Kuschall Compact User manual

Service Manual

3© Küschall AG,Schweiz | 03/2010
Service Manual
Contents
General ......................................................................................................................... 4
Introduction 4
Spare parts and adaptations 4
Fastening with hexagon socket bolts 4
Torque 5
Checks 5
Identifying and repairing faults 5
Frame ......................................................................................................................... 6
Rear frame 7
Front frame 7
Retaining lever 7
Seat ............................................................................................................................... 8
Seat height front (SHv) 8
Seat height rear (SHh) 9
Seat width (SB) 9
Seat depth (ST) 9
Backrest...................................................................................................................... 11
Backrest height 11
Adjustable-angle backrest 12
Replacing push handles / push handles and
backrest 14
Leg rests .....................................................................................................................18
Footrests..................................................................................................................... 19
One-piece footrest 19
Two-piece footrest 21
Two-piece footrest, adjustable-angle 21
Side parts ................................................................................................................... 22
Clothes guard/mudguard 22
Siderests 23
Front wheels............................................................................................................... 26
Castor fork 26
Special housing guides 27
Rear wheels ................................................................................................................ 28
Adjusting the seat height rear 28
Tipping stability 28
Wheel camber 29
Adapter plate for drum brake 29
Distance sleeves for rear wheels 29
Brakes ......................................................................................................................... 30
Parking brakes 30
Drum brake 31
Options & accessories ............................................................................................... 32
Antitipper 32
Tipper aid 33
Cane holder 33
Transit wheels 34

4© Küschall AG,Schweiz | 03/2010
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 !""
Medium – technical knowledge required !!"
Dicult – technical knowledge and expertise in !
assembling wheelchairs required
!!!
The required tools and their sizes are listed before the instructions. The
various torque values with which the nuts are to be tightened are also
specied in the instructions. A torque spanner must be used, in order to
comply with the specied torque values.
Tool Symbol
Allen key #3, 4, 5
Torx wrench $10
Phillips head screwdriver %
Open-end spanner !8, 9, 10, 18
Socket spanner/Box spanner 8, 10, 19, 22
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 application
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 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.
#Ensure that the Allen key is of good quality and not worn.

5© Küschall AG,Schweiz | 03/2010
Service Manual
Torque
"All bolts must be tightened with the torque specied in the following instructions. If no value
is specied, tighten with 7 Nm.
Checks
Visual check
"Check the entire frame for cracks, especially in the vicinity of joints and weld seams (frame,
axle clamp components, back).
Check of the bolts
"Check that all bolts have been tightened with the torque specied in the instructions.
$
Several bolts are secured with adhesive. If these are loosened, they have to be secured with
adhesive again. The most important bolts with adhesive are:
t Central bolt on the cross (high-strength adhesive, 3 Nm)
t Longitudinal stopping bolts on the seat edge (=bolts, which come to rest on either side of the
rear seat locking mechanisms when the seat is unfolded) (low-strength adhesive, 13 Nm)
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
Support bearings in forks faulty Replace the support bearings
Steering error or trail angle, left and right, uneven Adjust steering error or trail angle
The wheelchair tips too
easily
Rear wheels are mounted too far forwards Mount the rear wheels further back
Backrest angle too large Reduce backrest angle
Seat angle too large Mount the adapter plate lower on the side
prole
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 not parallel Make rear wheels parallel
Drum brake set too narrow Set the drum brake
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 has worn smooth Replace front wheel
The front wheel is stior
stuck Bearings are dirty or faulty Replace the bearings
The wheelchair is very
dicult to unfold The backrest cover is too tight Loosen the topmost Velcro band of the backrest cover a little
Left and right side of the
wheelchair can be moved in
parallel to one another
Longitudinal stopping bolts on the seat edge are loose Tighten the longitudinal stopping bolts on the
seat edge

6© Küschall AG,Schweiz | 03/2010
Service Manual
Frame
Frame
!Rear frame
"Retaining lever
#Cross
$Front frame
%Upper connecting tube
&Lower connecting tube
'Seat locking mechanism
(Longitudinal stopping bolts
4
1
2
3
7
8
5
6
5
6
1
2
3
4
2
4a
4a
1a
1a
2a 1b
1b
4b
4b
7
2b
2c
8
4c

