KÜSCHALL ULTRA-LIGHT
Contents
1. Front wheel has worn smooth Replace front wheel The front wheel is stiff or stuck Bearings are dirty or faulty Replace the bearings The wheelchair is very difficult to unfold The backrest cover is too tight Loosen the topmost Velcro band of the backrest cover a little Left and right side of the wheelchair can be moved in parallel to one another Longitudinal stopping bolts on the seat edge are loose Tighten the longitudinal stopping bolts on the seat edge cck schall K schall AG Switzerland 2014 07 Service Manual FRAME FRAME Rear frame Da gt 153 Nm Ob gt 7 Nm Retaining lever a gt 4 Nm Cross Front frame a gt 15 Nm b gt 7 Nm c gt 7 Nm Upper connecting tube Lower connecting tube Seat locking mechanism Longitudinal stopping bolts lt k schall 6 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT E FRAME Rear frame Replacing the rear frame Difficulty O Tool 5 10 Remove backrest Loosen and remove bolts Wa and Ob Pull out rear frame to the back Push the rear frame onto the upper and lower connecting tubes Reinsert and tighten bolts Oa and Ob Front frame Replacing the front frame Difficulty O Tool 3 45 10 mM Disassemble brakes SS Loosen and remove bolts Ma and Mb on both sides If a flip t2. K schall AG Switzerland 2014 07 Service Manual BACKREST Adjustable angle backrest In order to make the backrest angle adjustable an adjustable angle backrest can be fitted Backrest angle K SCHALL ULTRA LIGHT E Deviation Angle between Position from standard backrest and u backrests seat Bo 7 d H 12 102 5 8 A 2 8 98 LC 3 4 94 4 Bis 4 0 90 5 4 86 ne 6 8 82 SZ 7 12 78 Fitting an adjustable angle backrest Difficulty O Tool 35 4 SCH 8 10 est 10 Shorter rear frame variant IIl required SS Push the lower joint pin into the rear frame and fix it using a bolt M Secure backrest tube to the upper joint pin using a bolt Assemble the upper and lower joint pins and and secure with bolt SS Retighten the bolt M Set the desired backrest angle and secure in the nearest hole using bolt SS Push the single Velcro band and then the other Velcro bands and end band over the backrest tube M Push the push handle into the telescopic tube and fix at the required height M Secure end band on the telescopic tube with a bolt cck schall 12 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT NB BACKREST Setting the backrest angle Difficulty oer Tool 5 10 est 10 fl Remove
3. 2 N ON 2 3 1 2 Si A 410 420 430 440 450 or oe Fire DEE 4 5 5 S 5 5 460 470 480 KANA a ee el ee ee e e mS A A IT it ft ft ee Allalla r r aa Ke Re Ee rr JO TAN 490 500 AIA 77 lm dle dle hd ho mm U I U l GO lf fF Fo FO u L it Con 1 f f f fF fF gem une mm mis a i Tae Te ee cer Vie a A age el ziel Malang NT ee COOMER I Tr fF amp TI Mm mm VA llO ff f f HUE 17 e O e o K MaE O o O O O O e 000000 OO 000 OO 0 0000 m K SCHALL ULTRA LIGHT 6 Mudguard removable with respect to the position of the rear wheels with standard adapter plate Pos 1 to 4 or rear wheel extension Pos 5 and 6 SHh Rear wheel 22 Rear wheel 24 Rear wheel 25 Rear wheel 26 mm 2 3 4 5 ZS tr 4 ei 6 1 2 3 4 5 2 d 4 2 390 AE AE e XL a e Go L K 2 3 400 410 ALA AE XL XL XL AL X i XL 420 XL gt lt gt lt E XL XL 430 XL 440 XL 450 Com m S f r GA A TC 1 fF VUE UGA IATA IA
4. iO Oo NS m RUN Mm oO NIJIaA U RAW MR La QO OOOO00000000 Seat width SB SBs range from 280 500 mm Once the SB Is specified it is very difficult to change It the cross Struts backrest cover on standard backs and on some configura tions the footrests must be replaced Seat depth ST sis range rom 320 500 mm To reduce the ST the cross struts Must be shortened and a new ap propriately sized seat cover fitted Atan ST gt 400 mm the frame can be shortened To enlarge the ST new cross struts a new appropriately sized seat cover and depending on the ST a new frame must be installed cck schall 9 K schall AG Switzerland 2014 07 Service Manual SEAT Replacing the seat cover Difficulty 660 Tool 10 fl Loosen bolts and remove plug PA Remove seat cover including plastic rods WM Position new seat cover Adjust seat cover to width SB 25 mm M Retighten bolts and plug Turning the seat locking mechanism If the seat edge can be too easily removed from the seat locking mechanisms either the front two or all four seat locking mechanisms can be rotated by 180 Difficulty OO Tool 3 SS Loosen bolt in seat locking mechanism SS Turn seat locking mechanism by 180 M Secure bolt with adhesive low strength E Retighten the bolt O Screw out the bolt only to the extent that the seat locking mechanism can
5. D 32457 Porta Westfalica Tel 49 0 57 31 754 540 e Fax 49 0 57 31 754 541 e edo invacare com Espana Invacare SA c Areny s n Poligon Industrial de Celra E 17460 Celra Girona Tel 34 0 972 49 32 00 e Fax 34 0 972 49 32 20 contactsp invacare com France Invacare Poirier SAS Route de St Roch F 57250 Fondettes Tel 33 0 2 47 62 64 66 Fax 33 0 2 47 42 12 24 e contactfr invacare com Ireland Invacare Ireland Ltd e Unit 5 Seatown Business Campus e Seatown Road e Swords e County Dublin Ireland Tel 353 1 810 7084 e Fax 353 1 810 7085 e ireland invacare com Italia Invacare Mecc San s r l e Via dei Pini 62 e 56016 Thiene VI Tel 39 0445 38 OO 59 e Fax 39 0445 38 OO 34 e italla invacare com Nederland Invacare BV e Celsiusstraat 46 e NL 6 16 BZ Ede Tel 31 0 318 695 757 e Fax 31 0 318 695 758 nederland invacare com e csede invacare com Norge Invacare AS e Grensesvingen 9 e Postboks 6230 e Etterstad e N 0603 Oslo Tel 47 0 22 57 95 OO e Fax 47 0 22 57 95 01 e norway invacare com island invacare com sterreich Invacare Austria GmbH e Herzog Odilostrasse 101 e A 5310 Mondsee Tel 43 6232 5535 O e Fax 43 6232 5535 4 info invacare austria com Portugal Invacare Lda Rua Estrada Velha 949 P 4465 784 Le a do Balio Tel 351 0 225 1059 46 47 Fax 351 0 225 1057 39 portugal invacare com Sverige D Suomi Invacare AB Fagerstagatan Oe S 163 91
