Kuschall CHAMPION User manual

Service Manual
KÜSCHALL CHAMPION
DEALER: Keep this manual.
The procedures in this manual MUST be performed by a
qualified technician.

©2014 Küschall AG
All rights reserved. Republication, duplication or modification in whole or in part is prohibited without prior written
permission from Küschall AG. Trademarks are identified by ™and ®.
All trademarks are owned by or licensed to Küschall AG or its subsidiaries unless otherwise noted.

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
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
OVERVIEW ....................................................................................................................6
Components 6
Dimensions 6
FRAME............................................................................................................................7
Changing Frame 7
SEAT .............................................................................................................................. 8
Fitting seat cover to frame 8
Front seat height (SHv) 8
Rear seat height (SHh) 9
Checking the folding unit 10
Adjusting the folding unit 10
BACKREST...................................................................................................................11
Tension adjustable backrest 11
Backrest height (RH) 14
Backrest angle (RW) 15
Push handles / backrest telescopes 15
Replacing foldable push handles 17
Stabilisation bar 17
FOOTRESTS ................................................................................................................18
Lower leg length (UL) 18
Footplate 19
SIDE PARTS .................................................................................................................21
Clothes-guard assembly 21
Mud guard assembly 23
Assembling and adjusting the siderest 24
Assembling the tubular armrest 24
FRONT WHEELS ........................................................................................................ 25
Replacing a front wheel 25
Replacing a front wheel fork 25
Checking and adjusting the castor angle 26
Checking and adjusting the drift angle 26
Shift supporter on the frame 27
REAR WHEELS ........................................................................................................... 28
Rear wheels, repositioning 28
Wheel camber, adapter sleeves 28
Adjusting the removable axle 28
Distance sleeves 29
Adapterplate, adjustment to folding unit or assembly of new adapter plate 29
BRAKES ....................................................................................................................... 30
Fitting / adjusting the parking brake 30
Antitipper / Transit wheels 31
Tipper aid / Cane holder 32
Fitting the pelvic belt 32

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
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 dealer.
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 Ã2x3, 4, 5, 6
Phillips screwdriver Ò2
Straddle spanner 19, 11
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.kuschall.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
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.

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
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 all components for cracks, especially the areas around joints and welded seams.
Checking the screw connections
Check all bolts with the torques specified in the instructions regularly, and adjust if required.
CAUTION!
Several screw connections have been secured with thread locking adhesive. If these are opened, they must be
secured again using new thread locking adhesive. Liquid high-strength and low-strength 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)
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 fitted 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 profile
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
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
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

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
Service Manual
OVERVIEW
OVERVIEW
Components
Dimensions
ASeat depth 340 – 480 mm, in increments of 20 mm
(AL / TI)
400 – 460 mm, in increments of 20 mm
(C)
BBackrest angle 76°/80,5°/85°/89,5°/94°
CKnee-to-heel length 220 – 500 mm, in increments of 10 mm
(AL / TI)
300 – 340 / 400 – 500 mm, in
increments of 10 mm (C)
DSeat height front 450 – 540 mm, stepless adjustable
ESeat height rear 390 – 490 mm, stepless adjustable
FBackrest height 300 – 465 mm, in increments of 15 mm
GTotal length 75°: approx. 825 – 1190 mm (AL / TI)
90°: approx. 775 – 1140 mm (AL / TI)
85°: approx. 800 – 1165 mm (C)
HSeat width 340 – 480 mm, in increments of 20 mm
ITotal width
Total width, folded
Seat width plus 160 – 240 mm
approx. 280 – 340 mm
AL = Aluminium / TI = Titanium / C = Carbon
ABackrest
BRear wheel with handrim
CQuick release axle
DFolding mechanism
EFront wheel fork with front wheel
FFootrest
GFrame
HSeat
IMudguard

