Otto Bock Motus User manual

Motus
Service Manual

3
Service Instructions for the Motus Adaptive Wheelchair
Tabel of contents Page
1 Introduction .......................................................................................................................5
1.1 Preface ....................................................................................................................5
1.2 Technical Support ...................................................................................................5
2 Safety Instructions ............................................................................................................6
2.1 Explanation of Symbols...........................................................................................6
2.2 General Safety Instructions ....................................................................................6
3 Required Tools, Maintenance Schedule ...........................................................................7
3.1 Required Tools.........................................................................................................7
3.2 Maintenance Schedule ...........................................................................................8
4 Settings / Replacement / Retrot.....................................................................................9
4.1 Assembly A: Frame .................................................................................................9
4.1.1 Replacing the Front Frame Part ..................................................................................9
4.1.2 Replacing the Rear Frame Part................................................................................. 10
4.1.3 Replacing the Spacer Sleeve.................................................................................... 12
4.1.4 Replacing / Retrotting / Setting the Anti-tipper ..................................................... 12
4.1.5 Replacing / Retrotting / Setting Transport Wheels, Crutch Holder, or Tip-assist.. 13
4.1.6 Replacing the Support Brackets............................................................................... 14
4.2 Assembly B: Footrest............................................................................................15
4.2.1 Replacing the Footrest Holder.................................................................................. 15
4.2.2 Replacing the Footrest .............................................................................................15
4.2.3 Replacing the Lock Piece ......................................................................................... 16
4.2.4 Replacing the Pivot Bearing ..................................................................................... 16
4.2.5 Replacing the Swivel Segment................................................................................. 16
4.2.6 Retrotting Elevating Footrests ................................................................................ 17
4.2.7 Setting the Lower Leg Length................................................................................... 17
4.2.8 Replacing the Footrest Bar/Footplate...................................................................... 17
4.2.9 Setting or Replacing the Calf Pads .......................................................................... 18
4.3 Assembly C: Seat..................................................................................................18
4.3.1 Replacing the Crossbrace ........................................................................................ 18
4.3.2 Replacing the Crossbrace Brackets and the Crossbrace Bearing.......................... 19
4.3.3 Replacing/Tightening the Seat Upholstery .............................................................. 19
4.3.4 Cleaning the Nylon Seat Upholstery ........................................................................20
4.3.5 Cleaning the Standard Seat Cushion.......................................................................20
4.3.6 Retrotting with the Seating System "Adjustable Seat" ..........................................20

4
4.4 Assembly D: Back / Push Handles.......................................................................20
4.4.1 Setting the Back Upholstery.....................................................................................20
4.4.2 Setting/Replacing the Back Tubes........................................................................... 21
4.4.3 Replacing the Push Handles .................................................................................... 21
4.4.4 Replacing the Rubber Hand Grips............................................................................22
4.4.5 Cleaning the Nylon Back Upholstery........................................................................22
4.4.6 Retrotting the Angle-adjustable Back ....................................................................22
4.4.7 Replacing the Cable of the Angle-adjustable Back .................................................25
4.4.8 Retrotting with the Back System "The Back".........................................................25
4.5 Assembly E: Side Panels ......................................................................................26
4.5.1 Replacing / Retrotting / Setting the Clothing Protector.........................................26
4.5.2 Retrotting / Setting the Plug-on Side Panels .........................................................27
4.5.3 Retrotting the Desk Side Panels ............................................................................28
4.5.4 Replacement / Length Adjustment of the Armrest ..................................................28
4.5.5 Retrotting a Tray .....................................................................................................29
4.6 Assembly F: Casters .............................................................................................29
4.6.1 Caster Trailing Adjustment........................................................................................29
4.6.2 Replacing the Caster Journal Bearings ....................................................................30
4.6.3 Replacing the Caster Forks ...................................................................................... 31
4.6.4 Replacing the Casters .............................................................................................. 31
4.7 Assembly G: Rear Wheels.....................................................................................32
4.7.1 Replacing the Tyres ...................................................................................................32
4.7.2 Replacing the Push Rings and Setting the Mounting Position "narrow / wide".......32
4.7.3 Setting the Quick-release Axle .................................................................................32
4.7.4 Changing the Rear Wheel Adapter Position in the Frame........................................33
4.7.5 Changing the Position of the Fitting in the Adapter .................................................33
4.7.6 Retrotting a Wheelbase Extension..........................................................................34
4.7.7 Retrotting Rear Wheels with Drum Brakes .............................................................35
4.4.8 Setting the Drum Brake............................................................................................36
4.7.9 Retrotting Spoke Protectors ...................................................................................36
4.8 Assembly H: Wheel Lock.......................................................................................36
4.8.1 Replacing / Setting a Wheel Lock ............................................................................36
4.8.2 Replacing the Wheel Lock Lever ..............................................................................37
4.8.3 Replacing the Brake Block .......................................................................................38
4.8.4 Retrotting the Plug-on Wheel Lock Lever Extension ..............................................38
5 Technical Data.................................................................................................................39