6. To bring the transit wheels into the upper or lower position the spring clip must be pressed in Fitting the pelvic belt Difficulty OO Tools Drill drill bi 6 mm 5 10 1 If not present drill a hole on both sides through the frame A 2 Attach the steel strap using bolts through the holes on both sides N Ensure that the webbing of the pelvic belt is not twisted during assembly and the locking mechanism shows towards the front lt kuschall 47 K schall AG Switzerland 2014 07 Service Manual KUSCHALL ULTRA LIGHT Ze OPTIONS amp ACCESSORIES Attaching the snap hook symbols Front side Rear side lt kuschall 38 K schall AG Switzerland 2014 07 cck schall designed for life nl K schall AG Benkenstrasse 260 CH 4108 Witterswil kueschall invacare com www kuschall com Service Manual k schall Ultra Light ENGLISH 2014 07 kuschall distributors Belgium amp Luxemburg Invacare nv e Autobaan 22 e B 8210 Loppem Tel 32 0 50 83 10 10 Fax 32 0 50 83 10 11 belgium invacare com Danmark Invacare A S Sdr Ringvej 37 DK 2605 Brandby Tel 45 0 36 90 OO OO e Fax 45 0 36 90 OO 01 e denmark invacare com Deutschland Invacare GmbH e Alemannenstra e 10 e D 88316 Isny Tel 49 0 75 62 7 OO O Fax 49 0 75 62 7 OO 66 kontakt invacare com European Distributor Organisation Invacare e Kleiststra e 49 e
7. an antitipper Difficulty OO Tool 5 10 WM Secure adaptation support with bolt onto the adapter plate Height adjustment Difficulty OO Tool 04 O 8 SR Loosen bolt and remove the upper end of the antitipper and the holder Remove the sealing cap e g push it out through the tube using the screwdriver Pl Loosen bolt of the antitipper tube and push sleeve into the correct position E Screw bolt in half way position spring in sleeve and screw bolt completely into the tube EI Put all the parts of the antitipper back together in doing so pull spring apart e g using a wire Nook and secure it with the top bolt WM Set the antitipper parallel to the wheel chair and tighten the bolts Function check The distance between the antitipper and the ground must be 40 60 mm It must be easy to fold up the antitipper Tip the wheelchair backwards using the antitipper until the axle is perpendicular to the antitippers point of contact with the ground In this position the distance between the rear wheel and the ground must be at least 50 mm x 50 mm lt kuschall 35 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT YAp OPTIONS amp ACCESSORIES Tipper aid Fitting the tipper aid Difficulty OO Tool 5 10 WM Secure adaptation support with bolt onto adapter plate Push in spring clio
8. 4 or rear wheel extension Pos 5 and 6 SHh Rear wheel 22 Rear wheel 24 Rear wheel 25 Rear wheel 26 mm No UN N Q 390 400 410 420 430 440 Or ate p i r tiie Wil Wi wml _ wil amp amp amp iy 450 460 470 480 Pk Bil tl Bil 11 eae se ada ah gt Dan ff fF amp IT mM HE DEZE f f HUE HUE WA A A ln KA A 1 OO WA A EA KA l 1 a KA F A TATA lA lA r JE TET ION 490 500 See ales Pk ee Te a AN ee G eO giffe femmt fest JA maa mt Wi mm GA Ion Lo 1 Con f ff eg mm GA Cimcon tonn 1 on GA A ED ME Lon 1 CO honn ln D E 1 ER 1 an ee A A es A ren re ie le iS li OS eS G GO fr fF MT Mm FO MT VA a gt I WT Ml WI wml nl n oo mm WwW WMI Wil wml w wn oO o mm cck schall Zo Kuschall AG Switzerland 2014 07 Service Manual SIDE PARTS Mudguard mounted fix O OOOO O 000000 Mudguard mounted fix with respect to the position of the rear wheels with standard adapter plate Pos 1to 4 SHh Rear wheel 22 Rear wheel 24 Rear wheel 25 Rear wheel 26 mm
9. CG 07 on ED O _ A Gay Car SA Pa way ta Zo GA Ga tr wa Ga amp ly XL 460 470 480 w Nee ze OREA ff TI ff mM nn vV IIA E fF TI Mm 3 EN 1 aa GAY GA a wa ISA Gay ay way tee tee 490 500 GO l GO I f mM V IA lA Ff f fF Mm mM vV ILA ITAI 1 f ff mM V IIA EA KM f ai Car te Gay Gay tay way way wa CA Ay Ay aj wa Way way we LE Mescht ee N Er Rt Aloe GAY NSA Way or tay tea a ee UN a A wa ar ica te ea ru Jm cck schall 26 K schall AG Switzerland 2014 07 Service Manual FRONT WHEELS FRONT WHEELS Replacing the front wheel Difficulty OO Tool 3 fl Remove bolts pull out wheel axle PA Remove front wheel and replace with a new one or move to a new position In the case of the Starec wheel skater wheel A sports wheel and the 5 soft roll wheel 2 sleeves must be pushed onto the axle These sleeves are already in place on the low resistance wheel the sports wheels and the pneumatic wheels Ki Re insert axle and tighten bolt Function check There must be no play in the wheel but it must turn easily Castor fork Replacing the castor fork Diff
10. Folding al adjustable Velcro push push l integrated push bands handles handles handles Backrest ZG 111 in I RH mm 0 0O OO 8 oO o 300 AN S S XXS S XXS S 4B S 315 S 5 S XS S XS S 4B S 330 S S SIS PS IES TES AB S 345 S 5 L M S M L 4B 5 360 5 S L M S M L 4B S 375 S 5 L M S ML 4B 5 390 S M S M LIM S Mi 4B M 405 S M S M LM S M L 48B M 420 S M S M LIMIS M S 6B M 435 M M L L L L S 68 M 450 M M LEWE deene En aerch 465 M M Lik L LI iL 6B M 480 M M ee eeh GE L 495 M M Lik kL ek L 6B L 510 M M E el iy sys L Assumption No stabilising bar fitted Angle adjustable backrest with adjustable backs with respect to push handles Standard Folding ich adjustable Velcro push push integrated push bands handles handles handles Backrest height 1 RH mm e O 300 5 S S L 1B 2B S 315 S S S L 1B 2B S 330 S S S S 1B 4B S 345 S S L 5 1B 4B S 360 S S L S 1B 4B S 375 S S L te L 1B 4B S 390 S M S M L gt L 1B 4B M lt 405 S M S M L y L 1B 4B M 420 S M S M L L 1B 4B M 435 M M L N S 1B 6B M 450 M M L S 1B 6B M 465 M M L x S 1B 6B M 480 M M L S 1B 6B L 495 M M L 3 L 1B 6B L 510 M M L L 1B 6B L Assumption No stabilising bar fitted For RH 510 with height adjustable
