Service Manual
Contents
1. Check that the mudguard or clothes guard is positioned correctly Replacing the axle Difficulty Tool fg 6 HH 22 E Remove the wheels and unscrew bolts on both axle clamp components El 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 EB Ensure the wheels are parallel gt Ensuring the rear wheels are parallel Ensuring the rear wheels are parallel Difficulty Tool fg 6 HH 22 The wheelchair will have ideal straight line stability when the rear wheels are exactly parallel to one another Place the wheelchair on a flat even surface Undo the bolts on the two axle clamp components At the level of the axle measure the distance between the wheels at the front y and back x The distance at the front y should be precisely the same or up to 2mm greater than the distance at the back x This difference evens itself out when someone sits in the wheelchair Once the wheels are aligned tighten bolts 9 Nm Check that the wheels are parallel once again Check that the parking brakes are positioned and adjusted correctly Repairing or changing an inner tube Difficulty Tool tyre lever Remove the rear wheel and release any air from the inner tube Lift one tyre wall away from the rim using a bicycle tyre lever Do not use sharp objects such as a screwdriver which could da2. have a used rim E Check the existing layer of adhesive An even and intact adhesive layer can still be used If the layer is very uneven remove all adhesive from the rim and apply a fresh layer of adhesive 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 N Never use tyres that have a damaged or loose protective strip c k schall 18 K schall AG Switzerland 04 2010 Service Manual Brakes Brakes Checking the parking brake BE Check that the parking brakes are positioned correctly 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 25mm from the tyre when the brake is released E Adjust the parking brakes if necessary Fitting and adjusting the parking brake Difficulty Tool 4 CAUTION
3. rear wheels are parallel Repairing or changing an inner tube Fitting tubed tyres to carbon wheels Brak s issssccsscicscaccessssssnssccsnscsesosssdenscendcescesscesiesecnscsvecesasbedacssosssessetens Checking the parking brake Fitting and adjusting the parking brake Options amp accessories essecssssssossensnnssnnennnnssnsssnnsnsssnsnsnssnssnsnsnssnnsnnsnen Fitting an antitipper c k schall vu SS E E a a NN o K schall AG Switzerland 04 2010 Service Manual General Introduction This Service Manual contains all the technical information necessary for the inspection configuration or repair of a K schall 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 Requirement Symbol Easy technical understanding required Medium technical knowledge required ee Difficult technical knowledge and expertise in see assembling wheelchairs required Spare parts All spare parts may be obtained from the K schall customer ser vice department An electronic spare parts catalogue can be found at www kueschall com Tipping point ofthe wheelchair The tipping point of the wheelchair can only be modified by fi
4. 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 A 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 Kingdom Invacare Limited Pencoed Technology Park Pencoed Bridgend CF35 5HZ 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
5. The parking brakes must be adjusted whenever the rear wheels are replaced BE Check the air pressure in the rear wheels El Fasten the brake holder to the frame using bolt Do not tighten the bolt El Push the brake into the brake holder and position it as required EB Tighten the bolts O The brake is set correctly if the brake rod presses into the tyre by no more than 4mm when the brake is applied ccktischall 19 K schall AG Switzerland 04 2010 Service Manual Options amp accessories Options amp accessories Fitting an antitipper Difficulty eg Tool MS El 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 Max torque 9Nm u 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 should be between 4 and 6 cm Functional check The antitipper should be able to swing underneath the wheelchair without any difficulty ccktischall 20 K schall AG Switzerland 04 2010 Service Manual c k schall 21 K schall AG Switzerland 04 2010 cck schall K schall AG Benkenstrasse 260 CH 4108 Witterswil kueschall invacare com www kueschall com Ser
6. acing push handles with adjustable backrest Difficulty ee Tool Ei 2 3 4 ES E Remove backrest cover E Remove bolts and end band E Push the backrest band down alittle to expose the bolt Remove nut and bolt on both sides E Pull push handle out of the backrest tube E Slip end band over the new push handle and secure in the desired position using bolt Secure end band with bolt c k schall 10 K schall AG Switzerland 04 2010 Service Manual Back Foldable backrest angle adjustable optional Optionally a foldable angle adjustable backrest can be fitted N 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 a Rear wheels section entitled lt Replacing the axle Pre assembling the foldable backrest Difficulty Tool Bo E 70 m3 m4 mes 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 9 Nm Fit the backrest angle adjustor through the back band on both backrest tubes facing forwards or backwards 4 Nm gt Backrest angle Fitting a foldable angle adjustable backrest Difficulty e e Tool 8 G10 m3 m4 mS drill ill bit 6 1 Remove mudguard or clothes guard from both s
