Otto Bock Discovery tmax User manual

discovery tmax
Service Manual

Introduction1 4.........................................................................................................................................................
Foreword 1.1 4............................................................................................................................................
Support1.2 4...............................................................................................................................................
Product Overview1.3 5.................................................................................................................................
Safety2 6....................................................................................................................................................................
Explanation of Warning Symbols2.1 6.............................................................................................................
General Safety Instructions2.2 7....................................................................................................................
Service Work3 7.......................................................................................................................................................
General Information3.1 7..............................................................................................................................
Instructions for Adjustment3.2 7.....................................................................................................................
Maintenance Schedule3.3 8..........................................................................................................................
Required Tools and Accessories3.4 8.............................................................................................................
Assembly A: Frame3.5 8...............................................................................................................................
Replacing the Adjustment Tubes3.5.1 8.............................................................................................................
Replacing the Adjustment Tubes on the Main Frame3.5.1.1 8.................................................................................
Replacing the Adjustment Tubes on the Seat Frame3.5.1.2 9..................................................................................
Replacing the Push Bar Adjustment Tubes3.5.1.3 10.............................................................................................
Replacing the Anti-Tipper3.5.2 10.....................................................................................................................
Retrofitting the Lashing Points3.5.3 11..............................................................................................................
Replacing the Back Plates3.5.4 11...................................................................................................................
Assembly B: Footrest3.6 12..........................................................................................................................
Adjusting the Foot Rests/Tube Foot Rest/Foot Plates3.6.1 12..............................................................................
Replacing the Footrest Adapter3.6.2 12............................................................................................................
Replacing the Footrest3.6.3 13.........................................................................................................................
Replacing the Foot Rest Bar/Swivel Segment3.6.4 13.........................................................................................
Replacing the Pivot Bearing3.6.5 14.................................................................................................................
Replacing the Locking Device3.6.6 14..............................................................................................................
Replacing the Footplate3.6.7 14.......................................................................................................................
Replacing the Heel Band3.6.8 15.....................................................................................................................
Retrofitting the Centre Footrest3.6.9 15.............................................................................................................
Retrofitting the Single-Panel Flip-up Footplate3.6.10 17........................................................................................
Retrofitting Anti-Slip Mats3.6.11 19....................................................................................................................
Assembly C: Seat/Seating System3.7 19........................................................................................................
Replacing the Locking Plate3.7.1 19.................................................................................................................
Replacing the Locking Plate Guide3.7.2 20.......................................................................................................
Replacing the Locking Unit3.7.3 20..................................................................................................................
Replacing the Locking Pedal3.7.4 22................................................................................................................
Replacing/Retrofitting the Seat Plate3.7.5 23.....................................................................................................
Replacing/Retrofitting the Seat Plate Supports3.7.6 24.......................................................................................
Retrofitting Seating Shells/Seating Systems3.7.7 24...........................................................................................
Retrofitting the Trapezoid Adapter3.7.7.1 24.........................................................................................................
Retrofitting an Ottobock Shape System3.7.7.2 25.................................................................................................
Retrofitting Adapters for Other Seating Systems3.7.7.3 25.....................................................................................
Retrofitting Other Seating Systems3.7.7.4 25........................................................................................................
Retrofitting a Tilt Limiter3.7.8 25.......................................................................................................................
Assembly D: Back/Push Handle3.8 25...........................................................................................................
Replacing the Push Handles3.8.1 25................................................................................................................
Replacing the Rubber Hand Grips3.8.2 26........................................................................................................
Replacing/Retrofitting the Push Bar3.8.3 26.......................................................................................................
Replacing the Back Plates3.8.4 26...................................................................................................................
Retrofitting the Angle-Adjustable Back with Pin3.8.5 26.......................................................................................
Retrofitting the Cross Tube with Back Guide3.8.6 27..........................................................................................
