Otto Bock Start M1 Intro User manual

Start Series
Service Manual
M1Intro • M2Effect • M3Hemi • M4XXL • M5Comfort • M6Junior

1
Table of Contents
1 Preface .............................................................................................................................. 2
2 Safety .............................................................................................................................. 2
3 Required Tools and Maintenance Plan ................................................................................ 3 - 8
Start M1 Intro / M2 Effect....................................................................................... 5
Start M3 Hemi........................................................................................................ 6
Start M4 XXL / M5 Comfort ................................................................................... 7
Start M6 Junior....................................................................................................... 8
4 Settings / Replacement / Retrot............................................................................................. 9
4.A Frame .................................................................................................................... 9
4.B Footrests.............................................................................................................. 11
4.C Seat ..................................................................................................................... 15
4.D Back / Push Handles ........................................................................................... 17
4.E Side Panel............................................................................................................ 19
4.F Caster.................................................................................................................. 21
4.G Rear Wheel.......................................................................................................... 23
4.H Brake / Wheel Lock ............................................................................................. 28
4.S Accessories, Accessory Products ........................................................................ 32

2
1 Preface
Regular maintenance is important. It increases safety and prolongs the service life 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 changing clinical
conditions, we recommend readjusting and servicing the product every 6 months.
Use only original spare parts for all service and maintenance.
The service and maintenance described in this manual should be performed by skilled specialists only and not
by the user.
This service and maintenance manual refers to the spare parts catalogs and instructions for use manuals for
the products described. For this reason, it is important to use these documents together.
Use the maintenance plans (check list) as a template for making copies. Retain completed maintenance plans
and provide the customer with a copy.
Instructions for Use Spare Parts Catalog
Start Series 647G324=D/GB 646K84=GB
2 Safety
For all maintenance and repair works, there are a few points you should always observe:
Use appropriate tools (refer to pages 3 & 4).
Wear appropriate clothing, including gloves and safety glasses, if necessary.
Secure the product to prevent it from tipping over or falling off the workbench.
Read the service and maintenance instructions before starting.
Familiarize yourself with the functions of the product. If you are not familiar with the product, read
the instructions for use manual before inspecting the product.
If you do not have an instructions for use manual, you can order one from the manufacturer (see
the overview of all Otto Bock Branches "Otto Bock Worldwide").
Alternatively, you can download documents from our home page at www.ottobock.de or
www.ottobock.com.
Clean or disinfect the product before starting inspection. See the instructions for use manual for
care instructions or specific product inspection information.
Many of the screw fastenings use thread lock or nylock nuts. If you have to undo such screw
fastenings, replace the nut or screw with a new thread lock and/or nut. If new screws or nuts
with thread lock are not available, use a medium-strength liquid thread lock substance (such as
Loctite 241 or Euro Lock A24.20).

3
3 Required Tools and Maintenance Plan
The following list shows you the tools and auxiliaries required for the service.
Reversible ratchet handle wrench
and sockets, sizes 8 - 24
Torque wrench,
measurement range 5 Nm to 50 Nm
Wrenches,
sizes 8 - 24*
Allen wrenches,
sizes 3 - 6*
Phillips head screwdriver,
size 2
Screwdrivers, blade widths
2.5, 3.5, and 5.5 mm
Hammer, approx. 300 g
Plastic hammer Stanley knife with sickle hooked
blade and standard blade
* Contained in 481C08=ST010 Tool Set
Liquid thread lock "medium strength"Side cutting pliers Pop rivet gun
for rivets up to ø 5 mm

4
Workbench as well as a vise with
plastic jaws and rubber insert
Hand drill Tire mounting levers*,
inner tube repair kit*
* Contained in 481C08=ST010 Tool Set

