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Service Manual

KÜSCHALL

ULTRA-LIGHT

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Summary of Contents for Ultra-Light

Page 1: ...Service Manual KÜSCHALL ULTRA LIGHT ...

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Page 3: ...handles and backrest 14 Replacing foldable push handles 16 FOOTRESTS 19 One piece footrest 19 Two piece footrest 21 Two piece footrest adjustable angle 21 SIDEPARTS 22 Clothes guard mudguard 22 Siderests 23 FRONT WHEELS 27 Castor fork 27 Special housing guides 28 REAR WHEELS 29 Adjusting the seat height rear 29 Tipping stability 29 Wheel camber 30 Adapter plate for drum brake 30 Distance sleeves f...

Page 4: ...d tools and their sizes are listed before the instructions The various torque values with which the nuts are to be tightened are also specified in the instructions A torque spanner must be used in order to comply with the specified torque values Tool Symbol Allen key Ã 3 4 5 Torx wrench ß 10 Phillips head screwdriver Ò Open end spanner 8 9 10 18 Socket spanner Box spanner 8 10 19 22 Spare parts an...

Page 5: ...d Clean or replace the bearings Support bearings in forks faulty Replace the support bearings Steering error or trail angle left and right uneven Adjust steering error or trail angle The wheelchair tips too easily Rear wheels are mounted too far forwards Mount the rear wheels further back Backrest angle too large Reduce backrest angle Seat angle too large Mount the adapter plate lower on the side ...

Page 6: ...ME FRAME 4 1 2 3 7 8 5 6 5 6 1 2 3 4 2 4a 4a 1a 1a 2a 1b 1b 4b 4b 7 2b 2c 8 4c Rear frame a à 13 Nm b à 7 Nm Retaining lever a à 4 Nm Cross Front frame a à 13 Nm b à 7 Nm c à 7 Nm Upper connecting tube Lower connecting tube Seat locking mechanism Longitudinal stopping bolts ...

Page 7: ... Seat Turning the seat locking mechanism 0 Push the front frame onto the upper and lower connecting tube 0 Reinsert and tighten bolts a b if required c on both sides 0 Set the castor fork angle Chap Front wheels Setting the steering error angle Retaining lever Replacing the retaining lever Difficulty Tool Ã 3 4 5 10 0 With mudguard or clothes guard fixed remove a and b with mudguard or side rest i...

Page 8: ...eels Replacing the castor fork Fit it high low with the housing guide Hemi Chap Front wheels Special housing guides Seat height front with respect to fork size castor fork size and position in the fork SHv mm Castor fork inch 410 3 420 3 430 440 4 3 450 4 3 460 5 4 3 470 5 4 3 480 490 6 5 4 3 500 6 5 4 3 510 7 6 5 4 520 7 6 5 530 540 7 6 Assumption Seat depth 400 mm seat angle 50 mm fitted high SH...

Page 9: ...430 6 4 3 2 440 7 5 4 3 450 460 8 6 5 4 470 9 7 6 5 480 10 8 7 6 490 9 8 7 500 10 9 8 1 2 3 4 5 6 7 8 9 10 11 12 Seat width SB SBs range from 280 500 mm Once the SB is specified it is very difficult to change it the cross struts backrest cover on standard backs and on some configura tions the footrests must be replaced Seat depth ST STs range from 320 500 mm To reduce the ST the cross struts must ...

Page 10: ...g mechanism If the seat edge can be too easily removed from the seat locking mechanisms either the front two or all four seat locking mechanisms can be rotated by 180 Difficulty Tool Ã 3 0 Loosen bolt in seat locking mechanism 0 Turn seat locking mechanism by 180 0 Secure bolt with adhesive low strength 0 Retighten the bolt i Screw out the bolt only to the extent that the seat locking mechanism ca...

Page 11: ...ards until you reach the required height Replace the bolt and tighten i If this setting range is insufficient use new push handle tubes i If the backrest height was changed considerably a new backrest cover may have to be fitted Adjusting the height of Velcro adjustable backrests Difficulty Tool Ã 3 4 6 8 10 Remove backrest cover and move the Velcro bands until bolt is visible Remove bolt and move...

Page 12: ... 4 5 8 10 10 Shorter rear frame variant III required Push the lower joint pin into the rear frame and fix it using a bolt Secure backrest tube to the upper joint pin using a bolt Assemble the upper and lower joint pins and and secure with bolt Retighten the bolt Set the desired backrest angle and secure in the nearest hole using bolt Push the single Velcro band and then the other Velcro bands and ...

Page 13: ...ame angle has been set on both sides Fitting the joint for a folding backrest Difficulty Tool Ã 4 5 10 Shorter rear frame variant III required Set the desired backrest angle insert bolt in the nearest position Pos 1 2 or 3 and tighten With the curved backrest tubes other positions can be achieved in addition to the 3 positions specified 0 Fold down upper joint pin with intermediate backrest tube 2...