11. Sp nga Tel 46 0 8 761 70 90 e Fax 46 0 8 761 81 08 e sweden invacare com e finland invacare com Switzerland Invacare AG e Benkenstrasse 260 e CH 4108 Witterswil Tel 41 0 61 487 70 80 e Fax 41 0 61 487 70 81 switzerland invacare com United Kingdom Invacare Limited e Pencoed Technology Park Pencoed Bridgend CF35 5AQ e Switchboard Tel 44 0 1656 776 200 Fax 44 0 1656 776 201 e Customer services Tel 44 0 1656 776 222 e Fax 44 0 1656 776 220 e UK invacare com e www invacare co uk Australia Invacare Australia Pty Ltd e ABN 45 074 676 378 PO Box 5002 1 Lenton Place North Rocks NSW 2151 Australia e Freephone 1800 069 042 Fax 02 8859 5353 E mail sales invacare com au e Web www invacare com au New Zealand Invacare New Zealand e PO Box 62 124 4 Westfield Place Mt Wellington Auckland New Zealand e Freephone 8000 468 222 Freefax O800 807 788 E mail sales invacare co nz e Web www invacare co nz K schall AG Switzerland 2014 07
12. a hole with a diameter of 6 mm through the front frame hole already made in the connecting tube and fit bolt Ob Screw the sleeve and bolt onto the rear fastening element Fit rear fastening element and clip loosely with bolts and sleeves normal rear frame 17 mm beneath the upper edge of the frame reinforcement on a shortened rear frame directly flush with the upper edge of the frame reinforcement Mount the side rest position rear fastening element precisely Attach the wedge and headless bolt The sleeves are different for flip to back side rest in frame colour and flip to back side rest with engagement mechanism To enlarge the distance between the wheels additionally a different adapter sleeve which is mounted from the inside has to be applied Fitting flip to back side rest with locking mechanism Difficulty O Tool 3 4 5 10 lo o Fit the side fastening element with bolt a For bolt Ob bore a hole with a diameter of 6 mm through the front frame hole already made in the connecting tube and fit bolt Ob Screw the sleeve and bolt onto the rear fastening element Fit rear fastening element and clip loosely with bolts and Sleeves normal rear frame 17 mm beneath the upper edge of the frame reinforcement on a shortened rear frame directly flush with the upper edge of the frame reinforcement Mount side rest position rear fastening eleme
13. and 2014 07 Service Manual K SCHALL ULTRA LIGHT NB BACKREST Replacing foldable push handles Difficulty OO Tools Hole punch pliers 6 mm 3 4 Remove the old foldable push handle Pull down the backrest cover on the telescopic tube until its hole is uncovered IMPORTANT Make sure that the threaded insert part no 1580450 supplied with the new push handle is used for assembly Place the threaded insert in the telescopic tube Punch a hole through the backrest cover with a distance of 10 mm from the upper egde using hole punch pliers see graphic below Slide the new foldable push handle amp onto the telescopic tube Fix the foldable push handle with screw M5x12 Pull up the backrest cover until it covers completely the rear hole in the pushhandle Fix the foldable push handle with screw M5x14 and washer Check screws on both sides of the push handle and re tighten if necessary TL gt 3 Nm low strength gt 7 Nm low strength E Carry out the same steps for the other push handle ol 10mm O cach IMPORTANT Make sure that the folding force is approximately 5 N 0 5 kg The retrofit of foldable push handles requires new tubing kuschall 16 K schall AG Switzerland 2014 07 Service Manual BACKREST Backrest with adjustable backs with respect to push handles Standard
14. and push the tipper aid into the adaptation Support M Make sure that the spring clip is correctly engaged in the adaptation support Height adjustment Difficulty OO E To adjust the height remove cap and e g using a screwdriver compress the spring inside the tube and push into the required position Cane holder Fitting a cane holder Difficulty OO Tool 5 C 10 WM Secure adaptation support with bolt onto adapter plate Push in spring clio and push the cane holder into the adaptation Support MW Make sure that the spring clip is correctly engaged in the adaptation support Height adjustment Difficulty OO M To adjust the height remove cap and eg using a screwdriver compress spring inside the tube and push into the required position cck schall 36 K schall AG Switzerland 2014 07 Service Manual KUSCHALL ULTRA LIGHT MN OPTIONS amp ACCESSORIES Transit wheels Fitting transit wheels Difficulty OO Tool 5 10 M Secure adaptation support with bolts onto adapter plate Push in spring clip and push the transit wheel into the adaptation support SS Make sure that the spring clip is correctly engaged in the adaptation support Height adjustment Difficulty OO M To adjust the height remove cap and e g using a screwdriver compress spring inside the tube and push into the required position O
15. be turned as otherwise the threaded insert can move and is then difficult to re position lt kuschall 10 K schall AG Switzerland 2014 07 sige KA b Wi kr Service Manual K SCHALL ULTRA LIGHT 4 BACKREST BACKREST Backrest height The backrest height can be changed by fitting the telescopic tubes into another position in the backrest tubes If this setting option Is insufficient the telescopic tubes can be replaced Adjusting the height of standard backrests Difficulty OO Tool 3 46 8 10 SS Push the backrest cover upwards and remove the bolt on both sides SS Push the push handles upwards or downwards until you reach the required height Replace the bolt and tighten d If this setting range is insufficient use new push handle tubes O If the backrest height was changed considerably a new backrest il cover may have to be fitted Adjusting the height of Velcro adjustable backrests Difficulty OO Tool 3 46 8 10 SS Remove backrest cover and move the Velcro bands until bolt IS visible M Remove bolt and move the push handle tube to the required height MW Insert bolt Ointo the appropriate hole and tighten O If the backrest height is changed considerably the push handles il must be replaced An additional Velcro band may have to be fitted or one may have to be removed lt kuschall 11
