Otto Bock Start 3 Series Service Manual Download

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Start Series

M1 Intro • M2 Effect • M3 Hemi • M4 XXL • M5 Comfort • M6 Junior

Service Manual

Summary of Contents for Start 3 Series

Page 1: ...Start Series M1 Intro M2 Effect M3 Hemi M4 XXL M5 Comfort M6 Junior Service Manual ...

Page 2: ......

Page 3: ... 5 Retrofitting the transport wheels 14 4 1 6 Attaching the crutch holder 14 4 1 7 Replacing the support brackets 15 4 1 8 Replacing the central unit 15 4 1 9 Replacing the reinforcement sheet 16 4 2 Component Group B Footrest 16 4 2 1 Replacing the footrest receiver 16 4 2 2 Footrests with foot rest holder 16 4 2 3 Elevating footrest 19 4 2 4 Individual plastic footrests 20 4 2 5 Footplate made o...

Page 4: ...ster journal bearings 33 4 6 3 Replacing Setting the caster fork 33 4 6 4 Replacing Setting the casters 34 4 7 Component Group G Rear wheel 34 4 7 1 Replacing the tires 34 4 7 2 Re tightening Adjusting the Spokes 35 4 7 3 Replacing the push rings 35 4 7 4 Adjusting the quick release axle 35 4 7 5 Setting the rear wheel position 36 4 7 6 Setting the wheel camber 38 4 7 7 Retrofitting rear wheels wi...

Page 5: ... refers to the spare parts catalogs and instructions for use manuals for the products described here For this reason it is important to use these do cuments together Use the maintenance schedule check list as a template for making copies Retain completed maintenance schedules and provide the customer with a copy Instructions for Use Start 3 647G324 D GB 1 2 Technical Support Should you have any qu...

Page 6: ...om our homepage www ottobock de or www ottobock com CAUTION Risk of injury as a result of inappropriate work clothes Wear appropriate clothing including gloves and protective goggles if required NOTICE Damage caused by inappropriate tools Use appropriate tools refer to page 7 NOTICE Damage to the product Secure the product to prevent it from tipping over or falling off the workbench NOTICE Damage ...

Page 7: ...d for service Ratchet wrench and socket set sizes 8 24 Torque wrench measurement range 5 50 Nm Wrenches sizes 8 24 Allen wrenches sizes 3 6 Screwdrivers blade widths 2 5 3 5 and 5 5 mm Phillips head screwdriver size 2 Plastic hammer Hammer approx 300 gr Stanley knife standard blade Pincers and combination pliers Side cutting pliers Folding reler and level Contained in 481C08 ST010 Tool Set ...

Page 8: ...Schedule Start Series Service Manual 8 Ottobock Liquid thread lock medium strength Pop rivet gun for rivets up to Ø 5 mm Workbench and vice with plastic jaws and rubber insert Hand drill Tyre mounting levers inner tube repair kit ...

Page 9: ...andle Back upholstery Angle adjustment M2 Fold down mechanism M2 Push handles Back tubes x x x x x x x x x Back accessories Side thoracic support M2 x x 4 E Side panels Height setting Swivel mechanism x x x x 4 F Caster Tires wear Air pressure M2 Caster journal angle Screw connection of the caster journal bearing Running behaviour of the wheels Swiveling of the wheel forks x x x x x x x x x 4 G Dr...

Page 10: ...Fold down mechanism Push handles x x x x x x x x x Back accessories Side thoracic support Stabilization bar x x x 4 E Side panels Height setting Swivel mechanism x x x x 4 F Caster Tires wear Air pressure Caster journal angle Screw connection of the caster jour nal bearing Running behaviour of the wheels Swiveling of the wheel forks x x x x x x x x x 4 G Drive wheel Tires wear Air pressure Running...

Page 11: ...le adjustment M5 Fold down mechanism M5 Push handles x x x x x x x x x Back accessories Side thoracic support M5 Stabilization bar M4 x x x x 4 E Side panels Height setting Swivel mechanism x x x x 4 F Caster Tires wear Air pressure Caster journal angle Screw connection of the caster journal bearing Running behaviour of the wheels Swiveling of the wheel forks x x x x x x x x x 4 G Drive wheel Tire...

