Otto Bock Start 3 Series Service Manual
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Otto Bock Start 3 Series Service Manual

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Start Series
M1 Intro • M2 Effect • M3 Hemi • M4 XXL • M5 Comfort • M6 Junior
Service Manual

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Summary of Contents for Otto Bock Start 3 Series

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

  • Page 3: Table Of Contents

    Contents Service Manual for the Start 3 Series Contents Page 1 Introduction ........................5 1.1  Preface  ........................5 1.2  Technical Support ....................5 1.3  Information for Service Staff  ..................5 2 Safety Instructions ......................6 2.1  Explanation of Symbols  ..................6 2.2  General Safety Instructions ...................6 3 Required Tools, Maintenance Schedule ................7 3.1 ...
  • Page 4 Contents 4.4  Component Group D: Back / Push Handles  ............25 4.4.1  Retrofitting with adaptable back upholstery ..........25 4.4.2  Adjusting the adaptable back upholstery ........... 26 4.4.3  Height setting/Replacement of the back tubes  .......... 26 4.4.4  Replacing the rubber hand grips  ..............27 4.4.5  Replacing the standard back upholstery ............ 28 4.4.6  Replacing the back angle adjustment mechanism  ........28 4.4.7  Replacing the fold-down back tubes  ............29 4.4.8  Retrofitting with the back system “The Back“ ..........29 4.5  Component Group E: Side Panels ...............29 4.5.1  Replacement / Retrofit / Setting the side panels ........29 4.5.2 ...

  • Page 5: Introduction

    Introduction 1 Introduction InfoRMaTIon Dateofthelastupdate:2013-04-26 • Pleasereadthisdocumentcarefully. • Followthesafetyinstructions. 1.1  Preface Regularmaintenanceisimportant–itimprovesthesafetyandincreasesthelifespanofthe product. Allmobilityproductsshouldbeinspectedandservicedonceayear. However,iftheproductisusedfrequently,orifitisusedbygrowingchildrenorpatientswithchan- gingclinicalconditions,werecommendreadjustingandservicingtheproductevery6months. Onlyuseoriginalsparepartsforallserviceandmaintenance. Theserviceandmaintenancetasksdescribedhereshouldonlybecompletedbytrained,qua- lifiedpersonnelandnotbytheuseroftheappliance. Thisserviceandmaintenancemanualreferstothesparepartscatalogsandinstructionsfor usemanualsfortheproductsdescribedhere.Forthisreason,itisimportanttousethesedo- cumentstogether. Usethemaintenanceschedule(checklist)asatemplateformakingcopies.Retaincompleted maintenanceschedulesandprovidethecustomerwithacopy. InstructionsforUse Start3 647G324=D/GB 1.2  Technical Support Shouldyouhaveanyquestionsoraproblemthatcannotberesolveddespiteusingtheservice instructions,pleasecontactOttoBockService(seebacksideofcoverforaddress). 1.3  Information for Service Staff Serviceandmaintenanceincludeavisualexaminationoftheproductfordamages,deforma- tions,framebreaksandcracking.Deformationsareoftenrecognizablebythattheproductdoes notstandevenlyonthegroundwithallwheels/feet.Sincenearlyallproductsaresymmetrical indesign,deformationscanalsobeidentifiedbycomparingthecorrespondingrightandleft framecomponentgroupswitheachother. Start Series | Service Manual Ottobock | 5...

  • Page 6: Safety Instructions

    Safety Instructions 2 Safety Instructions 2.1  Explanation of Symbols Warningsregardingpossiblerisksofaccidentorinjury. CaUTIon Warningsregardingpossibletechnicaldamage. NOTICE Informationregardingoperation.Informationforservicepersonnel. InfoRMaTIon 2.2  General Safety Instructions InfoRMaTIon Readtheserviceandmaintenanceinstructionsbeforestarting.Familiariseyourselfwiththefunctions oftheproduct.Ifyouarenotfamiliarwiththeproduct,readtheinstructionsforusebeforeinspecting theproduct. Ifyoudonothaveaninstructionsforusemanual,youcanorderonefromthemanufacturer(seethe overviewofallOttoBockBranches“OttoBockWorldwide“).Youcanalsodownloaddocumentsfrom ourhomepage:www.ottobock.deorwww.ottobock.com. CaUTIon Risk of injury as a result of inappropriate work clothes. Wearappropriateclothing,includinggloves andprotectivegogglesifrequired. NOTICE Damage caused by inappropriate tools. Useappropriatetools(refertopage7). NOTICE Damage to the product.

