Service Manual
Contents
1. bw LN J idi D S Service Manual c lt kuschall designed for life The KS CE Service Manual Table of contents GONG Mal E Introduction Spare parts Fastening with hexagon socket bolts Visual check Identifying and repairing faults Adjusting the frame Changing the frame Adjusting the seat height Replacing the seat cover Backrest ssesssssscsssccossissesscccssassesnesdsvssnscecsaecesosvensscsanssssssessscanesosossosssseess Adjusting the backrest height Backrest angle Tipping point of the wheelchair Replacing the Standard Light backrest cover Replacing Velcro tapes for adjustable backrests Replacing push handles with Light cover Replacing push handles with adjustable backrest Foldable backrest angle adjustable optional FOOUGSUES TAE AA E E E E Replacing the footrest Adjusting the height of the footrest Adjusting the angle of the footrest Fitting the clothes guard Fitting the mudguard Front WhEeISiscccsccsssisssscacsssscssssssessssvccsssassessssonesccassssssassoscssesescodecsssoees Replacing the front wheel fork Replacing the front wheel Cleaning the front wheel bearings EEI A AAEE OE A E E Checking the tyre pressure Checking the spoke tension Checking that removable axles are seated correctly Adjusting the removable axles Replacing the rear wheels Replacing the axle Ensuring the rear wheels are parallel Repairing or changing an inner tube Fitting tub2. OO Tools 4 8 E Remove bolts on both sides Pull out footrest and replace with new one E Insert the bolts through the frame and into the nearest holes at the same height on both sides and tighten them Adjusting the height of the footrest Difficulty OO Tools 4 8 The footrest can be adjusted in 10 mm steps E Remove bolts on both sides E Move the footrest to the required height E Insert the bolts through the frame and into the nearest holes at the same height on both sides and tighten them Adjusting the angle of the footrest Difficulty GC Tools 3 10 For option angle adjustable only E Undo the four bolts so that the footplate can be moved E Move the footplate to the required angle and tighten the bolted connections again O The bolts must be tightened very securely to prevent the footplate d from moving ccktischall 12 Kiischall AG Switzerland 2011 12 Service Manual Sides Sides Fitting the clothes guard Difficulty oe Tools 5 8 drill drill bit 05 2 O The clothes guard is customised to fit the geometry of the individual d wheelchair It must therefore only be replaced by another clothes guard of the same size E Remove bolts and and the old clothes guard E Use the old clothes guard as a template by placing it on the new one and marking the position of the holes Drill holes in the new clothes guard E Fit clothe
3. ance Invacare Poirier SAS Route de St Roch F 37230 Fondettes Tel 33 0 2 47 62 64 66 Fax 33 0 2 47 42 12 24 contactfr invacare com Ireland Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Road Swords County Dublin Ireland Tel 353 1 810 7084 Fax 353 1 810 7085 ireland invacare com Italia Invacare Mecc San s r l e Via dei Pini 62 36016 Thiene VI Tel 39 0445 38 00 59 Fax 39 0445 38 00 34 italia invacare com Nederland Invacare BV Celsiusstraat 46 NL 6716 BZ Ede Tel 31 0 318 695 757 Fax 31 0 318 695 758 nederland invacare com csede invacare com Norge Invacare AS Grensesvingen 9 Postboks 6230 Etterstad N 0603 Oslo Tel 47 0 22 57 95 00 Fax 47 0 22 57 95 01 norway invacare com island invacare com sterreich Invacare Austria GmbH Herzog Odilostrasse 101 A 5310 Mondsee Tel 43 6232 5535 0 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 amp Suomi Invacare AB Fagerstagatan 9 S 163 91 Sp nga Tel 46 0 8 761 70 90 Fax 46 0 8 761 81 08 sweden invacare com finland invacare com Switzerland Invacare AG Benkenstrasse 260 CH 4108 Witterswil Tel 41 0 61 487 70 80 Fax 41 0 61 487 70 81 switzerland invacare com United King
