progeo MOTOTRONIK User manual

REHATEAM s.r.l.—vicolo Negrelli 5—31038 Castagnole di Paese TV—www.rehateamprogeo.com Service Manual MOTOTRONIK 1
S E R V I C E M A N U A L
MOTOTRONIK
Rev. 0 - 2021/12
SERVICE MANUAL
ENGLISH

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SERVICE MANUAL
MOTOTRONIK
GENERAL WARNINGS
ANY ADJUSTMENT CAN BE CARRIED OUT EXCLUSIVELY BY QUALIFIED AND AUTHORIZED
BY REHATEAM S.R.L. PERSONNEL.
It is forbidden to carry out any modifications to the Mototronik, even when possible, to the original
design.
Any adjustments and/or any modification that is carried out by non-authorized personnel will
immediately void the warranty on the product and it relieves Rehateam s.r.l. from any responsibility
on any malfunctioning and/or damage due to such adjustments/modifications.
Always contact Rehateam s.r.l. and its technicians for any non-standard requirements or
modifications to allow them to evaluate such modifications and verify that they will not compromise
the normal and safe use of the wheelchair.
Any adjustment of the Mototronik could seriously compromise the safe use of the combination with
the wheelchair causing damage to both the user and the wheelchair itself.
After every adjustment made to the Mototronik, check carefully that all parts are correctly fixed.
Check that all screws and nuts are tightened and that all moving parts are functioning correctly.
After any adjustment, always test the Mototroink combined to with wheelchair before giving the
product to the user.
Rehateam s.r.l. disclaims any responsibility for damage to the product, to any object or to people
due to any modification that is not properly performed or that, in any case, does not guarantee
safety to the user.
The Mototronik device is compatible with most of the manual wheelchairs in the market, neverthe-
less, it is always advisable to consult Rehateam s.r.l. and/or the wheelchair’s manufacturer to know
about the actual compatibility or possible directions to be followed.

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SERVICE MANUAL
MOTOTRONIK
CONTENTS
Page Title
4 DESCRIPTION OF PARTS
5 GENERAL INFORMATION
7 NECESSARY TOOLS
8 MOTOR UNIT ASSEMBLY
WITH STANDARD HANDLEBAR
10 MOTOR UNIT ASSEMBLY
WITH ”TETRA” HANDLEBAR
11 CLAMP ASSEMBLY
12 COUPLING PAD
ASSEMBLY AND ADJUSTMENT
14 COUPLING FORK ASSEMBLY
15 CHECKING THE CONNECTION FRAME’S ARMS
16 CONNECTION FRAME’S ARMS
SIZES AVAILABLE
17 CONNECTION FRAME ASSEMBLY
17 —COUPLING UNIT
18 —ASSEMBLY OF ARMS ON COUPLING UNIT
19 —ASSEMBLY OF CONNECTION FRAME TO WHEELCHAIR
20 —WIDTH ADJUSTMENT
21 —DEPTH ADJUSTMENT
22 COUPLING SUPPORT ADJUSTMENT
23 FINAL ADJUSTMENT
25 CONTROL TOOLS
STANDARD HANDLEBAR
26 CONTROL TOOLS
”TETRA” HANDLEBAR
27 BRAKE LEVER
STANDARD HANDLEBAR
28 ACCELERATOR GRIP
STANDARD HANDLEBAR
29 DISPLAY
30 SPOILER
30 —REMOVAL/MOUNTING
31 —FITTING
32 LED HEAD LIGHT
33 STANDARD HANDLEBAR ADJUSTMENT
35 “TETRA” HANDLEBAR ADJUSTMENT
36 STEM EXTENSION
STANDARD HANDLEBAR
44 STEM EXTENSION
”TETRA” HANDLEBAR
Page Title
45 DISK BRAKE CABLE ADJUSTMENT
STANDARD HANDLEBAR
46 DISK, CALIPER and BRAKE PADS
POSITIONING AND ADJUSTMENT
47 BRAKE CALIPER
POSITIONING AND ADJUSTMENT
49 BRAKE DISK
REPLACING AND CETRING
50 BRAKE PADS
REPLACEMENT
52 REMOVING/ MOUNTING THE WHEEL
53 TYRE AND TUBE
REPLACEMENT
55 REMOVING / MOUNTING THE MUD GUARD
56 EASY RELEASE LEVER
57 BALLASTS
58 BASKET
61 REMOVING/MOUNTING THE ELECTRONIC UNIT
62 REAR VIEW MIRROR
63 SETTINGS
PARAMETRI DI GUIDA
65 TYPES OF CLAMPS AND ASSEMBLY
FOR WHEELCHAIR MODEL
65 —PROGEO