Table of contents
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Table of contents
discovery tmax

Retrofitting Back Systems3.8.7 28....................................................................................................................
Retrofitting Ottobock Back Systems3.8.7.1 28......................................................................................................
Retrofitting Other Back Systems3.8.7.2 28...........................................................................................................
Assembly E: Side Panels3.9 28.....................................................................................................................
Replacing/Retrofitting the Side Plates3.9.1 28....................................................................................................
Replacing the Armrest Pads3.9.2 29.................................................................................................................
Retrofitting a Channel Forearm Pad with Swivel Unit (Option)3.9.3 29..................................................................
Assembly F: Caster Wheels3.10 30.................................................................................................................
Replacing the Caster Wheels3.10.1 30...............................................................................................................
Replacing the Caster Fork3.10.2 30...................................................................................................................
Assembly G: Rear Wheels3.11 31...................................................................................................................
Replacing the Rear Wheels3.11.1 31..................................................................................................................
Replacing the Wheel Attachments for Wheels with Quick-Release Axle3.11.2 32.....................................................
Replacing the Rear Wheel Adapters3.11.3 33......................................................................................................
Assembly H: Wheel Lock/Brake3.12 35............................................................................................................
Adjusting the Wheel Lock3.12.1 35....................................................................................................................
Replacing the Knee Lever Wheel Lock for 12"/16" Wheels3.12.2 35......................................................................
Replacing the Knee Lever Wheel Lock for 22"/24" Wheels3.12.3 35......................................................................
Retrofitting the Drum Brake3.12.4 36..................................................................................................................
Drum Brake 22"/24"3.12.4.1 36............................................................................................................................
Drum Brake 12"3.12.4.2 38..................................................................................................................................
Adjusting the Braking Force of the Drum Brake3.12.5 39......................................................................................
Appendices4 40........................................................................................................................................................
Technical Data4.1 40....................................................................................................................................
Maintenance Schedule4.2 41........................................................................................................................
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1 Introduction
1.1 Foreword
Regular maintenance is important – it improves safety and increases the lifespan of the product.
All Mobility products should be inspected and serviced once a year.
However, we recommend inspecting, readjusting, and if necessary servicing the product every 6 months if the
product is used frequently, by growing children or by users with changing clinical conditions.
Only use original spare parts for all service and maintenance work. The service and maintenance tasks described
here should only be completed by trained, qualified personnel and not by the user of the device.
This service and maintenance manual refers to the respective spare parts catalogues and the instructions for use of
the described products. Please use these documents together.
Use the maintenance schedule (checklist) as a template for making copies. Retain completed maintenance sched
ules and provide the customer with a copy.
Instructions for Use (Qualified Personnel) Instructions for Use (User)
discovery tmax 647G734=* 647G733=*
1.2 Support
Your national Ottobock team will be happy to answer any technical questions. The contact addresses and tele
phone numbers can be found on the back inside cover of the service manual.
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Introduction

1.3 Product Overview
1
discoverytmax with 12"/16" wheels – Non self-propelling version
1 Main frame 8 Caster wheel
2 Seat frame 9 Footrest
3 Pivot point for angle adjustment 10 Footplate
4 Hole channel for angle adjustments (2.5° increments) 11 Side panel with armrest
5 Locking pedal 12 Back frame
6 Rear wheel 13 Push handle
7 Knee lever wheel lock 14 Lashing point (option)
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2
discoverytmax with 22"/24" wheels – self-propelling version with push rings
1 Main frame 8 Caster wheel
2 Seat frame 9 Footrest
3 Pivot point for angle adjustment 10 Footplate
4 Hole channel for angle adjustments (2.5° increments) 11 Side panel with armrest
5 Locking pedal 12 Back frame
6 Rear wheel 13 Push handle
7 Knee lever wheel lock 14 Lashing point (option)
2 Safety
2.1 Explanation of Warning Symbols
WARNING Warnings regarding possible risks of severe accident or injury.