4. band E Push the backrest band down alittle to expose the bolt Remove nut and bolt on both sides E Pull the push handles from the backrest tubes E Slip the end band over the new push handles E Ft the push handles in the desired position using the bolts Secure the end band to the push handles again using the bolts gt 4Nm gt 7 Nm ccktischall 10 Ktischall AG Switzerland 2011 12 Service Manual Back Foldable backrest angle adjustable optional Optionally a foldable angle adjustable backrest can be fitted A For assembling a special K schall training is necessary O When switching to the foldable backrest the axle of the rear wheels must also be replaced with a new one that is 2 cm wider gt Chap Rear wheels Replacing the axle Pre assembling the foldable backrest Schwierigkeit Werkzeug 3 4 5 8 10 E Push the back band onto the back tubes Fit the end plugs into the backrest tubes on both sides Mount the backrest joint plates on both backrest tubes Fit the backrest angle adjustor through the back band on both backrest tubes facing forwards or backwards gt Chap Back Backrest angle Fitting a foldable angle adjustable backrest Schwierigkeit Werkzeug 3 4 5 _ 8 10 drill rill bit 06 1 Remove mudguard or clothes guard from both sides Remove the seat cover Remove old backres
5. bolts on both axle clamp components E Remove both axle clamp components and the axle E Insert new axle re attach the axle clamp components and bolts Tighten the bolts only slightly E Ensure the wheels are parallel gt Chap Rear wheels Ensuring the rear wheels are parallel Ensuring the rear wheels are parallel Difficulty O Tools 5 mmm 22 The wheelchair will have ideal straight line stability when the rear wheels are exactly parallel to one another E Place the wheelchair on a flat even surface E Undo the bolts on the two axle clamp components E Atthe level of the axle measure the distance between the wheels at the front y and back x The distance at the front y must be precisely the same or up to 2 mm greater than the distance at the back x This difference evens itself out when someone sits in the wheelchair E Once the wheels are aligned tighten bolts E Check that the wheels are parallel once again E Check that the parking brakes are positioned and adjusted correctly Repairing or changing an inner tube Difficulty OO Tool tyre lever E Remove the rear wheel and release any air from the inner tube E Lift one tyre wall away from the rim using a bicycle tyre lever Do not use sharp objects such as a screwdriver which could damage the inner tube E Pull the inner tube out of the tyre E Repair the inner tube using a bicycle repair kit or if necessary repla
6. ce the tube E Inflate the tube slightly until it becomes round E Insert the valve into the valve hole on the rim and place the tube inside the tyre the tube must lie right round the tyre with no creases E Starting close to the valve push the tyre wall over the edge of the rim using both hands When doing this check all the way round to ensure that the inner tube is not trapped between the tyre and the rim E inflate the tube to its maximum operating pressure gt Table chap Rear wheels Checking the tyre pressure Check that no air is escaping from the tyre ccktischall 16 O gt 9Nm Ktischall AG Switzerland 2011 12 Service Manual Rear wheels Fitting tubed tyres to carbon wheels Difficulty O Tubed tyres must be attached to the rim using a special adhesive Carry out a test fitting first without using any adhesive E Check the valve length insert extension if necessary Recommendation inflate the tyres slightly before putting them on the rim This makes them easier to mount E Apply an even coating of adhesive to the protective strip on the tyres and allow to dry for at least 6 hours 3 If you have a new rim E Degrease the rim and roughen its base with fine sandpaper if required 1 E Apply an even coating of adhesive to the rim 2 and allow to dry for at least 6 hours If you have a used rim E Check the existing layer of adhesive An even and intact adhesive layer ca
7. dom Invacare Limited Pencoed Technology Park Pencoed Bridgend CF35 5AQ Switchboard Tel 44 0 1656 776 200 Fax 44 0 1656 776 201 Customer services Tel 44 0 1656 776 222 Fax 44 0 1656 776 220 Ktischall AG Schweiz 2011 12