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SERVICE MANUAL
DESCRIPTION OF PARTS
1. Spoiler
2. Battery
3. Two cane frame
4. Fender
5. Steering wheel
6. Motor unit
7. Brake disk
8. Disk brake caliper
9. Stand
10. Connection frame
21. Electronic brake button
22. Acceleration lever
23. Handlebar “Tetra”
24. Arm (ambidextrous)
25. Arm’s fixing clamp
26. Coupling support
27. Connection frame’s central tube
28. 12” motorised wheel
29. 14” motorised wheel
11. Clamps (fixed to the wheelchair’s frame)
12. Coupling fork
13. Lock lever
14. Handlebar
15. Manual wheelchair
16. On/off and settings switch
17. Driving direction and cruise control switch
18. Bell
19. Display
20. Brake lever
8 9 10 11 12 13
1
2
3
4
14 15
24 12
25 26 27
28
29
11
21 22
16 17 18 19 20 16 17 19 18 21
23

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SERVICE MANUAL
GENERAL INFORMATION
RIGID FRAME WHEELCHAIR
FOLDING WHEELCHAIR WITH
FIX FRONT FRAME
FOLDING WHEELCHAIR WITH SWING-AWAY,
REMOVABLE FRONT FRAME
The assembly of the clamps is always base on the same principle, that is, they must be mounted to a fixed part thus, not to the removable
footplate frame, for instance) of the folding or rigid wheelchair’s frame.
The positioning the clamp along such fixed part is variable and it depends on the model of the wheelchair that, according to its frame tube’s
section, also determines the type of the clamp and the suitable assembly - See also last chapter of this manual, sheet “CLAMPS TYPE
AND ASSEMBLY PER MODEL OF WHEELCHAIR”
The assembly procedure of the MOTOTRONIK system is always the same, but, according to the wheelchair, it is necessary the proper ad-
aptation and adjustment.
The instructions for the proper installation take as reference what we may call “standard” installation.
Nelle istruzioni di montaggio appariranno delle note con utili informazioni.
In the standard assembly instructions, you will see notes with useful information.

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SERVICE MANUAL
GENERAL INFORMATION
The clamp positioning in height depends on the wheelchair model and on its configuration: the front seat height, in particular, determines,
according to the usable stretch of frame where you can fix the clamps, the lowest and highest fixing point.
The longer the usable stretch, the greater the vertical adjustment.
If the clamp fixing point is one only point (fix point), there will be no vertical adjustment.
In this drawing, X1and X2show the points within which you can fix the clamps; H1and H2are two different front heights, whereas min.
max. indicate the clamp positioning heights.
The range between X1and X2can help to adjust the connection frame to a more convenient angle.
If X1(or X2) is a fix point, the connection frame inclination will depend on the final assembly of the device.
You can insert the connecting frame horizontally (fig. aand b), “downhill” (fig. c) and also “uphill” (fig. d).
That depends on the height positioning of the clamps and on the coupling forks X orientation: facing down ↓or facing up ↑.
In any case, the system works in the same manner.
The connection frame inclination will be the result of the combination of all parts involved in the installation.
X

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SERVICE MANUAL
NECESSARY TOOLS

