Rehab HD Balance Series Manual

HD Balance - Comfort Wheelchair
Technical Information | English
HD Balance 24 & 16.

© 2012 HANTVERKSDESIGN & REHABILITERINGSPRODUKTER AB
WE MANUFACTURE QUALITY OF LIFE
HD Rehab helps people achieve an improved quality of life. Our products make the
lives of users, their families, and their caregivers easier, safer, and more comfortable.
HD Rehab offers aids for people living with disability. We have designed, developed, and
manufactured comfort wheelchairs for over 40 years. We never compromise when it comes to
quality. Precision, safety for users and caregivers, function, and comfort are important bywords
for us. We are condent that whatever other wheelchairs you try, you will be able to feel the
difference.
GLAD TO BE FLEXIBLE
Whether you are a user, a family member, a technician ,or a caregiver, we welcome your
requests and opinions. Our designers and developers work closely with each other and with
the production team at our Lidingö base. Our skilled employees use their specialist knowledge,
experience, and creativity to nd solutions for the unique needs of each individual user.

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HD BALANCE | Technical Information
TABLE OF CONTENTS
1 General Information 4
1.1 Important documents 4
1.2 Lubricants and Threadlockers 4
1.3 Finishes 4
2. Chassis Construction 5
2.1 Chassis configuration options 5
2.2 Change of back frame 5
2.3 Change of seat frame 5
2.4 Change of balancing plates 6
2.5 Enabling increased tilt 7
2.6 Change of tilt rod and tilt lock 7
2.7 Change from gas spring to rod for
fixed back angle 8
2.8 Replacing a defetive gas spring 8
2.9 Drive wheel and cross tube positions 8
3. Construction of Various Components 10
3.1 Disc brake system 10
3.1.1 Adjust of disc brakes 10
3.1.2 Change of cable 10
3.1.3 Change of brake pads and/or brake disc 10
3.2 Tire brakes 11
3.2.1 Assembly 11
3.2.2 Adjustment 11
3.3 Seat tilt - Controls and tilt lock 11
3.3.1 Adjustment of cable 11
3.3.2 Change of cables and controls 11
3.3.3 Change of cable alone 12
3.4 Recline - Controls and Gas spring 12
3.4.1 Adjustment of cable 12
3.4.2 Change/assembly of cable and controls 13
3.4.3 Fixed back angle 13
3.5 Drive wheel attachment 13
3.5.1 Change of wheel axle 13
3.5.2 Wheel axle quick release 13
3.6 Castors 13
3.6.1 Change of castor fork 13
3.6.2 Change of castor 13
3.7 Armrest 14
3.7.1 Height adjustment mechanism 14
3.7.2 Depth adjustment mechanism 14
3.7.3 Change of armrest pad 14
3.8 Leg rest 14
3.8.1 Knee joint attachment 14
3.8.2 Change of knee joint inner pad 15
3.8.3 Change of knee joint outer pad 15
3.8.4 Change of leg rest tube 15
4. Accessory Information 15
4.1 Electrical actuator 15
5. Overview Diagram 16
Document information 16

4HD BALANCE | Technical Information
1 General information
HD Balance is a comfort wheelchair intended for users who need excellent support and comfort
in their daily routine. The back and seat can tilt in different positions to give the user a variety of
seating options for activity and rest.
HD Balance is a Medical Device Class 1 per the Swedish Medical Products Agency.
1.1 Important Documents
The following documents are good to have available when working with an HD Balance:
95431-1 Information about custom-made products
Information about regulations for adaptations and modications of medical
products.
95707-1 Risk information about special congurations and accessories for HD Balance
Information about increased risks when using certain special congurations
and accessories.
95758-1 Reference table - balancing modes
Information on the consequences of different balancing congurations. E.g. if
restrictions exist, or if further modications to the wheelchair are required.
95759-1 Reference table balance congurations
Table of which balancing congurations are allowed on different models and
with different designs.
95764-1 Labeling - HD Balance
Contains information about which labels are to be found on an HD Balance.
95730-1 Maintenance Schedule
1.2 Lubricants and threadlockers
The following table details recommended lubricants and threadlockers:
Usage area Lubricant /Threadlocker type Product used by HD Rehab
General lubrication of sliding
surfaces etc.
Synthetic food grade grease Fuchs Cassida EPS 2
Vendor: Ikaros AB
Tilt lock / tilt rod
Wheel attachments (internal)
Thin long-lasting synthetic
lubricating oil
Zee Zyynth Oil
Vendor: Chemlight Systems AB
Knee joint (internal) Penetrating oil with good
adhesive properties, water
repellant
LUBRI 40
Vendor: Chemlight Systems AB
Locking of screws, permanent
e.g. wheel axle pin
High strength threadlocker Loctite 2700
Locking of screws to crossbars etc
that may be removed for repairs
Medium strength threadlocker Loctite 2400
1.3 Finishes
The following nishes are used on HD Balance:
Powdercoat painting. Colour code RAL 9005 Black, gloss 40.
Anodizing.
Nitrocarburizing.