CAUTION Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
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Safety
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2.2 General Safety Instructions
CAUTION
Failure to observe installation instructions
Pinching, crushing due to installation errors
►Do not reach between force-actuated surfaces during installation work.
CAUTION
Use of unsuitable tools
Pinching, crushing or damaging the product
►When working, use only tools that are suitable for the conditions at the workplace and whose proper use
ensures safety and health protection.
CAUTION
Re-use of self-locking nuts
Unintended loosening of the screw connections
►Always replace self-locking nuts with new self-locking nuts after disassembly.
NOTICE
Tipping or falling of the product
Damage to the product
►When you work on the product, secure it so that it cannot tip over or fall over.
►Use a clamping device to secure the product for all work at a workbench.
3 Service Work
3.1 General Information
INFORMATION
Read the service manual before starting work. Familiarise yourself with the functions of the product prior to
inspection and use. In order to do so, you can request this service manual and other documentation from the
manufacturer (see the overview of national Ottobock branches on the inside of the back cover) or download from
our homepage www.ottobock.de or www.ottobock.com.
INFORMATION
Clean and disinfect the product before commencing service work.
Observe all care instructions and product-specific inspection instructions in the instructions for use.
INFORMATION
Many screw connections utilise screws and nuts equipped with thread lock. If you loosen screw connections, be
sure to replace the respective nut or screw with one equipped with a new thread lock. If new screws or nuts with
thread lock are not available, apply a medium-strength liquid thread locking compound (such as Loctite® 241 or
Euro Lock A24.20) to the existing screws.
3.2 Instructions for Adjustment
WARNING
Failure to verify tipping resistance
Risk of the user falling or tipping over
►Changing the settings can lead to instability of the system as a whole. Verify tipping resistance after any
changes to the settings.
The sections that follow describe the replacement and retrofitting of standard and option parts on the product
shown on the cover.
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All instructions concerning the adjustment of the parts installed are included in the Instructions for Use (qualified
personnel) – see the section "Foreword" for the order number.
3.3 Maintenance Schedule
Maintenance schedule as a template for copying: see Page41.
3.4 Required Tools and Accessories
The following tools are required in order to perform the service work:
• Reversible ratchet handle wrench and sockets (size: 8–24)
• Torque wrench (measurement range 5-50 Nm)
• Wrench (size: 8–24)1)
• Allen wrench (size: 2.5–6)2)
• Screwdriver (blade width: 2.5/3.5/5 mm)
• Phillips head screwdriver (size: 2)
• Hammer (approx. 300 g); soft-faced hammer
• Pliers: cutting pliers, combination pliers, snap ring pliers
• Rivet gun (for rivets up to ø 5mm)
• Pin punch, ø 3/4/5/6 mm
• Drill/twist drill ø 3.2/5/5.2/6 mm
• Stanley knife with sickle hooked blade and standard blade
• Tyre mounting levers and inner tube repair kit*
• Workbench and vice with plastic jaws and rubber insert
• Measurement equipment: rule, spirit level
• Liquid thread locker, "medium" and "strong"
1) Included in 481C08=ST010 Tool Set
2) Size 3 – 6 contained in the 481C08=ST010 Tool Set
3.5 Assembly A: Frame
3.5.1 Replacing the Adjustment Tubes
The adjustment tubes must be replaced in the course of retrofitting seat widths that cannot be achieved with the
installed adjustment tubes.
To simplify replacement, the main frame and seat frame adjustment tubes should be replaced at the same time.
This saves removing the seat frame from the main frame.
If the frame width is altered, the width of the push bar also has to be changed (see Page10).
Existing seat plates must be removed in advance.