  • Page 7: Required Tools, Maintenance Schedule

    Required Tools, Maintenance Schedule 3 Required Tools, Maintenance Schedule 3.1  Required Tools Thefollowinglistshowsthetoolsandaccessoriesrequiredforservice. Ratchetwrenchandsocketset,sizes Torquewrench, Wrenches, 8–24 measurementrange5–50 nm sizes8–24* Allenwrenches, Screwdrivers,bladewidths Phillipsheadscrewdriver,size2 sizes3–6* 2.5;3.5and5.5mm Plastichammer Hammer(approx.300gr.) Stanleyknife,standardblade Pincersandcombinationpliers Sidecuttingpliers Foldingrelerandlevel *Containedin481C08=ST010ToolSet Start Series | Service Manual Ottobock | 7...
  • Page 8 Required Tools, Maintenance Schedule Liquidthreadlock“mediumstrength” PoprivetgunforrivetsuptoØ5mm Workbenchandvicewithplasticjaws andrubberinsert Handdrill Tyremountinglevers*,innertuberepairkit* 8 | Ottobock Start Series | Service Manual...

  • Page 9: Maintenance Schedule

    Required Tools, Maintenance Schedule 3.2  Maintenance Schedule Customer: Maintenance Start M1 Intro/M2 Effect scheduleforregularinspections -LightweightWheelchair- Item Inspection (checklist) Component group Serialnumber: Function/setting Damage/ Screwconnections (referto647G324InstructionsforUse) deformation M1Intro M2Effect Frame -Frame -Centralunit Frameaccessories -Anti-tipper -Transportwheels(onlyM2) -Crutchholder Footrest -Flip-upmechanism -Lowerleglengthsetting -Angleadjustment Seat -Crossbrace -Seatupholstery -Seatcushion Back/pushhandle...
  • Page 10 Required Tools, Maintenance Schedule Customer: Maintenance Start M3 Hemi scheduleforregularinspections -LightweightWheelchair- Item Inspection (checklist) Component group Serialnumber: Function/setting Damage/ Screwconnections (referto647G324InstructionsforUse) deformation M3 Hemi Frame -Frame -Centralunit Frameaccessories -Anti-tipper -Transportwheels -Crutchholder Footrest -Flip-upmechanism -Lowerleglengthsetting -Angleadjustment Seat -Crossbrace -Seatupholstery -Seatcushion Back/pushhandle -Backupholstery -Backtubes -Angleadjustment...
  • Page 11 Required Tools, Maintenance Schedule Customer: Maintenance Start M4 XXL /M5 Comfort scheduleforregularinspections -LightweightWheelchair- Item Inspection (checklist) Component group Serialnumber: Function/setting Damage/ Screwconnections (referto647G324InstructionsforUse) deformation M4XXL M5Comfort Frame -Frame -Centralunit Frameaccessories -Anti-tipper -Transportwheels -Crutchholder Footrest -Flip-upmechanism -Lowerleglengthsetting -Angleadjustment Seat -Crossbrace -Seatupholstery -Seatcushion Back/pushhandle -Backupholstery...
  • Page 12 Required Tools, Maintenance Schedule Customer: Maintenance Start M6 Junior scheduleforregularinspections -LightweightWheelchair- Item Inspection (checklist) Component group Serialnumber: Function/setting Damage/ Screwconnections (referto647G324InstructionsforUse) deformation M6 Junior Frame -Frame -Centralunit Frameaccessories -Anti-tipper -Transportwheels -Crutchholder Footrest -Flip-upmechanism -Lowerleglengthsetting -Angleadjustment Seat -Crossbrace -Seatupholstery -Seatcushion Back/pushhandle -Backupholstery -Backtubes -Angleadjustment...

