Kushall K-Series User manual
Mentor
Technical module
Version > 1/2005
Technical module
1
Copyright © 08/2008,Küschall AG
K-Series
K-Series 05
Changing configurations
Table of contents
1 Adjustment possibilities 2
1.1 Seat width (SB) 2
1.2 Seat depth (ST) 2
1.3 Leg length (UL) 2
1.4 Rear seat height (SHh) 3
1.5 Front seat height (SHv) 4
1.6 Siderest / Armrest 5
1.7 Clothes guard / Mudguard 5
1.8 Backrest height 6
1.9 Backrest angle 6
2Assembly and adjustment methods 7
2.1 Footrest replacement 7
2.2 Footrest height adjustment 7
2.3 Footrest mounted in high position 7
2.4 Footplate angle adjustment 8
2.5 Front fork replacement 8
2.6 Quick release fork 9
2.7 Front wheel replacement 9
2.8 Rear seat height adjustment 10
2.9 Front seat height adjustment 10
2.10 Tipping Point adjustment 11
2.11 Parking brakes assembly and adjustment 11
2.12 Clothes guard assembly 12
2.13 Mudguard assembly and adjustment 12
2.14 Armrest assembly and adjustment 13
2.15 Siderest assembly and adjustment 13
2.16 Rear wheel extension assembly and adjustment 14
2.17 Rear wheel camber adjustment 14
2.18 Control of rear wheel parallelism 15
2.19 Suspension assembly 16
2.20 Backrest height adjustment 17
2.21 Backrest angle adjustment 19
2.22 Antitipper assembly and adjustment 19
2.23 Active-Antitipper assembly and adjustment 20
2.24 Transit wheels assembly and adjustment 21
4ROUBLESHOOTING
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Copyright © 08/2008,Küschall AG
K-Series 1 Adjustment possibilities
1.1 Seat width (SB)
Available seat widths: SB34 to SB46, in 2 cm steps.
The seat width cannot be modified easily once it has been set. It would be necessary to
replace the seat module, backrest, camber bar and footrest.
This modification is not described in the Mentor.
1.2 Seat depth (ST)
Available seat depths: ST35 to ST50 in 2.5 cm steps.
* not possible with 26’’rear wheel and not with SB46.
Adjusting the seat depth requires replacing the entire seat module including the seat
upholstery and seat rails as well as the seat cushion.
1.3 Leg length (UL)
The footrest must be attached in a higher or lower position to adjust the leg length.
(Chapter 2.2)
The UL can be adjusted from 29cm to 48cm.
Compatible frame to seat depth
K4 (75°) AirLite (90°)
ST SHv 48 SHv 49 SHv 50 SHv 51 SHv 49 SHv 50 SHv 51
35 * K4-5 K4-5 K4-5 K4-5 AirLite AirLite AirLite
37.5 K4-5 K4 K4 K4 AirLite AirLite AirLite
40 K4-5 K4 K4 K4 AirLite AirLite AirLite
42.5 K4 K4
K4+5
K4
K4+5
K4
K4+5
AirLite
AirLite+5
AirLite
AirLite+5
AirLite
AirLite+5
45 K4 K4
K4+5
K4
K4+5
K4
K4+5
AirLite
AirLite+5
AirLite
AirLite+5
AirLite
AirLite+5
47.5 — K4+5 K4+5 K4+5 AirLite+5 AirLite+5 AirLite+5
50 — K4+5 K4+5 K4+5 AirLite+5 AirLite+5 AirLite+5
UL Configuration Footrest
UL29 – UL33 all
UL34 – UL40
Frame K4+5
Frame AirLite+5
with SHv ≥50cm
all others
UL41 – UL48 all
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Copyright © 08/2008,Küschall AG
K-Series
1.4 Rear seat height (SHh)
To adjust the rear seat height, change the position of the seat module on the frame
(Chapter 2.8).The vertical seat brace is available in three sizes for seat heights of 38 cm
to 49 cm.
We generally recommend attaching the vertical seat brace to the lower hole on the
frame.
Rear seat height depending on rear wheel position and size
24‘‘ wheel 25‘‘ wheel 26‘‘ wheel
SHh S M L S M L S M L
38 1
39 1 1
40 2 1 1
41 3 5a 2 1
42 4 5 3 5a 2
43 64535a
44 7 9a 6 4 5
45 8 9 7 9a 6
46 10 8 9 7 9a
47 11 10 8 9
48 12 11 10
49 12 11
Please note: Adjust-
ments made to the
rear seat height
changes the seat
angle.The front seat
height may need to
be adjusted accord-
ingly.