Page 14: ...2 Push the backrest bands and end band onto the telescopic tube end band first 3 Secure end band on the telescopic tube with a bolt Fitting height adjustable integrated push handles Difficulty Tools Ò Ã 3 4 5 8 10 Special rear frame required for RH 300 465 variant II Push lower telescopic tube and upper telescopic tube into one another and insert bolt Secure pre assembled element telescopic tubes ...

Page 15: ...ith a bolt Attach protective cushion Fitting angle adjustable backrest with height adjustable push handles Difficulty Tools Ò Ã 3 4 5 8 10 10 Shorter rear frame variant III required Push the lower joint pin into the rear frame and fix it using the bolts Fit backrest tube onto the upper joint pin using bolts Assemble the upper and lower joint pins and and secure with a bolt Set the desired backrest...

Page 16: ...he backrest cover with a distance of 10 mm from the upper egde using hole punch pliers see graphic below 0 Slide the new foldable push handle A onto the telescopic tube 0 Fix the foldable push handle with screw C M5x12 0 Pull up the backrest cover until it covers completely the rear hole in the pushhandle 0 Fix the foldable push handle with screw D M5x14 and washer H 0 Check screws E on both sides...

Page 17: ... L S 1B 6B M 480 M M L S 1B 6B L 495 M M L L 1B 6B L 510 M M L L 1B 6B L Assumption No stabilising bar fitted For RH 510 with height adjustable integrated push handles S 2x4B Backrest with adjustable backs with respect to push handles Backrest height RH mm Standard push handles Folding push handles Height adjustable integrated push handles Velcro bands 2B 4B 300 S S S XXS S XXS S 4B S 315 S S S XS...

Page 18: ...S 315 S S S S S 330 S S S S S 345 S S S S L 2B S 360 S S S S L 2B S 375 S S S S L 2B S 390 S S L S L 2B M 405 S S L S S 4B M 420 S S L S S 4B M 435 M M L S S 4B M 450 M M L L S 4B M 465 M M L L L 4B M 480 M M L L L 4B L 495 M M L L L 4B L 510 M M L L L 4B L Assumption No stabilising bar fitted For RH 375 with height adjustable integrated push handles S und 2B 4B Additionally a band is fixed close ...

Page 19: ...sembling fitting the footrest Difficulty Tool Ã 4 8 1 Remove bolts on both sides 2 Pull out the footrest 3 Insert new footrest 4 Tighten bolts on both sides at the same height and in the required position Adjusting the height of the footrest Difficulty Tool Ã 4 8 1 Remove bolts on both sides 2 Hold the telescopic tubes with both hands and push the footrest into the required position 3 Insert bolts...

Page 20: ...both sides 2 Set the required footplate incline Re tighten bolts fixed side of the footplate Turn the little tube on the moving side of the footplate such that it engages properly Tighten bolts Changing the position of the footrest set to rear set to front Difficulty Tool Ã 4 10 1 Loosen bolts on both sides and remove 2 Turn the footplate with the clamp component 3 Re insert bolts and tighten 1 2 ...

Page 21: ...ht of the footrests Difficulty Tool Ã 4 8 Remove bolts Push the footplates into the required position Insert bolts into the nearest hole on both sides and at the required height and tighten Changing the position of the footrests set to rear set to front Difficulty Tool Ã 5 1 Remove bolts 2 Pull the footrests away downwards and replace 3 Re insert bolts and tighten Two piece footrest adjustable ang...

Page 22: ...lothes guard mudguard 0 Retighten bolts or 2 Loosen and remove bolts 3 Re fit clothes guard mudguard in another position Fitting and adjusting the removable mudguard Difficulty Tool Ã 3 4 5 10 1 Fit side fastening element with bolts a and b 2 Insert mudguard in the side fastening element Adjust the height by loosening the three bolts on the end stop 3 If the edge of the mudguard does not run evenl...

Page 23: ...agement mechanism i To enlarge the distance between the wheels additionally a different adapter sleeve which is mounted from the inside has to be applied Fitting flip to back side rest with locking mechanism Difficulty Tool Ã 3 4 5 10 0 Fit the side fastening element with bolt a 0 For bolt b bore a hole with a diameter of 6 mm through the front frame hole already made in the connecting tube and fi...

Page 24: ...y Tool Ã 4 5 10 1 Fit the side fastening element with bolts and 2 Insert side rest into the fastening element 0 Adjust height by adjusting the clamp component Fitting a simple swivelling armrest Difficulty Tool Ã 4 5 1 Fit the rear fastening element 2 Insert the armrest 0 Adjust height by adjusting the bolt in the tube of the armrest 1 2 à 4 Nm à 7 Nm ...

Page 25: ...apter plate Pos 1 to 4 or rear wheel extension Pos 5 and 6 SHh mm Rear wheel 22 Rear wheel 24 Rear wheel 25 Rear wheel 26 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 390 L L L S S S L L L L L L 400 L L L S S S L L L L L L 410 L L S S S S L L L S L L L L L L L L 420 L L S S S S L L L S L L L L L L L L L L L L L L 430 L S S S S S L L L S L L L L L S S S L L L L S S 440 L S S S S S L L L S S S L ...