  • Page 13: Settings / Replacement / Retrofit

    Settings / Replacement / Retrofit 4 Settings / Replacement / Retrofit 4.1  Component Group A: Frame InfoRMaTIon Usenewscrewscoatedwiththreadlockforassemblingtheframeandtherearwheeladapters. 4.1.1 Replacing the frames Inordertoreplaceoneorbothframes(Fig.1),youfirsthavetoremoveallcomponentgroups andaccessorieswhichareconnectedtotheframe. • Centralunitaccordingtodrawing, • footrests(refertoSection4.2) • sidepanels(refertoSection4.3) • back/upholstery/pushhandles(refertoSection4.4), • sidepanels(refertoSection4.5) • castersandcasterjournalbearings(refertoSection4.6), • rearwheelsandrearwheeladapters(refertoSection4.7), • andbrakes/wheellocks(refertoSection4.8). Itisadvisabletostartwithdisassemblingtheaccessorieswhichareattachedtotheframe,i.e. anti-tipper,transportwheelsorcrutchholder.Allpartsmountedtotheframeareattachedwith screws. 4.1.2 Cover cap replacement Thereisacapatthetubeend,whichcanbecutopenwhendamagedusingabladeandpulled offthetubeend.Putthenewcovercaponthetubeend(Fig.2).

  • Page 14: Replacement / Retrofit / Setting Of The Swinging Anti-Tipper

    Settings / Replacement / Retrofit 4.1.3 Replacement / Retrofit / Setting of the swinging anti-tipper Loosenandremovethescrewconnections(Fig.3)andremovetheanti-tipperholderfromthe frame. Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingnuts. Forsettingtheanti-tipperpleaseobservetheinformationgivenintheinstructionsforusemanual. 4.1.4 Replacing/Retrofitting/Setting a plug-in anti-tipper Theanti-tipperisdeliveredcompletelypre-assembled. Presstherearbuttonontheuppertubepiece(Fig.4),slidetheanti-tipperintotherearframe tubeofthewheelchairandreleasethebutton.Slidetheanti-tipperforwardsuntilitautomati- callyengages. Forremoving,proceedinthereverseorder. Forheightadjustment,fullypressthebuttononthelowertubeandmovethesleeveuptothe requiredpoint. 4.1.5 Retrofitting the transport wheels Thetransportwheelsareattachedtotherearwheeladapter.Toattachthetransportwheels, removetheattachmentscrewsfromtherearwheeladapters.Replacethescrewsbythelonger ovalheadscrewsM6x80enclosedandfastenthemwithhexagonnutsenclosed(Fig.5,item A).Thepropertorqueofthescrewconnectionis10 nm. Putthetransportwheelsandspacersleevesenclosedontotheprotrudingscrewsandsecure thetransportwheelswithcapnutsenclosed(Fig.5,itemB).

  • Page 15: Replacing The Support Brackets

    Settings / Replacement / Retrofit 4.1.7 Replacing the support brackets Swingthesidepaneltotherearandloosenandremovethecapscrewinthesupportbrackets (Fig.7).Removethesupportbracketsfromtheframe. Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingscrews. 4.1.8 Replacing the central unit FirstdisassembletherearwheeladapterasdescribedinSection4.7. Alsoremoveallframeaccessoriesasdescribedintheprecedingsection.Loosenallscrewsof thecentralunit(Fig.8),removethebacktubesbypullingthemupandthenremovethecentral unitfromtheframebypullingittotheback. Forassembly,pleaseproceedinreverseorder. Start Series | Service Manual Ottobock | 15...

