Otto Bock BRAVOracer Service Manual Download Page 7

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3 Required tools, maintenance schedule

3.1 Required tools

The following list shows the tools and accessories required for service.

Ratchet wrench and socket set,

sizes 8 – 4

Torque wrench,

measurement range 5 – 50 Nm

Wrenches,

sizes 0 – 4

Allen wrenches,

sizes – 6

Screwdrivers, blade widths

.5, .5, and 5.5 mm

Phillips screwdriver,

size

Plastic hammer

Hammer, approximately 00 g

Stanley knife with sickle hooked

blade and standard blade

Side cutting pliers

Liquid thread lock “medium strength”

Rivet gun

for rivets up to ø 5mm

Summary of Contents for BRAVOracer

Page 1: ...BRAVOracer Service Manual ...

Page 2: ......

Page 3: ...cing the anti tipper 9 4 1 4 Retrofitting replacing adjusting the transport wheels 10 4 1 5 Retrofitting replacing the crutch holder 10 4 2 Assembly B Footrest 11 4 2 1 Adjusting replacing the footplate 11 4 2 2 Adjusting the lower leg length 12 4 2 3 Adjusting the footplate angle 13 4 2 4 Replacing retrofitting the lateral heel blocks on the footplate 14 4 3 Assembly C Seat 15 4 3 1 Replacing the...

Page 4: ...on 29 4 5 5 Replacing the arm pad lengthwise adjustment 30 4 6 Assembly F Casters 30 4 6 1 Replacing the caster axle 30 4 6 2 Removing replacing the casters 31 4 6 3 Replacing the caster forks 32 4 7 Assembly G Rear wheels 32 4 7 1 Centre of gravity and seating position 32 4 7 2 Replacing the rear wheel attachment assembly 32 4 7 3 Replacing the fitting and camber adapter 33 4 7 4 Installing a whe...

Page 5: ...e wheelchair user This service and maintenance manual refers to the spare parts catalogues and instructions for use for the products described Please use these documents together Use photocopies of the maintenance schedule checklist in Section 3 2 Retain completed maintenance schedules and provide the customer with a copy Instructions for Use Spare Parts Catalogue BRAVO Racer 647G447 D GB 1 2 Tech...

Page 6: ... you do not have a copy of the instructions for use you can order one from the manufacturer see the overview of all Otto Bock branches Otto Bock Worldwide You can also download documents from our homepage www ottobock de or www ottobock com Attention Clean or disinfect the product before you start the inspection Consult the instructions for use regarding product care or product specific inspection...

Page 7: ...t sizes 8 24 Torque wrench measurement range 5 50 Nm Wrenches sizes 10 24 Allen wrenches sizes 3 6 Screwdrivers blade widths 2 5 3 5 and 5 5 mm Phillips screwdriver size 2 Plastic hammer Hammer approximately 300 g Stanley knife with sickle hooked blade and standard blade Side cutting pliers Liquid thread lock medium strength Rivet gun for rivets up to ø 5mm ...

Page 8: ... Workbench and vice with plastic jaws and rubber insert Hand drill Tyre mounting levers and inner tube repair kit ...

Page 9: ...olding mechanism Push handles Push bar x x x x x x x x x E Side panel Height setting Retracting mechanism Removability x x x x x x F Caster Tyres wear Air pressure Running characteristics of the wheels Threaded axles Swivelling characteristics of the wheel forks x x x x x x x G Rear wheel Tyres wear Air pressure Running characteristics of the wheels Spokes Push rings Quick release axles Wheel camb...

Page 10: ...rst remove the rear wheels by pressing the button on the quick release axle with your thumb and pulling off the wheel Figure 1 Then loosen the cap nuts on the front of the rear wheel attachment Figure 2 and remove them completely Pull the U shaped section off towards the rear Figure 3 Loosen the counter nut on the top end of the adjustment tube and move the adjustment tube forward by several centi...

Page 11: ...described in Section 4 1 1 Then press in the spring mounted push button on the tip assist and push the tip assist onto the multi function adapter to the desired mounting position Figure 7 4 1 3 Retrofitting replacing the anti tipper First proceed as described in Section 4 1 1 up to the point where the adjustment tube is loosened Now push the pre assembled anti tipper onto the exposed rear wheel ax...