8. e Manual Frame Frame Adjusting the frame The seat width seat depth lower leg length and tipping point are determi ned by the design of the frame and cannot be changed retrospectively A modification of the tip behaviour can only be achieved by ordering a new one off backrest The seat depth can be adjusted by changing the hole position Changing the frame Please contact the Kuischall customer service department if you wish to change the frame ccktischall 6 Ktischall AG Switzerland 2011 12 Service Manual Seat Seat Adjusting the seat height The seat height can only be adjusted by fitting a larger or smaller rear wheel and at the same time using a larger or smaller front wheel fork Possible front seat heights SHv mm 450 510 As the seat angle is dictated by the design of the frame the seat height rear SHh also changes by 10 mm The following settings are possible 90 75 N iiij O To ensure that the frame is straight and the axles of the front d wheel forks are perpendicular to the ground choose one of the combinations listed in the table j Front wheel ae ma Rear wheel f oat R SHv mm 450 500 400 480 24 460 510 400 480 Replacing the seat cover Difficulty Tools 3 4 5 8 10 E Remove mudguard or clothes guard by loosening bolts E Remove bolts on both sides of the
9. e front wheels will start to wobble when travelling at high speeds Replacing the front wheel Difficulty OO Tools 2x3 Er Remove bolts pull out wheel axle P Remove the front wheel and replace with a new one or move to a new position d Two extra sleeves per wheel are fitted for some front wheels EJ Replace the axle and tighten bolt Functional check There must be no play in the wheel but it must turn easily Cleaning the front wheel bearings E Check that the front wheels turn freely E Remove any dirt or hair from the front wheel bearings cckischall 14 Ktischall AG Switzerland 2011 12 Service Manual Rear wheels Rear wheels Checking the tyre pressure Tyre Max pressure Low resistance tyre 7 bar 700 kPa 101 psi Treaded tyre marathon 7 5 bar 750 kPa 108 psi Slick tyres speed run 10 bar 1000 kPa 145 psi Mountain bike tyre 4 bar 400 kPa 58 psi Tubed tyre carbon wheel 14 bar 1400 kPa 202 psi E Measure the tyre pressure E inflate the tyres to the required pressure E Check the tyre tread Change the tyres if necessary O The air pressure in tubed tyres on carbon wheels must be not less 1l than 10 bar in order to prevent damage to the carbon rim Checking the spoke tension The spokes may not be loose or distorted E Tighten any loose spokes with a suitable spoke spanner E Replace broken or distorted spokes and check that the wheel is run
10. ed tyres to carbon wheels Fitting adjusting the parking brake Options amp accessotles sisissosssesssssssnssossonssssonossssssssonsussssss sassasssssso si Fitting an antitipper cckischall un pn E SS a A Ktischall AG Switzerland 2011 12 Service Manual General Introduction This Service Manual contains all the technical information necessary for the inspection configuration or repair of a Kuischall wheelchair To maintain the necessary levels of safety and reliability every wheelchair 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 therefore break the various tasks down into 3 categories st Requirement Symbol Easy technical understanding required 00 Medium technical knowledge required e 0 Difficult technical knowledge and expertise in KE assembling wheelchairs required The required tools and their respective sizes are listed above each instruc tion The instructions include information on the torques with which the respective screw connections must be tightened Adhering to the given torques requires the use of a torque spanner Tools Symbol Allen key 3 4 5 Phillips screwdriver x2 Straddle spanner mat 10 11 19 Socket spanner ring spanner 8 10 Spare parts All spare parts can be purchased from Kti
11. ging the backrest angle also modifies the tipping point of the wheelchair Tipping point of the wheelchair The tipping point of the wheelchair can only be modified by fitting a new backrest with a larger or smaller backrest angle The seat depth can also be adjusted by changing the hole position Replacing the Standard Light backrest cover Difficulty OO Tools 3 Q 8x2 E Remove push handles if fitted gt Chap Back Replacing push handles Remove bolts and clothes guard or mudguard Open the Velcro fastener on both sides Pull the backrest cover up and off and slip the new backrest cover over the backrest tubes Close the Velcro fasteners again on both sides Fit mudguard or clothes guard E Fit push handles if required ccktischall 8 Ktischall AG Switzerland 2011 12 Service Manual Back Replacing Velcro tapes for adjustable backrests Difficulty Tools 3 4 5 8 10 2 The upper backrest bands can be taken straight off the backrest must be removed in order to access the lower ones E Remove backrest cover fi Remove mudguard or clothes guard E Push the backrest band down in order to access the bolts Remove nuts and bolts on both sides Pull the push handle and end band out of the backrest tube if fit ted Pull the upper backrest band off the backrest tube Remove bolts on both sides Remove the seat cover the bolts on bo