1
2
3
45
6
7
89
10
11
12
5a
6a
7a
8a 9a
10a
11a
12a
SM L
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Copyright © 08/2008,Küschall AG
K-Series 1.5 Front seat height (SHv)
The front seat height depends on several factors that influence each other.
The dimension of the front and rear wheels determine the frame height. Position and
size of the hinge bracket to the seat module as well as the frame, seat depth and rear seat
height influence the front seat height.
1. Frame
The minimum front seat height depends on the combination of front wheels and rear
wheels:
Only choose combinations that are specified in the table on page 3 to ensure that the
frame is straight and the front wheel supporters are perpendicular to the ground.
2. Seat module
Once the rear and front wheels as well as the front forks have been defined, the front seat
height can be varied by adjusting the mounting position of the seat module on the frame.
There are 2 sizes of front hinge brackets with each 2 fastening possibilities to choose from:
(Chapter 2. 9)
Please note:
Adjustments made
to the front seat
height changes the
seat angle.The rear
seat height may
need to be adjusted
accordingly.
Possible combinations of front and rear wheels
Rear wheel Frame 3'' 4'' 5''
24‘‘
K4-5 FED
K4 / K4+5 DCB
AirLite / AirLite+5 BA--
25‘‘
K4-5 -- F E
K4 / K4+5 EDC
AirLite / AirLite+5 CB--
26‘‘ K4 / K4+5 FED
AirLite / AirLite+5 DCB
1cm
26''
25''
24''
3'' 4'' 5''
A B C D E F
K4 / K4+5 K4-5
AirLite
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Copyright © 08/2008,Küschall AG
K-Series
1.6 Siderest / Armrest
The standard clothes guard can be complemented with an armrest.
Mounting the armrest (Chapter 2.14)
1.7 Clothes-guard / Mudguard
The standard clothes-guard can be replaced by a mudguard. (Chapter 2.13)
Clothes-guard / mudguard size
Rear wheel
M
L
SHh 24‘‘ 25‘‘ 26‘‘
38 L — —
39 L L —
40 L L L
41 L L L
42 L L L
43 M L L
44 M L L
45 M L L
46 M L L
47 M M L
48 M M L
49 M M L
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Copyright © 08/2008,Küschall AG
K-Series 1.8 Backrest height
To adjust the backrest height, replace the backrest tubes. (Chapter 2.20)
1.9 Backrest angle
To adjust the backrest angle re-position the eccentric plate in the backrest joint.
(Chapter 2.21)
The following angles can be set (in relation to the seat):
Backrest height depending on push handle and backrest tube
RH No push handles Standard push handles Foldable push handles Upholstery
27SSSSSSS
28.5 S S S S S S S
30SSSSSSS
31.5 S S S S S S M
33LSSSLSM
34.5 L M L S L S M
36LMLSLSM
37.5 L M L S L S L
39 L M L S L M L
40.5 L M L L L M L
42 L L L L L M L
43.5 L L L L L M L
45 L L L L L M L
46.5 L L L L L M L
48 L L L L L M L
-8
0
+8
-4
+4
0
-8
0
+8
-4
+4
0
-8
0
+8
-4
+4
0
-8
0
+8
-4
+4
0
-8
0
+8
-4
+4
0
-8° -4° 0° +4° +8°
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Copyright © 08/2008,Küschall AG
K-Series
2 Assembly and adjustment methods
2.1 Footrest replacement
Remove the bolts on both sides.
Remove the footrest holder from the frame
and insert the new footplate.
Tighten the bolts securely on both sides.
2.2 Footrest height adjustment
The footrest height adjusts in 1 cm steps.
Proceed as follows:
Remove the bolts from both sides of
footrest.
Slide the tube into the correct position,
re-assemble the bolts on both sides of
the footrest and tighten.
The footrest holder must be firmly attached in the frame tube.
A high-mounted footplate may be required if the leg length cannot be achieved with
the regular footrest.(Chapter 2.3)
2.3 Footrest mounted in high position
Slide the footrest for the high-mounted footplate into the frame and attach with
bolt on both sides.
Fasten the clamp set with bolt to both sides of the frame, tighten slightly.
Slide the high-mounted footplate in the clamp set to the required height.
Tighten bolt .