  • Page 16: Replacing The Reinforcement Sheet

    Settings / Replacement / Retrofit 4.1.9 Replacing the reinforcement sheet Inordertoremovebutthereinforcementsheetthestandardrearwheeladaptermustberemo- ved.Thenloosenallscrewsonthereinforcementsheetandremovethesheet. Forassembly,pleaseproceedinreverseorder. 4.2  Component Group B: Footrest InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. 4.2.1 Replacing the footrest receiver Allfootrestsfitintothereceiverwithouthavingtoexchangeanyparts. Loosenandremovethetwoscrews(Fig.10)andremovethefootrestreceiverfromtheframe. Forassembly,pleaseproceedinreverseorder.Usenewscrewswiththreadlock. 4.2.2 footrests with foot rest holder a) Replacing the footrest Insertthefootrestholders–inlaterallyturnedposition–fromaboveintothefootrestreceiver (Fig.11). Turnthefootrestholderstothefrontuntiltheswivelsegmentengageswiththelock. Fordisassembly,pleaseproceedinreverseorder. 16 | Ottobock Start Series | Service Manual...
  • Page 17 Settings / Replacement / Retrofit b) Setting the lower leg length / replacing the footrest bar Afterlooseningthesetscrew,thefootrestbarcanbeadjustedorcompletelypulledoutofthe footrestholder(Fig.12). c) Replacing the pivot bearing Loosenandremovethescrew(Fig.13)andremovethepivotbearing. Forassembly,pleaseproceedinreverseorder.Usenewscrewscoatedwiththreadlock. Start Series | Service Manual Ottobock | 17...
  • Page 18 Settings / Replacement / Retrofit d) Replacing the swivel segment Removethefootrestholderfromtheframe. Loosenthesetscrewontheinnersideoftheswivelsegment(Fig.14)andremovethefootrest barbypullingitdownwards. Nowyoucanalsopullofftheswivelsegmentandputdownthepartsasshowninthephoto (Fig.15). InfoRMaTIon Payattentiontotheclamppiecewhichisonlylaidin. Forassembly,pleaseproceedinreverseorder. Beforeputtingthepartstogether,laytheclamppieceintotheopeningoftheframetubeas showninthephoto(Fig.16).Usenewsetscrewscoatedwiththreadlock. Retightenthescrewconnectionduringtheassemblywithatorqueof6 nm. 18 | Ottobock Start Series | Service Manual...

  • Page 19: Elevating Footrest

    Settings / Replacement / Retrofit 4.2.3 Elevating footrest a) attachment Mountthepre-assembledelevatingfootresttothefrontframeinthesamewayasthestandard footrest(Fig.17). b) Setting the lower leg length / replacing the footrest bar Afterlooseningthescrew(arrowed)thefootrestbarcanbeadjustedinlength(Fig.18).After looseningandremovingthescrewthefootrestbarcanbepulledoutcompletely. Retightenthescrewconnectionduringtheassemblywithatorqueof6 nm. c) Setting / replacing the calf pads Afterlooseningthescrewintheclampingunitthecalfpadcanbeadjustedinheight(Fig.19). Aftercompletelylooseningandremovingthescrewconnectionthecalfpadcanberemoved. Forreassembly,snuglyretightenthescrewconnections. Start Series | Service Manual Ottobock | 19...

  • Page 20: Individual Plastic Footrests

    Settings / Replacement / Retrofit 4.2.4 Individual plastic footrests a) adjusting the angle Loosenthelowerofthetwoscrewsonthefootplateholderasshowninthephoto(Fig.20)and movethefootplatetothedesiredangleposition. Thenclampthefootplateagainbytighteningthescrew. b) Replacing Loosenandremovethescrewandremovethefootplate(Fig.21). Inordertoalsoremovethejointpiecefromthefootrestbar,thetwoscrewsontheoutsidemust beloosened,refertoSection4.2.4“Adjustingtheangle“. Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingscrewsandnuts. 4.2.5 footplate made of aluminum (M4) a) Replacing / setting Afterlooseningthescrewconnection(Fig.22)thefootplatecanbepulledoffthesupport. Forassembly,pleaseproceedinreverseorder. 20 | Ottobock Start Series | Service Manual...

  • Page 21: Amputation Leg Rest

    Settings / Replacement / Retrofit 4.2.6 amputation leg rest a) attaching Theamputationlegrest(Fig.23)isinsertedfromaboveintothefootrestreceiverintheplace ofafootrest. Theamputationlegrestcanbeadjustedbythesamelever-operatedangleadjustmentmecha- nismaswiththeelevatingfootrest. b) Replacing the pad Loosenandremovethescrewsontheclamppieceandremovethecalfpad(Fig.24). Forassembly,pleaseproceedinreverseorder. Theclampconnectioncanalsobeusedtochangethepad‘smountingheight. Start Series | Service Manual Ottobock | 21...