12. ld up the antitipper Tip the wheelchair backwards using the antitipper until the axle is perpen dicular to the antitipper s point of contact with the ground In this position the distance between the rear wheel and the ground must be at least 50 mm ccktischall 19 X x250mm Ktischall AG Switzerland 2011 12 c lt kuschall Kiischall AG Benkenstrasse 260 CH 4108 Witterswil kueschall invacare com www kueschall com Service Manual Ka ENGLISH 2011 12 kiischall distributors Belgium amp Luxemburg Invacare nv Autobaan 22 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 Br ndby Tel 45 0 36 90 00 00 Fax 45 0 36 90 00 01 denmark invacare com Deutschland Invacare GmbH Alemannenstrafe 10 D 88316 Isny Tel 49 0 75 62 7 00 0 Fax 49 0 75 62 7 00 66 kontakt invacare com Deutschland Ulrich Alber GmbH Vor dem Weissen Stein 21 D 72461 Albstadt Tailfingen Tel 49 0 74 32 2006 0 Fax 49 0 74 32 2006 299 info ulrich alber de European Distributor Organisation Invacare Kleiststrae 49 D 32457 Porta Westfalica Tel 49 0 57 31 754 540 Fax 49 0 57 31 754 541 edo invacare com Espa a Invacare SA c Areny s n Pol gon Industrial de Celr E 17460 Celr Girona Tel 34 0 972 49 32 00 Fax 34 0 972 49 32 20 contactsp invacare com Fr
13. n still be used If the layer is very uneven remove all adhesive from the rim and apply a fresh layer of adhesive E Apply a fresh layer of adhesive to the rim 2 and mount the tyre immediately E Mount the tyre Insert the valve Pull the tyre down forcefully so that the final part of the tyre can be lifted easily and in a controlled manner over the edge of the rim 4 7 E Inflate the tyre a little and ensure it is centred The edge of the protective seam strip 8 can be used as a guide E inflate the tyre to about 9 bar and use your full body weight to press it on all round Clean any excess adhesive from the braking surfaces of the rim E Important Keep under pressure for 24 hours Check tyre frequently f Never use tyres that have a damaged or loose protective strip cckischall 17 Ktischall AG Switzerland 2011 12 Service Manual Brakes Brakes Fitting adjusting the parking brake Difficulty oer Tools 5 Following each positioning the rear wheel parking brakes e g when changing the wheel chamber must be readjusted The parking brake function is only guaranteed if the tire has the corresponding air pressure E Check that the rear wheels have sufficient air i Loosely fix the clamping piece to the frame with the screw A Slide the brake into the correct position and tighten the screw When the brake is on the brake shoe must press approx 4 mm d into the
14. ning true Checking that removable axles are seated cor rectly E To check that a removable axle is seated correctly grasp the rear wheel by the hub and try to pull it off You should not be able to pull it off and it must only exhibit a very small amount of play E Ifthe rear wheels are not engaged properly remove any dirt or deposits If the problem persists adjust the removable axles Adjusting the removable axles Difficulty OO Tools mmm 17 79 E Remove the rear wheel adjust the removable axle slightly using two aN L spanners and replace If there is too much play shorten length L a little If the removable axle does not engage properly extend the length L O The adjustment must be carried out on both wheels When neither e d removable axle exhibits any play fit the wheels on the other side of the wheelchair The axles are adjusted correctly if one of them now exhibits a small amount of play c lt ktischall 15 Kiischall AG Switzerland 2011 12 Service Manual Rear wheels Replacing the rear wheels Difficulty 0 Proceed as follows if the rear wheels are replaced by ones of a different size or with other tyres E Check function of the parking brakes Adjust seat height gt Chap Seat Adjusting the seat height E Check that the mudguard or clothes guard is positioned correctly Replacing the axle Difficulty eg Tools 5 22 E Remove the wheels and unscrew