7. age to the carbon rim Checking the spoke tension The spokes should 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 running 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 EB 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 Tool HZ 19 11 El Remove the rear wheel adjust the removable axle slightly using 2 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 Dee L O The adjustment must be carried out on both wheels When neither 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 SCH c k schall 16 K schall AG Switzerland 04 2010 Service Manual Rear wheels Replacing the rear wheels Difficulty Proceed as follows if the rear wheels are replaced by ones of a different size or with other tyres Check that the parking brakes are positioned correctly
8. ange the frame c k schall 6 K schall AG Switzerland 04 2010 Service Manual Seat Seat Adjusting the seat height The seat height can only be adjusted by fitting a larger or smaller rear wheel and atthe same time using a larger or smaller front wheel fork Possible front seat heights SHv cm 50 51 As the seat angle is dictated by the design of the frame the seat height rear SHh also changes by 1cm The following settings are possible 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 possible SHh Front wheel 03 04 38 47 Replacing the seat cover Difficulty e e Tool Ei 3 3 4 mS E Remove mudguard or clothes guard E Remove bolts on both sides of the seat cover Remove seat cover and replace with new one 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 BE Ensure the rear wheels are parallel see section entitled Rear wheels and tighten axle holder bolts E Fit mudguard or clothes guard ccktischall 7 K schall AG Switzerland 04 2010 Service Manual Back Backrest Backrest height The backrest mo
9. cck schall designed for life The ei at ce Service Manual Service Manual Contents Introduction Spare parts Tipping point of the wheelchair 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 sisscssscsccdessccscssssssccasssosssvdsosssauessssncssscsaesesesasscusssusscesiecedesssesense Backrest height Backrest angle 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 FOOTE tS ios sssssccssscciccciccisccecdescssesssstbecasodacsssosseadsosssacsacecssssceseveasssscessees Replacing the footrest Adjusting the height of the footrest Adjusting the angle of the footrest Fitting the clothes guard Fitting the mudguard Front wheels scisicssscscccssccscnscevectedassensdensacecesvacsiescscesessosssesendsnesesssvosessas Replacing the front wheel fork Replacing the front wheel Cleaning the front wheel bearings Rear wheels ssseessasssssssosnsnsansesssssesssssunnsssssusussnnsnnnsssssasssassenssnnssssssene 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
10. des 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 both 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 see section entitled Rear wheels 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 c k schall 9 K schall AG Switzerland 04 2010 Service Manual Back Replacing push handles with Light cover Difficulty ee Tool 3 4 ES El Remove bolts on both sides El Push the cover down a little to expose the bolt Remove bolt 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 must be used Repl
11. dule must be replaced if you want to alter the backrest height Possible backrest heights The ae RH cm ER 28 5 30 315 33 34 5 36 37 5 39 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 Changing the backrest angle also modifies the tipping point of the 1 wheelchair Replacing the Standard Light backrest cover Difficulty Too Bs e ES El Remove push handles if fitted gt Replacing the push handles the backrest tubes EB Fit push handles if required cckischall Fit mudguard or clothes guard Open the Velcro fastener on both sides Close the Velcro fasteners again on both sides Remove bolts and clothes guard or mudguard Pull the backrest cover up and off and slip the new backrest cover over K schall AG Switzerland 04 2010 Service Manual Back Replacing Velcro tapes for adjustable backrests Difficulty e e Tool E 3 E 10 m3 m E 5 ES 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 El Remove mudguard or clothes guard E Push the backrest band down in order to access the bolts Remove nuts and bolts on both si
12. eplacing the front wheel Difficulty Tool 3 3 El Remove bolts pull out wheel axle El Remove the front wheel and replace with a new one or move to a new position In the case of the Starec wheel Skater wheel 3 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 EI Replace the axle and tighten bolt Functional check There must be no play in the wheel but it must turn easily c k schall 14 K schall AG Switzerland 04 2010 Service Manual Front wheels Cleaning the front wheel bearings BE Check that the front wheels turn freely El Remove any dirt or hair from the front wheel bearings cckiischall 15 K schall AG Switzerland 04 2010 Service Manual The si 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 El Measure the tyre pressure E inflate the tyres to the required pressure E Check the tyre tread Change the tyres if necessary The air pressure in tubed tyres on carbon wheels must be not less 1l than 10 bar in order to prevent dam