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SERVICE MANUAL
MOTOR UNIT ASSEMBLY
WITH STANDARD HANDLEBAR
ASSEMBLY OF HANDLEBAR AND DISPLAY
Remove the four bolts of the stem’s head and remove the head.
Lean the central part of the handlebar onto the stem paying attention not to twist the
cables.
Lean the stem’s head and fit the two bolts on the lower side.
Make sure the assembly side is correct, that is, with the brake lever facing forward.
Align the display support’s holes with those of the stem and screw the two bolts all
the way down.
Center the handlebar by taking the marks as reference - if necessary, loosen the
two bolts that also fix the display.
Turn the handlebar to the position you may consider initial.
Tighten the two bolts that also fix the display and then the other two..
UNPACKAGING
Remove all packaging elements as carefully as to avoid damaging any part of the product.
If you use scissors or a cutter, pay attention not to cut any cables or scratch any part.
STAND
Insert the stand - see also the user’s manual - and remove the spoiler to make the following steps easier.
Follow next page

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SERVICE MANUAL
MOTOR UNIT ASSEMBLY
WITH STANDARD HANDLEBAR
CABLES CONNECTION
The rear side of the display shows four different coloured sockets that should match with the same coloured plug to connect.
Be careful when fitting the plugs, in fact, there is one only position that allows the connection: the groove on the plug, that is externally indi-
cated by the arrow on the rubber cover, should fit along the tooth of the socket.
Light blue: accelerator cable; Black: power cable; Green: headlight
It is advisable to cover the unused sockets with the rubber cap.
Within the cables holder bag (or sticking out of it) you will find two
other plugs: one light blue and one red; these are not used and,
as long as it is possible, you should stow them within the bag.
BATTERY
Insert the battery - see also user’s manual.
SWITCH-ON TEST
Switch the battery on.
Switch the display on.
Lift the driving wheel and try to accelerate and brake.
Switch off the display and then the battery.
See also user’s manual.
Before using the device, you need to centre the handlebar (with
respect to the driving wheel) and make sure the bolt B is hard
tightened—see sheet “STANDARD HANDLEBAR ADJUSTMENT
—1 post height”
B

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SERVICE MANUAL
MOTOR UNIT ASSEMBLY
WITH “TETRA” HANDLEBAR
Follow the instruction of the sheet “MOTOR UNIT ASSEMBLY - with standard handlebar” and the following directions.
Make sure the assembly side is correct, that is, with the accelerator lever Aon the right hand side; this way, by turning the handlebar down-
ward, you accelerate, whereas, by turning it upward, you will activate the brake.
Pay particular attention to the route of the cables that should be as rational as possible and without squeezing them; furthermore, the brake
cable, should not form tight curves.
Stow the cables in the cable holder bag Bin such a way to leave out just the necessary. This operation may require a little of patience and ,
if needed, fit one cable at time detaching the plug and then plug it back after routing it rationally, that is, avoiding entanglement, squeezing
and stretching. Plugs and sockets should always be matched according to colour and their fitting is guided by the arrow on the plug’s rubber
cover —see also sheet “DISPLAY”.
The support Cfor the display has a longer fixing plate.
A
A
B
B
C
C
To activate the brake
To accelerate