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HD BALANCE | Technical Information
2. Chassis Construction
The HD Balance chassis is constructed of three interacting frames; wheel frame, seat frame, and
back frame. These are attached to each other at a number of points such that desired geometry
for balance, recline, and seat tilt can be achieved. The wheel frame and seat frame are connected
by balance plates. The balance plates are critical to the characteristics of the wheelchair.
The two models, 16 and 24, have identical chassis with the exception of the wheel frame, where
the plates for wheel attachment have different designs.
2.1 Chassis conguration options
The HD Balance chassis can be modied to change the wheelchair characteristics. The standard
conguration is the reference point for any given data in terms of characteristics, function,
measurements, and tests against existing standards. Changes to the chassis conguration come
with both positive and negative consequences. Therefore the standard conguration should be
used wherever possible.
The following modications can be made:
- Change of balancing plates. Provides raised seat height, lowered seat height, or moving
the balance point forward or backward. Described in section 2.4.
- Lengthened seat frame. Provides increased seat depth. Must be selected with initial
wheelchair order, cannot be changed after assembly.
- Increased / Limited tilt. Described in section 2.5.
- Change of tilt rod. Eects tilt range per document 95758-1. Described in section 2.6.
- Change to rod in place of gas spring. Provides a xed back angle between 90 and105
degrees. Described in section 2.7.
- Moving wheel mounting point 50 mm backward. Makes the wheelchair more stable but
with somewhat poorer handling. Described in section 2.9.
2.2 Change of back frame
1. Remove the push handle by pulling it competely out of the back
frame. Be careful with the cables!
2. Remove the back cushion and disassemble back system (Flexi-
back or Fixed back).
3. Release the rear bracket of the gas spring by pulling out the pin
so that the gas spring can be gently removed.
4. Remove the retaining rings on the inside of the back system
attachment points (A, g1). Tap the pins so that the back frame
can be lifted o. NOTE! It is not necessary to remove the pins
completely in order to release the back frame.
5. Remove the back frame and replace it with the new frame.
6. Assemble the new frame by repeating the same steps in reverse
order. Be careful not to damage the retaining rings, replace
them with new rings if necessary!
2.3 Change of seat frame
1. Remove the back frame per section 2.2 steps 1-4.
2. Remove seat cushion, seat board, leg rests and armrests.
3. Remove tilt rod and gas spring per section 2.6 steps 1-5.
4. Remove the screws from both balance plates (A, g 2).
5. Carefully press one balance plate outwards (B) so that
the seat frame can be lifted o. Be careful when the seat
frame comes free as there can be a pinching hazard and
cables can be damaged.
A
Fig 1
B
Fig 2
A

6HD BALANCE | Technical Information
6. Change out the seat frame and re-attach by reversing the
above steps. NOTE! Refer to Figure 3 and be sure that the
bushings (C) that sit between the balance plate (B) and
seat frame (D) are seated in the correct direction! The
longer side must face outwards.
The bolt (E) should be tightened rmly but with moderate
force. After driving the bolt into the lock nut (F) check that
the armrest bracket is working properly. If there is any
doubt the nut should be replaced by lifting the armrest
out of the frame (G). Take care that the inner washer (H)
does not fall out.
Check that the seat frame turns easily between the
balance plates.
2.4 Change of balancing plates
When changing the balancing plates it must always be ensured that the wheelchair conguration
follows the guidelines from HD Rehab. The congurations that are approved are detailed in
document 95759-1. Commentary on limitations and other adjustments that must be made is
found in document 95758-1. Risk information is given in document 95707-1.
NOTE! The balancing plates cannot be changed if the wheelchair is equipped with electric tilt.
Always read this before commencing work and have it at hand during the process!
PARTS INCLUDED: Balancing plates, screws for movement of cross tubes (as required), new tilt rod (as required)
Change and assembly of balancing plates is done as follows:
1. Remove wheel and take o brake cable from wheel mount, per section 3.1.2 steps 1-3.
2. Remove armrest and back and seat cushions, fold back into transport position.
3. Loosen the tilt rod as follows:
- Unscrew the lower stop ring and remove it.
- Tilt the wheelchair backwards until the tilt rod draws completely out.
Be careful with seat and back frames when the tilt rod is released as they
then hang freely in the balance plates and can be a pinching risk!
4. Take apart the tilt lock per section 2.6 steps 7-8.
5. Remove the screws (A, gures 4 and 5) that hold the seat frame in place.
6. With a rm grip on the seat and back frame, carefully press one balance
plate outwards so that the seat frame can be removed from the
suspension. Lift o the seat and back system. Be careful with the cables!
7. Switch to the desired balancing plates by removing the screws (B, g 5),
changing plates, and attaching again with the same screws.
C
G
D
E
FB
Fig 3
H
Standard Raised 5cm Lowered 3cm Moved forward 3cm
Moved backward 3cm
A
Fig 4
A
B
Fig 5