  • Page 22: Component Group C: Seat

    Settings / Replacement / Retrofit 4.3  Component Group C: Seat InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. 4.3.1 Replacing the cross brace mounting kit - center InfoRMaTIon Withremovalofthecentralscrewconnectionofthemountingkit,thestabilityofthecrossbraceand framegetslost.Attachanewmountingkitbeforemovingthechair. Loosenandremovethescrewsasshowninthephoto(Fig.25)andpulltheplastichalf-shells outfrombetweenthecrossbracetubes. Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingnuts. 4.3.2 Scale on the crossbrace bracket Thecrossbracebracketsareprovidedwithascaleshowingtheappropriatesettingforthecor- respondingseatwidth(Fig.26). 4.3.3 Replacing the crossbrace brackets Afterlooseningandremovingthescrewconnectionyoucanunclipthecrossbracebracketfrom theframeandreplaceit(Fig.27).Pleasepayattentiontothescaleasdescribedabove. 4.3.4 Replacing the seat upholstery Firstremovethefrontendstoppersusinga(nottoosharp-edged)screwdriver(Fig.28).

  • Page 23: Adjusting The Seat Depth

    Settings / Replacement / Retrofit 4.3.5 adjusting the seat depth a) Version from September 2008 Theseatdepthisadjustedbyshiftingthecentralunit. First,loosenallhook-and-loopattachmentsandremovethebackupholstery/seatcushion. Loosenthescrewconnectionsthatconnectthecentralunittotheopenframetubesandremove thescrews(Fig.29).Shiftthecentralunit(withbacktube)intothedesiredpositionontheframe (Fig.30).Threedifferentseatdepthadjustments,in3cmincrements,arepossibledepending onthestructuralconditions. InfoRMaTIon Makesuretofirmlyretightenallscrewsandnutsaftermakingadjustments.Thepropertorqueis8 nm. Fastenthehook-and-loopattachmentsagainbetweenthebackpaddingandtheseatcushion. b) Version until august 2008 TheStartcrossbraceallowsyouthreeseatdepthadjustmentsinincrementsof2.5cminad- ditiontothefineadjustment. Removethetwoplasticclips(Fig.31)onthelowerframetubeandmovethecrossbraceonthe frame.Inserttheplasticclipintothenextboreholesothatthefootofthecrossbraceislimited bythetwoplasticclips. InfoRMaTIon Besuretoproperlyengagetheplasticclipsintheboreholesprovidedforthisafteralladjustments. Start Series | Service Manual Ottobock | 23...

  • Page 24: Cleaning The Seat Cushion

    Settings / Replacement / Retrofit 4.3.6 Cleaning the seat cushion (example:Evolight) Openthezipperandremovethefoamcoreandthespacerfabric(Fig.32).Cleanthecushion coveraccordingtothesewnincareinstructionslabel. 4.3.7 Cleaning the nylon seat upholstery (nofigure) Cleantheseatupholsterywithregularmildhouseholdcleaner. 4.3.8 Retrofitting with the “adjustable Seat“ seating system (nofigure) Pleaseobservetheinformationgivenintheproduct‘sInstructionsforUse647H450. 24 | Ottobock Start Series | Service Manual...

  • Page 25: Component Group D: Back / Push Handles

    Settings / Replacement / Retrofit 4.4  Component Group D: Back / Push Handles InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. 4.4.1 Retrofitting with adaptable back upholstery Cleanthebacktubespriortoattachmentoftheself-adhesivehook-and-loopstrips. Attachthefirst/lowerhook-and-loopstriptotheoutsideofthebacktube.Thedistancebetween theupperedgeofcentralunitandloweredgeofthehook-and-loopstripshouldbeapprox.60- 65mm(Fig.33). Attachthesecondhook-and-loopstriptotheoutsideofthebacktube.Thedistancebetween theupperedgeofthefirst/lowerhook-and-loopstripandloweredgeofthesecondhook-and- loopstripmeasurementshouldbeapprox.50mm(Fig.34). Attachanotherhook-and-loopstripstothebacktubeatthesamedistance.Makesurethatthe hook-and-loopstripsareattachedsymmetricallytotheotherbacktube. Nowfastenthestrapstotheattachedhook-and-loopstrips.Todoso,feedtheshortendwith beltslideovertherightbacktubeandthelongstrapendovertheleftbacktube.Fastenthe strappartssymmetricallyandcentrallyontotheattachedhook-and-loopstraps. Feedthestrapthroughthebeltslide(Fig.37).Pullthestrapstautasnecessaryandattach them(Fig.35). Followthesameprocesstoattachtheotherthreestraps. Theuppermoststrapisfedfromthetopandscrewedinplace(Fig.36). ca. ca. 50mm 60–65mm Start Series | Service Manual Ottobock | 25...

