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.

10
Replacing the central unit
First disassemble the rear wheel adapter as described
in section 4.G.
Also remove all frame accessories as described in the
preceding section. Loosen all screws of the central
unit, remove the back tubes by pulling them up and
then remove the central unit from the frame by pulling
it to the back.
For reassembly, please proceed in reverse order.
Replacing the reinforcement sheet
In order to remove but the reinforcement sheet the
standard rear wheel adapter must be removed. Then
loosen all screws on the reinforcement sheet and
remove the sheet.
For reassembly, please proceed in reverse order.

11
4.B - Footrests
Replacing the footrests with footrest holders
Insert the footrest holders – in outwards turned
position (approx. 30°) – from above into the footrest
receivers.
Turn the footrest holders to the front until the swivel
segment engages with the lock.
For disassembly, please proceed in reverse order.
All footrests fit into the receiver without having to ex-
change any parts.
Replacing the footrest receiver
Loosen and remove the two screws and remove the
footrest receiver from the frame.
For reassembly, please proceed in reverse order.
Use new screws with thread lock.
Replacing the pivot bearing
Loosen and remove the screw and remove the pivot
bearing.
For reassembly, please proceed in reverse order.
Use new screws coated with thread lock.
Replacing the swivel segment
Remove the footrest holder from the frame.
Loosen the set screw on the inner side of the swivel
segment and remove the footrest bar by pulling it
downwards.

12
Now you can also pull off the swivel segment and put
down the parts as shown in the photo.
Pay attention to the clamp piece, which is only
laid in.
For reassembly, please proceed in reverse order.
Before putting the parts together, lay the clamp piece
into the opening of the frame tube as shown in the
photo.
Use new set screws coated with thread lock.

13
Setting or replacing the calf pads of the elevating
footrests
After loosening the screw in the clamping unit the calf
pad can be adjusted in height.
After completely loosening and removing the screw
connection the calf pad can be removed.
For reassembly, snugly tighten the screw connec-
tions.
Setting the lower leg length / Replacing the footrest
bar in case of footrests with footrest holder
After loosening the set screw the footrest bar can
be adjusted or completely pulled out of the footrest
holder.
Adjusting the angle of the plastic footplate
Loosen the lower screw of the two screws on the
footplate holder as shown in the photo and move the
footplate to the desired angle position. Then clamp the
footplate again by tightening the screw.
Setting the lower leg length / Replacing the footrest
bar in case of elevating footrests
After loosening the screw (arrowed) the footrest bar can
be adjusted in length. After loosening and removing the
screw the footrest bar can be pulled out completely.

14
Replacing the pad of the amputation legrest
Loosen and remove the screws on the clamp piece
and remove the calf pad.
For reassembly, please proceed in reverse order.
The clamp connection can also be used to change the
pad's mounting height.
Replacing the plastic footplates
Loosen and remove the screw and remove the foot-
plate.
In order to also remove the joint piece from the footrest
bar, the two screws on the outside must be loosened,
refer to "Adjusting the angle".
For reassembly, please proceed in reverse order.
Use new, self-locking screws and nuts.
Replacing / Setting the aluminum footplates (M4)
After loosenging the screw connection the footplate
can be pulled off the support.
For reassembly, please proceed in reverse order.
Attaching an amputation legrest
The amputation legrest is inserted from above into the
footrest receiver in the place of a footrest.
For adjustment of the amputation legrest the same
angle adjustment system with lever release is used as
with the elevating footrest.

15
4.C - Seat
Replacing the center crossbrace mounting kit
Loosen and remove the screws as shown in the
photo and pull the plastic half-shells out from be-
tween the crossbrace tubes.
For reassembly, please proceed in reverse order.
Use new, self-locking nuts.
Attention: With removal of the central screw connection of the mounting kit, the stability of the crossbrace
and frame gets lost. Attach a new mounting kit before moving the chair.
Replacing the seat upholstery
First remove the front end stoppers using a (not too
sharp-edged) screwdriver.
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.
For reassembly, please proceed in reverse order.
Replacing the crossbrace brackets
After loosening and removing the screw connection you
can unclip the crossbrace bracket from the frame and
replace it.
Please pay attention to the scale as decribed above.
Scale on the crossbrace bracket
The crossbrace brackets are provided with a scale
showing the appropriate setting for the correspond-
ing seat width.