Page 12: ...function adapter to the desired mounting position Follow the same procedure on the other side 9 4 1 5 Retrofitting replacing the crutch holder First proceed as described in Section 4 1 1 Then press in the spring mounted push button on the crutch holder Figure 10 and push the crutch holder onto the multi function adapter to the desired mounting position Attach the hook and loop strap to hold the cr...

Page 13: ...otplate can be moved forward in the following ways a Fine adjustment Move the footplate on the footrest bars without following any additional steps Retighten the screws b Larger adjustments Pull the footplate off the footrest bars Figure 13 Loosen and reposition the clamps Figure 14 then proceed as described under a Note The approach allows you to mount the footplate further forward and closer to ...

Page 14: ...est bars Figure 15 and adjust the footplate to the desired height b Changing the lower leg length from long to short or short to long Remove the footplate and then remove the exposed footrest bars Turn the footrest bars around Figure 16 and reinstall them Put the footplate back in place and retighten all screws Figure 17 15 16 17 Note Follow the same process to replace the footrest bars ...

Page 15: ...e 18 Loosen the centre Allen screws on the same clamps so you can open the rotation joint Figure 19 Then open the screw connections located on the frame tube between the clamps Figure 20 Now loosen the crossbrace screw connection on the seat tube Figure 21 so that the nuts can move freely in the guide groove 18 19 20 21 ...

Page 16: ...oned evenly on both sides 22 23 Retighten all screws Note On wheelchairs with narrow seats the footplate is mounted in the centre Figure 24 4 2 4 Replacing retrofitting the lateral heel blocks on the footplate The lateral heel blocks are attached to the bottom of the footplate using screws or rivets You have to drill the required bore holes The positions are pre punched on the footplate Figure 25 ...

Page 17: ...e seat upholstery and upholstery bars out of the guides towards the front Figure 28 use pliers if required Either re use the same upholstery bars or replace them with new ones Insert the upholstery bars into the loops on the new seat upholstery if required Reinsert the upholstery bars into the guides on the seat tube Figure 29 and pull them back evenly Refasten the hook and loop connections on the...

Page 18: ... same procedure on the other side 30 31 32 4 3 3 Vertical seat adjustment Fully loosen the two cap nuts on the front of the adjustment tube Figure 33 and remove them Now pull the U shaped component back Figure 34 until you can move the adjustment tube up and down freely Follow this procedure on both sides Then loosen the two outer screws on the front of the clamps that guide the footrest bar and c...

Page 19: ...nt tubes Loosen the screw connections on both sides of the crossbrace in the guide grooves of the seat tubes Figure 37 Move the seat tubes lengthwise until they reach the desired position Figure 38 Use the scale on the bottom of the seat tubes in order to make sure the position is even on both sides Retighten all screws 37 38 ...

Page 20: ...e follows automatically Once the desired angle is set retighten all screws 39 40 41 4 3 6 Adjusting the seat depth Remove the rear wheels Loosen the counter nuts on the top end of the adjustment tubes Loosen the screw connections on both sides of the crossbrace in the guide grooves of the seat tubes Loosen the four screw connections nuts of the back unit on the seat tubes Figure 42 Loosen the scre...

Page 21: ...eels Loosen the four seat tube screw connections nuts of the back unit on the seat tubes so that you can move it freely later Then loosen the back tube screw connections on the side panels Figure 45 Now move the back unit on the seat tubes until it reaches the desired position Figure 46 Use the scale on the bottom of the seat tubes in order to make sure the position is even on both sides Retighten...

Page 22: ...eat First remove the seat cushion seat upholstery and front tube end caps Loosen the hook and loop connections on the tension adjustable upholstery in order to slacken it Evenly pull the seat upholstery and upholstery bars out of the guides towards the front use pliers if required Figure 47 Now remove the push handles and back upholstery as described in Section 4 4 3 4 4 4 and 4 4 6 If clothing pr...

Page 23: ...h the new unit Loosen and remove the crossbrace screw connections on the seat tube Figure 50 and the crossbrace screw connections on the footrest clamps Figure 51 Also loosen the footrest screw connections on the footrest clamps until the footrest can be turned on the frame tube Figure 52 Pull the crossbrace out towards the front 49 50 51 52 ...