15. s guard using bolts and Fitting the mudguard Difficulty O Tools 5 8 drill drill bit 05 2 O The mudguard is customised to fit the geometry of the individual il wheelchair It must therefore only be replaced by another mudguard of the same size E Remove bolts and and the old mudguard E Use the old mudguard from the other side as a template by placing it on the new one and marking the position of the holes Drill holes in the new mudguard E Fit mudguard using bolts and ccktischall 13 Kiischall AG Switzerland 2011 12 Service Manual Front wheels Front wheels Replacing the front wheel fork Difficulty OO Tools 910 E Remove the sealing cap Do this by inserting two screwdrivers into the notches and carefully prising the sealing cap out E Remove nut and washer E Remove the front wheel fork E Check bearings and renew if necessary CAUTION Overtightening of the nuts may cause damage to the bearings E Insert the new castor fork and secure it using the washer and nut E Fit sealing cap Functional check Tip the wheelchair backwards 90 so that it rests on the backrest and rear wheels Turn the fork up A and allow it to fall down It 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 th
16. schall s Customer Services An electronic spare parts catalog is available by logging onto www kueschall com Only original spare parts may be used Installing additional adaptations to a Ktischall wheelchair requires the prior written approval of Ktischall AG Fastening with hexagon socket bolts Hexagon socket bolts are not designed to withstand an excessive applicati on 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 E Turn the nut using an open end spanner or preferably a socket span ner using the Allen key simply to stop the bolt turning 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 By d and not worn ER cckischall 4 Ktischall AG Switzerland 2011 12 Service Manual Torque All screw connections must be tightened with the torques specified in the following instructions Adhering to the given torques requires the use of a torque spanner Checks E Check that all bolts have been tightened with the torque specified in the instructions E Check the entire frame for cracks especially in the vicinity of joints and weld seams frame axle clamp components backrest A A Identifying and repairing faults Several bolts are sec
17. seat cover Remove seat cover and replace with new one O Owing to the tension inherent in the design of the frame it may not d be possible to fit the seat cover In this case the axle holders must be undone E Undo axle holders Fit new seat cover using bolts E Ensure the rear wheels are parallel gt Chap Rear Wheels Ensuring the rear wheels are parallel and tighten axle holder bolts E Fit mudguard or clothes guard using bolts ccktischall 7 K schall AG Switzerland 2011 12 Service Manual Back Backrest Adjusting the backrest height Readjusting the push handle telescopic tube Difficulty OO Tools 3 8 E Remove the backrest padding E Remove the screw connection and adjust the desired height of the push handle or the telescopic tube Insert the screw connection again and tighten the nut E Carry out the same setting on both sides E Refit the backrest padding O Ifthe desired height cannot be achieved you must use a different d telescopic tube or push handle If the backrest height is too high the backrest tube can be cut off and redrilled Possible backrest heights RH mm 270 285 300 315 330 345 360 375 390 Backrest angle If you want to change the backrest angle then the complete backrest will have to be replaced Possible backrest angles RW 74 78 82 86 90 O Chan
18. t Drill a new hole in the frame on both sides with 6 1 mm bit ata distance of 203 mm from the rearmost hole Re fit the seat cover Push the seat tube into the frame on both sides and secure with bolt E Fit end plugs into end of both seat tubes E Push the pre assembled backrest onto seat tubes and secure on both sides with bolt F Secure support plate using bolt through the seat cover E Secure support plate using bolt spacer plastic washer washer if required bolt and plastic washer in the required adjustor position gt Chap Back Backrest angle E On both support plates pull the strap through hole and make a knot at both ends E Position the mudguard or clothes guard on the support plate and drill at position E Screw the mudguard or clothes guard onto the support plate 7 Nm Backrest angle The backrest angle adjustor can be fitted facing forwards or facing backwards El Fitted facing forwards for seat angles 82 86 and 90 F Fitted facing backwards for seat angles 74 and 78 ccktischall 11 K schall AG Switzerland 2011 12 Service Manual Footrests Footrests Three types of footrest are available A footrest in aluminium or titanium and a footrest with an adjustable footplate O The titanium footrest requires a different sleeve in order to secure it d in the frame Replacing the footrest Difficulty