5
1 Introduction
1.1 Preface
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.
However, if the product is used frequently, or if it is used by growing children or patients with chang-
ing 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 the maintenance plan (check list) as a template for making copies. Retain completed main-
tenance schedules and provide the customer with a copy.
Instructions for use Spare parts catalogue
Motus 647G232=D/GB
1.2 Technical Support
The Otto Bock Team of your country will be pleased to answer your technical questions. Contact
addresses and telephone numbers are listed on the last page of this manual.

6
2 Safety Instructions
2.1 Explanation of Symbols
CAUTION Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
INFORMATION Information regarding operation. Information for service personnel.
2.2 General Safety Instructions
INFORMATION
Please read the service and maintenance instructions before commencing work. Familiarize yourself
with the functions of the product. 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.
CAUTION
Risk of injury as a result of inappropriate work clothes. Wear appropriate clothing, including gloves
and protective goggles if required.
NOTICE
Damage caused by using inappropriate tools. Use appropriate tools (refer to page 5).
NOTICE
Damage as a result of unsecured product. Secure the product to prevent it from tipping over or fall-
ing off the workbench.
NOTICE
Damage caused by neglected cleaning. Clean or disinfect the product before you start the inspection.
Consult the instructions for use regarding product care or product specific inspection information.
INFORMATION
The screws and nuts for many of the screw connections are equipped with thread lock. If you have to
undo such screw connections, replace the nut or screw with a new one equipped with thread lock.
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.

7
* Contained in 481C08=ST010 Tool Set
3 Required Tools, Maintenance Schedule
3.1 Required Tools
The following list shows the tools and accessories required for service.
Reversible ratchet handle wrench and
sockets, sizes 8 mm - 21 mm
Torque wrench,
measurement range 5 - 50 Nm
Wrenches, sizes 8 mm - 24 mm *
Allen wrenches, sizes 3 mm - 6 mm* Screwdrivers, blade width 5 mm Hammer, approx. 300 g
Stanley knife with standard blade Pincers and combination pliers Workbench and vice with plastic jaws
and rubber insert
Folding ruler and level Liquid thread lock “medium strength” Inner tube repair kit

8
3.2 Maintenance Schedule
Maintenance schedule
for regular inspections
Motus
- Adaptive Wheelchair -
Customer:
Item Component (assembly) Inspection (checklist)
Serial number: 1.)
Function / setting
(see 647G232=D/GB Instructions for Use)
2.)
Damage /
deformation
3.)
Screw connections
A Frame · Frame x x
Frame accessories · Transport wheels
· Anti-tipper
· Tip-assist
· Crutch holder
x
x
x
x
x
x
x
x
B Footrests · Folding mechanism
· Lower leg length adjustment
· Angle adjustment
x
x
x
x
x
x
Footrest accessories · Lateral heel blocks
· Heel band
x
x
x
x
C Seat · Crossbrace
· Seat Upholstery
· Seat cushion
x
x
x
x
x
D Back / push handles · Back upholstery
· Back height
· Angle adjustment
· Push handles
x
x
x
x
x
E Side panels · Height setting
· Swivel mechanism
· Removability
x
x
x
x
x
Side panel accessories · Armrest padded/swing-away
· Tray
x
x
x
x
F Caster · Tyres (wear)
· Air pressure
· Caster journal angle
· Screw connection to the frame
· Running characteristics of the
wheels
· Swivelling of the caster forks
x
x
x
x
x
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 device
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories · Drum brake
· One-arm drive
· Wheelbase extension
· Spoke protector
x
x
x
x
x
x
x
x
H Wheel locks · Brake function x x
Wheel lock accessories · Wheel lock lever extension x x
Do the settings of the wheel-
chair comply with the user's
requirements?
The maintenance service was carried out by: on:

9
4 Settings / Replacement / Retrot
4.1 Assembly A: Frame
4.1.1 Replacing the Front Frame Part
First remove the rear wheels (Fig. 1). Place the unfolded wheelchair on its side on a flat work
surface. Grasp into the pivot lever and remove the footrests (Fig. 2).
Undo and remove the screws of the caster wheel mountings and take the mountings off with the
forks and caster wheels still attached to them (Fig. 3).
Undo the screws of the front support brackets and remove them (Fig. 4).
12
34
Loosen and remove the screws at the upper frame tube (Fig. 5). Loosen and remove the screws
on the inside of the wheel lock clamp fitting (Fig. 6).
You can now pull off the frame part to the front (Fig. 7).
Loosen and remove the screw connection of the clamp fitting and remove the wheel lock
(Fig. 8).
Replace the front frame part. For assembly, please proceed in reverse order.