Page 24: ...he position is the same on both sides 53 54 c Finishing the back unit Now mount the push handles see Section 4 4 3 and the back upholstery see Section 4 4 6 onto the new back unit Mount the back unit to the back plates and to the side panels if applicable To do so proceed in reverse order Finally reattach the back upholstery flap d Finishing the seating unit Reinstall the seat upholstery and uphol...

Page 25: ...will be delivered pre assembled and then turn the key rings into the bolt ends Test the back release for proper function 55 56 57 4 4 2 Replacing the back release spring Remove the seat cushion Unlock the back rest and fold it ahead to the stop Lift the back up holstery flap Remove the upper screw connection on both back plates Figure 58 Pull the back tubes to wards the back until they are exposed...

Page 26: ...sh handles up and out off the back tubes Replace the push handles with the desired version or with new parts For assembly please proceed in reverse order 60 61 4 4 4 Replacing the push handles Height adjustable version First remove the back upholstery flap Figure 62 Loosen and remove the outer screws from the clamps and remove the strap Figure 63 Loosen the four screws on the inside of the clamps ...

Page 27: ...oth sides Figure 65 Insert the supplied nuts into the seat tube grooves from the rear Figure 66 Position the support bar against the seat tubes from below Figure 67 and screw the support bar connectors into the nuts Figure 68 Insert the support bar approximately 2 cm along the seat tube groove and tighten the screws 65 66 ...

Page 28: ...pull all strap loops located above the back stabiliser up and off the back tubes Unlock the back rest and fold it ahead to the stop Remove the upper screw connection on both back plates Figure 71 Pull the back tubes towards the back until they are exposed Remove the back release key rings as described in Section 4 4 1 Open the hook and loop straps on the back upholstery Remove all hook and loop st...

Page 29: ...ure 73 and remove them Push the side panel up and out of the way Now you can access the back angle pre adjustment mechanism on the back plates Remove the pre adjustment screws on both sides Figure 74 and position the back as desired Once you have found the desired position tighten the screws For assembly please proceed in reverse order 73 74 ...

Page 30: ... bottom of the seat tubes in order to make sure the position is even on both sides Retighten all screws 75 76 4 5 2 Replacing the side panels Clothing protector version Loosen and remove the screw connection below the lip of the clothing protector and the screw on the eccentric disk Figure 77 Now you can remove the side panel Draw the pull release cable down and out of the guide and unhook it from...

Page 31: ...s in order to make sure the position is even on both sides Retighten all screws 79 80 4 5 4 Replacing the side panels Height adjustable version Loosen and remove the two screw connections on the outside of the side panel attachment Figure 81 Now you can remove the side panel Draw the pull release cable down and out of the guide and unhook it from the wheel lock lever Figure 82 Replace the side pan...

Page 32: ...onnections 83 84 1 1 3 2 2 3 4 6 Assembly F Casters 4 6 1 Replacing the caster axle Remove the dust protection cap Figure 85 Loosen and remove the axle screw connection Figure 86 Pull the caster fork and axle down and out of the housing and remove the axle Figure 87 Note the location and number of spacer washers in the housing these need to be replaced in the correct position during assembly Repla...

Page 33: ...ew connections on the caster fork Figure 88 Remove the caster and spacers Replace the caster ball bearing and spacers with new parts as required Figure 89 Insert the caster into the desired correct bore hole on the caster fork Figure 90 also consult the technical data 88 89 90 ...

Page 34: ...heelchairs such as the Blizzard the centre of gravity and seating position for the BRAVO Racer active wheelchair are adjusted by changing the position of the seat on the base frame see Section 4 3 The position of the frame always remains constant in relation to the ground There fore the centre of gravity and seating position are not adjusted via the rear wheel position 4 7 2 Replacing the rear whe...

Page 35: ...rn parts with new ones where required and or replace the camber adapter with a different version Follow this procedure on both sides For assembly please proceed in reverse order 94 95 4 7 4 Installing a wheelbase extension First proceed as described in Section 4 7 2 to remove the U shaped component on both sides Insert the pre assembled wheelbase extension into the adjustment tube over the rear wh...

Page 36: ...ake drum To secure the brake drum using the supplied extension fitting in the camber adapter proceed as follows Insert the fitting through the brake drum Place the smaller counter nut onto the fitting Figure 97 followed by the larger counter nut Figure 98 Push the fitting through to the camber adapter while holding the counter nuts in the centre of the fitting Figure 99 Tighten the fitting until t...