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
Service Manual
FRAME
FRAME
The küschall Champion frame is available in aluminium,
titan or carbon.
Aluminium or titan frames are available with frame angles of 75° and
85°, carbon frames with a frame angle of 85°
Changing Frame
Fitting frame tubes
Diculty:  Tools: Ã4 10
Fit both frame tubes into the side supporters Ausing bolts Band
tighten lightly.
Attaching the side supporters, frame tubes and seat cover
Diculty:  Tools: Ã5 10
iThe purpose of the threaded connection through the frame
mounting holes is to provide additional fixing. 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 siderests using bolts F through the frame
mounting holes on both sides and tighten.
Bà13 Nm / 10 Nm with carbon frame
Fà13 Nm / 10 Nm with carbon frame

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
Service Manual
SEAT
SEAT
Fitting seat cover to frame
Diculty:  Tools: Ã3, 4 10
Fit seat cover to side supports and frame on both sides using
bolts Aand B.
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.
- Move the side support on the frame,
Chap. Front wheels; Shift supporter on the frame.
iAdjusting the front seat height changes the seat angle. It may be necessary to adjust the rear seat height correspondingly.
iIt 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.
After adjusting the front seat height the verticality of the castor pins
need to be checked and adjusted if neccessary, Chap. Front
wheels; Checking and adjusting the alignment of the supporters.
Front seat height (SHv) per frame size, castor fork and front wheel
SHv
[mm]
Aluminium / Titan frame 75°
(long frame) (short frame)
ST 40-48 ST 34-38 ST 40-48 ST 34-38
3'' 4'' 5'' 3'' 4'' 5'' 3'' 4'' 5'' 3'' 4'' 5''
540 -  - - ------
530  -  ------
520  ------
510  - - ---
500  -  - - 
490  - 
480 
470 
460 
450 
Aà13 Nm / 10 Nm with carbon frame
Bà5 Nm

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
Service Manual
SEAT
Front seat height (SHv) per frame size, castor fork and front wheel
SHv
[mm]
Aluminium / Titan frame 85°
(long frame) (short frame)
ST 40-48 ST 34-38 ST 40-48 ST 34-38
3'' 4'' 5'' 3'' 4'' 5'' 3'' 4'' 5'' 3'' 4'' 5''
540 -  - - ------
530  -  ------
520  ------
510  - - ---
500  -  - - 
490  - 
480 
470 
460 
450 
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
adapterplate.
- Replacement of the rear wheel with a larger or smaller one.
iIt 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.
iIt must be ensured that the the castor pins are vertical after
changing the rear seat height, If required, they must be readjusted,
Chap. Front wheels; Checking and adjusting the alignment
of the supporters.
Front seat height (SHv) per frame size,
castor fork and front wheel
SHv
[mm]
Carbon frame 85°
(long frame)
ST 40-48
3'' 4'' 5''
540 - - 
530 - 
520 - 
510 
500 
490 
480   -
470   -
460   -
450 - -

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KÜSCHALL CHAMPION
© Küschall AG, Switzerland | 2015-09
Service Manual
SEAT
Checking the folding unit
Diculty:  Tools: Ã5
The bolt A of the scissor mechanism must be checked regularly for
play.
The scissor mechanism must open and close easily.
Check that the retaining rings Bare sitting well, replace if
neccessary.
Adjusting the folding unit
Diculty:  Tools: Ã3 16
Remove the end-stop nut Cfrom bolt E.
Apply new thread locking adhesive on bolt E.
Screw the end-stop nut completely on the bolt again, but do not
tighten.
Adjust the end stop F of the folding unit by tightening resp.
loosening the grub screw D.
Tighten the end-stop nut.
Carry out the same settings on both sides.
Check that the scissor mechanism opens and closes easily.
Check the seat cover for sucient tension in unfolded condition of
the wheelchair.
If neccessary, repeat the steps above until all settings are correct.
Adjustment screw
iThe screw Ain the folding unit has the aim to reduce play. Depending on the play the screw head is slightly above the
surface. The screw is secured and cannot become loose.
IMPORTANT!
Do not modify the screw Aas it can result in a less
easy folding and unfolding of the wheelchair.
Aà4 Nm
Cà13 Nm (high-strength)