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Copyright © 08/2008,Küschall AG
K-Series 2.4 Footplate angle adjustment
The footplate angle can only be adjusted if the footrest is angle adjustable. Proceed as
follows:
Loosen all four bolts until the footplate can be moved.
Pivot the footplate into the required position and tighten the bolts.
The footplate must fit tightly to the wheelchair with no room for movement.
2.5 Front fork replacement
Remove the bearing block cap by inserting
two screwdrivers into the grooves and pushing
it upward.
Loosen the nut and washer .
Remove the front fork .
Check the ball bearing block and replace if
necessary.
Attach the new front fork with the washer
and nut; tighten.
Perform functional check (see below)
Attach the sealing cap again.
Functional check:
Tip the wheelchair 90° backwards, so that the
chair is lying on the backrest and rear wheels.
Turn the fork upwards (position A) and let it
tip downwards.
The fork is positioned correctly when it turns
slightly over the lowest point and stays there
(position B).
The fork hasn’t been tightened sufficiently if
it turns back into the lowest position (position
C). If tightened wrongly, there is a possibility
for the front wheels to start fluttering at high
speeds.
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4
A
B
C
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Copyright © 08/2008,Küschall AG
K-Series
2.6 Quick release fork
The quick-release fork can only be used with the corresponding frame.
To retrofit a wheelchair with a regular fork, the frame must be exchanged. In this case,
please contact your Küschall reference person.
Fork replacement
Press the pin on the bearing block and remove the fork.
Slide the new fork into the bearing block until the
mechanism locks into place and can no longer be removed.
2.7 Front wheel replacement
Loosen the bolts . Remove the front wheel axle .
Remove the front wheel .
Attach a new front wheel
or
Place the front wheel in its new position.
(2 bushings must be slid onto the axle with a Starec wheel, Skater wheel, 3’’ Sport
wheel or 5’’Softrollwheel.The bushings are already attached in the smooth running
wheel, sports wheel and pneumatic wheel.)
Guide the front wheel axle through the fork and the wheel (and the bushing ).
Tighten the bolts again.
Functional check:The wheel must be fastened firmly, but still be able to spin easily.
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1
2
1
4
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Copyright © 08/2008,Küschall AG
K-Series 2.8 Rear seat height adjustment
Remove the rear wheels and tip the wheelchair, so that it is positioned on its back.
Loosen the front hinge bracket bolt on both sides of the wheelchair.
If the seat height is adjustable with the existing vertical seat brace , loosen bolt
and remove bolt and the horizontal seat brace .
If a new vertical seat brace is required, remove the existing one as well as the
horizontal seat brace and loosely attach the new vertical seat brace to the frame
with bolt .
Move the vertical seat brace along the plate at the rear so that the required holes
correspond.
Insert the horizontal seat brace and fix it with bolt .
Remount the rear wheels, turn the wheelchair over and verify the position of the
vertical seat brace . It should be at perpendicular to the ground as possible.
Tighten bolts ,and .
2.9 Front seat height adjustment
Remove the rear wheels and position the wheelchair on its back.
Loosen bolts and connecting the vertical seat brace to the seat module and
the frame respectively, on both sides of the wheelchair.
Replace the front hinge bracket or fasten it to the other hole on the front frame.
Remount the rear wheels, turn the wheelchair over and verify the position of the
vertical seat brace . It should be perpendicular to the ground as possible.
Tighten bolts and on the vertical seat brace.
The seat angle is the
difference between
rear seat and front
seat height.
Please note:
Adjustments made to
the front seat height
change the seat angle.
The rear seat height
may need to be ad-
justed accordingly.
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5
1
3
2
4
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Copyright © 08/2008,Küschall AG
K-Series
2.10 Tipping Point adjustment
The horizontal position of the seat module permits alterations of the tipping point.
Loosen bolts and .
Remove bolts and ; slide the seat module to the forward or backward.
Reattach the seat module with bolts and .
By default, the front hinge brackets are attached to the middle position on the seat
module.The seat module can be set in 5 positions thanks to the 3 fixation possibilities in
the rear and the 5 in the front.
The vertical seat brace must be kept as perpendicular as possible after the adjustment.
2.11 Parking brakes assembly and adjustment
The parking brakes must be readjusted after adjusting the position of the rear wheels
(e.g. camber adjustment).
Ensure sufficient air is in the tires.
Loosen the hexagon socket bolt
at the brake holder
(hex. socket wrench 5mm).