3.5.1.1 Replacing the Adjustment Tubes on the Main Frame
Article Number Adjustment Tube (for front/rear)* Quantity
471C22=SS021 Adjustment Tube for seat width 12"–16" / 30–40 cm 2
471C22=SS022 Adjustment Tube for seat width 14"–18" / 35–45 cm 2
471C22=SS023 Adjustment Tube for seat width 16"–20" / 40–50 cm 2
471C22=SS024 Adjustment Tube for seat width 18"–22" / 45–55 cm 2
* Seat width between the armrests, measured between the lateral guides of the armrest (lateral guides without optional seat
plates)
1) Loosen 4 x Allen head screws on each of the adjustment tubes at the rear (see Fig.3, item1) and front (see
Fig.4, item2).
INFORMATION: In some cases, the Allen head screws on the locking pedal also have to be loosened
(see Fig.3, item3).
2) Push the adjustment tubes to the side and replace them one by one.
3) Symmetrically preinstall the adjustment tubes in the desired width.
INFORMATION: The connection between the adjustment tube and frame always has to be realised on
both sides with 2 Allen head screws + washers (use inner 2 bores).
INFORMATION: If required, an asymmetry of 12.5 mm (1/2") is allowable when adapting the adjust
ment tubes. The asymmetry must be on the same side on all adjustment tubes. However, the allow
able adjustment range must not be exceeded.
4) Retighten all Allen head screws to a torque of 10 Nm.
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3 4
3.5.1.2 Replacing the Adjustment Tubes on the Seat Frame
INFORMATION
If a push bar is installed, it needs to be replaced at the same time (see the next chapter).
Article Number Adjustment Tube (for front/rear)* Quantity
471C22=SS021 for seat width 12"–16" / 30–40 cm 2
471C22=SS022 for seat width 14"–18" / 35–45 cm 2
471C22=SS023 for seat width 16"–20" / 40–50 cm 2
471C22=SS024 for seat width 18"–22" / 45–55 cm 2
Article Number Adjustment Tube (for seat fork/locking mechanism)* Quantity
471D22=SS022 for seat width 12"–16" / 30–40 cm 2
471D22=SS023 for seat width 14"–18" / 35–45 cm 2
471D22=SS024 for seat width 16"–20" / 40–50 cm 2
471D22=SS025 for seat width 18"–22" / 45–55 cm 2
* Seat width between the armrests, measured between the lateral guides of the armrest (lateral guides without optional seat
plates)
1) Loosen 4 x Allen head screws on each of the adjustment tubes at the front (see Fig.5, item1) and rear (see
Fig.5, item2).
2) Loosen 2 x Allen head screws with counter nuts on the adjustment tube of the central seat fork (see Fig.5,
item3).
3) Loosen 2 x Allen head screws with counter nuts on the adjustment tube of the locking mechanism (see Fig.5,
item4).
4) Push the adjustment tubes to the side and replace them one by one.
5) Symmetrically preinstall the adjustment tubes one by one in the desired width.
INFORMATION: The connection between the adjustment tube and frame always has to be realised on
both sides with 2 Allen head screws + washers (use inner 2 bores).
INFORMATION: If required, an asymmetry of 12.5 mm (1/2") is allowable when adapting the adjust
ment tubes. The asymmetry must be on the same side on all adjustment tubes. However, the allow
able adjustment range must not be exceeded.
6) Tighten all Allen head screws to the following torque values:
→Item1/2: 10 Nm
→Item3/4: Allen head screw – 8 Nm; counter nut – 10 Nm
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5 6
3.5.1.3 Replacing the Push Bar Adjustment Tubes
Article Number Adjustment Tube (for push bar)* Quantity
471D22=SS022 for seat width 12"–16" / 30–40 cm 1
471D22=SS023 for seat width 14"–18" / 35–45 cm 1
471D22=SS024 for seat width 16"–20" / 40–50 cm 1
471D22=SS025 for seat width 18"–22" / 45–55 cm 1
* Seat width between the armrests, measured between the lateral guides of the armrest (lateral guides without optional seat
plates)
1) With push bar option: loosen 2 x Allen head screws on the adjustment tube (see Fig.6).