16. chall wheelchair WARNING Danger of accident and severe injuries If the wheelchair is improperly set it can cause accidents and severe injuries gt Changes to the wheelchair may only be carried out by the dealer To maintain the necessary levels of safety and reliability every wheel chair must be thoroughly examined once a year Some aspects of the assembly and configuration of the wheelchair require a high level of expertise These assembly instructions there fore break the various tasks down into three categories Requirement Symbol Easy technical understanding required 600 Medium technical knowledge required UI 76 Difficult technical knowledge and expertise in 66 assembling wheelchairs required The required tools and their sizes are listed before the Instructions The various torque values with which the nuts are to be tightened are also specified in the Instructions A torque spanner must be used In order to comply with the specified torque values Tool Symbol Allen key 3 4 5 Torx wrench 10 Phillios head screwdriver x Open end spanner mm C 8 9 10 18 Socket spanner Box spanner 8 10 19 22 Spare parts and adaptations All spare parts may be obtained from the kuschall customer service department An electronic spare parts catalogue can be found at www kuschall com Only original spare parts may be used The written authorisat
17. elcro bands may have to be replaced with narrower ones as space is required to secure the holder on the telescopic tube Secure the telescopic tube to the rear frame at the required height Press the cover cap onto the end of the telescopic tube Push the Velcro bands onto the telescopic tube Push the holder onto the telescopic tube and fix in place by tightening the clamp bolts Fit end band onto the telescopic tube and secure with a bolt Attach protective cushion Fitting angle adjustable backrest with height adjustable push handles Difficulty O Tools 5 4 5 8 10 m 10 Shorter rear frame variant III required Push the lower joint pin into the rear frame and fix it using the bolts Fit backrest tube onto the upper joint pin using bolts Assemble the upper and lower joint pins and and secure with a bolt Set the desired backrest angle and secure in the nearest hole using a nut and bolt Retighten the bolt Push the single Velcro band and then the other Velcro bands and end band over the backrest tube Push in push handle completely Using the clamp bolt fit the height adjustable push handles through the telescopic tube Fit end band onto the telescopic tube with a bolt cck schall 15 KIT ae nee EI NEN NGANAN 2 7 K schall AG Switzerl
18. emovable axle cck schall 31 gt 35 Nm K schall AG Switzerland 2014 07 Service Manual REAR WHEELS Adjusting the removable axle Difficulty 660 Tools eat 11 19 mM Remove the rear wheel SS Hold the end of the removable axle using the straddle spanner SS Adjust the length L of the removable axle by turning the nut The length is correctly adjusted if the removable axle engages correctly when fixing the wheel and wheel has Just minimal clearance O The wheels must be exchanged left to right side and vice versa il after adjusting both removable axles The adjustment must now be checked or carried out again to ensure the wheels can be switched cck schall 352 Kuschall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT Ss H Le BRAKES BRAKES Parking brakes Fitting adjusting the parking brake Difficulty OO Tool 5 10 CAUTION The parking brakes must be adjusted whenever the rear wheels are replaced M Check the air pressure in the rear wheels fl Secure the brake holder loosely to the frame using bolt PA Push the brakes into the brake holder and position then 2 tighten the bolt O The brake is set correctly if the brake rod presses into the tyre by no more than 4 mm when the brake is applied and the tyres are properly pumped Visual check Check that the parking brakes are positioned c
19. fficulty 00Tool 4 10 E Loosen bolts on both sides E Remove footplate and replace with anew one E Re insert bolts Dand tighten gt 13 Nm Disassembling fitting the footrest Difficulty oc Too 04605686 EI Remove bolts on both sides Pull out the footrest u Insert new footrest Tighten bolts on both sides at the same height and in the required position A Adjusting the height of the footrest Difficulty OO Tool 4 8 EI Remove bolts on both sides Si Hold the telescopic tubes with both hands and push the footrest into the required position E Insert bolts into the nearest hole on both sides and at the same height and tighten securely lt kuschall 19 K schall AG Switzerland 2014 07 Service Manual FOOTRESTS Centring and adjusting the angle Difficulty OO Tool 60460 10 SS Loosen bolts and slightly fl Set the same distance from the side tube to the footplate on both Sides PA Set the required footplate incline Re tighten bolts fixed side of the footplate SS Turn the little tube on the moving side of the footplate such that it engages properly M Tighten bolts Changing the position of the footrest set to rear set to front Difficulty OO Tool 60460 10 SR Loosen bolts on both sides and remove Pl Turn the footplate with the clamp component E Re insert bolts and tigh
