Otto Bock BRAVOracer User manual

BRAVOracer
Service Manual

1
Service Manual for the BRAVO Racer Active Wheelchair
Table of contents Page
1 Introduction .......................................................................................................................3
1.1 Foreword.....................................................................................................................3
1.2 Technical support.......................................................................................................3
1.3 Explanation of symbols..............................................................................................3
2 General safety instructions ...............................................................................................4
3 Required tools, maintenance schedule ............................................................................5
3.1 Required tools ............................................................................................................5
3.2 Maintenance schedule...............................................................................................7
4 Adjustments / replacement / retrotting..........................................................................8
4.1 Assembly A: Frame ....................................................................................................8
4.1.1 Retrotting the multi-function adapter for frame accessories......................................... 8
4.1.2 Retrotting / replacing / adjusting the tip-assist ............................................................ 9
4.1.3 Retrotting / replacing the anti-tipper ............................................................................. 9
4.1.4 Retrotting / replacing / adjusting the transport wheels .............................................. 10
4.1.5 Retrotting / replacing the crutch holder ...................................................................... 10
4.2 Assembly B: Footrest............................................................................................... 11
4.2.1 Adjusting / replacing the footplate ................................................................................ 11
4.2.2 Adjusting the lower leg length ....................................................................................... 12
4.2.3 Adjusting the footplate angle......................................................................................... 13
4.2.4 Replacing / retrotting the lateral heel blocks on the footplate .................................. 14
4.3 Assembly C: Seat.....................................................................................................15
4.3.1 Replacing the seat upholstery / upholstery bars .......................................................... 15
4.3.2 Replacing / removing the adjustment tube................................................................... 16
4.3.3 Vertical seat adjustment................................................................................................ 16
4.3.4 Horizontal seat adjustment............................................................................................ 17
4.3.5 Adjusting the seat angle ................................................................................................ 18
4.3.6 Adjusting the seat depth................................................................................................ 18
4.3.7 Fine adjustments to the back unit ................................................................................. 19
4.3.8 Adjusting the seat width ................................................................................................ 20

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4.4 Assembly D: Back / push handles ..........................................................................23
4.4.1 Replacing the back release ........................................................................................... 23
4.4.2 Replacing the back release spring ................................................................................ 23
4.4.3 Replacing the push handles: Standard / folding version.............................................. 24
4.4.4 Replacing the push handles: Height-adjustable version............................................... 24
4.4.5 Retrotting the push bar................................................................................................ 25
4.4.6 Replacing the back upholstery ...................................................................................... 26
4.4.7 Pre-adjusting the back angle......................................................................................... 27
4.5 Assembly E: Side panels .........................................................................................28
4.5.1 Adjusting the side panels: Clothing protector version................................................... 28
4.5.2 Replacing the side panels: Clothing protector version ................................................. 28
4.5.3 Adjusting the side panels: Height-adjustable version ................................................... 29
4.5.4 Replacing the side panels: Height-adjustable version .................................................. 29
4.5.5 Replacing the arm pad / lengthwise adjustment .......................................................... 30
4.6 Assembly F: Casters ................................................................................................30
4.6.1 Replacing the caster axle............................................................................................... 30
4.6.2 Removing / replacing the casters ................................................................................. 31
4.6.3 Replacing the caster forks............................................................................................. 32
4.7 Assembly G: Rear wheels ........................................................................................32
4.7.1 Centre of gravity and seating position ........................................................................... 32
4.7.2 Replacing the rear wheel attachment assembly ........................................................... 32
4.7.3 Replacing the tting and camber adapter ..................................................................... 33
4.7.4 Installing a wheelbase extension................................................................................... 33
4.7.5 Retrotting the rear wheels with drum brakes .............................................................. 34
4.7.6 Adjusting the quick-release axle .................................................................................... 36
4.7.7 Changing tyres ............................................................................................................... 37
4.7.8 Replacing the push rings – narrow / wide mounting position ....................................... 37
4.7.9 Replacing / retrotting spoke protectors....................................................................... 37
4.8 Assembly H: Wheel lock ..........................................................................................38
4.8.1 Adjusting the wheel lock ................................................................................................ 38
4.8.2 Replacing the wheel lock............................................................................................... 39
4.9 Accessories..............................................................................................................40
4.9.1 Installing the lap belt...................................................................................................... 40
5 Technical data .................................................................................................................41