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SERVICE MANUAL
CLAMP ASSEMBLY
Mount the two clamps so that its mid-line in front is approximately between 32 and 35 cm form the ground and check they are at the same
height (it is advisable to use a rod and spirit level).
Should be impossible to fix the clamps at that height, just position them where possible according to what the wheelchair and its configura-
tion allow for.
Screw up the bolt A5 until the two parts touches and unscrew it by half of a turn to keep them sligtly apart.
Then, tighten the two bolts A4.
On some models, the assembly has the clamps facing frontward (therefore, opposite to
the standard assembly). The assembly instruction is very much the same, but the hole
A2 may be above the mid-line. See also last chapter of this manual, sheet “CLAMPS
TYPE AND ASSEMBLY PER MODEL OF WHEELCHAIR”
A3
A5
OUTER SIDE OF THE WHEELCHAIR INNER SIDE OF THE WHEELCHAIR AERIAL VIEW
A1
A2
A1
A4 A5
A3
A1
C
B
B2 B1
A4
A5
A2
A
The clamps A, are symmetrical to one another and, except for specific
cases, they can be mounted both on the right and on the left side of the
wheelchair.
The external face A1 has an off-set threaded hole A2 which, according to
the assembly, will result to be above or below the clamp’s mid-line.
In most cases, the clamp is mounted with the hole A2 below the mid-line as
shown hereafter.
Position the clamp on the frame so that its externa face is facing backward
and parallel to the driving line of the wheelchair (to be checked, especially,
when fixing on round tubes), with the threaded hole A2 below the mid-line.
Now mount the plate A3 and fit the bolts A4 A5 on the clamp.
Follow next page

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SERVICE MANUAL
COUPLING PAD
ASSEMBLY AND ADJUSTMENT
A3
The coupling pad Bis fixed to the clamp Awith the bolts B1 (M8 x 20 mm) and
B2 (M8 x 30 mm)
The pad’s rounded side should be facing frontward.
The bolt B1 screws into the clamp’s threaded hole A2, whereas the bolt B2 goes
through the slot A6 and screws into the one of the two holes of the hexagon C.
Screw the bolt B1 all the way down without tightening; this way, you will be able
to swing the pad with no effort and, consequently, to easily fix the bolt B2 to the
hexagon.
The six sides of the hexagon are marked with the numbers from 1 to 6, while
the two faces, marked with the letters A and B, have the two threaded holes
(for fixing the bolt B2). In total, 12 possible fixing position.
12
B1
B2
Rounded side
B
Side number
Face letter
For the inner side of the clamp, fit the hexagon into the housing and screw the bolt B2 into either of the two holes.
Before fully screwing the bolt, make sure the upper and the lower sides of the hexagon are completely leaning on the housing’s walls.
If not, you can either change hole or, as in the example below, if you need to keep the same coupling pad inclination, reverse the hexagon
horizontally (from face A to B, or vice-versa) and keep the same side and the same hole.
B2 B2
5
A
B2
5
B
Follow next page
B1
B2
A2 A6
A
C
Rounded side

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SERVICE MANUAL
COUPLING PAD
ASSEMBLY AND ADJUSTMENT
A3
As initial position, it is advisable to adjust the coupling pads at an intermediate inclination between minimum and maximum, in
fact, il will be useful during the next installation steps; you will make the final adjustment afterward.
If the clamp is mounted facing to the front of the wheelchair, the
assembly is the same, but make sure the rounded side of the pad is
facing frontward.
To fix the second pad, replicate the fixing of the first pad symmetrically, that is, using the same side (1, 2 , 3, 4, 5 or 6) and the same hole,
but the opposite face (A or B).
Accordingly, if letter A on the hexagon is visible on the right clamp, then the letter B should be visible on the left clamp.
This way, the two pads will be fixed at the same inclination that can be taken as initial. You will probably need to adjust it later.
It is advisable to start with a mid way inclination as in the pictures, just ensure right and left side are equally adjusted.
Tighten the bolts that fix the two pads..
Rounded side
B2
B
B2
A
Minimum inclination Maximum inclination Minimum inclination Maximum inclination
A2
A2
Front of wheelchair