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HD BALANCE | Technical Information
8. Change the tilt rod per the instructions in section 2.6 (if required by the desired wheelchair conguration).
Refer to document 95758-1.
9. Move the rear cross tube to its new position per the instructions in section 2.9 (if required by the desired
wheelchair conguration). Refer to document 95758-1.
10. Reassemble the seat and back frame unit in the balancing plates and tighten the screws, per section 2.2
step 6 and 2.3 step 6.
11. Reassemble tilt lock. Check that retaining ring is in good condition and replace with new ring if necessary.
12. Tilt the seat back and t the tilt rod into the tilt lock. Assemble the stop ring in the correct position for the
desired wheelchair conguration. Refer to document 95758-1.
13. Fold the back up to the normal position and reassemble the gas spring with the pin through
the rear part. Ensure the pin passes through both plates of the mount on the back frame.
14. Reassemble brake cables and check braking function. Put the cushions and armrests in place.
2.5 Enabling increased tilt
Icreased forward tilt to -5 degrees (in some cases less depending
on conguration) and increased backward tilt to 30 degrees can
be achieved by moving the stop rings on the tilt rod. The tilt
rod may also need to be changed to a longer version (refer to
document 95758-1).
Follow these steps to move the stop rings:
1. Check that the tilt lock has locked the tilt rod in a set position rather
than the tilt rod sitting between two positions.
2. Loosen the set screw (A, g 6) that holds the stop ring in position.
3. Move the stop ring to the desired position. Read carefully
in 95758-1 which position is correct for dierent wheelchair
congurations.Note that if the stop ring is moved up from the
lowest hole a screw (C) must be placed in that hole and the set screw
(A) must be replaced by a shorter version (B), and vice versa.
4. If the tilt is increased forward (under 0 degrees) or backward (over
20 degrees) a warning sticker must be attached per document
95764-1 ”Labeling, HD Balance”.
5. Always check the tilt lock is functioning correctly before using the
wheelchair!
2.6 Change of tilt rod and tilt lock
The tilt lock controls the position of the tilt rod depending on the desired seat tilt. The green
tilt lever on the push bar releases the tilt lock via a cable. Follow these steps to change out the
tilt lock and/or tilt rod:
1. Remove leg rests, armrests, seat and back cushions from wheelchair.
2. Fold the back frame into the transport position by releasing the rear
connection of the gas spring.
3. Remove the lower stop ring (tilt the wheelchair backwards to access).
4. Move the seat plate backward and remove one of the retaining rings
that holds the tilt rod and the gas spring (A, g 7). Hold the gas spring and
knock out the pin incrementally such that only the gas spring comes free.
Set aside the gas spring. Take hold of the seat frame and knock the pin out
completely so that the tilt rod comes free.
5. Swing out the seat frame without damaging the cables.
6. Change out the tilt rod and reassemble by reversing the above steps.
B
C
A
Fig 6
Fig 7
A
B