20. guard with bolts and nuts onto the side fastenings CAUTION Fit the mudguard such that it is positioned either lt 8 mm or gt 25 mm above the tyres to avoid the risk of trapping one s fingers Adjusting the clothes guard mudguard Difficulty O Tool 03 Q 8 El Loosen bolts Move the clothes guard mudguard SS Retighten bolts or P Loosen and remove bolts E Re fit clothes guard mudguard in another position Fitting and adjusting the removable mudguard Difficulty oer Tool 3 4 5 10 fl Fit side fastening element with bolts Ga and b Si Insert mudguard in the side fastening element Adjust the height by loosening the three bolts on the end stop Ki If the edge of the mudguard does not run evenly over the tyre loosen bolts and push the mudguard into the required position Retighten bolts CAUTION Fit the mudguard such that it is positioned either lt 8 mm or gt 25 mm above the tyres to avoid the risk of trapping one s fingers a gt 4 Nm b gt 7 Nm gt 7 Nm gt 7 Nm lt k schall gt K schall AG Switzerland 2014 07 Service Manual SID E PARTS Siderests In general a torque of 7 Nm is used to fit the side rests Fitting a flip to back side rest in the frame colour KUSCHALL ULTRA LIGHT Difficulty O Tool 5 4 5 C 10 Fit the side fastening element with bolt a For bolt Ob bore
21. hall be made whether an adhesive and which adhesive needs to be used Identifying and repairing faults Fault Possible cause Action The wheelchair does not travel in a straight line Incorrect tyre pressure on one rear wheel Correct tyre pressure One or more spokes broken Replace broken spoke s Spokes tightened unevenly Front wheel bearings are dirty or damaged Tighten loose spokes Clean or replace the bearings Support bearings in forks faulty Replace the support bearings Steering error or trail angle left and right uneven Adjust steering error or trail angle The wheelchair tips too easily The brakes are gripping poorly or asymmetrically Rear wheels are mounted too far forwards Mount the rear wheels further back Backrest angle too large Reduce backrest angle Seat angle too large Incorrect tyre pressure in one or both rear tyres Mount the adapter plate lower on the side profile Correct tyre pressure Brake setting incorrect Correct brake setting The rolling resistance is very high Tyre pressure in rear tyres is too low Correct tyre pressure Rear wheels not parallel Make rear wheels parallel Drum brake set too narrow Bearings are dirty or faulty Set the drum brake Replace the bearings The front wheels wobble when moving fast Too little tension on the clevis pin housing Tighten the nut on the castor fork slightly
22. he same time the distance between the individual wheels Il and the relevant side frame can be checked for conformity and adjusted if necessary E Retighten nuts of adapter sleeves on both sides Adapter plate for drum brake Fitting the adapter plate for the drum brake Difficulty OO Tool 5 10 il Remove the adapter sleeve and adapter plate Si Position the adapter plate for the drum brake at the required height and tighten it securely on the counterpiece using bolts and gt Chap Breaks Fitting the drum brake Distance sleeves for rear wheels If new side parts are fitted on a wheelchair side rests arm rests clothes guard or mudguard the gap between the rear wheels must be increased by attaching additional distance sleeves Likewise dis tance sleeves may also have to be fitted if other rear wheels are fitted or if the seat height rear is altered cck schall 30 K schall AG Switzerland 2014 07 Service Manual REAR WHEELS Fitting the hub brake BE Remove the adapter plate BE Remove the adapter sleeve from the adapter plate Fitting the locking ring Difficulty 666 Tool Drill press drill 4 19 22 IMPORTANT For fitting in axle position 1 the front hole in the adapter plate must be prepared for the use of a countersunk bolt 90 counter bore Axle position 4 cannot be used u Fit
23. iculty O Tool 3 19 fl Remove bolts wheel axle and front wheel Si Remove nuts and pull the castor fork from the clevis pin WM Replace castor fork and secure with nut such that the fork has no play u Re insert the front wheel CAUTION Do not overtighten nut as this can damage the fork bearing Function check Tip the wheelchair backwards 90 so that It is lying on the backrest and rear wheels Turn the fork up A and allow it to swivel down The fork is adjusted correctly if it Just passes the lowest point and stops there B If the fork moves back when in its lowest position C it has not been tightened enough There is a risk that the front wheels will start to wobble when travelling at high speeds lt kuschall 27 K schall AG Switzerland 2014 07 service Manual KUSCHALL ULTRA LIGHT FRONT WHEELS Setting the steering error angle Difficulty oer Tool 5 10 SS Loosen bolts and nuts SS Hold spirit level against the clevis pin housing SS Turn the bolt until the clevis pin housing is vertical SS Retighten bolts and nuts Gi CAUTION It is Important that the settings on the left and right are precisely the same Correcting the trail angle Difficulty oer Tool 5 10 SS Loosen bolts and nuts M Remove clevis pin housing M Attach adjustment template for toe out insert template at the bottom f
