FIOR & GENTZ NEURO FLEX MAX Tutorial Download

Page: 2 / 55

09-12-18

2/55

Joint Assembly NEURO FLEX MAX

09-12-18

2/55

Joint Assembly NEURO FLEX MAX

Basic Function

Step 1/23

Clean the system joint.

Step 2/23

If you are using a supporting joint, shorten the extension stop damper with a

sharp knife. Now, the system joints reach the extension stop at the same

time and the locking pawl should lock without diﬃculty.

Step 3/23

Summary of Contents for NEURO FLEX MAX

Page 1: ... the NEURO LOCK MAX and the NEURO FLEX MAX no permanent unlock function Furthermore a ﬂexion stop disc is already integrated into the joint s lower part of the NEURO LOCK MAX system knee joint whereas in the case of the NEURO FLEX MAX it still needs to be mounted Consult the manual chapter 11 Assembly Instructions of the corresponding system joint to learn about the diﬀerences regarding mounting t...

Page 2: ... FLEX MAX Basic Function Step 1 23 Clean the system joint Step 2 23 If you are using a supporting joint shorten the extension stop damper with a sharp knife Now the system joints reach the extension stop at the same time and the locking pawl should lock without diﬃculty Step 3 23 ...

Page 3: ...rst sliding washer and adhere it to the cover plate Grease the other side of the sliding washer slightly with the delivered orthosis joint grease Step 4 23 Place the ﬂexion stop disc on the joint s lower part and press both by using a vice Note Use a vice with plain or soft jaws in order not to aﬀect the joint function Step 5 23 ...

Page 4: ...nt s upper part Step 6 23 If you have to demount the extension stop screw it out of the joint s upper part by using the pan head screw delivered with the system joint If it is mounted correctly you do not have to demount the extension stop Step 7 23 Insert the pressure spring by pushing it from below into the spring duct of ...

Page 5: ...ease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease Step 9 23 Put the bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Mount the locking pawl Step 10 23 ...

Page 6: ...op Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl Step 11 23 Push the locating pin against the spring force into the system joint until it locks in the joint s upper part The locking pawl is now secured which facilitates the following assembly of the system joint Step 12 23 ...

Page 7: ...faces of the bearing nut with the delivered orthosis joint grease Step 13 23 Put the joint axis bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Step 14 23 Grease the second sliding washer slightly with the delivered orthosis joint grease Step 15 23 ...

Page 8: ... ﬁxing the bearing nut place the second sliding washer onto the joint s upper part and mount the joint s lower part Step 16 23 Mount the cover plate Turn in the ﬁrst countersunk ﬂat head screw axle screw Continue with the second countersunk ﬂat head screw while still ﬁxing the bearing nut Step 17 23 ...

Page 9: ...tended openings Note The delivered screws are always matching the system joint Even if the screws are not as long as the thread of the bearing nuts that does not aﬀect the system joint s load capacity Step 19 23 Check if the system joint moves freely Bring the system joint in extension In order to check the ﬂexion hold the orthosis in a horizontal position and then let go of the femoral shell The ...

Page 10: ...ll and try to move the femoral shell in varus valgus direction If the system joint runs with lateral play mount the next thicker sliding washers repeat all steps from step 12 onwards and check again Note At a bilateral orthosis only check one system joint at a time Step 21 23 Bring the system joint as far as possible in extension Then disable the permanent unlock function by pressing the locking p...

Page 11: ...t Note Mind the information on the locking pawls in the manual Step 22 23 Check the position of the locking pawl You can see the correct position on the left picture If the locking pawl does not ﬁt well exchange it Step 23 23 Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width ...

Page 12: ...ative function 1 by exchanging the locking parts To do so exchange the extension stop according to the intended extension position by choosing a degree Note You will ﬁnd the article numbers of the extension stops in our product catalogue System Joints and Articulated System Side Bars Step 2 28 Secure the locking pawl permanent unlock function Disassemble the system joint Step 3 28 ...

Page 13: ... so clamp the ﬂexion stop disc in a vice and carefully lever it of the joint s upper part Note Use a vice with plain or soft jaws in order not to aﬀect the joint function Step 4 28 Demount the extension stop To do so screw it out of the joint s upper part by using the pan head screw delivered with the system joint Step 5 28 ...