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1 Introduction
1.1 Foreword
Regular maintenance is important – it improves the safety and increases the lifespan of the
product.
All mobility products should be inspected and serviced once a year.
If the product is frequently used, or if it is used by growing children or patients with changing
clinical conditions, we recommend readjusting and servicing the product every 6 months.
Only use original spare parts for all service and maintenance.
The service and maintenance tasks described here should only be completed by trained, quali-
fied personnel and not by the wheelchair user.
This service and maintenance manual refers to the spare parts catalogues and instructions for
use for the products described. Please use these documents together.
Use photocopies of the maintenance schedule (checklist in Section 3.2). Retain completed
maintenance schedules and provide the customer with a copy.
Instructions for Use Spare Parts Catalogue
BRAVO Racer 647G447=D/GB
1.2 Technical support
Your national Otto Bock Team will be pleased to answer your technical questions. Contact ad-
dresses and telephone numbers are listed on the last page of this manual.
1.3 Explanation of symbols
Caution!
Personal injury warning.
Attention!
Product damage warning.
Note!
Useful tips for the technician.
Please read!
Please read the Instructions for Use first!

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2 General safety instructions
Observe the following guidelines for maintenance or repair work:
Caution!
Use appropriate tools (refer to pages 5 ff.).
Caution!
Wear appropriate clothing, including gloves and protective goggles if required.
Attention!
Secure the product to prevent it from tipping over or falling off the workbench.
Please read!
Please read the service and maintenance instructions before commencing work.
Please read!
You should become familiar with the functions of the product first. If you are not familiar
with the product, read the instructions for use before inspecting the product.
If you do not have a copy of the instructions for use, you can order one from the
manufacturer (see the overview of all Otto Bock branches “Otto Bock Worldwide”).
You can also download documents from our homepage:
www.ottobock.de or www.ottobock.com.
Attention!
Clean or disinfect the product before you start the inspection. Consult the instructions
for use regarding product care or product specific inspection information.
Attention!
The screws and nuts for many of the screw connections are coated with thread lock.
If such screws must be replaced or the connections undone, be sure to use a new
screw or nut coated with threadlock. If new screws or nuts with thread lock are not
available, apply a medium-strength liquid thread lock substance (such as Loctite
241 or Euro Lock A24.20) to the existing screws.

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3 Required tools, maintenance schedule
3.1 Required tools
The following list shows the tools and accessories required for service.
Ratchet wrench and socket set,
sizes 8 – 24
Torque wrench,
measurement range 5 – 50 Nm
Wrenches,
sizes 10 – 24
Allen wrenches,
sizes 3 – 6
Screwdrivers, blade widths
2.5, 3.5, and 5.5 mm
Phillips screwdriver,
size 2
Plastic hammer Hammer, approximately 300 g Stanley knife with sickle hooked
blade and standard blade
Side cutting pliers Liquid thread lock “medium strength” Rivet gun
for rivets up to ø 5mm

6
Workbench and vice with plastic
jaws and rubber insert
Hand drill Tyre mounting levers and inner tube
repair kit

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3.2 Maintenance schedule
Maintenance schedule
for regular inspections
BRAVO Racer
- active wheelchair -
Customer:
Item Component (assembly) Inspection (checklist)
Serial number: 1.)
Function / setting
(refer to 647G447GB Instructions for Use)
2.)
Damage /
deformation
3.)
Screw connections
A Frame - Base frame x x
Frame accessories - Anti-tipper
- Transport wheels
- Crutch holder
- Tip-assist
x
x
x
x
x
x
x
B Footrest - Lengthwise setting
- Lower leg length setting
- Angle adjustment
x
x
x
x
x
x
C Seat - Seat upholstery
- Lengthwise adjustment of the
seating unit
- Seat height
- Seat cushion
x
x
x
x
x
DBack / push handle - Back upholstery
- Back tubes
- Folding mechanism
- Push handles
- Push bar
x
x
x
x
x
x
x
x
x
E Side panel - Height setting
- Retracting mechanism
- Removability
x
x
x
x
x
x
F Caster - Tyres (wear)
- Air pressure
- Running characteristics of the wheels
- Threaded axles
- Swivelling characteristics of the wheel forks
x
x
x
x
x
x
x
G Rear wheel - Tyres (wear)
- Air pressure
- Running characteristics of the wheels
- Spokes
- Push rings
- Quick-release axles
- Wheel camber
- Rear wheel attachment
x
x
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories - Spoke protectors
- Wheelbase extension
x
x x
H Wheel lock - Wheel lock function
- Lever assembly
- Clamp fittings
- Pull-release cables
x
x
x
x
x
x
x
Wheel lock accessories - Wheel lock lever extension x x
S Accessories - Lap belt x x
Do the settings of the
wheelchair comply with the
user’s requirements?
The maintenance service was carried out by: on:

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4 Adjustments / replacement / retrotting
4.1 Assembly A: Frame
4.1.1 Retrotting the multi-function adapter for frame accessories
Before mounting frame accessories (tip-assist, crutch holder, and transport wheels), a multi-
function adapter must be installed. Please proceed as follows:
First remove the rear wheels by pressing the button on the quick-release axle with your thumb
and pulling off the wheel (Figure 1). Then loosen the cap nuts on the front of the rear wheel
attachment (Figure 2) and remove them completely. Pull the U-shaped section off towards the
rear (Figure 3).
Loosen the counter nut on the top end of the adjustment tube and move the adjustment tube forward
by several centimetres so that you have sufficient clearance for the installation (Figure 4).
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34

9
Now push the hexagonal multi-function adapter past the loosened adjustment tube onto the
exposed hexagon nut on the rear wheel axle (Figure 5). Secure the multi-function adapter using
the clamping screw (Figure 6).
56
Reinstall the adjustment tube, rear wheel attachment, and wheels. Repeat the steps described
above in reverse order.
4.1.2 Retrotting / replacing / adjusting the tip-assist
First, proceed as described in Section 4.1.1. Then press in the spring-mounted push button on
the tip-assist and push the tip-assist onto the multi-function adapter to the desired mounting
position (Figure 7).
4.1.3 Retrotting / replacing the anti-tipper
First, proceed as described in Section 4.1.1 up to the point where the adjustment tube is loosened.
Now push the pre-assembled anti-tipper onto the exposed rear wheel axle until the anti-tipper
adapter (hexagonal shape) is in place on the hexagon nut of the axle. Secure the anti-tipper us-
ing the clamping screw (Figure 8) and test the swing-away and locking functions.
78

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Note!
Subject to technical changes.
4.1.4 Retrotting / replacing / adjusting the transport wheels
First, proceed as described in Section 4.1.1. Follow the same process to install a second multi-
function adapter across from the rear wheel attachment in order to attach the transport wheels
on both sides.
Then press in the spring-mounted push button on the transport wheel (Figure 9) and push it
onto the multi-function adapter to the desired mounting position. Follow the same procedure on
the other side.
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4.1.5 Retrotting / replacing the crutch holder
First, proceed as described in Section 4.1.1. Then press in the spring-mounted push button on the
crutch holder (Figure 10) and push the crutch holder onto the multi-function adapter to the desired
mounting position. Attach the hook and loop strap to hold the crutches to the back tube.
To replace the bucket, loosen the screw connection on the bottom and remove the bucket (Fig-
ure 11). Put a new bucket in place and secure it with the screw removed from the old one.
10 11

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4.2 Assembly B: Footrest
4.2.1 Adjusting / replacing the footplate
If the footplate is too small or has become damaged, or if the leg length needs to be adjusted
due to the growth of a child, proceed as follows:
First, completely loosen all screws on the clamps on the top of the footplate and remove them
(Figure 12). The footplate can be moved forward in the following ways:
a) Fine adjustment: Move the footplate on the footrest bars without following any additional steps.
Retighten the screws.
b) Larger adjustments: Pull the footplate off the footrest bars (Figure 13). Loosen and reposition
the clamps (Figure 14); then proceed as described under a). Note: The approach allows you
to mount the footplate further forward and closer to the frame.
c) Replacement: Loosen all screws on the top and the the clamps. Mount the footplate as de-
scribed above.
12 13
14

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4.2.2 Adjusting the lower leg length
The lower leg length can be adjusted as follows:
a) Fine adjustment of the lower leg length: Loosen the outer screws on the clamps that guide
the footrest bars (Figure 15) and adjust the footplate to the desired height.
b) Changing the lower leg length (from long to short or short to long): Remove the footplate, and
then remove the exposed footrest bars. Turn the footrest bars around (Figure 16) and reinstall
them. Put the footplate back in place and retighten all screws (Figure 17).
15 16
17
Note!
Follow the same process to replace the footrest bars.