24. ighten the bolt of the adapter sleeve Perform the same setting on both sides After the SHh is changed the steering error angle must be checked gt Chap Front wheels Setting the steering error angle and with a wheel camber of 3 the angle of the rear wheels must also be checked gt Chap Rear wheels Changing the wheel camber o O After the SHh is changed distance sleeves may also have to be il fitted in order to increase the distance to the rear wheels Tipping stability The tipping stability is influenced by the rear wheel being fitted further forward or further backward on the adapter plate The further back the adapter sleeve is fitted the greater the tipping stability of the wheelchair If the rear wheel is to be fitted even further back a rear wheel exten sion can be fitted to increase the tipping stability even more Adjusting the position of the rear wheel on the adapter plate Difficulty OO Tool 19 22 EI Remove the adapter sleeve PJ Set the adapter sleeve at the required position in the adapter plate and tighten the nut securely E Perform the same setting on both sides O Brakes and mudguard must be repositioned if the position of the il rear wheel is changed Fitting the rear wheel extension Difficulty OO Tool 5 10 19 22 il Remove the adapter sleeve and adapter plate Pl Position the adapter plate for the rear wheel extension at
25. integrated push handles S 2x4B cck schall 17 K schall AG Switzerland 2014 07 Service Manual BACKREST Foldable angle adjustable backrest with respect to push handles Standard Folding en adjustable Velcro push push integrated push bands handles handles handles Backrest height 1 me RH mm aD E O OO e O 0 300 5 S 5 S S S S S 5 S S S S 5 S S S S S L 2B S 5 S S S L 2B S 5 S S S S x L 2B 5 390 S 5 a o mu WM 2B M lt 405 S S L b S S 4B M 420 S S L S S 4B M 435 M M 2 s s 4B AM gt gt 450 M M L S L eos 4B M 465 M M Lis L S L M 480 M M DZ EE iL 495 M M iL 3 L 3 L 4B L 510 M M KH o Be L Assumption No stabilising bar fitted For RH 375 with height adjustable integrated push handles S und 2B 4B Additionally a band is fixed close to the backrest joint The band is of different length according to the seat width SB There are 3 lengths SB 280 360 gt short SB 380 440 gt medium SB 460 500 gt long lt kuschall 18 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT ES FOOTRESTS FOOTRESTS One piece and two piece footrests are available One piece footrest Replacing the footplate Di
26. ion of Kuschall AG must be obtained before installing additional adaptations on a k schall wheelchair Fastening with hexagon socket bolts Hexagon socket bolts are not designed to withstand an excessive application of force When tightening or undoing a hexagon socket bolt force must be applied to the nut wherever possible to avoid damaging the bolt Tightening and undoing SS Turn the nut using a socket spanner only use an open end Spanner if there is insufficient space using the Allen key simply to stop the bolt turning lt kuschall A K schall AG Switzerland 2014 07 Service Manual Tightening and undoing when no nut is present If a hexagon socket bolt is screwed directly into a thread the bolt must be tightened using the Allen key O Ensure that the Allen key is of good quality d and not worn Torque Ov x K SCHALL ULTRA LIGHT Es SS All bolts must be tightened with the torque specified in the following instructions Checks Visual check M Check the entire frame for cracks especially the areas around joints and welded seams Checking the screw connections M Check all bolts with the torques specified in the instructions regularly and adjust if required CAUTION Several screw connections have been secured with safety seals If these are opened they must be secured again using new safety seals High power and low power adhesives are available For torque entries notice s
27. k schall ck designed for life KUSCHALL 1 ue CC service Manual Service Manual TABLE OF CONTENTS ES ME Introduction Spare parts and adaptations Fastening with hexagon socket bolts Torque Checks Identifying and repairing faults Rear frame Front frame Retaining lever Seat height front SHv Seat height rear SHh Seat width SB Seat depth ST BA FIR E Backrest height Adjustable angle backrest Replacing push handles push handles and backrest Replacing foldable push handles FOOTREST o One piece footrest Two piece footrest Two piece footrest adjustable angle SIDEPAR KE Clothes guard mudguard Siderests FRONT WHEELS Seripaino eTEN E a Eri Castor fork Special housing guides REAR WHEELS een ee Adjusting the seat height rear Tipping stability Wheel camber Adapter plate for drum brake Distance sleeves for rear wheels Fitting the hub brake Adjusting the removable axle BRAKE E Parking brakes Drum brake OPTIONS G ACCESSORIES une ee ee Antitipper Tipper aid Cane holder Transit wheels Fitting the pelvic belt Attaching the snap hook symbols cck schall LO SS A On K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT 4 s e NL Kay Kal GENERAL Introduction This Service Manual is part of the instructions and contains all the technical information necessary for the inspection configuration or repair of a kus
28. les e g height adjustable ones it can happen that the rear frame must also be replaced Changing the backrest height can also mean that the configuration of the Velcro bands must be changed Fitting standard push handles Difficulty O Tools X 3 4 5 O 8 10 fl Secure the telescopic tube to the rear frame at the required height Si Push the backrest bands and end band onto the telescopic tube end band first E Secure end band on the telescopic tube with a bolt Fitting height adjustable integrated push handles Difficulty O Tools 3 45 Q 8 10 Special rear frame required for RH 300 465 variant Mm Push lower telescopic tube and upper telescopic tube into one another and insert bolt HB Secure pre assembled element telescopic tubes and at the required height on the rear frame with a bolt 7 Nm SS Push the Velcro bands and end band onto the telescopic tubes E Using the clamp bolt secure the height adjustable push handles through the telescopic tube SS Push in push handle completely M Secure end band on the telescopic tube with a bolt c k schall 14 K schall AG Switzerland 2014 07 Service Manual BACKREST Fitting height adjustable rear set push handles K SCHALL ULTRA LIGHT E Difficulty O Tools 3 45 O 8 10 The V
