Whirlwind Cargo Assembly Instructions Manual Download Page 1

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Whirlwind Cargo Tricycle Assembly

Assembly instructions for the Whirlwind Cargo handcycle Tricycle

For videos on assembly and adjustment visit

http://www.whirlwindwheelchair.org/tech-support

Ralf Hotchkiss riding the Cargo Handcycle Tricycle

Summary of Contents for Cargo

Page 1: ...icycle Assembly Assembly instructions for the Whirlwind Cargo handcycle Tricycle For videos on assembly and adjustment visit http www whirlwindwheelchair org tech support Ralf Hotchkiss riding the Cargo Handcycle Tricycle ...

Page 2: ...2 1 2 4 3 5 9 8 6 7 10 11 12 13 14 15 16 24 25 17 18 20 21 22 23 ...

Page 3: ...3 CARGO TRIKE ADJUSTMENTS SEAT HEIGHT UP AND DOWN SEAT POSITION FRONT BACK CRANK HEIGHT UP AND DOWN BACKREST HEIGHT SEAT ANGLE TENSION ADJUSTABLE BACKREST ...

Page 4: ...4 SCI SEATING KIT LATERAL WEDGES CHEST STRAP AND PRESSURE RELIEF CUSHION BACKREST ANGLE ...

Page 5: ...5 Accessories Additional Accessories not pictured SCI Kit Cargo Canopy Overhead storage and shelter Sun Canopy ...

Page 6: ...ke 10 Steering Centering Spring 11 Front Frame 12 Frame attachment location with bolts 13 Rear Frame 14 Brakes 15 Brake Mount Clamp 16 Brake Lock Assembly 17 Seat Frame 18 Seat base cushion 19 Optional Pressure relief cushion with separate seat base not shown 20 Backrest Frame 21 Backrest posts 22 Tension adjustable backrest straps 23 Backrest cover 24 Rear wheel Left 25 Rear wheel right ...

Page 7: ... when viewed from the back of the trike Handrims rim strip tube and tire are installed on rear wheels Refer to the RoughRider wheelchair assembly materials available from Whirlwind Note There are different left and right wheels The right wheel has the adjustable cup of the hub on the same side as the handrim and the left wheel has the fixed cup on of the hub on the same side as the handrim The cra...

Page 8: ...se to the bearing cups on the headtube 2 Apply grease to the bearing on the crown race of the fork The bearing should be installed with the ball retaining ring on the bottom side 3 Insert the fork steerer tube through the head tube GREASE ...

Page 9: ...9 4 Install the centering spring this is easier to install before the headset is tightened 5 Install the top bearing with the ball retaining ring on the top side ...

Page 10: ... the idler wheels on the same side as the chain rings right side when viewed from the rear 8 Install the crank boom with the crank facing backwards 9 The bottom bracket crank spindle is the same as a bicycle Make sure that the longest side of the spindle is on the right side with the gears when viewed from the back of the trike Note the left side may be left hand threaded and tighten counter clock...

Page 11: ...e secured quite tight and is a standard bicycle assembly 11 Attach the left crank to the spindle make sure that the bolt touches the flat face in the spindle securely and is very tight 12 Attach the right crank with the gear to the spindle make sure that the bolt touches the flat face in the spindle and is very tight Note The cranks can be installed with handles together or opposite depending on u...

Page 12: ... that the crank gears are aligned and parallel on the top and bottom 14 Check that the centering spring is installed correctly 15 Install the stem quill into the fork steerer tube Tighten The height of the exposed tube should be approximately 50mm above the top of the fork steerer tube ...

Page 13: ...the chain idler down over the stem quill Position the chain idler such that the idler wheels can rotate freely without touching the crank boom quick release bolts Tighten the chain idler with the quick release bolt ...

Page 14: ... cassette on the wheel Third rotate the Chain idler 1 one full revolution or until the torsion spring is wound enough to hold the chain tight Install the chain as shown Make sure that the chain is guided over the tensioned idler wheel TENSION FROM SPRING KEEPS CHAIN TIGHT SPRING EXHERTS FORCE THIS DIRECTION ...