5
Maintenance Plan
for regular service
Start M1 Intro / M2 Effect
- Lightweight Wheelchair -
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
(see 647G324 Instructions for Use)
2.)
Damages /
deformations
3.)
Screw connections
M1 Intro  M2 Effect
4 A Frame - Frame
- Central unit
x
xx
Frame accessories - Anti-tipper
- Transport wheels (only M2)
- Crutch holder
x
x
x
x
x
x
4 B Footrests - Flip-up mechanism
- Lower leg length setting
- Angle adjustment
x
x
x
x
x
x
4 C Seat - Crossbrace
- Seat upholstery
- Seat cushion
x
x
x
x
4 D Back / push handle - Back upholstery
- Angle adjustment (M2)
- Fold-down mechanism (M2)
- Push handles
- Back tubes
x
x
x
x
x
x
x
x
x
Back accessories - Side thoracic support (M2) x x
4 E Side panel - Height setting
- Swivel mechanism
x
x
x
x
4 F Caster - Tires (wear)
- Air pressure (M2)
- Caster journal angle
- Screw connection of the caster
journal bearing
- Running behavior of the wheels
- Swiveling of the wheel forks
x
x
x
x
x
x
x
x
x
4 G Rear wheel - Tires (wear)
- Air pressure (M2)
- Running behavior of the wheels
- Spokes
- Push rings
- Quick-release axles
- Rear wheel adapter
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories - Drum brakes
- Spoke protectors
x
x
x
x
4 H Brake / wheel lock - Brake function x x
Brake / wheel lock accessories - Wheel lock lever extension x x
4 S Accessories - Tray
- Lap belt
x
x
x
x
Do the settings of the
wheelchair comply with the
user's requirements?
Maintenance performed by: on:

6
Maintenance Plan
for regular service
Start M3 Hemi
- Lightweight Wheelchair -
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
(see 647G324 Instructions for Use)
2.)
Damages /
deformations
3.)
Screw connections
M3 Hemi
4 A Frame - Frame
- Central unit
x
x x
Frame accessories - Anti-tipper
- Transport wheels
- Crutch holder
x
x
x
x
x
x
4 B Footrests - Flip-up mechanism
- Lower leg length setting
- Angle adjustment
x
x
x
x
x
x
4 C Seat - Crossbrace
- Seat upholstery
- Seat cushion
x
x
x
x
4 D Back / push handle - Back upholstery
- Back tubes
- Angle adjustment
- Fold-down mechanism
- Push handles
x
x
x
x
x
x
x
x
x
Back accessories - Side thoracic support
- Stabilization bar
x
x
x
4 E Side panel - Height setting
- Swivel mechanism
x
x
x
x
4 F Caster - Tires (wear)
- Air pressure
- Caster journal angle
- Screw connection of the caster
journal bearing
- Running behavior of the wheels
- Swiveling of the wheel forks
x
x
x
x
x
x
x
x
x
4 G Rear wheel - Tires (wear)
- Air pressure
- Running behavior of the wheels
- Spokes
- Push rings
- Quick-release axles
- Rear wheel adapter
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories - Drum brakes
- Spoke protectors
- One-arm drive
x
x
x
x
x
4 H Brake / wheel lock - Brake function
- One-handed operation
x
x
x
x
Brake / wheel lock accessories - Wheel lock lever extension x x
4 S Accessories - Tray
- Lap belt
x
x
x
x
Do the settings of the
wheelchair comply with the
user's requirements?
Maintenance performed by: on:

7
Maintenance Plan
for regular service
Start M4 XXL/ M5 Comfort
- Lightweight Wheelchair -
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
(see 647G324 Instructions for Use)
2.)
Damages /
deformations
3.)
Screw connections
M4 XXL  M5 Comfort
4 A Frame - Frame
- Central unit
x
x x
Frame accessories - Anti-tipper
- Transport wheels
- Crutch holder
x
x
x
x
x
x
4 B Footrests - Flip-up mechanism
- Lower leg length setting
- Angle adjustment
x
x
x
x
x
x
4 C Seat - Crossbrace
- Seat upholstery
- Seat cushion
x
x
x
x
4 D Back / push handle - Back upholstery
- Back tubes
- Angle adjustment (M5)
- Fold-down mechanism (M5)
- Push handles
x
x
x
x
x
x
x
x
x
Back accessories - Side thoracic support (M5)
- Stabilization bar (M4)
x
x
x
x
4 E Side panel - Height setting
- Swivel mechanism
x
x
x
x
4 F Caster - Tires (wear)
- Air pressure
- Caster journal angle
- Screw connection of the caster
journal bearing
- Running behavior of the wheels
- Swiveling of the wheel forks
x
x
x
x
x
x
x
x
x
4 G Rear wheel - Tires (wear)
- Air pressure
- Running behavior of the wheels
- Spokes
- Push rings
- Quick-release axles
- Wheel camber (M5)
- Rear wheel adapter
x
x
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories - Drum brake
- Spoke protectors
x
x
x
x
4 H Brake / wheel lock - Brake function x x
Brake / wheel lock accessories - Wheel lock lever extension x x
4 S Accessories - Tray
- Lap belt
x
x
x
x
Do the settings of the
wheelchair comply with the
user's requirements?
Maintenance performed by: on:

8
Maintenance Plan
for regular service
Start M6 Junior
- Lightweight Wheelchair -
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
(see 647G324 Instructions for Use)
2.)
Damages /
deformations
3.)
Screw connections
M6 Junior
4 A Frame - Frame
- Central unit
x
x x
Frame accessories - Anti-tipper
- Transport wheels
- Crutch holder
x
x
x
x
x
x
4 B Footrests - Flip-up mechanism
- Lower leg length setting
- Angle adjustment
x
x
x
x
x
x
4 C Seat - Crossbrace
- Seat upholstery
- Seat cushion
x
x
x
x
4 D Back / push handle - Back upholstery
- Back tubes
- Angle adjustment
- Fold-down mechanism
- Push handles
x
x
x
x
x
x
x
x
x
Back accessories - Side thoracic support x x
4 E Side panel - Height setting
- Swivel mechanism
x
x
x
x
4 F Caster - Tires (wear)
- Caster journal angle
- Screw connection of the caster
journal bearing
- Running behavior of the wheels
- Swiveling of the wheel forks
x
x
x
x
x
x
x
x
4 G Rear wheel - Tires (wear)
- Air pressure
- Running behavior of the wheels
- Spokes
- Push rings
- Quick-release axles
- Rear wheel adapter
x
x
x
x
x
x
x
x
x
x
x
Rear wheel accessories - Drum brakes
- Spoke protectors
x
x
x
x
4 H Brake / wheel lock - Brake function x x
Brake / wheel lock accessories - Wheel lock lever extension x x
4 S Accessories - Tray
- Lap belt
x
x
x
x
Do the settings of the
wheelchair comply with the
user's requirements?
Maintenance performed by: on:

9
4 Settings / Replacement / Retrofit
Replacing the frames
In order to replace one or both frames, you first have to
remove all component groups and accessories which
are connected to the frame.
- Central unit according to drawing,
- footrests (refer to section 4.B),
- crossbrace (refer to section 4.C),
- back/upholstery/push handles (refer to section 4.D),
- side panels (refer to section 4.E),
- casters and caster journal bearings (refer to section 4.F),
- rear wheels and rear wheel adapters (refer to sec
tion 4.G),
- and brakes / wheel locks (refer to section 4.H).
It is advisable to start with disassembling the acces-
sories which are attached to the frame, i.e. anti-tipper,
transport wheels or crutch holder. All parts mounted to
the frame are attached with screws.
Replacing the cap
There is a cap a the tube end, which can be cut open
when damaged using a blade and pulled off the tube
end. Put the new cap on the tube end (arrowed).
Replacing the support brackets
Swing the side panel to the rear and loosen and remove
the cap screw in the support brackets. Remove the
support brackets from the frame.
For reassembly, please proceed in reverse order.
Use new, self-locking screws.
4.A - Frame
Replacement / Retrot / Setting of the swinging
anti-tipper
Loosen and remove the screw connections (arrowed)
and remove the anti-tipper holder from the frame.
For reassembly, please proceed in reverse order.
Use new, self-locking nuts.
For setting the anti-tipper please observe the information
given in the instructions for use manual.