Move the brake to the required position.
Tighten the hexagon socket bolt at the brake
holder again.
The brake is adjusted correctly if the distance between the wheel and
the brake shoe is 25 mm when the brake is released. With the brake
applied, the brake shoe should not sink more than 4 mm into the tire.
The good function of
the parking brakes
can only be ensured
if the tires are suffici-
ently inflated.
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4
2
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Copyright © 08/2008,Küschall AG
K-Series 2.12 Clothes guard assembly
The clothes guard fixation piece should be already fitted on the backrest tube.
Remove existing clothes guard by removing screw .
Align the clothes guard to the rear wheel. Locate the required position to fasten the
clothes guard to the fixation piece . Remove rear wheels
Fasten the clothes guard to the fixation piece with screw .
If the seat module fixation piece needs to be replaced, remove the screw .
When unfolded, the tip of the clothes guard should be below the seat module and the up-
per rim should run parallel to the rear wheel.
2.13 Mudguard assembly and adjustment
Remove the clothes-guard and the fastening elements on backrest tube and seat module.
Remove the rear wheel.
Attach the bracket to the seat module and remount the rear wheels.
Slightly loosen the bolts on the adjustment plate and shift it along the mounting
bracket until the mudguard is in position.
The position of the mudguard can be altered to ensure a consistent wheel coverage:
loosen the bolts and and position the mudguard as required.
Tighten the bolts .
The distance between the mudguard and the wheel must be at least 4 cm if the
wheelchair is equipped with a suspension.
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4
1
1
3
4
2
5
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Copyright © 08/2008,Küschall AG
K-Series
2.14 Armrest assembly and adjustment
Fold the backrest onto the seat.
Remove the backrest bolt and replace with the armrest adapter on both sides.
Mount the connecting tube .
To establish the correct armrest height, position the cylinder in the tube so that
the bolt can be fastened to the required hole.
Insert the armrest into the socket.
2.15 Siderest assembly and adjustment
Remove the rear wheels.
Attach the bracket und mounting plate to the seat module on both sides of the
wheelchair. Do not fully tighten the screws .
Fit the bar between both mounting plates . Fully tighten the screws .
To set the height of the armrest, first fit the armrest in the bracket .
Loosen the screws on the height adjustment clamp and slide the armrest to the
desired position.
Tighten the screws on the height adjustment clamp.
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46
5
2
1
4
5
1
2
3
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Copyright © 08/2008,Küschall AG
K-Series 2.16 Rear wheel extension assembly and adjustment
Unscrew bolts from both sides and remove axle clamp with axle.
Remove bolts and , dismantle axle clamp.
Attach the axle clamp with bolts to the required hole in the rear wheel
extension .
The correct clamp must be used if a Vario-Ax is being mounted.
Slide both rear wheel extensions onto the axle. Mount rear wheel extensions with
bolts to wheelchair.
Adjust rear wheel parallelism. (chapter 2.17)
Tighten bolt to attach axle.
2.17 Rear wheel camber adjustment
Assembly standard axle
A new axle has to be attached when adjusting the rear wheel camber.
Remove bolts and fold down the lower part of the axle clamp on both sides.
Replace axle with new axle having the correct camber.
Fold up the lower part of the axle clamp and insert bolt on both sides.
Adjust rear wheel parallelism. (chapter 2.18)
Tighten bolts firmly.
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Copyright © 08/2008,Küschall AG
K-Series
Assembly Vario-Ax
Unscrew bolts and remove axle clamp with axle.
Mount the upper part of the Vario-Ax clamp with bolt .
Attach Vario-Ax and mount the lower part of the Vario-Ax clamp with bolts
and .
Adjust rear wheel parallelism. (chapter 2.18)
Adjusting Vario-Ax
Loosen the blue knurled head bolt from the Vario-Ax.
Pull out the wheel from the hub until required camber is aligned.The following
positions are possible: 1, 3, 7 and 10 degrees.
Slightly tighten the blue knurled head bolt until a resistance is felt (do not force).
2.18 Control of rear wheel parallelism
Loosen bolts on both clamps.Pivot
the camber bar, using the spirit level
to adjust it to the right position (the
bubble must be centered in the spirit
level).Tighten bolts again.
Note:
This adjustment must be carried out on a perfectly horizontal surface. The track of
the rear wheel is correct if (measured at height of hub) the distance between the rear
wheels is the same at the front and back (x=y).