Page 26: ...S S XL XL XL XL S S 450 S S S S S S L L S S S S L L L L S S XL XL L L S S 460 L L S S S S L L L S S S L L L L S S 470 L S S S S S L L S S S S L L L S S S 480 S S S S S S L S S S S S L L L S S S 490 S S S S S S L L S S S S 500 S S S S S S L L S S S S L S Mudguard mounted fix with respect to the position of the rear wheels with standard adapter plate Pos 1 to 4 SHh mm Rear wheel 22 Rear wheel 24 Rea...

Page 27: ...n easily Castor fork Replacing the castor fork Difficulty Tool Ã 3 19 1 Remove bolts wheel axle and front wheel 2 Remove nuts and pull the castor fork from the clevis pin Replace castor fork and secure with nut such that the fork has no play Re insert the front wheel j CAUTION Do not overtighten nut as this can damage the fork bearing Function check Tip the wheelchair backwards 90 so that it is ly...

Page 28: ...he angle Chap Front wheels Setting the steering error angle Correcting the trail angle Special housing guides Fitting special housing guide for smaller SHv housing guide fitted high Difficulty Tool Ã5 10 Remove clevis pin housing Remove standard housing guide Attach bolt Fit special housing guide high Fit clevis pin housing Set the angle Chap Front wheels Setting the steering error angle Correctin...

Page 29: ...he rear wheel being fitted further forward or further backward on the adapter plate The further back the adapter sleeve is fitted the greater the tipping stability of the wheelchair If the rear wheel is to be fitted even further back a rear wheel exten sion can be fitted to increase the tipping stability even more Adjusting the position of the rear wheel on the adapter plate Difficulty Tool 19 22 ...

Page 30: ...e adapter sleeves so that the distance between the rear wheels is the same at the front and the back x y measured at the height of the center of the axle i At the same time the distance between the individual wheels and the relevant side frame can be checked for conformity and adjusted if necessary Retighten nuts of adapter sleeves on both sides Adapter plate for drum brake Fitting the adapter pla...

Page 31: ...tions by marking them with a pencil and correct if necessary Drill the adapter plate through the fixing holes of the locking ring Remove the locking ring and adapter sleeve from the adapter plate Drill through the adapter plate using the drill press and deburr the holes Re fit the locking ring with adapter sleeve in the required adapter plate hole using the nut and ribbed washer Push the pins thro...

Page 32: ...raddle spanner Adjust the length L of the removable axle by turning the nut The length is correctly adjusted if the removable axle engages correctly when fixing the wheel and wheel has just minimal clearance i The wheels must be exchanged left to right side and vice versa after adjusting both removable axles The adjustment must now be checked or carried out again to ensure the wheels can be switch...

Page 33: ...t correctly if the brake rod presses into the tyre by no more than 4 mm when the brake is applied and the tyres are properly pumped Visual check Check that the parking brakes are positioned correctly The brake is set correctly if the brake shoe depresses the tyre by no more than 4 mm when the brake is applied In the case of active brakes and standard brakes this will be the case when the brake sho...

Page 34: ...or the drum brake Fit the drum brake plate and rotary fixing to adapter plate Connect the drum brake plate and rotary fixing with bolt Fit brake lever on the push handle and secure Bowden cable with fixing set Setting the drum brake Difficulty Tool Tighten or loosen the brake by turning the setting sleeve If the setting sleeve cannot be turned any further demount brake cable loosen clamp bolt usin...

Page 35: ...t in half way position spring in sleeve and screw bolt completely into the tube 4 Put all the parts of the antitipper back together in doing so pull spring apart e g using a wire hook and secure it with the top bolt Set the antitipper parallel to the wheel chair and tighten the bolts Function check The distance between the antitipper and the ground must be 40 60 mm It must be easy to fold up the a...

Page 36: ...ust the height remove cap and e g using a screwdriver compress the spring inside the tube and push into the required position Cane holder Fitting a cane holder Difficulty Tool Ã 5 10 Secure adaptation support with bolt onto adapter plate Push in spring clip and push the cane holder into the adaptation support Make sure that the spring clip is correctly engaged in the adaptation support Height adju...

Page 37: ...adjust the height remove cap and e g using a screwdriver compress spring inside the tube and push into the required position i To bring the transit wheels into the upper or lower position the spring clip must be pressed in Fitting the pelvic belt Difficulty Tools Drill drill bit 6 mm Ã 5 10 1 If not present drill a hole on both sides through the frame 2 Attach the steel strap using bolts through t...

Page 38: ...38 KÜSCHALL ULTRA LIGHT Küschall AG Switzerland 2014 07 Service Manual OPTIONS ACCESSORIES Attaching the snap hook symbols Front side Rear side ...

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Page 40: ...18 695 758 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 Österreich Invacare Austria GmbH Herzog Odilostrasse 101 A 5310 Mondsee Tel 43 6232 5535 0 Fax 43 6232 5535 4 info invacare austria com Portugal Invacare Lda Rua Estrada Velha 949 P 4465 784 Leça...

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