2) Slide the adjustment tube to the side and replace it.
3) Symmetrically preinstall the adjustment tube in the desired width.
4) Tighten the Allen head screws to a torque of 8 Nm.
3.5.2 Replacing the Anti-Tipper
CAUTION
Incorrect installation of the anti-tipper/missing anti-tipper
Risk of the user tipping to the rear
►Depending upon the settings of the chassis, the centre of gravity, the back angle and the experience of the
user, the use of an anti-tipper may be necessary.
►For a small wheelbase and a backrest that is tilted far back, an anti-tipper may need to be installed on both
sides, depending upon the user's experience.
►Verify that the anti-tipper has been installed and adjusted properly. Find the appropriate position with the
assistance of a helper.
1) Press in the tripod spring (see Fig.7) and pull the anti-tipper (see Fig.8, item1) out of the cross tube (see
Fig.8, item2).
2) Insert the new anti-tipper. In order to do so, push in the tripod spring and allow the front pin to engage in a
bore hole on the cross tube.
3) Visually check that the anti-tipper has engaged.
4) For adjustment, see the Instructions for Use (Qualified Personnel), reference number 647G734.
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7 8
3.5.3 Retrofitting the Lashing Points
WARNING
Unauthorised retrofitting for transportation in a wheelchair accessible vehicle
Serious injuries resulting from accidents
►Retrofitting for transportation in a wheelchair accessible vehicle is only permitted for approved versions.
►Please refer to section 11 in the brochure on using our products in wheelchair accessible vehicles, order
number 646D158.
WARNING
Prohibited installation of parts after an accident
Serious injuries due to unidentifiable product defects
►Continuing to use the product after a traffic accident is prohibited.
1) Screw the front lashing points onto the seat frame using the 2 supplied Allen head screws, but do not tighten
the screws (see Fig.9, item1).
INFORMATION: The front lashing points must face to the outside.
2) Screw on the rear lashing points using the back plate mounting screws (see Fig.10, item1). Also mount a pin
between the rear mounting screws, respectively (see Fig.10, item2; see Fig.11, item3).
INFORMATION: The rear lashing points must face to the inside.
3) Tighten all Allen head screws/mounting screws to a torque of 10 Nm.
4) Attach the "Anchor Point/Fixing Point" sticker to the lashing points so it is readily visible from the outside (no
illustration).
9 10
3.5.4 Replacing the Back Plates
INFORMATION
To adjust the back angle, see the Instructions for Use (Qualified Personnel), reference number 647G734.
1) Loosen 2 x Allen head screws on the back plate/seat frame connection (see Fig.11, item1). The rear cross
tube on the seat frame does not have to be removed (see Fig.12, item1).
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2) If a lashing point is installed, also loosen 1 x Allen head screw and 1 x pin (see Fig.11, item2).
3) Loosen 3 x Allen head screws on the back plate/push handle connection (see Fig.11, item3, 1 x Allen head
screw not illustrated).
4) Remove and replace the back plate.
INFORMATION:If required, the back plate depth position can be adjusted after loosening the 2nd back
plate (see Fig.12, item2).
5) Reinstall the back plate. Screw the rear cross tube into place at the same time (see Fig.12, item1).
6) Tighten all Allen head screws to 10 Nm.
11 12
3.6 Assembly B: Footrest
3.6.1 Adjusting the Foot Rests/Tube Foot Rest/Foot Plates
All instructions concerning the adjustment of the foot rests are included in the Instructions for Use (qualified per
sonnel) – order number 647G585.
3.6.2 Replacing the Footrest Adapter
INFORMATION
►The process for installing the footrest adapter for the standard footrest and the elevating footrest is generally
the same.
►If footrests for short lower leg lengths are to be installed, the footrest adapters have to be switched and
rotated 180°. The locking devices also have to be repositioned (see Page14).
1) Loosen the Allen head screws on the seat frame (see Fig.13, item1).