Page 12: ... upholstery Back tubes Angle adjustment Fold down mechanism Push handles x x x x x x x x x Back accessories Side thoracic support x x 4 E Side panels Height setting Swivel mechanism x x x x 4 F Caster Tires wear Caster journal angle Screw connection of the caster jour nal bearing Running behaviour of the wheels Swiveling of the wheel forks x x x x x x x x 4 G Drive wheel Tires wear Air pressure Ru...

Page 13: ...n 4 2 side panels refer to Section 4 3 back upholstery push handles refer to Section 4 4 side panels refer to Section 4 5 casters and caster journal bearings refer to Section 4 6 rear wheels and rear wheel adapters refer to Section 4 7 and brakes wheel locks refer to Section 4 8 It is advisable to start with disassembling the accessories which are attached to the frame i e anti tipper transport wh...

Page 14: ...ng proceed in the reverse order For height adjustment fully press the button on the lower tube and move the sleeve up to the required point 3 4 4 1 5 Retrofitting the transport wheels The transport wheels are attached to the rear wheel adapter To attach the transport wheels remove the attachment screws from the rear wheel adapters Replace the screws by the longer oval head screws M6x80 enclosed an...

Page 15: ...me For assembly please proceed in reverse order Use new self locking screws 4 1 8 Replacing the central unit First disassemble the rear wheel adapter as described in Section 4 7 Also remove all frame accessories as described in the preceding section Loosen all screws of the central unit Fig 8 remove the back tubes by pulling them up and then remove the central unit from the frame by pulling it to ...

Page 16: ... liquid thread lock to the existing screws 4 2 1 Replacing the footrest receiver All footrests fit into the receiver without having to exchange any parts Loosen and remove the two screws Fig 10 and remove the footrest receiver from the frame For assembly please proceed in reverse order Use new screws with thread lock 4 2 2 Footrests with foot rest holder a Replacing the footrest Insert the footres...

Page 17: ...the footrest bar After loosening the set screw the footrest bar can be adjusted or completely pulled out of the footrest holder Fig 12 c Replacing the pivot bearing Loosen and remove the screw Fig 13 and remove the pivot bearing For assembly please proceed in reverse order Use new screws coated with thread lock 12 13 ...

Page 18: ...nwards Now you can also pull off the swivel segment and put down the parts as shown in the photo Fig 15 Information Pay attention to the clamp piece which is only laid in For assembly please proceed in reverse order Before putting the parts together lay the clamp piece into the opening of the frame tube as shown in the photo Fig 16 Use new set screws coated with thread lock Retighten the screw con...

Page 19: ...crew arrowed the footrest bar can be adjusted in length Fig 18 After loosening and removing the screw the footrest bar can be pulled out completely Retighten the screw connection during the assembly with a torque of 6 Nm 17 18 c Setting replacing the calf pads After loosening the screw in the clamping unit the calf pad can be adjusted in height Fig 19 After completely loosening and removing the sc...

Page 20: ... the screw b Replacing Loosen and remove the screw and remove the footplate Fig 21 In order to also remove the joint piece from the footrest bar the two screws on the outside must be loosened refer to Section 4 2 4 Adjusting the angle For assembly please proceed in reverse order Use new self locking screws and nuts 20 21 4 2 5 Footplate made of aluminum M4 a Replacing setting After loosening the s...

Page 21: ...ceiver in the place of a footrest The amputation legrest can be adjusted by the same lever operated angle adjustment mecha nism as with the elevating footrest b Replacing the pad Loosen and remove the screws on the clamp piece and remove the calf pad Fig 24 For assembly please proceed in reverse order The clamp connection can also be used to change the pad s mounting height 23 24 ...