8HD BALANCE | Technical Information
NOTE! The tilt rod must be properly locked in the tilt lock when the fastening
fork of the tilt rod is placed between the plates on the seat frame. If the
fork is twisted and will not pass between the holes, the nut under the fork
must be loosened so that the angle can be adjusted (Refer to Spart Parts
document 95740-1, page A6.1 item 16). Check that the retaining ring is not
damaged and replace if necessary. Pause the reassembly at this point if the
tilt lock will also be changed.
If the tilt lock (B, g 7) is to be changed (requires cable change):
7. Remove the green control lever and housing from the push bar.
8. Remove retaining ring (C, g 8) from tilt lock and pull it out of the bracket.
9. Place the new tilt lock in the bracket and secure with the retaining ring.
Check that the retaining ring is in good condition. Note! The tapped hole
where the wire will be attached must be above the cross tube.
10. Assemble a new cable package per the instructions in section 3.3.2 steps
5-9, or assemble just a new cable per section 3.3.3.
2.7 Change from gas spring to rod for xed back angle
1. Remove cushions, leg rests, and seat plate.
2. Disassemble the back tilt lever (grey) from the push bar.
3. Release the rear connection of the gas spring by pulling out the peg and
folding the back frame forwards. Be carefeul as the back frame can fall
down when the peg is pulled out.
4. Remove the retaining ring from the pin (A, g 9) that holds the front of
the tilt rod and the gas spring. Carefully knock out the pin such that the
tilt rod and gas spring come free but the pin remains partially engaged
and holds the seat frame in place.
5. Replace the gas spring and tilt rod with the desired conguration.
6. Reassemble by reversing the above steps and adjust the cable as
necessary per section 3.4.1.
2.8 Replacing a defective gas spring
1. Remove cushions, leg rests, and seat plate.
2. Release the rear connection of the gas spring by pulling out the peg and
folding the back frame forwards. Be carefeul as the back frame can fall
down when the peg is pulled out.
3. Use a wrench to relese the gas spring (A, g 10) and replace it. Be careful
that all components remain in their correct orientations.
4. Reassemble the back and test that gas spring is functioning correctly.
2.9 Drive wheel and Cross tube positions
The wheel frame cross tube (A, g 11) has three possible positions.
The position must sometimes be changed depending on the chair
conguration or use of certain accessories.
The wheel mount unit has two attachment points with 50 mm
spacing to allow for variation in the wheel base length. The forward
poistion is the standard conguration.
For easier assembly screws can be driven through the large hole in
the disc brake. Be careful when assembling not to damage the disc.
Fig 8
C
Fig 9
A
Fig 10
A
Fig 11
A

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HD BALANCE | Technical Information
In some positions the cross tube is assembled “through” the wheel mount and in others to
the side, as detailed in document 95758-1. Different screw lengths are used for the different
variations. Be careful that the correct screws are used!
The following gures show which type of screws should be used for each mounting alternative.
Note that locking nuts are used for the screws that are not driven into the cross tube, and medium
strength threadlocker (such as Loctite 2400) for the screws that are driven into the cross tube.
Wheel position: FRONT Wheel position: REAR
Cross tube position: FRONT Cross tube position: FRONT
Wheel position: FRONT Wheel position: REAR
Cross tube position: REAR  UPPER Cross tube position: REAR  UPPER
Wheel position: FRONT Wheel position: REAR
Cross tube position: REAR  LOWER Cross tube position: REAR  LOWER
MC6S M8x40
With M8 lock nut
MC6S M8x50 MLC6S M8x25
Cross tube
position

10 HD BALANCE | Technical Information
3. Construction of Various Components
3.1 Disc brake system
The disc brake system (g 12) consists of a disc (g 16) that
attaches to the drive wheel. A caliper (J, g 16) pushes
against the disc when activated by a brake piston (L, g
17). This is controlled by a lever (g 14) via a cable that is
attached to a turntable (D, g 13) which moves the piston.
The cable is of xed length with nipple connections at both
ends.
3.1.1 Adjustment of disc brakes
The brakes are adjusted by moving the cap (A, g 13).
Loosen the nut (B) and screw the sleeve out for more
braking force, in for less braking force. Tighten the nut
(B) after the adjustment. NOTE! Handle sleeve (E) with
care! NOTE! The brakes must always be adjusted such that
the braking force is correct with the braking levers in the
parking position. Verify!
3.1.2 Change of cable
Damaged cables must be replaced immediately! Follow these steps:
1. Remove the wheel and completely unscrew the wire length adjustment cap (A).
2. Remove the sleeve from the plate by unscrewing the nut (C) and threading it out of the slot.
3. Release the end of the wire from the turntable (D).
4. Unscrew the wire attachment (E) from the push bar and thread the end of the wire out of the
braking lever as seen in gure 14.
5. Assemble the new cable by reversing the above steps and adjust per section 3.1.1.
6. The brake cable (F, g 15) is attached by a clip (G) below the back
mounting plate. Figure 15 also shows how the clip (H) for the tilt-/
recline cable (I) should be placed and how the two cables run in relation
to each other. If a tiltable push bar is used the clips should switch places
with each other. The brake cables should then also run behind the tilt-/
recline cable as in gure 15.
3.1.3 Change of brake pads and/or brake disc
Worn or damaged brake pads or brake discs are
changed as follows (see spare parts list for details):
1. Take o the wheel and unscrew the caliper (J, g 16).
2. Remove the retaining ring (K) with correct pliers and
remove disc. Note that there is a plastic washer between
the disc and the wheel hub.
3. Now the brake piston (L, g 17), disc, and caliper can be
changed out for new parts.
If lubricating, be careful that no lubrication gets on the disc or
the caliper. NOTE! The caliper can be cleaned but must remain
completly at to function correctly.
Fig 12
E
A B
CD
Fig 13
I
F
G
H
Fig 15
Fig 14
E
Fig 16
J
K