Page 15: ...en viewed from the back of the trike Tighten the front wheel securely with a 15mm wrench Make sure that the tire is centered in the fork and is vertical when viewed from the front or rear 19 Install the chain guard on the axle of the front wheel This chain guard helps keep the chain on the lower gear cassette if the chain tension is too loose and on very rough terrain ...

Page 16: ...s difficult to align the holes install one at a time and do not tighten fully until they are all installed Tighten fully with two 19mm wrenches socket wrenches Note If required a screwdriver or other flat metal tool can be inserted between the locknut and the trike frame to prevent rotation Tighten securely with large wrenches if possible It is unlikely that these bolts will need to be removed ...

Page 17: ...REAR WHEEL This wheel has the Adjustable cup of the hub with lockring on the same side as the handrim Install the right wheel onto the right side of the main frame chassis when viewed from the rear Inflate the right rear wheel ...

Page 18: ...tighten the M12 axle clamp bolt with two 2 19mm wrenches ABOVE LEFT WHEEL VIEWED FROM UNDER SEAT LOOKING OUT RIGHT WHEEL AXLE SLOT FACES UP FOR INSTALLATION ON BOTH WHEELS 23 Repeat for the LEFT REAR WHEEL Inflate the left rear wheel The left wheel has the Fixed cup of the hub on the same side as the handrim 24 Install the Left rear wheel same method as right side BOLT TIGHTENS INTO AXLE SLOT WHIC...

Page 19: ...ed forward and backwards after it is installed FRONT SEAT RAIL GUIDE Shown with bolt above tube and can be installed with bolt below tube for low seats for riders with short legs REAR SEAT CLAMP Shown with bolt above tube and can be installed with bolt below tube for low seats for riders with short legs Example Seat mounting for 46cm seat height at 12 degree seating angle ...

Page 20: ...seat off of the tricycle Install the front seat rail guides with M8 bolts to the front ladder of the seat as shown The bolt head should be outside the seat and the M8 locknut is trapped inside the channel Align the faces of the nut so that it is secured inside the channel LOCK NUT TRAPPED INSIDE CHANNEL BOLT HEADS CAN BE ABOVE OR BELOW SEAT RAIL IN ANY ONE OF THE 6 HOLES TO SET SEAT HEIGHT AND SEA...

Page 21: ...is trapped inside the channel Do not tighten fully yet Install the opposite side seat clamp into the matching hole 29 Tighten 2 two rear clamps and two front seat rail guides securely with a 13mm wrench Note The seat can be adjusted front back by simply loosening the two rear seat clamp bolts and sliding the seat These clamps must be removed in order to adjust the seat height or seat angle 30 Inst...

Page 22: ...est and attach to the seat using M8 bolts 32 Attach the springs between the adjustment ladder and the seat pulling securely Check to make sure that the backrest ladder falls into every set of notches evenly and easily For rider safety view from center of trike looking outward ...

Page 23: ...n The wide Velcro is on the front of the TAB Each strap should wrap around each backrest cane without tangle Refer to the RoughRider backrest installation and fitting guides for information about installing the backrest http www whirlwindwheelchair org backrest and tab ...

Page 24: ...s much as possible The number of straps below the backrest ladder will change depending on the backrest cane height which will be selected in a seating assessment One strap will be below for the tall backrest height two straps for the medium backrest height and three straps for the low backrest height ...

Page 25: ...to the seat The cushion should be installed with the cut out relief position matching the tubes on the seat The front edge is square the rear edge has notches Note If this trike will be set up with the SCI Kit a different seat base is used that is thinner 37 Attach the left and right brakes together if required Washers should be used to space the components and can be adjusted if needed later Some...

Page 26: ...bushing should have the wide flange on the outside edge When tightened they must allow the brake cross tube to rotate inside 41 Press the brake clamp over the seat rail and bend the clamp together as needed to secure with the bolt Attach the clamp the seat rail at a position so that the Brake does 1 not touch the tire when the lock is released and 2 holds the tire securely when the lock is engaged...