7© Küschall AG,Schweiz | 03/2010
Service Manual
Frame
Rear frame
Replacing the rear frame
Diculty: !!!" Tool: #510
"Remove backrest.
"Loosen and remove bolts 1a and 1b.
"Pull out rear frame !to the back.
"Push the rear frame onto the upper %and lower &connecting tubes.
"Reinsert and tighten bolts 1a and 1b
(torque 1a: 13 Nm, 1b: 7 Nm).
Front frame
Replacing the front frame
Diculty: !!!" Tool: #3, 4, 5 10
"Disassemble brakes.
"Loosen and remove bolts 4a and 4b on both sides. (On abduction frames,
the connecting tube &is welded onto the front frame; in this case loosen 1a
and 4b.) If a ip to back side rest is tted, also loosen 4c.
"Pull out front frame $to the front.
"Remove seat locking mechanism 'with threaded insert from old front
frame and t it on the new front frame ()Section Seat; Turning the seat
locking mechanism).
"Push the front frame onto the upper and lower connecting tube.
"Reinsert and tighten bolts 4a, 4b (if required 4c) on both sides (torque 4a:
13 Nm, 4b: 7 Nm, 4c: 7 Nm).
"Set the castor fork angle ()Section Front wheels; Castor fork, Setting the
steering error angle).
Retaining lever
Replacing the retaining lever
Diculty: !!!" Tool: #3, 4, 5 10
"With mudguard or clothes guard, xed: remove 1a and 4b, with mudguard
or side rest, insertable and siderest, foldable: remove 1a and 1b.
"Remove bolt 2a.
"Pull the retaining lever "from the upper connecting tube %.
"Remove sleeve 2b.
"Push the new retaining lever over the upper connecting tube %.
"Position sleeve 2b with wide edge in joint 2c.
"Secure retaining lever with bolt 2a (4 Nm).
"With mudguard or clothes guard, xed: reinsert and tighten bolts 1a
and 4b, with mudguard or side rest, insertable and side rest, ip to back:
reinsert and tighten bolts 1a and 1b
(torque 1a: 13 Nm, 1b: 7 Nm, 4b: 7 Nm)

8© Küschall AG,Schweiz | 03/2010
Service Manual
Seat
Seat
Seat height front (SHv)
Options for changing the SHv:
t Replace front wheel with larger or smaller one or t it at another posi-
tion on the castor wheel ()Section Front wheels)
t Replace castor fork with a larger or a smaller one ()Section Front
wheels)
t Fit it high/low with the housing guide ‹Hemi› ()Section Front wheels)
Seat height front with respect to fork size, castor fork size and position in the fork
SHv [cm]
Castor fork [inch]
41 3''
42 3''
43/44 4'' 3''
45 4'' 3''
46 5'' 4'' 3''
47 5'' 4'' 3''
48/49 6'' *5'' 4'' 3''
50 6'' *5'' 4'' 3''
51 7'' *6'' *5'' 4''
52 7'' *6'' *5''
53/54 7'' *6'' *
(Assumption: Seat depth = 40 cm, seat angle = 5 cm)
tted high: SHv - 3 cm
tted low: SHv + 3 cm
* 6’’ and 7’’ front wheels cannot be used on the Ultra-Light dynamic frame (80°), if a 2-part angled footrest is tted.

9© Küschall AG,Schweiz | 03/2010
Service Manual
Seat
Seat height rear (SHh)
Options for changing the SHh:
t Replace rear wheel with a larger or a smaller one
t Change the position of the adapter plate ()Section Rear wheels)
Seat height rear with respect to the rear wheels and positioning on the frame
SHh [cm]
Rear wheel size [inch]
22’’ 24’’ 25’’ 26’’
37 1
38 2
39 3 1
40/41 4 2 1
42 5 3 2 1
43 6 4 3 2
44 7 5 4 3
45/46 8 6 5 4
47 9 7 6 5
48 10 8 7 6
49 9 8 7
50 10 9 8
1
2
3
4
5
6
7
8
9
10
11
12
Seat width (SB)
SBs range from 28 - 50 cm.
Once the SB is specied, it is very dicult to change it: the cross struts, back-
rest cover (on standard backs) and, on some congurations, the footrests
must be replaced.
Seat depth (ST)
STs range from 32 - 50 cm.
To reduce the ST, the cross struts must be shortened and a new appropri-
ately sized seat cover tted. At an ST ≥40 cm, the frame can be shortened.
To enlarge the ST, new cross struts, a new appropriately sized seat cover and,
depending on the ST, a new frame must be installed.