Page 22: ...ly please proceed in reverse order Use new self locking nuts 4 3 2 Scale on the crossbrace bracket The crossbrace brackets are provided with a scale showing the appropriate setting for the cor responding seat width Fig 26 25 26 4 3 3 Replacing the crossbrace brackets After loosening and removing the screw connection you can unclip the crossbrace bracket from the frame and replace it Fig 27 Please ...

Page 23: ... are possible depending on the structural conditions Information Make sure to firmly retighten all screws and nuts after making adjustments The proper torque is 8 Nm Fasten the hook and loop attachments again between the back padding and the seat cushion b Version until August 2008 The Start crossbrace allows you three seat depth adjustments in increments of 2 5 cm in ad dition to the fine adjustm...

Page 24: ... and the spacer fabric Fig 32 Clean the cushion cover according to the sewn in care instructions label 4 3 7 Cleaning the nylon seat upholstery no figure Clean the seat upholstery with regular mild household cleaner 4 3 8 Retrofitting with the Adjustable Seat seating system no figure Please observe the information given in the product s Instructions for Use 647H450 32 ...

Page 25: ...etween the upper edge of the first lower hook and loop strip and lower edge of the second hook and loop strip measurement should be approx 50 mm Fig 34 Attach another hook and loop strips to the back tube at the same distance Make sure that the hook and loop strips are attached symmetrically to the other back tube Now fasten the straps to the attached hook and loop strips To do so feed the short e...

Page 26: ... added refer to Section 4 4 1 4 4 3 Height setting Replacement of the back tubes The back tube which is integrated into the rear frame allows for the adjustment of the back height in increments of 2 5 cm To do so remove all screws from the vertical retainer in the central unit Fig 38 and move the back tube to the desired position In this way the back tube can also be removed completely from the ho...

Page 27: ...esive Use the spatula to squeeze out all the contents of the sachet into the centre of the mixing card Mix the adhesive using the spatula Ensure you work effectively after mixing since the adhesive sets quickly Apply half of the adhesive into each of the rubber hand grips using the spatula Evenly distribute the adhesive in the rubber hand grip up to a depth of approx 4 5 cm Fig 40 Slide the rubber...

Page 28: ...using an open end wrench and pull the bolt out of the eyelet Fig 42 If you only want to replace the cable remove the O ring from the device by turning key ring principle 41 42 To completely replace the back angle adjustment mechanism unlock the back and fold it down onto the seat surface as for transporting Loosen the three screw connections which connect the back angle adjustment mechanism to the...

Page 29: ...ge out of the two tube ends For assembly please proceed in reverse order 4 4 8 Retrofitting with the back system The Back Please observe the information given in the product s Instructions for Use 647H491 no figure 45 4 5 Component Group E Side Panels 4 5 1 Replacement Retrofit Setting the side panels a Desk side panels Release the side panel from the anterior guide using the locking lever Fig 46 ...

Page 30: ...use your fingers Fig 49 48 49 c Clothing protector M5 version until June 2008 First remove the desk side panels Then loosen the front screw from the central unit and screw the adapter of the clothing protector with the two screws provided to the two anterior holes of the central unit Fig 50 Insert the clothing protector into the adapter s guides and fix it at the desired height with the clamping s...

Page 31: ...using other bore ho les beneath the pad Fig 54 For assembly please proceed in reverse order 52 53 b Height adjustable desk side panel While pressing the button on the plastic element of the slide pull the armrest pad into the desired position The slide contains different locking positions in which the armrest will engage Fig 55 c Plug on side panel For height adjustment of the side panel press the...

Page 32: ...ht adjustable desk side panel Plug on side panel For better accessibility of the screws bring the armrest into the highest possible position Loosen the two screws on the underside of the armrest and remove the armrest pad Fig 56 For assembly please proceed in reverse order 4 5 4 Replacing the locking lever desk side panels Loosen and remove the attachment screw together with the spring and remove ...

Page 33: ...onnection Fig 58 item A the caster journal bearing can be removed from the frame For assembly please proceed in reverse order Use new self locking nuts 4 6 3 Replacing Setting the caster fork After loosening and removing the two screw connections the complete component group can be removed from the frame Fig 59 For assembly please proceed in reverse order Use new self locking nuts Tighten the scre...