Page 27: ...he SCI kit has thin foam on a plastic base This replaces the standard seat cushion on the tricycle The Pressure Relief Cushion PRC attaches with Velcro to the seat base Refer to Whirlwind and WHO information about seating assessment and pressure relief cushion fitting The lateral support wedges are inserted between the front of the TAB backrest straps and the backrest cover Refer to the informatio...

Page 28: ...ner of a riders preference Please note that while this rack is strong and attached to the tricycle frame instead of the fork wheel it is not designed to carry passengers and that steering will be difficult with heavy cargo on the Front Cargo Rack e Front Cargo Box This box is installed on the front cargo rack with bolts installed through the tube frame of the Front Cargo Rack This box can also be ...

Page 29: ...r experienced wheelchair providers The Whirlwind Cargo Tricycle may be an appropriate product for riders who can maintain an upright seated position and have good head control With the optional SCI Kit the tricycle may be appropriate for riders without trunk control if determined to be appropriate by the rider and an experienced service provider Refer to the Whirlwind RoughRider service provision ...

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Page 36: ...36 Size Adjustments Trike Hip Width The Whirlwind Cargo tricycle is available in one width only 18 1 8 Riders with narrower hip widths may prefer to place foam between their hips and the frame ...

Page 37: ...o be 14 16 or 18 above the seat surface The Tension Adjustable backrest straps can be adjusted to fit each rider Refer to the RoughRider backrest adjustment information From http whirlwindwheelchair squarespace com backrest and tab Video of backrest strap adjustment for changing backrest height http vimeo com 60119609 ...

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Page 39: ...pper trunk area are tightened next They are tightened lightly only Check with the rider to make sure they feel balanced and that the strap is not pushing them forward The straps over the buttocks area are tightened last These are also done up very lightly to prevent pushing the bottom forward For riders with lots of soft tissue in this area ensure that the straps are sufficiently loose Check the r...

Page 40: ...he cranks also affected by TAB adjustment and backrest angle relative to seat Note that as the seat angle is adjusted the backrest angle changes with the seat Example To achieve a 90 90 90 seating position the most upright backrest angle is approximately 86 degrees from the seat the seat angle might be set at 12 degrees with the backrest in the most upright position with the top straps loosened to...

Page 41: ...nstalled with bolt below tube for low seats for riders with short legs REAR SEAT CLAMP Shown with bolt above tube and can be installed with bolt below tube for low seats for riders with short legs Example Seat mounting for 46cm seat height at 12 degree seating angle ...

Page 42: ...osition with 5 degree seat angle 34cm seat height from footrest The rear seat clamp is bolt on bottom in the top hole 1 of 6 The front seat guide is bolt on bottom in second hole 2 of 6 2nd Hole bolt on bottom 1st Hole bolt on bottom Seat height 34 cm ...

Page 43: ...on without the strap to provide a handle for transfer The seat extension can be installed following the instructions for the Roughrider Wheelchair Note that the cushion is 14 deep only Note This seat extension is not included with each tricycle and must be ordered as an accessory Please inform Whirlwind if your experience fitting tricycles indicates that this should be included with each tricycle ...

Page 44: ...hen propelling the trike forward To set the crank height before the rider sits in the trike measure from the ground or footrest where the rider s feet are resting to the top of the knee and add 5 cm for the hand and clearance Set the center of the handgrip at its lowest this distance from the trike footplate Note A longer chain can be used for the highest chain positions This should be available f...

Page 45: ...n is set so that their shoulder is still in contact with the backrest and the farthest part of the crank stroke A good starting point for this setting is 3 cm shorter than the fully extended arm length from the center of a closed fist to the surface supporting the rider s back Remember that the trike backrest is a sling backrest and to accommodate for the curve of the backrest when measuring rider...

Page 46: ...46 For more information contact info whirlwindwheelchair org and visit http www whirlwindwheelchair org tech support http www whirlwindwheelchair org provider resources ...

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