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SERVICE MANUAL
COUPLING FORK ASSEMBLY
A3
The coupling forks Dshow, on one side, a half-moon housing D1 that couples the shape of the pad B, while, on the opposite side, a round
housing D2 for the washer E1 of the lock lever E; on this last side the plate D3 and related bolts D4 are meant to fix the connection frame’s
tubes.
The two forks are not ambidextrous, but you can mount them both on the right and on the left hand side, thus, the connection frame’s tube
can either be above or below the clamp A.
Insert and screw the lever E into the hole B3 leaving approximately a 10 mm gap to allow sliding the fork in.
Slide the fork in and lock it with the lever.
D
D3 D2
D1
D3
D4
E1
E
≈ 10 mm
XX cm
Due to the several variants that affect
the final adjustment of the complete
system, you may need to reverse the
fork assembly regardless the instruc-
tion here reported.
B
A
B3
The lever’s washer must
couple with the round
housing of the fork.
If the positioning in height of the clamps is lower than 34 cm, mount the forks with the tube low fixing (D↓ );
If the positioning in height of the clamps is higher than 34 cm, mount the forks with the tube high fixing (D↑);
34 cm
> 34 cm
< 34 cm
D↓
D↑

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SERVICE MANUAL
CHECKING
THE CONNECTION FRAME’S ARMS
Loosen the three bolts D4 of the plate and slide in
the tube F1 of the arm F.
Screw the bolts just enough to eliminate the play
but without preventing the tube from being moved.
Repeat the same operation on the other side.
Now position the two arms so as to be able to
check whether, at the same height, inclination and
depth, they are horizontally aligned.
Also check that the distance between the two arms
is at least 25 mm, but not more than 190 mm.
Finally, unscrew the lever and remove the unit
arm/coupling fork.
Min. 25 mm
D4
F1
F
IF THE TWO ARMS ARE NOT ALIGNED,
check that the two coupling forks are well fixed with the locking levers and that the three bolts D4 of the clamps that fix the tubes do not
allow any play to the tubes themselves. If this is not enough, it is necessary to fix the clamps fixed to the frame.
If the tube on which the clamp is fixed is round, slightly loosen the clamp bolts A4 and A5 and
leverage the arm until alignment. This may be necessary for one or both sides.
Once alignment is achieved, tighten the clamps tightly.
If the tube on which the clamp is fixed is NOT round, you need to give the external side of the
clamp a compensation move by working on the three fixing bolts.
Loosen the bolt A5 hall a turn, tighten the two bolts A4 and check the alignment of the arms.
If that is not enough, repeat the same operation by another half of a turn of the bolt A5.
If the result is opposite to what expected, repeat the same operation, but start with loosening the
bolts A4 and then tightening the bolt A5.
This operation may be needed for one or both sides and it may not lead to a perfect alignment,
however, a few millimetres tolerance is acceptable.
Finally, tighten the clamps.
If the arms are too wide, you can cut off the exceeding part; on the other hand, if they are too narrow, you need to replace them
with wider ones.
We will check the length of the tubes later on.
See chapter “FRAME CONNECTION’S ARMS” for further information on sizes of the arms.
A4
A5
Few mm tolerance

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SERVICE MANUAL
CONNECTION FRAME’S ARMS
SIZES AVAILABLE
The connection frame’s arms are available in three widths and two lengths.
f necessary, you can cut both the steel round tube and the aluminium sqaure tube.
Always put the cap into the steel tube end to avoid scratching the surface you will lean the device on.
X Y
NARROW 16 SHORT 25
LONG 35
MEDIUM 21 SHORT 25
LONG 35
WIDE SHORT 25
26 LONG 35
If you need to cut the tubes:
• When using the Mototronik, the square tube must be inserted (and tightened) into connection frame’s central tube for at
least 30 mm, otherwise the stability of the system is not guaranteed.
• The steel round tube must always be embraced along the entire width of the clamp; the exceeding part may be cut off until
reaching the line of the rearmost side of the clamp.
Min. 30 mm
Exceeding part
Clamp
width
56 mm
16 cm
21 cm
26 cm
35 cm
25 cm
X Y
The size Y includes
the L-shaped tube.
The length of the
straight tube is 310
or 210 mm