29. maller one gt Chap Front wheels Replacing the castor fork e Fit it high low with the housing guide Hemi gt Chap Front wheels Special housing guides Seat height front with respect to fork size castor fork size and position in the fork Service Manual K SCHALL ULTRA LIGHT E Castor fork inch SHv mm ga Ba L As NG Ze Is Za 410 03 420 03 430 440 04 oz 450 04 03 460 05 04 03 470 05 04 03 480 490 oe 05 04 03 500 oe 05 04 03 gt 10 oz oe os 04 S 07 oe os 530 540 07 o6 Assumption Seat depth 400 mm seat angle 50 mm fitted high SHY 30 mm fitted low SHv 30 mm 6 and 7 front wheels cannot be used on the Ultra Light dynamic frame 80 if a 2 part angled footrest is fitted cck schall 8 K schall AG Switzerland 2014 07 SEAT Seat height rear SHh Options for changing the SHh e Replace rear wheel with a larger or a smaller one e Change the position of the adapter plate gt Chap Rear wheels Adjusting the seat height rear Service Manual K SCHALL ULTRA LIGHT Y Seat height rear with respect to the rear wheels and positioning on the frame Rear wheel size inch SHh mm 22 24 Zo 26 370 380 390 400 410 420 430 440 450 460 470 480 490 500 WWO AINIADN m NIW Nm Mm La QO 0 oo NS A IAIA NIR
30. nt precisely Attach the wedge and headless bolt The sleeves are different for flip to back side rest in frame colour and flip to back side rest with engagement mechanism To enlarge the distance between the wheels additionally a different adapter sleeve which is mounted from the inside has to be applied cck schall 23 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT NB SIDE PARTS Fitting side rest insertable continuously height adjustable Difficulty O9 Tool 64 5 10 HI Fit the side fastening element with bolts and PJ Insert side rest into the fastening element m Adjust height by adjusting the clamp component Fitting a simple swivelling armrest Difficulty 660 Tool 4 5 fl Fit the rear fastening element FA Insert the armrest mM Adjust height by adjusting the bolt in the tube of the armrest lt kuschall 24 K schall AG Switzerland 2014 07 Service Manual SIDE PARTS Size of the clothes guard mudguard The clothes guard and mudguard can be adjusted to suit the height of the rear wheel exactly Two sizes of each are available For the removable carbon mudguard there is an additional size XL for the two smallest rear seat hights SHh Clothes guard mounted fix 000000 Clothes guard with respect to the position of the rear wheels with standard adapter plate Pos 1 to
31. o back side rest is fitted also loosen c M Pull out front frame to the front M Remove seat locking mechanism with threaded insert from old front frame and fit it on the new front frame gt Chap Seat Turning the seat locking mechanism SS Push the front frame onto the upper and lower connecting tube E Reinsert and tighten bolts Ma Mb if required c on both sides M Set the castor fork angle gt Chap Front wheels Setting the steering error angle Retaining lever Replacing the retaining lever Difficulty O Tool 3 45 10 With mudguard or clothes guard fixed remove Wa and b with mudguard or side rest insertable and siderest foldable remove a and Ob Remove bolt a Pull the retaining lever from the upper connecting tube Remove sleeve b Push the new retaining lever over the upper connecting tube Position sleeve b with wide edge in joint c Secure retaining lever with bolt a With mudguard or clothes guard fixed reinsert and tighten bolts Da and b with mudguard or side rest insertable and side rest flip to back reinsert and tighten bolts Oa and Ob lt kuschall 7 K schall AG Switzerland 2014 07 SEAT SEAT Seat height front SHv Options for changing the SHv e Replace front wheel with larger or smaller one or fit it at another position on the castor wheel gt Chap Front wheels Replacing the front wheel e Replace castor fork with a larger or a s
32. or toe in insert template at the top SS Fit clevis pin housing WM Set the angle gt Chap Front wheels Setting the steering error angle Correcting the trail angle Special housing guides Fitting special housing guide for smaller SHv housing guide fitted high Difficulty oer Tool 5 10 Remove clevis pin housing Remove standard housing guide Attach bolt Fit special housing guide high Fit clevis pin housing Correcting the trail angle Fitting special housing guide for larger SHv housing guide fitted low Set the angle gt Chap Front wheels Setting the steering error angle Difficulty oer Tool 5 10 M Remove clevis pin housing Remove standard housing guide Fit special housing guide low Fit clevis pin housing Correcting the trail angle c lt kuschall 28 Set the angle gt Chap Front wheels Setting the steering error angle gt 13 Nm gt 153 Nm gt 13 Nm gt 13 Nm K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT 4 REAR WHEELS REAR WHEELS Adjusting the seat height rear Difficulty OO Tool 5 10 19 22 SS Loosen the bolt of the adapter sleeve and bolts M Remove bolts and move the adapter plate into the required position Insert bolts at the appropriate height Insert the bolt of the adapter sleeve Tighten bolts and T
33. orrectly The brake is set correctly if the brake shoe depresses the tyre by no more than 4mm when the brake is applied In the case of active brakes and Standard brakes this will be the case when the brake shoe is approx 25mm away from the tyre when released Function check Place a weighted wheelchair with parking brake engaged facing uphill and then facing downhill on a ramp with an incline of 7 The wheelchair may not move lt kuschall 33 K schall AG Switzerland 2014 07 Service Manual BRAKES Drum brake Fitting the drum brake Difficulty Tool 4 X O gt 10 22 M Remove standard adapter plate and replace with adapter plate for drum brake gt Chap Rear wheels Fitting the adapter plate for the drum brake HI Fit the drum brake plate and rotary fixing to adapter plate Connect the drum brake plate and rotary fixing with bolt PJ Fit brake lever on the push handle and secure Bowden cable with fixing set Setting the drum brake Difficulty 660 Tool SS Tighten or loosen the brake by turning the setting sleeve SS If the setting sleeve cannot be turned any further demount brake cable loosen clamp bolt using the screwdriver and retighten the cable cck schall 34 K schall AG Switzerland 2014 07 Service Manual OPTIONS amp ACCESSORIES OPTIONS amp ACCESSORIES Antitipper Fitting
