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Whirlwind RoughRider, User Manual

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Whirlwind RoughRider User Manual Download Page 37

 

Your RoughRider

™

 

Basic Riding Skills 

Maintenance and Repair 

Bent Caster Barrels 

Have someone sit in the chair or put something nearly equal to your weight in the seat, then look to 
see if the caster barrels are straight by checking whether the barrel and the side frame are parallel 
with each other and at a right angle to the ground. 

 

If a caster barrel is not vertical, the caster wheel will be pulled 
in the direction that the barrel is tilted and the chair will turn to 
that side.  

 
Solution:

 Re-align the caster barrel. Get the help of a mechanic 

with a very large adjustable wrench to bend the caster barrel so 
that it is parallel with the side frame and perpendicular to the 
ground. Check very carefully for cracks in the frame after 
making any bends.  Any cracks must be welded shut and 
reinforced.  

 

Caster Wheel Rubs on the Fork 

Caster fork in a vice 

with stem pointing up 

Tube over 
caster stem  

The caster wheel is not centered in 
the fork. 
 
Solution: 

If the caster wheel is not 

centered on the axle, center it by 
removing or adding washers. 

 

Replace any missing nuts.   
 

Remove or Add 

Washers 

Center Wheel 

in Fork 

A chair will veer to one side if the caster wheel rubs against the fork; friction will act like a brake on 
the wheel and your RoughRider will pull to that side.  
 
The caster wheel could be rubbing on the fork for two reasons: the caster fork could be bent or the 
caster wheel is not centered in the fork. 

 

The stem of the caster fork is bent – 

The chair will veer to 

one side if the stems of both forks are not precisely at a right 
angle to the axle of the caster wheel.

   

 
Solution: 

If the caster fork is bent at the junction between the 

fork and the bolt (stem) get the help of a mechanic with a 
large vise to straighten the fork; after making any bends, 
check very carefully for cracks in the fork and where the fork 
and stem meet.  The angle between the fork and the stem 
should be 130 degrees.  You can put the caster fork in a vise 
with the bolt pointing upward.  Be careful not to dent the fork 
by clamping it too tight.  You can protect the fork from the 
jaws of the vise with two scraps of wood or heavy leather.  
Put a thick-walled tube over the bolt and pull to change the 
angle of bolt. 

 

page 

39 

of 

57

 

 

Whirlwind RoughRider

™

 User Manual 

Summary of Contents for RoughRider

Page 1: ...USER MANUAL ...

Page 2: ...mler Memorial Fund The Fred Gellert Family Foundation Written by Alida Lindsley Carol Maddox Contributions Chris Howard Ralf Hotchkiss Editors Joan Rogin Marc Krizack Whirlwind RoughRider User Manual Copyright 2007 by Whirlwind Wheelchair International First Edition June 2007 Whirlwind welcomes your ideas and suggestions for improving our wheelchairs and manuals The best information we get is from...

Page 3: ...es and Limits 11 Pressure Relief 14 Pressure Relief Techniques 16 Moving Around 19 Riding Techniques 20 Tranfers Getting in and out of your RoughRider 24 Traveling with your RoughRider 28 Maintenance and Repair 31 Maintenance Schedule 32 Cushion 33 Bearings 35 Upholstery 40 Wheel Locks 42 Spokes 43 Lubricating your RoughRider 45 Tires 46 Cleaning your RoughRider 48 Routine Inspections 49 Nuts and ...

Page 4: ...f tipping The RoughRider is compact lightweight and has a comfortable seat The RoughRider s folding frame makes travel easy on buses and automobiles The RoughRider was designed with few removable components to minimize the loss of parts The RoughRider was also designed for easy repair and maintenance using commonly available parts and tools The RoughRider s design is the culmination of ideas and i...

Page 5: ...in and an upper leg length longer than 40 7 cm 16 in The length measurement is taken while seated and measures from back of pelvis to back of lower leg With some standard modifications however the RoughRider may be suitable for riders outside of these ranges See end of section for more information Seat widths may vary depending on manufacturer RoughRider Specifications Effective Seat Widths seat f...

Page 6: ...hat you can easily adjust them in the future It is recommend that you write down the following critical measurements and refer to them when performing inspections or maintenance on your RoughRider Seat Width __________________cm measured between inside edges of side frames Seat Height __________________cm measured from floor to front edge of seat Right __________cm Footrest Height Left __________c...

Page 7: ...traveling over uneven terrain such as rocks or uneven dirt roads Easier to push because more weight is on the rear drive wheels and less on your front caster wheels which gives you better traction on uneven ground and makes it easier to roll straight on a side slope Why have a foldable X brace Chair folds flat for easy storage and transport If your chair does not fit under or behind the rear seat ...

Page 8: ...ghRiders come with all terrain pneumatic tires mid to heavy weight that fit on standard wheel rims 24 x 1 75 in However you might prefer light weight tires and rims if you will be mostly riding indoors or in well paved urban environments Wheel Locks Parking Brakes Stabilize your chair when it is stopped for easier and safer transfers reaching weight shifting etc Parking brakes should not be used t...