13. ides Remove the seat cover Remove old backrest Drill a new hole in the frame on both sides with 6 1 mm bit at a 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 9 Nm EB 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 9 Nm fA Secure support plate using bolt through the seat cover 9 Nm E Secure support plate using bolt spacer plastic washer washer if required bolt and plastic washer in the required adjustor position gt 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 El Screw the mudguard or clothes guard onto the support plate 7 Nm Backrest angle The backrest angle adjustor can be fitted facing forwards or lt facing backwards El Fitted facing forwards for seat angles 82 86 and 90 Fitted facing backwards for seat angles 74 and 78 c k schall 11 K schall AG Switzerland 04 2010 Service Manual Footrests Footrests Three types offootrest 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
14. it clothes guard using bolts and Fitting the mudguard Difficulty e Tool KR drill drill bit 05 2 O The mudguard is customised to fit the geometry of the individual it wheelchair It should 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 c k schall 13 K schall AG Switzerland 04 2010 Service Manual Front wheels Front wheels Replacing the front wheel fork Difficulty Tool Hi 8 6 E Remove the sealing cap Do this by inserting two screwdrivers into the notches and carefully prising the sealing cap out Remove nut and washer Remove the front wheel fork Check bearings and renew if necessary Insert new front wheel fork with washer and nut tighten nut 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 tighte ned enough There is a risk that the front wheels will start to wobble when travelling at high speeds R
15. mage the inner tube Pull the inner tube out of the tyre Repair the inner tube using a bicycle repair kit or if necessary replace the tube Inflate the tube slightly until it becomes round Insert the valve into the valve hole on the rim and place the tube inside the tyre the tube should lie right round the tyre with no creases 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 Inflate the tube to its maximum operating pressure see table at the start of the Rear wheels section Check that no air is escaping from the tyre ccktischall 17 K schall AG Switzerland 04 2010 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 El 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 Apply an even coating of adhesive to the rim 2 and allow to dry for at least 6 hours If you
16. secure it 1l in the frame Replacing the footrest Difficulty Too Hi 8 4 E Remove bolts on both sides E Pull out footrest and replace with new one E Insert the bolts through the frame and into the nearest holes on both sides and tighten them Adjusting the height of the footrest Difficulty Tool 4 The footrest can be adjusted in 1cm 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 on both sides and tighten them Adjusting the angle of the footrest Difficulty e Tool fl 3 E 5 ES 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 bolts again The bolts must be tightened very securely to prevent the footplate from moving c k schall 12 K schall AG Switzerland 04 2010 Service Manual Sides Sides Fitting the clothes guard Difficulty Tool KR drill drill bit 05 2 The clothes guard is customised to fit the geometry of the individual d wheelchair It should 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 EB F
17. tting a new backrest with a larger or smaller backrest angle The seat depth can also be adjusted by changing the hole position Fastening with hexagon socket bolts Hexagon socket bolts are not designed to withstand an excessive appli cation of force When tightening or undoing a hexagon socket bolt force should 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 and not worn il Pox c lt kischall 4 SHh K schall AG Switzerland 04 2010 Service Manual Visual check Part of the regular maintenance of the wheelchair includes the following visual checks Test all bolt connections BE Check the entire frame for cracks especially in the vicinity of joints and weld seams frame axle clamp components backrest 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 Tighten loose spokes The
18. vice Manual Ks ENGLISH 2010 04 k schall 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 Aquatec GmbH Alemannenstra e 10 D 88316 Isny Tel 49 0 75 62 7 00 0 Fax 49 0 75 62 7 00 66 info invacare aquatec 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 Kleiststra e 49 D 32457 Porta Westfalica Tel 49 0 57 31 754 540 Fax 49 0 57 31 754 541 edo invacare com Espana 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 France 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
19. wheelchair tips too easily Frame geometry does not meet specifications Fitting an antitipper Backrest angle too great Replace backrest with smaller backrest angle Removable axles cannot be inserted correctly Removable axles dirty Clean removable axles Adjust removable axles Removable axles misaligned The brakes are gripping poorly or asymmetrically Incorrect tyre pressure in one or both rear tyres Correct tyre pressure The rolling resistance is very high Tyre pressure in rear tyres is too low Correct tyre pressure Rear wheels not parallel Ensure rear wheels are parallel The front wheels wobble when moving fast Too little tension in front wheel bearing block Front wheel has worn smooth Tighten the nut on the bearing block axle slightly Change front wheel The front wheel is stiff or stuck Bearings are dirty or faulty Clean or replace the bearings cckischall K schall AG Switzerland 04 2010 Service 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 po sition Changing the frame Please contact the K schall customer service department if you wish to ch
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