2) Remove the lashing point if applicable.
3) Remove and replace the footrest adapter.
4) Bring the footrest adapter to the desired position (see Fig.13, item2).
INFORMATION: Note the minimum insertion depth. The footrest adapter needs to be secured with 2
screws.
5) Tighten all Allen head screws to a torque of 10 Nm.
13
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3.6.3 Replacing the Footrest
INFORMATION
The process for installing the standard footrest and the elevating footrest (plastic) is generally the same.
Note that the elevating footrest cannot be installed on the version for children (size 1).
1) If necessary: open the calf band and disengage it from the holder. Flip the footplate up.
2) Release the footrest locking mechanism (see Fig.14) and swing the footrest 90° to the outside (see Fig.15).
3) Pull the footrest up, remove and replace it.
4) Slide the footrest into the holder on the front frame tube from above (see Fig.16).
The footrest has to face out by 90°.
5) Swing the footrest in until the locking mechanism engages.
6) Fold down the footplate. If necessary: engage the calf band on the holder (see Fig.17, item1) and adjust the
length of the calf band. In order to do so, open/adjust/close the hook-and-loop closure (see Fig.17, item2).
14 15
16 17
3.6.4 Replacing the Foot Rest Bar/Swivel Segment
INFORMATION
The footrest bars and footplates are available in different lengths. See the information in the spare parts catalogue
and on the order form.
1) Remove the footrest.
2) Replace the footrest bar:
→Loosen the bottom Allen head screw size4 on the swivel segment (see Fig.18, item1).
→Remove the footrest bar from the swivel segment. Replace if required.
3) Replace the swivel segment:
→Loosen the bottom Allen head screw size4 on the swivel segment (see Fig.18, item1).
→Also loosen and remove the upper Allen head screw size4 on the swivel segment (see Fig.18, item2).
→Slide off the swivel segment. Replace if required.
4) Insert the footrest bar at least 40mm into the swivel segment (see Fig.19; similar illustration).
5) Tighten the Allen head screws on the footrest bar to 10Nm.
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18 19
3.6.5 Replacing the Pivot Bearing
1) Remove the footrest.
2) Loosen the size5 Allen head screw at the centre of the pivot bearing (see Fig.20).
3) Remove/replace the pivot bearing.
4) Reinstall the pivot bearing. Tighten the Allen head screw to 5Nm.
20 21
3.6.6 Replacing the Locking Device
INFORMATION
►The process for installing the locking device for the standard footrest and the elevating footrest (plastic) is
generally the same.
►If footrests for short lower leg lengths are to be installed, the locking devices have to be installed on the other
end of the rotated footrest adapter (see Page12).
1) Remove the footrest.
2) Loosen the size5 Allen head screw on the locking device (see Fig.21).
3) Remove/replace the locking device.
4) Reinstall the locking device. Tighten the Allen head screw to 10Nm.
3.6.7 Replacing the Footplate
Standard footrest
1) Loosen the size5 Allen head screw on the footrest bar (see Fig.22, item1).
2) Slide the footplate off the footrest bar and replace it.
3) Tighten the Allen head screw to a torque of 8 Nm.
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22
Aluminium footplate
1) Loosen the size5 Allen head screw on the lower footrest bar (see Fig.23).
2) Slide off and replace the footplate (see Fig.24).
3) Tighten the Allen head screw to a torque of 10Nm.
23 24
3.6.8 Replacing the Heel Band
1) Remove the footrest.
2) Remove the footrest bar with footplate if required (see Page13).
3) Unscrew the Phillips head screw on the heel band holder (see Fig.25).
4) Remove/replace the heel band holder and the heel band.
5) Reinstall the heel band.
25 26
3.6.9 Retrofitting the Centre Footrest
Preparatory Work
►If necessary: Remove existing footrest adapters (see Page12).