Page 9: ... tip backward Start with the rear wheel in a position that feels secure to you As your skill level increases with practice the wheel position can be adjusted forward Your Cushion If you have limited feeling in your buttocks you should use a high quality foam cushion that is highly resilient If you do not use a suitable cushion you are likely to develop a pressure sore You should also perform regul...

Page 10: ...RoughRider with 12 degrees seat tilt Rider slumps forward and uses effort to sit Standard chair with little seat tilt Cambered wheels tilt inward at the top of the wheel and outward at the bottom The RoughRider has approximately 3 degrees of camber Why have cambered wheels More stability side to side because the chair is wider at the bottom Easier to push the push rims because they are in line wit...

Page 11: ... further forward you may also want to move your rear wheels forward Common Modifications If you are taller than 1 8m 6 ft you may need to make some modifications to make the chair fit better This is especially important if you do not have full feeling in your body In order to bear more weight under your thighs and less on your buttocks to prevent pressure sores you can Adjust footrests to their lo...

Page 12: ...r buttocks seated in the wheelchair A lap belt can also help you feel more secure when riding your wheelchair You can add a lap belt by attaching two strips of soft material such as webbing to the guide tubes the inner curved tube on side frame or to the back tubes and connecting the strips together with a buckle Heel Strap and Lap Belt Prevent areas of high pressure It is very important when usin...

Page 13: ...manual it is a good idea to discuss anything that is not clear with the manufacturer distributor or an experienced Whirlwind RoughRider user They should be able to show you how to perform different maintenance and repair tasks In an emergency situation you may be able to Drive the wheelchair with a flat or completely missing tire by leaning your weight away from the missing flat tire though this w...

Page 14: ...il to use Page 45 Wheel locks Adjust to correct position Lubricate moving parts Tighten nuts Every other month OR when wheel locks are not holding chair in position OR when wheel locks become difficult to lock Page 42 Spokes Inspect and tighten spokes to true the wheels Every other month OR when spokes are broken or loose OR if wheels wobble when spinning Page 43 Cleaning and Routine Inspection Cl...

Page 15: ...e hard spots which can contribute to the development of pressure sores Try to prevent your cushion from getting wet or being exposed to direct sunlight Maintaining your Cushion Regularly inspect your cushion for worn spots dirt holes in the cover and foam How to inspect your cushion Remove the cover and inspect the top foam and base They should be solid without crumbling or excessive discoloration...

Page 16: ...If well cared for the base of a cushion will last longer than the top foam Compared to new cushion Used cushion on left shows significant deformation It is time to replace top foam or entire cushion The cushion cover can be patched if doing so will not cause pressure or skin damage Pay attention to where the edges of the patch will be and make sure these are not in places already under pressure su...

Page 17: ... oil to use is 90 or 140 weight gear oil the next best is 20 weight electric motor oil Do NOT use Automotive engine oil The detergent in automotive engine oil will mix with water Common penetrating household lubricants and degreasers like WD40 should not be used Use of penetrating lubricants can damage the seals and remove grease Bearing life will be significantly shortened if you use your chair w...

Page 18: ...boat trailer ball bearing grease Automobile ball bearing grease is very good but is less water resistant Maintaining your Bearings Basic Maintenance every month OR when you feel your chair slowing down and you don t have time to do more Lubricate our caster wheel caster barrel and rear wheel bearin y gs with oil ...

Page 19: ...e Turn the wheel over and remove the other bearing The same process can be used to remove the bearings from the caster barrel If the bearings will not come out put some light oil not penetrating oil around the bearings and try again later Once the bearings are removed carefully pop the seals off with the tip of a knife Clean all parts with kerosene making sure to get all of the dirt out A brush su...

Page 20: ...er enough to pry out of fork To disassemble bearings unscrew the cones outward away from wheel until balls fall out Clean all parts with kerosene Allow to dry then replace the balls and reassemble bearings with as much bearing grease as possible Dipping the balls in grease will hold them in place and make assembly easier Thorough maintenance for front wheel bearings 2 3 times year if in rough envi...

Page 21: ...legs Can cause you to sit in an uncomfortable position Can rip suddenly and cause you to fall out of the chair By inspecting your upholstery regularly you will know when you need to replace your upholstery Your upholstery will not last as long as the wheelchair and will have to be replaced over time Make sure all bolts or screws that hold the upholstery in place are there Replace any missing bolts...

Page 22: ...ir that has holes or tears in the seat because sitting on an uneven surface can cause bad posture and may increase the pressure on your buttocks If there are any holes or tears in your seat or seat back either repair them or replace your seat upholstery If the holes are not too big it should be possible to patch the holes It is best to use the same fabric as the original upholstery If the holes ar...

Page 23: ...that aren t adjusted correctly may not fully lock the wheels and can cause you to fall while getting into or out of your chair resulting in injury to you or damage to the chair To adjust your wheel locks Make sure that the wheels are sufficiently inflated before adjusting Loosen the bolt that holds the tube clamp tight around the side frame tube Move the wheel lock into a functional locking positi...