Page 14: ...e ﬂexion stop disc is marked with lines that serve as a guide when ﬁling the desired ﬂexion and thus enable an accurate locking of the pawl at the lock area R1 The marked lines are not straight but slightly bent Do not use a ﬂat ﬁle and ensure a smooth transition from lock area to lock disc R2 Note Mount the system joint in order to check the proper locking function and to be able to readjust the ...

Page 15: ...d to the sides Step 8 28 Place the ﬂexion stop disc on the joint s lower part and press both by using a vice Note Use a vice with plain or soft jaws in order not to aﬀect the joint function Step 9 28 Apply spray adhesive to one side of the ﬁrst sliding washer and adhere it to the cover plate Grease the other side of the sliding washer slightly with the delivered orthosis joint grease Step 10 28 ...

Page 16: ...tension stop to the joint s upper part Step 11 28 Insert the pressure spring by pushing it from below into the spring duct of the joint s upper part Step 12 28 If you exchange the delivered locking pawl with another choose the smallest possible locking pawl that still ﬁts As locking pawls are wear parts ...

Page 17: ...ormation on the locking pawls in the manual Step 13 28 Grease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease Step 14 28 Put the bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Mount the locking pawl Step 15 28 ...

Page 18: ... top Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl Step 16 28 Push the locating pin against the spring force into the system joint until it snaps in the joint s upper part The locking pawl is now secured which facilitates the further assembly of the system joint Step 17 28 ...

Page 19: ...rfaces of the bearing nut with the delivered orthosis joint grease Step 18 28 Put the joint axis bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Step 19 28 Grease the second sliding washer slightly with the delivered orthosis joint grease Step 20 28 ...

Page 20: ...l ﬁxing the bearing nut place the second sliding washer onto the joint s upper part and mount the joint s lower part Step 21 28 Mount the cover plate Turn in the ﬁrst countersunk ﬂat head screw axle screw Continue with the second countersunk ﬂat head screw while still ﬁxing the bearing nut Step 22 28 ...

Page 21: ...he intended openings Note The delivered screws are always matching the system joint Even if the screws are not as long as the thread of the bearing nuts that does not aﬀect the joint s load capacity Step 24 28 Check if the system joint moves freely Bring the system joint in extension In order to check the ﬂexion hold the orthosis in a horizontal position and then let go of the femoral shell The fe...

Page 22: ...o move the femoral shell in varus valgus direction If the system joint runs with lateral play you need to mount the next thicker sliding washers and repeat all steps starting at step 18 Check again Note At a bilateral orthosis only check one system joint at a time Step 26 28 Bring the system joint as far as possible in extension Then disable the permanent unlock function by pressing the locking pa...

Page 23: ...t Note Mind the information on the locking pawls in the manual Step 27 28 Check the position of the locking pawl You can see the correct position on the left picture If the locking pawl does not ﬁt well exchange it Step 28 28 Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width ...

Page 24: ...moving monocentric joint with integrated posterior oﬀset alternative function 2 by removing the locking parts Note the next work steps for the removal of the locking parts Note You will ﬁnd further information on alternative function 2 in the manual Step 2 16 Secure the locking pawl permanent unlock function Disassemble the system joint Step 3 16 ...

Page 25: ...pper part by using the pan head screw delivered with the system joint If the extension stop is mounted correctly you do not have to demount it Step 4 16 Demount all system components Clean the system joint Check all system components and exchange them if there are signs of wear Note Follow the maintenance instructions in the manual of the system joint Step 5 16 ...

Page 26: ... correctly on the joint s upper part now Step 6 16 Apply spray adhesive to one side of the ﬁrst sliding washer and adhere it to the cover plate Grease the other side of the sliding washer slightly with the delivered orthosis joint grease Step 7 16 Grease the friction surfaces of both bearing nuts with the delivered orthosis joint grease Step 8 16 ...

Page 27: ... nuts into the intended openings of the joint s upper part and make sure that they are in the correct position Fix the bearing nut of the locking pawl with one ﬁnger The locking pawl is not mounted again Step 9 16 Grease the second sliding washer slightly with the delivered orthosis joint grease Step 10 16 ...

