4 Nm
1
à4 Nm

16 © Küschall AG,Schweiz | 2011-12
Service Manual
Footrests
Fitting and adjusting high-mounted footrest
Diculty:  Tools: Ã4, 5 8, 10
Fit the frame bar for the high-mounted footrest to the front frame on
both sides using the screw connections .
Fix the clamp set to both sides of the frame using the screw
connection . Only tighten lightly.
Slide the high-mounted footplate into the clamp set and to the
desired height.
Tighten the screw connections on both sides.
Angle-adjustable footplate, adjusting the angle
Diculty:  Tools: Ã4 10
To adjust the angle, release the four screw connections until the
footplate can be moved.
Check and/or adjust the distance between the left and the right sides
by pushing in or pulling out the tubes below the footplate in such a way
that the bearings blocks are perpendicular to the ground.
Tilt the footplate into the desired position and tighten the screw
connections .
jThe angle of the footplate must be set so that the user’s feet cannot slide o the plate.
1
4
5
2
3
à7Nm
à7 Nm
1
1
à13 Nm

17 © Küschall AG,Schweiz | 2011-12
Service Manual
Side parts
Side parts
Clothes-guard/mudguard
The clothes-guard tted as standard can be replaced by a mudguard.
Clothes-guard and mudguard are available in plastic or in carbon. For the
carbon mudguard there is an additional size (XL) for the two smallest rear
seat hights (SHh).
Mudguard size carbon
Wheel size
SHh 24‘‘ 25‘‘
400 L L / XL
410 L L
420 L L
430 L L
440 M L
450 M L
460 M L
470 M M
480 M M
490 M M
L
XL
Mudguard size plastic
Wheel size
SHh 24‘‘ 25‘‘
400 L L
410 M L
420 M L
430 M L
440 M M
450 M M
460 M M
470 M M
480 M M
490 M M
L
Clothes-guard size
Wheel size
SHh 24‘‘ 25‘‘
400 L L
410 L L
420 L L
430 L L
440 M L
450 M L
460 M L
470 M M
480 M M
490 M M
L
M

18 © Küschall AG,Schweiz | 2011-12
Service Manual
Side parts
Replacing the clothes-guard
The mounting element on the backrest must already be tted.
Diculty:  Tools: Ã3, 4
If present, remove the clothes-guard to be replaced by loosening the
screw connection .
Check the correct position of the clothes-guard with tted rear
wheel. Here, nd the suitable height on the clothes-guard for xing
the screw connection to the backrest mount .
If necessary, the holder on the seat module can be replaced. Here,
remove the screw .
i
The clothes-guard is correctly positioned if it can be inserted between
the seat module and the holder and the upper edge runs above the
rear wheel.
Fitting the mudguard
Diculty:  Tools: Ã3, 4 10 Ò2
Remove the clothes-guard and the mounting elements on the backrest and
the seat.
Fit the holder to the seat module using the screw connections and
then ret the rear wheel.
Slightly loosen the screws on the adjustment plate and slide it along
the mudguard carrier until the mudguard is at the right height.
The position of the mudguard can also be adjusted: Here, loosen the
screw connections and , position the mudguard as required and
tighten the screw connections and again.
Tighten the screws again.
Carry out the same setting on both sides.
By tightening or loosening the screws you can adjust how easily the
armrest can be pulled out or pushed in.
iThe existing axle may not be suciently long for the new conguration with mudguard. In this case, a longer axle must be
tted. ‹Changing the wheel chamber / tting and adjusting an axle›
jThe distance between the mudguard and the wheel must be > 25 mm in loaded condition to prevent ngers from becoming
caught between the wheel and the mudguard.
1
3
4
2
5
à4 Nm
à4 Nm
2
3
4
1
5
à7 Nm
à4 Nm
à7 Nm
à7 Nm

19 © Küschall AG,Schweiz | 2011-12
Service Manual
Side parts
Siderests
Fitting and adjusting a height-adjustable siderest
Diculty:  Tools: Ã4, 5 Ò2
Fit the holder and the bracket to the seat module on both sides.
Tighten the screws only lightly.
Fit the bar between the two brackets using the screws . Tighten
the screws .
To adjust the armrest height, insert the armrest into the holder .
Loosen the screws for the height adjustment and slide it into the
desired position.
Then retighten the screws for the height adjustment.
By tightening or loosening the screws , you can adjust how easily the
armrest can be pulled out or pushed in.
6
1
1
2
3
4
7
5
2
8
à7 Nm
à7 Nm
à4 Nm

20 © Küschall AG,Schweiz | 2011-12
Service Manual
Front wheels
Front wheels
Replacing a front wheel
Diculty:  Tools: Ã2x3
Remove the screw with disk on one side. Remove the wheel axle .
Remove the front wheel .
Place the sleeves between the new front wheel and the fork.
Slide the axle through the fork, sleeves and the front wheel and
x the axle using the screw . Here, use the new screw supplied with
the wheel as this screw comes with a thread-locking device.
Function check:
The wheel may not wobble, but must rotate easily.
Replacing a front wheel fork
Diculty:  Tools: 10
Remove the sealing cap of the bearings block by inserting two
screwdrivers into the grooves and ipping it o.
Remove the nut with the washer .
Remove the front wheel fork .
Check the ball bearings and replace them if necessary.
Insert the new front wheel fork with the washer and the nut and
tighten the nut.
Carry out the function check (see below).
Replace the sealing cap .
Function check:
Tip the wheelchair backwards by 90° so that it is lying on the backrest and
the rear wheels. Turn the fork upwards (position A) and let it tip down-
wards.
The fork has been correctly adjusted if it easily turns to beyond the bottom-
most point and remains there (position B).
If the fork turns back to the lower position (position C), it has not been suf-
ciently tightened. There is a risk that the front wheels will start to wobble
at high speeds.
2
3
1
4
4
1
1
2
3
4
5
4
A
B
C
à4 Nm