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Preassembly of the Centre Footrest
INFORMATION
The preassembly described below should only be performed in advance if the necessary setting values are known
(depth, lower leg length, angle).
If the values are not known, the pivot bearings and footplates should only be assembled after positioning the user
in the product at the end of the assembly process.
1) Install the pivot bearings on the footplates in the desired depth (see Fig.27/see Fig.28).
2) Install the pivot bearings on the footrest bars (see Fig.29).
3) Preinstall the footrest bar on the footrest adapter (see Fig.30). In doing so, slide the footrest bar at least
40mm into the footrest adapter.
27 28
29 30
Installing the centre footrest
1) Preinstall 2 clamping pieces, each with 2 Allen head screws, centred on the adjustment tubes or cross tubes
(see Fig.31, item 1):
→For seat widths from 13"/33 cm:
Slide the clamping piece onto the front/rear adjustment tube respectively and push it to the side (if
required, loosen the screw connection between the adjustment tube and cross tube).
Slide one spacer piece onto each adjustment tube (see Fig.32, item 1).
Slide the clamping piece over the spacer piece and preinstall with the Allen head screws.
→For seat width 12"/30cm:
Loosen the screw connection between the front/rear adjustment tube and the cross tubes respectively.
Slide the clamping piece onto the centre of each of the cross tubes.
Preinstall each clamping piece on the bores of the cross tubes with the longer Allen head screws.
2) Slide the attachment tube into both clamping pieces (see Fig.33).
3) Preinstall the attachment tube on the rear clamping piece with Allen head screws (not illustrated).
4) Slide the footrest adapter onto the attachment rod. Preinstall the attachment rod on the front clamping piece
with Allen head screws (see Fig.34).
5) Slide the footrest bar at least 40mm into the swivel segment.
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6) Adjust the footplates (depth, lower leg length, angle).
All instructions concerning the adjustment of the footrests are included in the Instructions for Use (qualified
personnel) – order number 647G734.
INFORMATION: Please note that a collision of the footplates with the caster wheels is possible at full
seat tilt in case of extreme lower leg length settings. Install a tilt limiter in this case (see Page25).
7) Tighten all Allen head screws:
→On the clamping pieces: 10Nm.
→On the pivot bearings: 8Nm.
→On the footrest bar: 10Nm.
31 32
33 34
3.6.10 Retrofitting the Single-Panel Flip-up Footplate
Preparatory Work
►If necessary: Remove existing footrest adapters (see Page12).
Preassembling the Footplate Unit (see Fig.35)
INFORMATION
The preassembly described below should only be performed in advance if the necessary setting values are known
(depth, lower leg length, angle).
If the values are not known, the pivot bearings and footplates should only be assembled after positioning the user
in the product at the end of the assembly process.
1) Install the pivot bearings on the footplate at the desired width (see Fig.36, item1).
2) Preinstall the pivot bearings on the footrest bars (see Fig.36, item2). In doing so, set the pivot mechanism
horizontally so that the footplate can be flipped up and down easily.
3) Preinstall the footrest bars on the footrest adapters (see Fig.36, item 3).
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35 36
Installing the footplate unit
1) Preinstall 2 clamping pieces at the front and rear respectively with 2 Allen head screws each in the correct spa
cing (according to the chosen footplate) on the adjustment tubes or cross tubes (see Fig.37, item1):
→As a rule:
Loosen the screw connection between the front/rear adjustment tube and the cross tubes respectively.
Slide 2 clamping pieces onto the cross tubes respectively.
Front: Preinstall the clamping pieces on the bores of the cross tubes with the longer Allen head screws.
Rear: Slide 2 spacer pieces onto the adjustment tube respectively (see Fig.32, item 1). Slide the clamping
pieces over the spacer pieces and preinstall with the Allen head screws.