Page 28: ...part and mount the joint s lower part Step 11 16 Mount the cover plate Turn in the ﬁrst countersunk ﬂat head screw axle screw Continue with the second countersunk ﬂat head screw while still ﬁxing the bearing nut Step 12 16 If the sliding washer has been damaged during the assembly of the cover plate audible cracking remove the particles and place a new sliding washer Step 13 16 ...

Page 29: ...joint s load capacity Step 14 16 Check if the system joint moves freely Bring the system joint in extension In order to check the ﬂexion hold the orthosis in a horizontal position and then let go of the femoral shell The femoral shell should smoothly fall downward until it reaches the maximum possible ﬂexion grade If the system joint does not move freely mount the next thinner sliding washers repe...

Page 30: ...l and try to move the femoral shell in varus valgus direction If the system joint runs with lateral play mount the next thicker sliding washers repeat all steps from step 8 onwards and check again Note With a bilateral orthosis only check one system joint at a time Step 16 16 Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width Step 1 26 ...

Page 31: ...ction and want to convert it exchange the mounted ﬂexion stop disc and the locking pawl with a step lock stop disc and a step lock pawl This enables a gradual locking of the system joint from a ﬂexed position of 55 or 60 via 10 steps to the required ﬂexed position premounted is it at 5 Note You will ﬁnd the article numbers of the step lock stop disc and the step lock pawl in our product catalogue ...

Page 32: ... stop and choose a corresponding step lock stop disc AF3 with 0 10 20 or 30 The system joint locks the ﬁrst time in a ﬂexed position of 60 and after that in 10 steps You do not need an extension stop for a 0 knee ﬂexion angle Step 4 26 If you have to demount the ﬂexion stop disc clamp the ﬂexion stop disc in a vice and carefully lever it of the joint s upper part Note Use a vice with plain or soft...

Page 33: ...lower part and press both by using a vice Note Use a vice with plain or soft jaws in order not to aﬀect the joint function Step 6 26 If you have to demount the extension stop screw it out of the joint s upper part by using the pan head screw delivered with the system joint If it is mounted correctly you do not have to demount the extension stop Step 7 26 ...

Page 34: ...ystem components Clean the system joint Check all system components and exchange them if there are signs of wear Note Follow the maintenance instructions in the manual of the system joint Step 8 26 If you have demounted the extension stop before place it correctly on the joint s upper part now Step 9 26 ...

Page 35: ...h the delivered orthosis joint grease Step 10 26 Insert the pressure spring by pushing it from below into the spring duct of the joint s upper part Step 11 26 If you exchange the delivered locking pawl with a step lock pawl choose the smallest possible ﬁtting step lock pawl As locking pawls are wear parts and wear out you can then mount the next bigger locking pawl if necessary Note Mind the infor...

Page 36: ...xle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease Step 13 26 Put the bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Mount the locking pawl Step 14 26 ...

Page 37: ...top Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl Step 15 26 Push the locating pin against the spring force into the system joint until it snaps in the joint s upper part The step lock pawl is now secured which facilitates the further assembly of the system joint Step 16 26 ...

Page 38: ...rfaces of the bearing nut with the delivered orthosis joint grease Step 17 26 Put the joint axis bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Step 18 26 Grease the second sliding washer slightly with the delivered orthosis joint grease Step 19 26 ...

Page 39: ...l ﬁxing the bearing nut place the second sliding washer onto the joint s upper part and mount the joint s lower part Step 20 26 Mount the cover plate Turn in the ﬁrst countersunk ﬂat head screw axle screw Continue with the second countersunk ﬂat head screw while still ﬁxing the bearing nut Step 21 26 ...

Page 40: ... intended openings Note The delivered screws are always matching the system joint Even if the screws are not as long as the thread of the bearing nuts that does not aﬀect the joint s load capacity Step 23 26 Check if the system joint moves freely Bring the system joint in extension In order to check the ﬂexion hold the orthosis in a horizontal position and then let go of the femoral shell The femo...

Page 41: ...and try to move the femoral shell in varus valgus If the system joint runs with lateral play you need to mount the next thicker sliding washers and repeat all steps starting at step 14 Check again Note At a bilateral orthosis only check one system joint at a time Step 25 26 Bring the system joint as far as possible in extension Then disable the permanent unlock function by pressing the step lock p...