34. ten cck schall 20 gt 13 Nm gt 13 Nm gt 13 Nm K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT 4 NGA D FOOTRESTS E Kal Two piece footrest Difficulty OO Tool 4 O 8 Disassembling fitting footrests bl Remove bolts on both sides PA Pull out footrests EI Push the new footplates into the frame and at the required height LI Insert bolts into the nearest hole on both sides and at the required height and tighten Adjusting the height of the footrests Difficulty OO Too 04 O8 M Remove bolts MW Push the footplates into the required position WM Insert bolts into the nearest hole on both sides and at the required height and tighten Changing the position of the footrests set to rear set to front Difficulty OO Tool 5 fl Remove bolts Pl Pull the footrests away downwards and replace E Re insert bolts and tighten Two piece footrest adjustable angle Adjusting the angle Difficulty OO Tool 5 fh Loosen bolt Si Change the angle of the footrest until it reaches the required position E Retighten bolt lt kuschall 21 K schall AG Switzerland 2014 07 Service Manual SIDE PARTS SIDEPARTS Clothes guard mudguard Fitting the clothes guard mudguard Difficulty O Tool 3 8 fl Fit side fastenings onto the frame Si Fit clothes guard mud
35. the required height and tighten securely on the counterpiece using bolts and Set the adapter sleeve at the required position in the adapter plate and tighten the nut securely c lt kuschall 29 NG D G Li gt 13 Nm gt 35 Nm gt 13 Nm K schall AG Switzerland 2014 07 Service Manual REAR WHEELS Wheel camber A wheel camber of either 1 or 3 is possible Changing the wheel camber Difficulty oe Tool eat 18 19 22 The wheel camber is changed by replacing the adapter sleeve fl Remove adapter sleeves or on both sides Si Insert new adapter sleeves and on both sides at the required identical position in the adapter plate and fasten securely with nut Ensuring the rear wheels are parallel Difficulty Tools eat 18 19 22 M Loosen nuts of adapter sleeves on both sides Mm At the height of the center of the axle measure the distance between the rear wheels at the front and back x y Distance back gt distance Turn adapter sleeve towards rear front viewed from above Distance front gt distance Turn adapter sleeve towards front back viewed from above M Ir accordance with the table turn the adapter sleeves so that the distance between the rear wheels is the same at the front and the back x y measured at the height of the center of the axle O At t
36. the backrest cushion and push the Velcro bands Upwards until the backrest joint is invisible PA Remove the bolt E Set the desired backrest angle insert the bolts in the nearest hole and tighten E Retighten the bolt M Perform the same setting on both sides Visual check By looking from the side check that both backrest tubes are level and thus that the same angle has been set on both sides Fitting the joint for a folding backrest Difficulty oer Tool 45 10 Shorter rear frame variant III required fl Set the desired backrest angle insert bolt in the nearest position Pos 1 2 or 5 and tighten With the curved backrest tubes other positions can be achieved in addition to the 3 positions specified SS Fold down upper joint pin with intermediate backrest tube PA Push the joint housing into the rear frame and fit it using a bolt Backrest angle Position 1 rear position 82 with curved backrest tube 90 Position 2 mid position 86 with curved backrest tube 94 Position 3 front position 90 with curved backrest tube 98 cck schall 12 gt 13 Nm Z N gt 13 Nm oo0o00200200009009 K schall AG Switzerland 2014 07 Service Manual K SCHALL ULTRA LIGHT 4 BACKREST GD j iha y Replacing push handles push handles and backrest If the push handles are replaced with a different type of push hand
37. the locking ring with the adapter sleeve at the required axle position in the adapter plate using the nut and ribbed washer IMPORTANT Make sure that the fixing holes of the locking ring are at ap prox 45 to the adapter plate to allow sufficient clearance to the outside edge of the adapter plate or to the adjacent axle position hole gt Before drilling check the drill hole positions by marking them with a pencil and correct if necessary E Drill the adapter plate through the fixing holes of the locking ring BE Remove the locking ring and adapter sleeve from the adapter plate E Drill through the adapter plate using the drill press and deburr the holes WM Re fit the locking ring with adapter sleeve in the required adapter plate hole using the nut and ribbed washer E Push the pins through the fixing holes of the locking ring and the adapter plate E Tighten the nut BE Re attach the adapter plate to the frame Fitting the rear wheel Difficulty OOO MW Insert the removable axle through the rear wheel Art No 1568697 EB Push the removable axle and rear wheel together into the adapter Sleeve CAUTION If the removable axle of a rear wheel is not correctly adjusted there will be lateral play at the rear wheel or it may even become detached from the wheelchair gt Make sure that the removable axle length is correctly adjusted gt Sec Rear wheels Adjusting the r
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