Page 34: ...tion The casters must be replaced if the material shows signs of cracking or damage and when the tread becomes worn down to such an extent that there is only 5 mm of radius left on the outer edges of the tire Information Replace the casing of wheels with pneumatic Tires if it is bald or shows signs of cracking or other damage 60 61 4 7 Component Group G Rear wheel Information Use new screws coated...

Page 35: ...eed in reverse order 4 7 4 Adjusting the quick release axle The quick release axle Fig 65 should be set so the wheel is properly engaged with no play on the axle Use a wrench to hold the quick release axle on the inside and adjust the play by turning the nut on the end of the quick release axle in or out Fig 65 item A Information Please also observe the information regarding maintenance cleaning a...

Page 36: ...justment Loosen the two screws of the rear wheel adapter Fig 66 item A and reposition the adapter upwards downwards as desired The setting must always be equal on both sides For fine adjustment loosen the nut of the fitting on the inside of rear wheel adapter Fig 66 item B and move the adapter in the slotted hole The setting must always be equal on both sides Horizontal position adjustment Loosen ...

Page 37: ...down wards The setting must always be equal on both sides Horizontal position adjustment Loosen the nut of the fitting on the inside of the rear wheel ad apter and shift the adapter forwards rearwards Fig 69 The setting must always be equal on both sides Make sure to firmly retighten all screws and nuts after making adjustments The proper torque for the screw connection of the rear wheel adapter i...

Page 38: ... 70 Setting the rear wheel camber to 2 5 Position the camber washer with the thinner side up ward into the desired locking position Fig 43 on the outside of the rear wheel adapter Position the second camber washer with the thicker side upwards into the respective locking position on the inside of the rear wheel adapter Further proceeding Slightly tighten the nuts on the rear wheel fitting once you...

Page 39: ...ormation given in the instructions for use manual 73 4 7 8 Retrofitting rear wheels with one arm drive M3 The one arm drive is delivered with special fittings that must first be attached to the rear wheel adapter Fig 74 item 1 Position the fittings on the adapter in the desired position and fix the fittings with the nut on the inner side Then attach the rear wheels to the fittings it does not matt...

Page 40: ...rt 481G53 ST096 2 4 40 5 361 short 481G53 ST096 3 4 43 386 long 481G53 ST097 4 8 45 5 411 long 481G53 ST097 5 8 48 436 long 481G53 ST097 6 8 50 5 461 long 481G53 ST097 7 8 4 7 9 Attaching a spoke protector to the standard wheel Lay the spoke protector onto the wheel so that the notches match the screw connections of the push ring Starting with a round hole press on the spoke protector with an atta...

Page 41: ...t use only original rear wheels with an approved radial excursion of maximally 1 mm Information Use new screws coated with thread lock or apply a liquid thread lock to the existing screws Information The wheel lock should then be remounted such that the distance between the tyre and brake block is max 4 mm when the wheel lock is not activated subject to technical changes 4 8 1 Wheel lock a Replaci...

Page 42: ...l lock lever extension to the pre drilled hole in the wheel lock housing using the screw provided Fig 81 Pull the wheel lock lever handle cover off the wheel lock lever If necessary cut open the handle cover Fig 82 Remove any residues of old glue or rubber from the wheel lock lever Plug the wheel lock lever extension onto the wheel lock lever Fig 83 81 82 83 ...

Page 43: ...long fitting to the rear wheel adapter in the desired position Fig 84 Screw the lock against rotation to the central unit by means of a drilled tongue Fig 85 Insert the spacer sleeve between the parts during screwing Fig 86 Finally fix the fitting to the inside of the rear wheel adapter with washer and nut Fig 87 Connect the Bowden cable to the drum brake Insert the rear wheel with drum brake into...

Page 44: ...chment of the brake handles left right the push handles must be equipped with an ex tension To do this first remove the rubber hand grips as described under section 4 4 4 Replacing the rubber hand grips and mount the brake lever unit using the clamp which is screwed to the push handle Fig 89 Next mount the handle extension to the push handle To do this insert the extension into the push handle and...