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4.2.3 Adjusting the footplate angle
First, loosen the set screws on the clamps that hold the T-shaped crossbrace (Figure 18). Loosen
the centre Allen screws on the same clamps so you can open the rotation joint (Figure 19). Then
open the screw connections located on the frame tube between the clamps (Figure 20).
Now loosen the crossbrace screw connection on the seat tube (Figure 21), so that the nuts can
move freely in the guide groove.
18 19
20 21

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Move the crossbrace back along the seat tube until the footplate reaches the desired angle
(Figure 22). Use the scale on the bottom of the seat tube (Figure 23) in order to make sure the
footplate is positioned evenly on both sides.
22 23
Retighten all screws.
Note!
On wheelchairs with narrow seats, the footplate is mounted in the centre
(Figure 24).
4.2.4 Replacing / retrotting the lateral heel blocks on the footplate
The lateral heel blocks are attached to the bottom of the footplate using screws or rivets. You have
to drill the required bore holes. The positions are pre-punched on the footplate (Figure 25).
24 25

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4.3 Assembly C: Seat
4.3.1 Replacing the seat upholstery / upholstery bars
First remove the seat cushion. Remove the front tube end caps (Figure 26).
Loosen the hook-and-loop connections on the tension-adjustable upholstery in order to slacken
it (Figure 27). Evenly pull the seat upholstery and upholstery bars out of the guides towards the
front (Figure 28) (use pliers if required).
Either re-use the same upholstery bars or replace them with new ones. Insert the upholstery
bars into the loops on the new seat upholstery, if required.
Reinsert the upholstery bars into the guides on the seat tube (Figure 29) and pull them back
evenly. Refasten the hook-and-loop connections on the tension-adjustable upholstery. Reinsert
the tube end caps.
26 27
28 29

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4.3.2 Replacing / removing the adjustment tube
Remove the rear wheels, rear wheel attachment, and U-shaped component as described under
4.1.1. Loosen the counter nut on the top of the adjustment tube (Figure 30) and remove it. Replace
the adjustment tube, counter nut, or guide bushings with new parts as required (Figure 31).
Remove the guide bushings from the adjustment tube and insert them in the desired position
(Figure 32). Move the U-shaped component to the new position. Follow the same procedure on
the other side.
30 31
32
4.3.3 Vertical seat adjustment
Fully loosen the two cap nuts on the front of the adjustment tube (Figure 33) and remove them.
Now pull the U-shaped component back (Figure 34) until you can move the adjustment tube up
and down freely. Follow this procedure on both sides.
Then loosen the two outer screws on the front of the clamps that guide the footrest bar and
crossbrace so that the crossbrace moves freely inside the clamp (Figure 35).
Reposition the adjustment tube over the hole channel (Figure 36). Position the guide bushings
in the corresponding locations (see Section 4.3.2). For assembly, please proceed in reverse
order.
Retighten all screws.

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33 34
35 36
4.3.4 Horizontal seat adjustment
Remove the rear wheels. Loosen the counter nuts on the top end of the adjustment tubes. Loosen
the screw connections on both sides of the crossbrace in the guide grooves of the seat tubes
(Figure 37).
Move the seat tubes lengthwise until they reach the desired position (Figure 38). Use the scale on
the bottom of the seat tubes in order to make sure the position is even on both sides. Retighten
all screws.
37 38

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4.3.5 Adjusting the seat angle
Slightly loosen the two cap nuts on the front of the adjustment tube. Follow this procedure on
both sides.
Then loosen the two inner screws on the front of the footrest clamps (Figure 39; for narrow seats,
loosen the outer screws) and the countersunk centre screws (Figure 40) until the crossbrace
moves easily inside the clamp.
Move the crossbrace vertically inside the clamps in order to adjust the seat angle. The rear wheel
axle (Figure 41) is the rotation point. The footrest angle follows automatically.
Once the desired angle is set, retighten all screws.
39 40
41
4.3.6 Adjusting the seat depth
Remove the rear wheels. Loosen the counter nuts on the top end of the adjustment tubes. Loosen
the screw connections on both sides of the crossbrace in the guide grooves of the seat tubes.
Loosen the four screw connections / nuts of the back unit on the seat tubes (Figure 42). Loosen
the screw connections on both sides below the lip of the clothing protector (Figure 43). Now
you can push the seat tubes with seat upholstery forward in order to increase the seat depth
(Figure 44). Use the scale on the bottom of the seat tubes in order to make sure the position is
even on both sides.
Retighten all screws.