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1
1
2
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Copyright © 08/2008,Küschall AG
K-Series 2.19 Suspension assembly
To assemble the suspension, remove the rear wheels, fold the backrest onto the seat and
tip the chair onto its back.
Disassemble the seat module by removing the front and rear hinge brackets , .
Remove the vertical seat brace .
Fasten the spring case to the frame: slide the bolt through the spring case and
attach the greased bushing and the distance elements to the bolt. Slide the bolt
through the frame into the axle retainer trap and tighten.
Functional check:The spring case must be able to swivel, but without any room for
play.
Insert the suspension vertical seat brace into the spring case from above. Slide
the bushing over the suspension vertical seat brace from below, and position it
at the required seat height. Fasten with a bolt and washer. Repeat for the other side.
Grease the springs and insert into the spring case .Tighten the bolt into the
spring case until it protrudes 25 mm.
Fasten the suspension hinge brackets to the seat module, insert the greased
threaded bushings (front and rear) and reattach the seat module to the frame.
Remount the rear wheels and turn the wheelchair over.
Functional Check: Check the front seat height.The minimal distance between mud-
guard and tyre should measure 4cm. Make sure that the suspension functions correctly.
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Copyright © 08/2008,Küschall AG
K-Series
2.20 Backrest height adjustment
Adjustment of the push handle or backrest telescope
A - Without push handles
Remove the backrest cover.
Locate the spring clips inside the backrest straps then press them into the tube.
Adjust the telescopic tube to the required height and let the spring clips snap into
the nearest holes.
Replace the backrest cover.
B - With push handles
Remove the backrest cover.
Slide the backrest strap either up or down to locate the fixing bolt . Remove nut
and bolt from both sides.
Adjust the push handle to the required height then fit the bolts into the nearest
holes and secure with the nuts.
Replace the backrest cover.
If the required height is not achieved, replace either the push handle, the telescopic
tube or the backrest tube.
2
B
A
1
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Copyright © 08/2008,Küschall AG
K-Series
Replacement of backrest tube
Remove the backrest cover.
Slide the backrest strap either up or down to locate the fixing bolt . Remove nut
and bolt from both sides.
Remove the push handles and the upper adjustable backrest straps.
If the wheelchair is fitted without push handles, remove the telescopic tubes and the up-
per adjustable backrest straps by pressing the spring clips into the tube and then pulling
the tubes out of the backrest.
Remove the screws securing the backrest tube to the seat module.
Remove the lower adjustable backrest straps and the sleeve with the stop bolt
from the backrest tube .
Assemble the lower adjustable backrest straps and the sleeve with the stop bolt
to the new backrest tubethen secure the backrest tube to the seat module with
the screws .
Replace the upper adjustable backrest straps and the push handles and secure with
the bolts and nuts.
If the wheelchair is fitted without push handles, replace the telescopic tubes and the up-
per adjustable backrest straps by pressing the spring clips into the tube and then sliding
the tubes to the required position until the spring clips snap into the nearest holes.
With the backrest in the upright position, check the
adjustment of the backrest stop screw .
The screw heads should only slightly touch the seat module
when the backrest clicks into its upright position. Adjust if
necessary by loosening the lock nut and moving the stop
screw either in or out as required.
Tighten the lock nuts.
Replace the backrest cover.
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Copyright © 08/2008,Küschall AG
K-Series
2.21 Backrest angle adjustment
Fold the backrest onto the seat and loosen the lock nut of the adjustment bolt .
Tighten the adjustment bolt completely.
Loosen bolt of the eccentric plate. Remove the eccentric plate and reinsert it in
the required position.
Reinsert bolt and tighten.
Unfold the backrest until the stop bolts engage; loosen the adjustment bolt until
it touches the frame and the backrest joint no longer has any leeway.
Tighten the lock nuts.
Functional check: Unfold the backrest.The stop bolt must lock into the groove on the
eccentric plate.
2.22 Antitipper assembly and adjustment
Without rear wheel extension
Fold down the backrest and turn the wheelchair over. Loosen the axle bolts .
Remove the lower part of the axle clamp .
Attach the adaptation clamp latch with the axle bolts . Close the adaptation axle
clamp latch and tighten.
Functional check: Adjust rear wheel parallelism. (chapter 2.18)
Place antitipper with screws onto the adaptation holder .The distance between
the ground and the antitipper wheels must measure 4-6 cm.Tighten bolts.
Function control: The antitipper should swing under the chair without difficulty.
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