10
INFORMATION Use new screws coated with thread lock for assembling the caster assembly. When
attaching the caster mountings, be sure to tighten them to the indicated torque values (see Sec-
tion 4.6).
56
78
4.1.2 Replacing the Rear Frame Part
First remove the rear wheels. Loosen and remove the four screws at the rear wheel adapter
(Fig. 9) and remove the adapter.
If applicable, loosen and remove the screw connection between the side panel and back tube
(Fig. 10).

11
910
Loosen and remove the screw connection at the upper frame tube (Fig. 11) as well as at the
lower frame tube (Fig. 12). Slightly fold the wheelchair and remove the rear support bracket.
Remove the seat padding from the backrest and open the hook and loop straps of the back
upholstery. Pull the back tube out of the rear frame part (Fig. 13).
Pull off the rear frame part to the rear (Fig. 14). You can now easily access and remove all the
accessory items mounted to the rear frame parts.
Replace the rear frame part. For assembly, please proceed in reverse order.
INFORMATION
Use new screws coated with thread lock for assembling the frame and the rear wheel
adapters.
11 12
13 14

12
4.1.3 Replacing the Spacer Sleeve
Loosen and remove the two screw connections between the side panels and frame tube
(Fig. 15).
You can now pull the spacer sleeve to the front off the joint tub (Fig. 16).
Replace the spacer. For assembly, please proceed in reverse order.
15 16
4.1.4 Replacing / Retrotting / Setting the Anti-tipper
Mount the receiver tube to the frame in the position shown (Fig. 17).
Slide the anti-tipper from below into the mounted receiver tube. Tighten the screw connection
of the anti-tipper in the uppermost position of the receiver tube as shown (Fig. 18).
Adjust the anti-tipper with the length adjustment (Fig. 19).
By changing the screw connection in the receiver tube, the anti-tipper can be horizontally
adjusted. The anti-tipper wheel must at least completely extend from the rear wheel to the
back, and the distance between the wheel and ground should not exceed 5 cm maximum.
17 18
1.
2.
3.
4.

13
19
4.1.5 Replacing / Retrotting / Setting Transport Wheels, Crutch Holder, or Tip-assist
Mount the receiver tube for transport wheels, crutch holder, or tip-assist on the inside of the
frame tube as shown (Fig. 20).
INFORMATION
The receiver tube for the anti-tipper has a slightly different design and cannot be used
for these options.
Insert the sleeve provided from below into the receiver tube (Fig. 21). Slide the desired accessory
item into the receiver tube until it audibly snaps into place (Fig. 22).
INFORMATION If using the crutch holder, an additional hook and loop strap is to be attached to the
upper back tube. To do this, loosen and remove the uppermost screw at the back tube. Position
the hook and loop strap between the screw and back tube (Fig. 22A) and retighten the screw.
20 21

14
22
22 A
4.1.6 Replacing the Support Brackets
Fix the wheel lock. Slightly fold the wheelchair (Fig. 23). Loosen and remove the oval head screw
at the support bracket (Fig. 24) and pull the bracket up to remove it. Replace the support bracket.
For assembly, please proceed in reverse order.
Replacement of the rear support bracket takes place correspondingly in the same way. Recom-
mendation: Remove the rear wheel first (Fig. 25).
23 24
25

15
4.2 Assembly B: Footrest
INFORMATION
Use new screws coated with thread lock or apply a liquid thread lock to the existing screws.
4.2.1 Replacing the Footrest Holder
Insert the footrest holders – in laterally turned position – from above into the front frame tubes
(Fig. 26).
Turn the footrest holders to the front until the swivel segment engages with the lock. For disas-
sembly, please proceed in reverse order.
For adjusting the lower leg length and for operation, please observe the information given in the
Instructions for Use.
26
4.2.2 Replacing the Footrest
Remove the footrest holder. Loosen and remove the lower set screw on the inside of the swivel
segment (Fig. 27).
Loosen the upper set screw until the footrest bar can be moved (Fig. 28). Then pull the footrest
bar downwards out of the swivel segment.
Replace the footrest. For assembly, please proceed in reverse order.
27 28