10 © Küschall AG,Schweiz | 03/2010
Service Manual
Seat
Replacing the seat cover
Diculty: !!" Tool: $10
%Loosen bolts !and remove plug ".
&Remove seat cover including plastic rods.
"Position new seat cover. Adjust seat cover to width SB + 2.5 cm.
"Retighten bolts !(4 Nm) and plug ".
Turning the seat locking mechanism
If the seat edge can be too easily removed from the seat locking mecha-
nisms, either the front two or all four seat locking mechanisms can be ro-
tated by 180°:
Diculty: !"" Tool: !#3
"Loosen bolt in seat locking mechanism.
"Turn seat locking mechanism by 180°.
"Secure bolt with adhesive (low-strength).
"Retighten the bolt (4 Nm).
#
Screw out the bolt only to the extent that the seat locking mechanism
can be turned as otherwise the threaded insert can move and is then
dicult to re-position.)
12
1

11 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Backrest
Backrest height
The backrest height can be changed by tting the telescopic tubes into an-
other position in the backrest tubes. If this setting option is insucient, the
telescopic tubes can be replaced.
Adjusting the height of standard backrests
Diculty: !!"" Tool: #3, 4, 6 8, 10
"Push the backrest cover !upwards and remove the bolt "on both
sides.
"Push the push handles #upwards or downwards until you reach the
required height. Replace the bolt and tighten.
#If this setting range is insucient, use new push handle tubes.
#If the backrest height was changed considerably, a new backrest
cover may have to be tted.
Adjusting the height of Velcro® adjustable backrests
Diculty: !!"" Tool: !#3, 4, 6 8, 10
"!Remove backrest cover and move the Velcro® bands until bolt !is
visible.
"!Remove bolt !and move the push handle tube to the required height.
"!Insert bolt !into the appropriate hole and tighten.
#If the backrest height is changed considerably, the push handles must
be replaced. An additional Velcro® band may have to be tted or one
may have to be removed.
1
2
3
4
1
2
3

12 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Adjustable-angle backrest
In order to make the backrest angle adjustable, an adjustable-angle back-
rest can be tted.
Backrest angle
Position
Deviation
from standard
backrests
Angle between
backrest and seat
1 12° 102°
2 8° 98°
3 4° 94°
4 0° 90°
5 -4° 86°
6 -8° 82°
7 -12° 78°
Fitting an adjustable-angle backrest
Diculty: !!!" Tool: !#3, 4, 5 8, 10 10
Shorter rear frame (variant III) required.
"!Push the lower joint pin "into the rear frame !and x it using a bolt.
"!Secure backrest tube &to the upper joint pin #using a bolt. Assemble
the upper and lower joint pins #and "and secure with bolt $
(13 Nm).
"!Retighten the bolt $(13 Nm).
"!Set the desired backrest angle and secure in the nearest hole using
bolt %(13 Nm).
"!Push the single Velcro® band (and then the other Velcro® bands *
and end band +over the backrest tube &.
"!Push the push handle 'into the telescopic tube &and x at the
required height.
"!Secure end band +on the telescopic tube 'with a bolt.
1
2
3
6
4
5
9
10
7
8

13 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Setting the backrest angle
Diculty: !!!" Tool: !#510 10
%!Remove the backrest cushion "and push the Velcro® bands #
upwards, until the backrest joint !is invisible.
&!Remove the bolt $.
'!Set the desired backrest angle, insert the bolts $in the nearest hole
and tighten (13 Nm).
"Retighten the bolt %(13 Nm).
"Perform the same setting on both sides.
Visual check
By looking from the side check that both backrest tubes are level and thus
that the same angle has been set on both sides.
Fitting the joint for a folding backrest
Diculty: !!!" Tool: !#4, 5 10
Shorter rear frame (variant III) required.
%!Set the desired backrest angle, insert bolt !in the nearest position
(Pos. 1, 2 or 3) and tighten (13 Nm). (With the curved backrest
tubes, other positions can be achieved in addition to the 3 positions
specied.)
"Fold down upper joint pin with intermediate backrest tube ".
&!Push the joint housing #into the rear frame $and t it using a bolt
(13 Nm).
Backrest angle
Position 1 (rear position): 82°, with curved backrest tube 90°
Position 2 (mid position): 86°, with curved backrest tube 94°
Position 3 (front position): 90°, with curved backrest tube 98°
2
3
1
4
5
1
2
3
4