19. th sides and the backrest EHEHE Replace the lower backrest band and put the backrest to one side O Owing to the tension inherent in the design of the frame it may be extremely difficult to reposition the backrest in the frame In this case the axle holders must also be undone Undo axle holders Insert the new backrest and secure using bolts Fit the seat cover insert and tighten bolts Ensure the rear wheels are parallel gt Chap Rear wheels Ensuring the rear wheels are parallel and tighten axle holder bolts Pull the upper backrest band O over the backrest tube Refit the push handles and end band and secure using bolts E Fit mudguard or clothes guard ccktischall 9 O gt 7Nm gt 4Nm gt 7Nm K schall AG Switzerland 2011 12 Service Manual Back Replacing push handles with Light cover Difficulty oer Tools 3 4 2 8 E Remove bolts on both sides E Push the cover down a little to expose the bolt Remove bolts on both sides Remove mudguard or clothes guard Pull out push handle and replace with new one Insert and tighten bolt on both sides Fit cover to both push handles using bolt O Ifa push handle is not going to be fitted a new Light cover that is d sealed at the top can be used Replacing push handles with adjustable backrest Difficulty oer Tools 3 4 8 2 E Remove backrest cover E Remove bolts and end
20. tire Furthermore please note that very little force is required for activating and deactivating the brake If necessary a brake lever extension can be fitted lo Visual check Check that the parking brake is correctly positioned The brake is correctly adjusted if the brake shoe does not press more than 4 mm into the tire when the brake is on Function check Place the loaded wheelchair on a ramp with a 7 slope with the parking brake on The wheelchair must not move Carry out this check with the wheelchair both facing down the ramp and facing up the ramp ccktischall 18 Ktischall AG Switzerland 2011 12 Service Manual Options amp accessories Options amp accessories Fitting an antitipper Difficulty Tools 5 E Undo bolt and remove the lower part of the axle holder fA Secure the adapter bracket with a bolt and apply a low strength adhesive e g Loctite 243 Fit antitipper to adapter bracket Tighten bolts Setting the height E Push in adjusting knob and pull the antitipper tube to the required position Allow the adjusting knob to latch into one of the holes Measure the distance to the ground it must be between 40 and 60 mm gt 9 Nm gt 9 Nm Function check The antitipper must be able to swing underneath the wheelchair without any difficulty The distance between the antitipper and the ground must be 40 60 mm It must be easy to fo
21. ured with adhesive If these are loosened they have to be cleaned and secured with adhesive again Self locking nuts and screws once loosened have to be replaced by new ones Fault Possible cause Action Incorrect tyre pressure on one rear wheel Correct tyre pressure The wheelchair does not travel One or more spokes broken Replace broken spoke s in a straight line Spokes tightened unevenly Tighten loose spokes Frame geometry does not meet specifications Fitting an antitipper The wheelchair tips too easily Backrest angle too great Replace backrest with smaller backrest angle Removable axles cannot be Removable axles dirty Clean removable axles inserted correctly Removable axles misaligned The brakes are gripping poorly Incorrect tyre pressure in one or both rear tyres or asymmetrically Adjust removable axles Correct tyre pressure The rolling resistance is very Tyre pressure in rear tyres is too low Correct tyre pressure high Rear wheels not parallel Ensure rear wheels are parallel The front wheels wobble when Too little tension in front wheel bearing block moving fast Front wheel has worn smooth The front wheel is stiff or stuck Bearings are dirty or faulty Tighten the nut on the bearing block axle slightly Change front wheel Clean or replace the bearings ccktischall 5 Ktischall AG Switzerland 2011 12 Servic
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