Page 42: ...t in the system joint Note Mind the information on the locking pawls in the manual Step 26 26 Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width Step 1 29 Alternative function 4 is an expansion of alternative function 1 At AF 1 the locked system joint can be used for locking in diﬀerent ﬂexed positions by exchanging the locking parts To do so excha...

Page 43: ...o so exchange the ﬂexion stop disc AF4 and cover plate AF4 Note You will ﬁnd the article numbers of the ﬂexion stop disc AF4 and cover plate AF4 in our product catalogue System Joints and Articulated System Side Bars Step 2 29 Secure the locking pawl permanent unlock function Disassemble the system joint Step 3 29 Demount the ﬂexion stop disc To do so clamp the ﬂexion stop disc in a vice and caref...

Page 44: ...nt s upper part by using the pan head screw delivered with the system joint If it is mounted correctly you do not have to demount the extension stop Step 5 29 Demount all other system components Clean the system joint Check all system components and exchange them if there are signs of wear Note Follow the maintenance instructions in the manual of the system joint Step 6 29 ...

Page 45: ...ﬂat ﬁle and ensure a smooth transition from lock area to lock disc R2 Note Mount the system joint in order to check the proper locking function and to be able to readjust the ﬂexion degree if required Step 7 29 If applicable ﬁle the ﬂexion stop disc AF4 according to the ﬂexion grade corresponding to the extension stop as well as the maximum possible ﬂexion position when the system joint is unlocke...

Page 46: ... MAX Place the ﬂexion stop disc AF4 on the joint s lower part and press both by using a vice Note Use a vice with plain or soft jaws in order not to aﬀect the joint function Step 9 29 If you demounted the extension stop before place it correctly on the joint s upper part now Step 10 29 ...

Page 47: ...th the delivered orthosis joint grease Step 11 29 If you exchange the delivered locking pawl with another choose the smallest possible locking pawl that still ﬁts As locking pawls are wear parts and wear out you can then mount the next bigger locking pawl if necessary Note Mind the information on the locking pawls in the manual Step 12 29 Insert the pressure spring by pushing it from below into th...

Page 48: ...xle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease Step 14 29 Put the bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Mount the locking pawl Step 15 29 ...

Page 49: ... top Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl Step 16 29 Push the locating pin against the spring force into the system joint until it snaps in the joint s upper part The locking pawl is now secured which facilitates the further assembly of the system joint Step 17 29 ...

Page 50: ...rfaces of the bearing nut with the delivered orthosis joint grease Step 18 29 Put the joint axis bearing nut into the intended opening of the joint s upper part and make sure that it is in the correct position Fix the bearing nut with one ﬁnger Step 19 29 Grease the second sliding washer slightly with the delivered orthosis joint grease Step 20 29 ...

Page 51: ...ﬁxing the bearing nut place the second sliding washer onto the joint s upper part and mount the joint s lower part Step 21 29 Mount the cover plate AF4 Turn in the ﬁrst countersunk ﬂat head screw axle screw Continue with the second countersunk ﬂat head screw while still ﬁxing the bearing nut Step 22 29 ...

Page 52: ...he intended openings Note The delivered screws are always matching the system joint Even if the screws are not as long as the thread of the bearing nuts that does not aﬀect the joint s load capacity Step 24 29 Check if the system joint moves freely Bring the system joint in extension In order to check the ﬂexion hold the orthosis in a horizontal position and then let go of the femoral shell The fe...

Page 53: ...and try to move the femoral shell in varus valgus If the system joint runs with lateral play mount the next thicker sliding washers repeat all steps from step 18 onwards and check again Note At a bilateral orthosis only check one system joint at a time Step 26 29 Bring the system joint as far as possible in extension Then disable the permanent unlock function by pressing the locking pawl against t...

Page 54: ...stem joint Note Mind the information on the locking pawls in the manual Step 27 29 Check the position of the locking pawl You can see the correct position on the left picture here AF1 If the locking pawl does not ﬁt well exchange it Step 28 29 Check the maximum possible ﬂexion grade Step 29 29 ...

Page 55: ...55 55 Joint Assembly NEURO FLEX MAX 09 12 18 55 55 Joint Assembly NEURO FLEX MAX PDF Download Online Tutorial Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width ...

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FIOR & GENTZ NEURO FLEX MAX, Tutorial

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Summary of Contents for NEURO FLEX MAX

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