14 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Replacing push handles / push handles and
backrest
If the push handles are replaced with a dierent type of push handles, e.g.
height-adjustable ones, it can happen that the rear frame must also be re-
placed.
Changing the backrest height can also mean that the conguration of the
Velcro® bands must be changed.
Fitting standard push handles
Diculty: !!!" Tool: %#3, 4, 5 8, 10
%Secure the telescopic tube $to the rear frame !at the required height.
&Push the backrest bands "and end band #onto the telescopic
tube $, end band rst.
'Secure end band #on the telescopic tube $with a bolt.
Fitting height adjustable integrated push handles
Diculty: !!!" Tool: %#3, 4, 5 8, 10
Special rear frame required for RH 30 – 46.5 (variant II)
"!Push lower telescopic tube "and upper telescopic tube #into one
another and insert bolt.
"!Secure pre-assembled element (telescopic tubes "and #) at the
required height on the rear frame !with a bolt (7 Nm).
"!Push the Velcro® bands $and end band %onto the telescopic tubes.
"!Using the clamp bolt 'secure the height adjustable push handles &
through the telescopic tube #.
"!Push in push handle completely.
"!Secure end band %on the telescopic tube #with a bolt.
1
2
4
3
2
1
2
4
5
3
7
6

15 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Fitting height adjustable, rear set push handles
Diculty: !!!" Tool: %#3, 4, 5 8, 10
The Velcro® bands may have to be replaced with narrower ones, as space is
required to secure the holder on the telescopic tube.
"!Secure the telescopic tube "to the rear frame !at the required
height.
"!Press the cover cap &onto the end of the telescopic tube.
"!Push the Velcro® bands #onto the telescopic tube.
"!Push the holder %onto the telescopic tube and x in place by
tightening the clamp bolts (13 Nm).
"!Fit end band $onto the telescopic tube and secure with a bolt.
"!Attach protective cushion.
Fitting angle-adjustable backrest with height-adjustable push
handles
Diculty: !!!" Tool: %#3, 4, 5 8, 10 10
Shorter rear frame (variant III) required.
"!Push the lower joint pin "into the rear frame !and x it using the
bolts.
"!Fit backrest tube &onto the upper joint pin #using bolts. Assemble
the upper and lower joint pins #and "and secure with a bolt $(13
Nm).
"!Set the desired backrest angle and secure in the nearest hole using a
nut and bolt %(13 Nm).
"!Retighten the bolt $(13 Nm).
"!Push the single Velcro® band (and then the other Velcro® bands *
and end band +over the backrest tube &.
"!Push in push handle completely.
"!Using the clamp bolt (t the height-adjustable push handles '
through the telescopic tube &.
"!Fit end band +onto the telescopic tube &with a bolt.
1
3
2
5
6
4
1
2
3
4
5
6
9
10
8
7
11

16 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Angle-adjustable backrest with adjustable backs with respect to push handles
Backrest
height
(RH)
Standard
push
handles
Folding
push
handles
Height-adjustable
integrated push
handles
Velcro bands
2B
4B
, - . / 0 12
30 S S S
dierent for every backrest height
L 1B+2B S
31.5 S S S L 1B+2B S
33 S S S S 1B+4B S
34.5 S S L S 1B+4B S
36 S S L S 1B+4B S
37.5 S S L L 1B+4B S
39 S/M S/M L L 1B+4B M
40.5 S/M S/M L L 1B+4B M
42 S/M S/M L L 1B+4B M
43.5 M M L S 1B+6B M
45 M M L S 1B+6B M
46.5 M M L S 1B+6B M
48 M M L S 1B+6B L
49.5 M M L L 1B+6B L
51 M M L L* 1B+6B* L
Assumption: No stabilising bar tted
* For RH51 with height-adjustable integrated push handles: 0=S, 1=2x4B
Backrest with adjustable backs with respect to push handles
Backrest
height
(RH)
Standard
push
handles
Folding
push
handles
Height-adjustable
integrated push
handles
Velcro
bands
2B
4B
, - ././01 2
30 S S S XXS S XXS S 4B S
31.5 S S S XS S XS S 4B S
33 S S S S S S S 4B S
34.5 S S L M S M L 4B S
36 S S L M S M L 4B S
37.5 S S L M S M L 4B S
39 S/M S/M L M S M L 4B M
40.5 S/M S/M L M S M L 4B M
42 S/M S/M L M S M S 6B M
43.5 M M L L L L S 6B M
45 M M L L L L S 6B M
46.5 M M L L L L L 6B M
48 M M L L L L L 6B L
49.5 M M L L L L L 6B L
51 M M L L L L L 6B L
Assumption: No stabilising bar tted