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SERVICE MANUAL
CONNECTION FRAME ASSEMBLY
COUPLING UNIT
Mount the plate on the coupling
support by just fitting the bolts on
the 4 corners and making sure
the hole in the middle is aligned
with that on the coupling support.
Position the coupling support so
as to be able to fit the remaining
bolt that can pass only through
G
G1
G2
H TOOTHED PART
SMOOTH PART
GROOVE
TOOTHED
PART
Now, making sure the toothed side of the central tube fit to that of the coupling support, turn the unit coupling support/plate until positioning
their joining parts where the smooth and toothed sectors of the tube begins/ends.
Screw the bolts until fixing the parts, no need to tighten hard now.
Do not put the central bolt, you will fix it after final adjustment of the entire system.
Consider this position as initial reference because you will probably need to change it in a following step of the installation.
The coupling support G is fixed to the frame connection’s central tube Hby means of the plate G1 and the bolts G2.
The central tube shows two sectors with a wider diameter separated by a groove that determines the centre of the tube itself
Half of such sectors is smooth, whereas the other is toothed and it is designed to adjust and fix the coupling unit that, on its turn, has a cou-
pling toothed section.
Follow next page
G
G1
H
Without bolt
This unit may be
supplied assembled.

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SERVICE MANUAL
CONNECTION FRAME ASSEMBLY
ASSEMBLY OF ARMS ON COUPLING UNIT
Insert the two clamps Ithat fix the arms so as the bolts I1 are, for convenience, facing down front and insert the two arms facing backward
and in such a way that the coupling unit is approximately perpendicular to the connection frame (the other three positions given by the
square section clearly results wrong).
Now the two clamps and the arms are free to move and they are ready for the next step of installation.
Even the coupling forks, in this phase, be them facing down (as in the pictures here below) or up, are not securely fixed.
Follow next page
≈ 90°
I I1
D
I1
I
I1
anteriore
posteriore
F
F2

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SERVICE MANUAL
CONNECTION FRAME ASSEMBLY
ASSEMBLY OF CONNECTION FRAME TO WHEELCHAIR
You can now fit the connection frame to the wheelchair.
It is necessary that the two coupling pads A are always tilted at the same inclination; you can do that in two ways:
1) adjust and fix the pad at the same inclination —see chapter “assembly and adjustment of the coupling pads”;
2) for each pad, unscrew the bolt A2 and remove the hexagon C(do not remove the bolt); loosen the bolt A1 and swing the pad to its maxi-
mum upward inclination and tighten the bolt; this way, the pad is free to swing once you insert the connection frame.
It is suggested the second method because you will need to adjust the pad inclination in the next step of installation.
Slide the two arms in or out of the central tube to make the connection frame wider or narrower until being able to fit the coupling forks to the
pads. Make sure the lock lever Fis enough unscrewed to allow the
D
F
H
I
≈ 10 mm
B
E
E D

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SERVICE MANUAL
CONNECTION FRAME ASSEMBLY
WIDTH ADJUSTMENT
For each side of the system, loosen the bolts D4 and then tighten the lock
lever to secure the coupling fork.
This way the forks will match the inclination of the clamps A.
Position the clamps Iover their housing on the central tube and, making use
of the reference marks on the arms, centre the central tube and temporarily
tighten the bolts I1.
Now, unscrew the lock levers and remove the connection frame.
You will notice that it is a bit hard because you have just adjusted the system
with the coupling fork pressed against the clamps.
You then need to adjust the width of the connection frame in such a way to
allow for an easy fitting and removal.
Loosen the bolts I1 and move the arms sideward until reaching a 0.5~1 mm
gap between fork and clamp.
Check the central tube is centred.
Tighten the bolts and check the connection frame is easy to insert and re-
move.
Follow next page
I
D4
A
I1 I1
0.5 ~1 mm
DO NOT move the arm out ex-
cessively (more than 2 mm) be-
cause, when you screw up the
lock lever, the tubes flex to reach
the proper coupling position,
therefore, the wider the connec-
tion frame, the more flexion the
tubes require, and the system
will results more difficult to fix.
It is advisable to spread a
drop of mild lock thread
glue on the bolts D4.