16
4.2.3 Replacing the Lock Piece
Remove the footrest holder. Loosen and remove the screw of the lock piece (Fig. 29) and remove
the lock piece.
Replace the lock piece. For assembly, please proceed in reverse order.
4.2.4 Replacing the Pivot Bearing
Remove the footrest from the footrest holder. Loosen and remove the screw of the pivot bearing
(Fig. 30) and remove the pivot bearing.
Replace the pivot bearing. For assembly, please proceed in reverse order.
29 30
4.2.5 Replacing the Swivel Segment
Remove the footrest from the footrest holder. Loosen and remove the screw of the swivel seg-
ment (Fig. 31) and remove the swivel segment (Fig. 32).
Replace the swivel segment. For assembly, please proceed in reverse order.
31 32

17
4.2.6 Retrotting Elevating Footrests
Remove the footrest holder from the front frame. Remove the lock piece (Fig. 29).
Put the provided lock piece of the elevating footrest onto the front frame and tighten the screw
connection with the screws provided (Fig. 33).
Mount the pre-assembled elevating footrest to the front frame in the same way as the standard
footrest (Fig. 34).
33 34
4.2.7 Setting the Lower Leg Length
After loosening the set screw, the footrest bar can be adjusted or completely pulled out of the
footrest holder (Fig. 35).
4.2.8 Replacing the Footrest Bar/Footplate
First remove the footrest from the swivel segment as described in Section 4.2.2.
Flip up the footplate. Loosen and remove the two screws on the outside of the footplate. Make
sure that the lower screw is provided with a counter nut (Fig. 36).
35 36
Loosen and remove the screw on the front of the footplate (Fig. 37). Now you can remove the
footrest bar from the footplate and replace with new ones, if necessary.

18
4.2.9 Setting or Replacing the Calf Pads
Loosen and remove the screw of the calf pad and remove the pad (Fig. 38).
Replace the calf pad. For assembly, please proceed in reverse order.
INFORMATION The slotted holes in the calf pad retainer plate allow for sideways adjustments of the
calf pad (Fig. 38, see arrows).
37 38
4.3 Assembly C: Seat
INFORMATION
Use new screws coated with thread lock or apply a liquid thread lock to the existing screws.
4.3.1 Replacing the Crossbrace
First remove the front frame parts as described in Section 4.1.1. You do not need to detach the
wheel locks. Then remove the spacers as described in Section 4.1.3.
Place the wheelchair frame on its rear frame parts and push handles. Pull the sleeves out of the
lower crossbrace tubes (Fig. 39).
Grasp the crossbrace and pull it up off the joint tubes (Fig. 40).
Replace the crossbrace. For assembly, please proceed in reverse order.
INFORMATION Removal of the crossbrace will separate the rear frame parts from each other. Care-
fully lay the rear frame parts onto the work surface once removed.

19
39 40
4.3.2 Replacing the Crossbrace Brackets and the Crossbrace Bearing
After removing the crossbrace from the joint tube, remove the clips of the crossbrace brackets
(Fig. 41) and pull the screw off to the rear.
Replace the crossbrace bracket. For assembly, please proceed in reverse order.
To replace the crossbrace bearing, lay the crossbrace onto the upholstery. Loosen and remove
the central screw connection of the crossbrace (Fig. 42).
Replace the crossbrace bearing. For assembly, please proceed in reverse order.
41 42
4.3.3 Replacing/Tightening the Seat Upholstery
First remove the two footrest holders. Remove the seat cushion. Remove the front tube end caps
using a (not too sharp-edged) screwdriver (Fig. 43).
If the wheelchair is unfolded, slightly fold it to reduce the tension on the seat upholstery and then
pull the seat upholstery out of the crossbrace's profile tubes (Fig. 44).
Replace the seat upholstery and upholstery bars, if necessary.
A hook and loop closure on the underside (Fig. 45) can be used to tighten the seat upholstery
as desired.
For assembly, please proceed in reverse order.

20
4.3.4 Cleaning the Nylon Seat Upholstery
Clean the seat upholstery with regular mild household cleaner.
4.3.5 Cleaning the Standard Seat Cushion
Open the zipper and remove the foam core (Fig. 46). Clean the cushion cover according to the
sewn in care instructions label.
43 44
45 46
4.3.6 Retrotting with the Seating System "Adjustable Seat"
Please observe the information given in the product's Instructions for Use 647H450.
4.4 Assembly D: Back / Push Handles
INFORMATION
Use new screws coated with thread lock or apply a liquid thread lock to the existing screws.
4.4.1 Setting the Back Upholstery
You can adjust the back upholstery in segments according to your needs.
To do this, remove the back upholstery padding (Fig. 47) and undo the hook-and-loop fasteners
of the straps (Fig. 48).