16
Retrotting with the seating system "Adjustable
Seat"
Please observe the information given in the product's
instructions for use manual 647H450.
Cleaning the seat cushion (example: Evolight)
Open the zipper and remove the foam core and the
spacer fabric. Clean the cushion cover according to
the sewn in care instructions label.
Cleaning the nylon seat upholstery
Clean the seat upholstery with regular mild household
cleaner.
Adjusting the seat depth
The Start crossbrace allows you setting of the seat depth in three positions in increments of 2.5 cm. To change
the seat depth remove the two plastic clips on the lower frame tube and move the crossbrace on the frame. Insert
the plastic clip into the next bore hole so that the foot of the crossbrace is limited by the two plastic clips.
Be sure to properly engage the plastic clips in the bore holes provided for this after all adjustments.

17
Setting the back upholstery
Please observe the information given in the instructions
for use manual.
After adjusting the back height the straps must be
redistributed. The space between the straps should
not be larger than one strap width (approx. 40 mm).
If necessary, another strap must be added.
Height setting/Replacement of the back tubes
The back tube which is integrated into the posterior frame
allows for the adjustment of the back height in increments
of 2.5 cm. Remove the uppermost screw in the central unit
and move the back tube to the desired position.
In this way, the back tube can also be removed completely
from the holding device.
Attention: Be sure that the back tube is seated
properly. It is of utmost importance to firmly retighten
the screws of this safety-relevant part!
4.D - Back / Push Handles
Replacing the rubber hand grips
Carefully cut open the rubber hand grip and remove the
old rubber hand grip. Using a knife remove the residue
of the old glue or rubber from the handle surface and
from inside the tube. Using a clean cloth and solvent,
fully degrease the ends of the push handle tubes.
Open the two part adhesive sachet. Observe the instruc-
tions given by the manufacturer of the adhesive.
Use the spatula to squeeze out all the contents of the
sachet into the center of the mixing card. Mix the ad-
hesive using the spatula.
Ensure you work effectively after mixing, since the
adhesive sets quite quickly. Apply half of the adhesive
into each of the rubber hand grips using the spatula.
Evenly distribute the adhesive in the rubber hand grip
up to a depth of approx. 4-5 cm. Slide the rubber hand
grips onto the push handles rotating them slightly as
they are pushed on.
Attention:
Now wait for at least 24 hours so as to allow full
curing of the adhesive.

18
Replacing the standard back upholstery
Remove the back tubes as described in the preceding
section.
Loosen and remove the screw connections at the top
of the back tubes.
Pull the upholstery downwards off the back tubes.
For reassembly, please proceed in reverse order.
To replace the frame element with the different locking
positions, loosen the screw on the inner side of the back
tube and completely remove the element.
For reassembly, please proceed in reverse order.
Replacing the back angle adjustment mechanism
To replace the release cable, loosen the spring bolt
with your hand or using an open-end wrench and pull
the bolt out of the eyelet.
If you only want to replace the cable, remove the O-ring
from the device by turning (key ring principle).
To completely replace the back angle adjustment
mechanism, unlock the back and fold it down onto
the seat surface as for transporting. Loosen the
three screw connections which connect the back
angle adjustment mechanism to the frame and re-
move the adjustment mechanism.
For reassembly, please proceed in reverse order.

19
Retrotting with the back system "The Back"
Please observe the information given in the product's
instructions for use manual 647H491.
Replacing the fold-down back tubes
To completely replace the back tubes, please proceed
as described under "Height setting/Replacement of the
back tubes" beschrieben.
To replace the fold-down mechanism, loosen the two screws
below as well as the two screws above the hinge and pull
the hinge out of the two tube ends.
For reassembly, please proceed in reverse order.