Page 45: ...from inside through between the side panel and central unit Fig 92 Make sure that the wheelchair can still be folded without trapping the brake cables 91 92 e Setting the drum brake The brake force of the drum brake can be adjusted with the adjusting nut Fig 93 item A To do this please observe the information given in Section 6 6 of the instructions for use manual After finishing the adjustment fa...

Page 46: ... the brake cable as shown in the photo underneath and along the frame and across to the opposite side Then rou te the brake cable forwards to the opposite wheel lock Fig 95 94 95 Locate the nipple end of the brake cable into the wheel lock with the wheel lock lever Fig 96 Insert the brake cable through the hole in the cable attachment pin Fig 97 96 97 Route the brake cable as shown in the photo un...

Page 47: ...s to obtain an even braking effect on both sides Cut off the brake cable to approx 1 cm only after all settings have been made Put the provided cable end sleeve onto the end of the brake cable Fig 102 and clamp the cable end sleeve using side cutting pliers 100 101 b Replacing the brake block With disassembled wheel lock loosen the screw of the brake block and remove the block Fig 102 For assembly...

Page 48: ...emove the clamping unit wheel lock for user and attendant Fig 103 item B If necessary replace the wheel lock for user and attendant For reassembling the brake cable proceed as described under the Section 4 8 3 a starting from Fig 98 Wheel lock for one handed operation Reattach the rear wheel After loosening the two screws on the clamping unit Fig 103 item B the distance between the wheel lock and ...

Page 49: ...ray A tray can be attached to all armrests Fig 105 104 105 4 9 3 Attaching a thoracic support The side thoracic support is mounted to the back tubes using the mounting kit provided For adapting the pad to the patient loosen the three screws on the back of the support Move the pad to the desired position and firmly retighten the screws Fig 106 4 9 4 Attaching a headrest mounting kit The headrest mo...

Page 50: ...vice Manual 50 Ottobock 106 107 4 9 5 Attaching a fold fixation strap Screw the loose end of the fold fixation strap with the Phillips head screw to the left support in driving direction Fig 108 Then screw the snap fastener to the right support 108 ...

Page 51: ...0 0 M5 101 0 88 0 104 0 91 0 M6 91 0 81 0 92 0 82 0 95 0 85 0 Overall width in cm 1 Seat width Rear wheel Standard max Rear wheel with drum brake max 28 0 49 5 52 0 30 5 51 5 54 5 33 0 54 5 57 0 35 5 57 0 59 5 38 0 59 5 62 0 40 5 62 0 64 5 43 0 64 5 67 0 45 5 67 0 69 5 48 0 69 5 72 0 50 5 72 0 74 5 53 0 74 5 77 0 77 0 77 0 79 5 79 5 79 5 82 0 1 Specified for narrow push ring installation in case o...

Page 52: ...ight aSH Caster fork in dependency of the anterior seat height and casters Rear wheel size in dependency of the posterior seat height hSH Start M1 M2 M3 M6 Posterior seat height in cm Posterior seat height Setting range Rear wheel size 20 37 43 22 38 45 24 41 49 Start M3 Anterior seat height in cm with wider foot space Caster fork short Position Setting range1 Caster diame ter 5 38 40 5 5 39 42 6 ...

Page 53: ...Technical Data Start Series Service Manual Ottobock 53 Rear wheel adapter M1 M2 M3 M6 M4 M5 ...

Page 54: ...Start Series Service Manual 54 Ottobock ...

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Page 56: ...ity Solutions GmbH Lindenstraße 13 07426 Königsee Rottenbach Germany T 49 0 69 9999 9393 F 49 0 69 9999 9392 ccc ottobock com www ottobock com Versandanschrift für Rücksendungen Address for Returns Otto Bock Manufacturing Königsee GmbH Lindenstraße 13 07426 Königsee Rottenbach Germany Ihr Fachhändler Your specialist dealer ...

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Otto Bock Start 3 Series, Service Manual

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