Kuschall KSL User manual

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

3© Küschall AG, Switzerland | 2015-05
Service Manual
TABLE OF CONTENTS
GENERAL...................................................................................................................... 4
Introduction 4
Spare parts 4
Fastening with hexagon socket bolts 4
Torque 5
Checks 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 9
Replacing Velcro®tapes for adjustable backrests 9
Replacing push handles with Light cover 10
From serial number 13G08000785: Replacing push handles with Light cover10
Replacing push handles with adjustable backrest 10
Replacing foldable push handles 11
Foldable backrest, angle adjustable (optional) 12
FOOTRESTS ................................................................................................................13
Replacing the footrest 13
Adjusting the height of the footrest 13
Adjusting the angle of the footrest 13
SIDES............................................................................................................................14
Fitting the clothes guard 14
Fitting the mudguard 14
FRONT WHEELS.........................................................................................................15
Replacing the front wheel fork 15
Replacing the front wheel 15
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
Fitting / adjusting the parking brake 19
OPTIONS & ACCESSORIES...................................................................................... 20
Fitting an antitipper 20

4© Küschall AG, Switzerland | 2015-05
Service Manual
GENERAL
Introduction
This service manual is part of the instructions and contains the
technical 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 acci-
dents and severe injuries.
▸Changes to the wheelchair may only be carried out
by the provider.
To maintain the necessary levels of safety and reliability, every
wheelchair must be thoroughly examined once a year.
Some aspects of the assembly and configuration of the wheelchair
require a high level of expertise. These assembly instructions therefo-
re 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
instruction. The instructions include information on the torques
with which the respective screw connections must be tightened. Ad-
hering 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.kuschall.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
application of force. When tightening or undoing a hexagon socket
bolt, force must be applied to the nut wherever possible to avoid
damaging the bolt.

5© Küschall AG, Switzerland | 2015-05
Service Manual
Tightening and undoing
Turn the nut using an open-end spanner, or preferably a socket spanner, using the Allen
key simply to stop the bolt turning.
Tightening and undoing when no nut is present
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
Prüfen Sie alle Komponenten auf Risse, insbesondere die Bereiche um Verbindungen
und Schweißnähte herum.
Checking the screw connections
Check all bolts with the torques specified in the instructions regularly, and adjust if
required.
CAUTION!
Mehrere Schraubverbindungen wurden mit Schraubensicherungslack gesichert.
Sollten diese Schraubverbindungen geönet werden, müssen sie wieder mit neuem
Schraubensicherungslack gesichert werden.
Zur Verfügung stehen hochfeste und niederfeste Sicherungsmassen in flüssiger Form.
Bei den Drehmomentangaben wird ggf. darauf hingewiesen, ob ein Sicherungskleber zu
verwenden ist, bzw. welcher zu verwenden ist.
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
specifications 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 | 2015-05
Service Manual
FRAME
FRAME
Adjusting the frame
The seat width, seat depth, lower leg length and tipping point are
determined by the design of the frame and cannot be changed retro-
spectively.
A modification 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 | 2015-05
Service Manual
SEAT
SEAT
Adjusting the seat height
The seat height can only be adjusted by fitting 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 (530*)
* From serial number 13G08000785
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 fit 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 (520*) 400 - 480 24‘‘ 75° D C B
90° B A --
460 - 510 (530*) 400 - 480 25‘‘ 75° E D C
90° C B --
* From serial number 13G08000785
25''
24''
3'' 4'' 5''
A B C D E
75°90°
1
2
3
1

8© Küschall AG, Switzerland | 2015-05
Service Manual
BACKREST
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.
Refit 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
From serial number 13G08000785:
Readjusting the push handle/telescopic tube
Diculty:  Tools: Ã3
Remove the backrest padding.
Remove the bolt and adjust the desired height of the push
handle or the telescopic tube by bringing the threaded insert to
the appropriate position.
Insert and tighten the bolt again
Carry out the same setting on both sides.
Refit the backrest padding.
iIf the desired height cannot be achieved, you must use a dierent telescopic tube or push handle.
Possible backrest heights:
RH [mm] 270 285 300 315 330 345 360 375 390 405 420
Backrest angle
If you want to change the backrest angle, then the complete back-
rest will have to be replaced.
Possible backrest angles:
RW 74° 78° 82° 86° 90°
iChanging the backrest angle also modifies the tipping point of the
wheelchair.
Tipping point of the wheelchair
The tipping point of the wheelchair can only be modified by fitting a
new backrest with a larger or smaller backrest angle. The seat depth
can also be adjusted by changing the hole position.
1
à7 Nm
1
à7 Nm

9© Küschall AG, Switzerland | 2015-05
Service Manual
BACKREST
Replacing the Standard Light backrest cover
Diculty:  Tools: Ã3 8 Ò2
Remove push handles, if fitted, 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.
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
(From serial number 13G08000785: Remove bolts on both sides).
Pull the push handle and end bandout of the backrest tube
(if fitted).
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 back-
rest.
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 .
Refit the push handles and end band and secure using bolts 
and nuts on both sides (From serial number 13G08000785:
secure using bolts on both sides).
Fit mudguard or clothes guard.
à7 Nm
à7 Nm
à7 Nm
à4 Nm
à7 Nm
4
1
7
2
3
6
5
2
3
1

10 © Küschall AG, Switzerland | 2015-05
Service Manual
BACKREST
Replacing push handles with Light cover
Diculty:  Tools: Ã3, 4 Ò2 8
Remove screwon both sides.
Push the cover down a little to expose the bolt connections .
Remove bolt connections on both sides.
If necessary, remove mudguard or clothes guard.
Pull out push handle and replace with new one.
Insert and tighten bolt connections on both sides.
Fit cover to both push handles using screw.
iIf a push handle is not going to be fitted, telescopic tubes with a new Light cover that is sealed at the top can be used.
From serial number 13G08000785:
Replacing push handles with Light cover
Diculty:  Tools: Ã3, 4 Ò2
Remove screwon both sides.
Push the cover down a little to expose the bolt .
Remove bolts from the backrest tube on both sides.
If necessary, remove mudguard or clothes guard.
Pull out push handle and replace with new one.
Insert bolt through the backrest tubes and the new push
handles and tighten bolts on both sides.
Fit cover to both push handles using screws.
iIf a push handle is not going to be fitted, telescopic tubes with 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 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 . Se-
cure the end bandto the push handles again using the
bolts .
à4 Nm
à7 Nm
à4 Nm
à7 Nm
à4 Nm
à7 Nm
1
2
6
2
5
4
3
1