If necessary: If the clamping pieces have to be screwed to the cross tubes with the horizontal Allen head
screws, the rear cross tube unit has to be rotated by 90°. In order to do so, loosen the seat plate (see
Fig.38, item1), remove the Allen head screws on the sides (see Fig.38, item2) and rotate the cross tube
unit by 90°. Now screw the clamping pieces to the cross tube unit with a torque of 10Nm.
→For very large seat widths:
Slide the clamping pieces onto the front/rear adjustment tube respectively and push them to the side (if
needed, loosen the screw connection between the adjustment tube and cross tube).
Slide 2 spacer pieces onto the adjustment tube respectively (see Fig.32, item 1).
Slide the clamping pieces over the spacer pieces and preinstall with the Allen head screws.
2) Slide in the attachment tubes through the clamping pieces at the front and rear (see Fig.39, item1; see
Fig.33).
3) Preinstall the attachment tubes on the rear clamping pieces with Allen head screws (not illustrated).
4) Slide the preassembled footplate unit into both attachment tubes/clamping pieces from the front and preinstall
it (see Fig.39, item 2).
5) Slide the footrest bar at least 40mm into the swivel segments.
6) Adjust the footplate (depth, lower leg length, angle).
All instructions concerning the adjustment of the single-panel footplate are included in the Instructions for Use
(qualified personnel) – order number 647G734.
INFORMATION: Please note that a collision of the footplate with the caster wheels is possible at full
seat tilt in case of extreme lower leg length settings. Install a tilt limiter in this case (see Page25).
7) Tighten all Allen head screws:
→On the clamping pieces: 10Nm.
→On the pivot bearings: 8Nm.
→On the footrest bar: 10Nm.
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37 38
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3.6.11 Retrofitting Anti-Slip Mats
The self-adhesive anti-slip mats are installed on the footrest, footplate or centre footrest according to the needs of
the user.
40 41
3.7 Assembly C: Seat/Seating System
CAUTION
Incorrect installation of the locking plate
Falling from the seating shell/seating system due to locking mechanism malfunction
►The locking pins must fully engage on both sides in the locking plate on the seat frame in all positions over the
entire adjustment range. Only then is the support of the seat assured with extreme settings or when driving
over rough surfaces.
3.7.1 Replacing the Locking Plate
1) Preparing for installation:
→Set the seat angle to 30° or higher.
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→If required, loosen the wheel lock and slide it to the side.
2) Loosen 3 x Allen head screws (see Fig.42, item1).
3) Unthread the locking plate between the locking pin (see Fig.42, item2) and locking plate guide (see Fig.42,
item3) and remove it.
INFORMATION: If necessary, you have to disengage the locking pin from the locking plate so you can
remove the locking plate.
4) Remove the attached pinch protector from the locking plate (see Fig.42, item4).
5) Replace the locking plate.
6) Attach the pinch protector to the locking plate with 1 x cap screw + washer (see Fig.42, item5). Tighten the
cap screw to a torque of 8 Nm.
7) Thread the new locking plate between the locking pin and locking plate guide. The angle marking faces out.
8) Mount the locking plate on the seat adapter with 3 x Allen head screws + washers (see Fig.42, item1). Tighten
the Allen head screws to 10 Nm.
9) Conduct a functional test. While doing so note the following:
→The locking pins must fully engage in the locking plate. Reference point: the locking pins protrude slightly from
the locking plate (see Fig.50, item1).
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3.7.2 Replacing the Locking Plate Guide
1) Remove the blind rivet (see Fig.43, item1).
2) Remove/replace the guide roller and glide piece (see Fig.43, item2/3).
3) Put the guide roller in place and attach with a blind rivet Ø 5x16. The broader ring of the guide roller has to
face out (see Fig.43, item2).
4) Put the glide piece in place and attach with a blind rivet Ø 5x20 (see Fig.43, item3).
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3.7.3 Replacing the Locking Unit
INFORMATION
The manufacturer recommends replacing the locking unit as a pair on both sides.
1) Remove the locking plate (see Page19).
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