17 © Küschall AG,Schweiz | 03/2010
Service Manual
Backrest
Foldable angle-adjustable backrest with respect to push handles
Backrest
height
(RH)
Standard
push
handles
Folding
push
handles
Height-adjustable
integrated push
handles
Velcro
bands
2B
4B
3
, - . / . / 0 1 2
30 S S S
dierent for every backrest height
S
dierent for every backrest height
S
31.5 S S S S S
33 S S S S S
34.5 S S S S L 2B S
36 S S S S L 2B S
37.5 S S S S L* 2B S
39 S S L S L 2B M
40.5 S S L S S 4B M
42 S S L S S 4B M
43.5 M M L S S 4B M
45 M M L L S 4B M
46.5 M M L L L 4B M
48 M M L L L 4B L
49.5 M M L L L 4B L
51 M M L L L 4B L
Assumption: No stabilising bar tted
* For RH37.5 with height-adjustable integrated push handles: 0=S und 1=2B+4B
Additionally a band 4is xed close to the backrest joint. The band is of dierent length according to the seat
width (SB).
There are 3 lengths: SB 28-36 )short, SB 38-44 )medium, SB 46-50 )long

18 © Küschall AG,Schweiz | 03/2010
Service Manual
Legrests
Legrests
Legrests with angle measurements of 70, 80 and 90° are available.
Replacing the locking mechanism
Diculty: !!"" Tool: $10 #3
"Screw ounlocking lever !manually.
"Remove hinge pin ".
"Loosen bolts $.
"Remove locking mechanism #and replace with a new one.
"Reinsert bolts $and tighten (3 Nm).
"Screw in the hinge pin "again (3 Nm).
"Screw the unlocking lever !back on manually.
Setting the locking lever
Diculty: !!!" Tool: #3, 5
It must be possible to move the unlocking lever !1-2 mm freely forward
and back, without having to move the bolt %. This guarantees that the bolt
is sitting optimally in the counterpiece &. If this free mobility is greater or
smaller than specied, the unlocking lever must be reset:
"Screw othe unlocking lever !manually.
"Loosen the hinge pin "(do not remove).
"Screw bolt %in deeper to reduce movement or screw bolt %further
out to increase movement.
"Set it so that the pin can move freely by 1-2 mm.
"Retighten the hinge pin "again (3 Nm).
"Screw the unlocking lever !back on manually.
1
2
4
3
5
6

19 © Küschall AG,Schweiz | 03/2010
Service Manual
Footrests
Footrests
One-piece and two-piece footrests are available.
One-piece footrest
Replacing the footplate
Diculty: !!"" Tool: !#4 10
"Loosen bolts !on both sides.
"Remove footplate "and replace with a new one.
"Re-insert bolts !and tighten (3 Nm).
Disassembling/tting the footrest
Diculty: !!"" Tool: !#4 8
%Remove bolts !on both sides.
&Pull out the footrest.
'Insert new footrest.
)Tighten bolts !on both sides at the same height and in the required
position (4 Nm).
Adjusting the height of the footrest
Diculty: !!"" Tool: !#4 8
%Remove bolts !on both sides.
&Hold the telescopic tubes "with both hands and push the footrest into
the required position.
'Insert bolts !into the nearest hole on both sides and at the same
height and tighten securely (4 Nm).
1
2
1
1

20 © Küschall AG,Schweiz | 03/2010
Service Manual
Footrests
Centring and adjusting the angle
Diculty: !!"" Tool: !#4 10
"Loosen bolts !and "slightly.
%Set the same distance from the side tube to the footplate on both sides.
&Set the required footplate incline.
"Re-tighten bolts !(xed side of the footplate) (13 Nm).
"Turn the little tube #on the moving side of the footplate such that it
engages properly.
"Tighten bolts "(13 Nm).
Changing the position of the footrest (set to rear – set to front)
Diculty: &!"" Tool: !#4 10
%Loosen bolts !on both sides and remove.
&Turn the footplate with the clamp component.
'Re-insert bolts !and tighten (13 Nm).
1
2
3
1