Page 24: ...You can also use a stationary object like your frame to see if the wheel stays the same distance away while spinning If the rim is bending or wobbling to one side of the wheel tighten spokes on the other side of the bent part of the rim to center the rim A bicycle mechanic will be able to do this if you need help To make sure your rear axle is tight push sideways on the wheel rim The wheel should ...

Page 25: ...spoke went through Thread the small end f the nipple through the hole in the rim and screw it onto the end of the spoke If a spoke of the same length is not available a longer spoke can be used Make a sharp bend in the long spoke at the non threaded end to the length needed The bend in the spoke will hook through the hole in the hub see the above left two pictures As you begin to tighten the nippl...

Page 26: ...a is saturated and the part moves smoothly Wheel locks Lubricating your RoughRider Formatted Font Default ZWAdobeF 1 pt Not Bold Font color Auto Superscript Consistently lubricating your RoughRider will keep all the moving parts operating smoothly and efficiently Use medium to heavy weight oil Do not use common penetrating lubricants like WD40 because they can damage the seals and remove grease Be...

Page 27: ...ssure harder tires helps the chair move faster but is less comfortable is harder to push on uneven terrain and can be slippery on wet pavement Lower pressure softer tires is more comfortable on uneven ground but the tire is more vulnerable to getting flats and can put more strain on your arms and shoulders If the tire pressure is not the same in both wheels your RoughRider will turn toward the sid...

Page 28: ...ain if it is not removed Find hole in tube by pumping halfway full and squeezing it You may be able to find the hole by the sound of escaping air If not put the tube under water Squeeze the tube and watch for bubbles escaping from the hole Another way to do this is to rub soapy water on the tube and watch for bubbles forming in the soap Mark around the hole with a pen or pencil Let any remaining a...

Page 29: ...ure to rinse and dry it completely afterward Pay special attention to all moving parts such as the axles the caster barrels pivots where the chair folds and areas where the upholstery is fastened to the frame dirt can be especially damaging to these areas After each cleaning and only after the chair is completely dry apply medium to heavy weight oil to all moving parts on the chair x brace pivots ...

Page 30: ...oon as possible To do routine inspections look over your RoughRider while not sitting in it to make sure there are no holes in the upholstery cracks in the welds bends in the tubes loose nuts or bolts bent axles uneven footrests or loose handgrips If you find major structural problems like cracks or bends you should have your RoughRider repaired as soon as possible by a capable technical professio...

Page 31: ...our RoughRider for loose nuts and bolts If loose tighten them with a wrench The center pivot bolt of the X brace should not be tight but the locknut used to keep the bolt from falling out should be very secure and hard to turn You should be able to hold one caster wheel down and lift the other 2 cm 3 4 in above the ground with little effort Lock nuts or split nuts should be repaired if you notice ...

Page 32: ...either standard commercial nylocks or with Whirlwind split nuts A nylock is a nut with a nylon ring on the inside If the nylock is easy to turn it has lost most of its locking capacity and should be replaced A Whirlwind split nut is a lock nut that can be easily made with the correct size standard nut and basic tools hacksaw and clamp vise A worn out nylock can be replaced with a Whirlwind split n...

Page 33: ...n your seat can cause bad posture make you uncomfortable and cause pressure sores if you have no sensation in your buttocks If the footrests are too high there is more pressure on your buttocks which may be uncomfortable and can cause pressure sores To adjust the footrest loosen the bolt on the footrest clamp tube Move the footrest to the correct position and tighten You will have to adjust your f...

Page 34: ...lued using strong glue A very good glue is heavy duty contact cement that is made especially for installing automobile weather stripping If strong glue cannot be found remove the handgrips completely and be cautious when lifting the chair by the bare handles Handgrips Loose handgrips can cause serious injury if they slip off while someone is pulling the chair especially pulling up stairs or curbs ...

Page 35: ...pumping up the lower pressure tire or by releasing some of the pressure in an over inflated tire Dirty or Damaged Bearings A chair will turn toward the side of the chair where the bearing is sticking like braking on one side Solution Check the bearings in the caster wheel and rear wheel See Bearings section Check and clean or replace bearings as appropriate Stuck X Brace A chair will turn toward o...

Page 36: ... back into alignment Check the angle of the axle block by putting multiple bolts into the block and measuring their angle by referencing a perpendicular surface Get the help of a mechanic with a very large adjustable wrench clamp the frame close to the axle block Check very carefully for cracks in the frame after making any bends Weld shut and reinforce any cracks Measuring the distance between th...

Page 37: ...oving or adding washers Replace any missing nuts Remove or Add Washers Center Wheel in Fork A chair will veer to one side if the caster wheel rubs against the fork friction will act like a brake on the wheel and your RoughRider will pull to that side The caster wheel could be rubbing on the fork for two reasons the caster fork could be bent or the caster wheel is not centered in the fork The stem ...

Page 38: ...e bent seat tube until they are both touching the square tube At the same time both people should carefully push or pull in the opposite direction that the seat tube bent Continue until the seat tube is straight Hammering the ends of the seat tube outward can correct the problem If the side frame bends inward again get a good welder to re align the entire X brace and reinforce both seat tubes by w...

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