Page 37: ...ove all adhesive and material residue A solvent may be used for this purpose Please observe any warnings provided by the manufacturer Open the superglue package Observe the instructions provided by the glue manufacturer Use a spatula to apply adhesive all around the inside of the rubber grip as deep as possible Figure 102 Push the grip onto the push handle tube so that 25 mm remains between the gr...

Page 38: ...his procedure on both sides Attach the rear wheels and verify that the drum brake is working properly Repeat the adjustment process if required 104 105 4 7 6 Adjusting the quick release axle The quick release axle has to be adjusted so that the wheel is fully engaged with no play on the axle Use a wrench to hold the quick release axle on the inside and adjust it by turning the nut on the end of th...

Page 39: ... 7 8 Replacing the push rings narrow wide mounting position First remove the tyres and inner tubes as described in Section 4 7 7 Loosen and remove the screw connection between the push ring and the rim If necessary replace the worn push ring with a new one Reassemble the push ring to the rim Attach it in the narrow or wide mounting position in relation to the rim by using the inner or outer bore h...

Page 40: ...ng pressure When you replace the rear wheels with a different size the wheel lock body first needs to be adjusted on the clamp To do so remove the two mounting screws from the wheel lock body Figure 111 Position the wheel lock body so that approximately 3 mm remains between the brake block and the tyre Figure 112 Fine adjustment is carried out using the two tension screws Figure 113 Follow this pr...

Page 41: ...e the pull release cable if required For reassembly proceed in the reverse order Adjust the wheel lock as described in Section 4 8 1 114 b Replacing the wheel lock handle Unhook the pull release cable from the adapters on the side panel as described in Section 4 5 4 Use a screwdriver to remove the rubber grip from the wheel lock handle Figure 115 Loosen the screw on the inside of the side panel un...

Page 42: ...at upholstery Pull the free ends of the belt through between the side panel and the back tube on both sides Screw the grommets on the ends of the belt into one of the unused bore holes on the back plate Figure 117 Adjust the length of the lap belt using the glide buckles Figure 118 117 118 ...

Page 43: ...ut push handles 54 88 5 With 22 rear wheel 56 5 91 With 24 rear wheel Weight Approx 8 5 kg Load capacity 60 kg Seat height in cm 1 Rear Wheel Size 20 22 24 Camber 3 6 9 3 6 9 3 6 9 Position Adjustment tube long Adjustment tube short 1 32 2 32 0 34 7 34 5 33 9 37 2 37 0 36 4 2 33 9 33 7 36 4 36 2 35 6 38 9 38 7 38 1 3 35 6 35 5 38 1 38 0 37 3 40 6 40 5 39 8 4 37 3 37 2 39 8 39 7 39 0 42 3 42 2 41 5...

Page 44: ...acers Caster 3 20 2 4 3 5 4 140mm 6 Caster 3 22 1 3 4 1 5 2 140mm 3 1 6 3 Caster 3 24 1 4 2 5 3 140mm 1 1 4 1 6 1 4 6 camber Rear Wheel Size Short Fork Position Number of Spacers Long Fork Position Number of Spacers Caster 3 20 2 4 3 5 4 140mm 6 Caster 3 22 1 3 4 1 5 2 140mm 3 1 6 3 Caster 3 24 1 4 2 5 3 140mm 1 1 4 1 6 1 4 ...

Page 45: ...r 3 24 2 1 4 3 1 5 1 1 4 1 140mm 1 2 4 2 6 2 1 Colour combinations Translucent Design Side Panel Orange 145 15007 Blue 145 13040 Red 145 12018 brilliant silver x x x sparkle bright orange x x snake clear red x dormant vinho sparkle x x dormant marine blue x x dormant apple green x x x candy red x x clear reptile glossy x x gecco style spooky yellow x x spooky blue x x ...

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Page 48: ...848 1304 1562 1590 1594 3663 Fax 49 5527 848 1676 e mail reha ottobock de Internet http www ottobock com Versandanschrift für Rücksendungen Address for Returns Otto Bock HealthCare GmbH Lindenstraße 13 07426 Königsee Germany Otto Bock HealthCare GmbH has been certified by the German Society for the Certification of Quality Assurance Systems DQS in accordance with DIN EN ISO 9001 standard reg no 77...

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