  • Page 26: Adjusting The Adaptable Back Upholstery

    Settings / Replacement / Retrofit 4.4.2 adjusting the adaptable back upholstery Thebackupholsterycanbeadjustedinsegments. Todothis,removethebackupholsterypaddingandundothehook-and-loopfastenersofthe straps(fig.37). Repositionthestrapsasdesired,attachthemagainwiththehook-and-loopfastenersandco- verwiththepadding. InfoRMaTIon Afteradjustingthebackheightthestrapsmustberedistributed.Thespacebetweenthestrapsshould notbelargerthanonestrapwidth(approx.40mm).Ifnecessary,anotherstrapmustbeadded(refer toSection4.4.1). 4.4.3 Height setting/Replacement of the back tubes Thebacktubewhichisintegratedintotherearframeallowsfortheadjustmentoftheback heightinincrementsof2.5cm. Todoso,removeallscrewsfromtheverticalretainerinthecentralunit(Fig.38)andmovethe backtubetothedesiredposition. Inthisway,thebacktubecanalsoberemovedcompletelyfromtheholdingdevice. InfoRMaTIon Makesuretofirmlyretightenallscrewsandnutsaftermakingadjustments.Thepropertorqueis8 nm forscrewconnectionAand10 nm forscrewconnectionB(rearwheeladapter)(seeFig.58).Forad- justmentofthemaximumbackheight,youhavetomountanadditionalscrewconnectionwithplastic spacersintotheuppermostholeofthecentralunit(Fig.58,itemC). 26 | Ottobock Start Series | Service Manual...

  • Page 27: Replacing The Rubber Hand Grips

    Settings / Replacement / Retrofit 4.4.4 Replacing the rubber hand grips Carefullycutopentherubberhandgrip(Fig.39).Removetheoldrubberhandgrips.Remove theresidueoftheoldglueorrubberfromthetubeandcleanthetubeendswithsolvent. Openthetwopartadhesivesachet.Observetheinstructionsgivenbythemanufacturerofthe adhesive. Usethespatulatosqueezeoutallthecontentsofthesachetintothecentreofthemixingcard. Mixtheadhesiveusingthespatula.Ensureyouworkeffectivelyaftermixing,sincetheadhesive setsquickly. Applyhalfoftheadhesiveintoeachoftherubberhandgripsusingthespatula.Evenlydistribute theadhesiveintherubberhandgripuptoadepthofapprox.4-5cm(Fig.40). Slidetherubberhandgripsontothepushhandlesrotatingthemslightlyastheyarepushedon. InfoRMaTIon Thepushhandleshouldnotbeusedforatleast24hourssoastoallowfullcuringoftheadhesive. Start Series | Service Manual Ottobock | 27...

  • Page 28: Replacing The Standard Back Upholstery

    Settings / Replacement / Retrofit 4.4.5 Replacing the standard back upholstery RemovethebacktubeasdescribedinSection4.4.3“Heightsetting/Replacementoftheback tubes” Loosenandremovethescrewconnectionsatthetopofthebacktubes(Fig.41).Pullthe upholsterydownwardsoffthebacktubes. Forassembly,pleaseproceedinreverseorder. 4.4.6 Replacing the back angle adjustment mechanism Toreplacethereleasecable,loosenthespringboltwithyourhandorusinganopen-endwrench andpulltheboltoutoftheeyelet(Fig.42). Ifyouonlywanttoreplacethecable,removetheO-ringfromthedevicebyturning(keyring principle). Tocompletelyreplacethebackangleadjustmentmechanism,unlockthebackandfolditdown ontotheseatsurfaceasfortransporting.Loosenthethreescrewconnectionswhichconnectthe backangleadjustmentmechanismtotheframeandremovetheadjustmentmechanism(Fig.43). Forassembly,pleaseproceedinreverseorder. Toreplacetheframeelementwiththedifferentlockingpositions,loosenthescrewontheinner sideofthebacktube(Fig.44)andcompletelyremovetheelement. Forassembly,pleaseproceedinreverseorder. 28 | Ottobock Start Series | Service Manual...

  • Page 29: Replacing The Fold-Down Back Tubes

    Settings / Replacement / Retrofit 4.4.7 Replacing the fold-down back tubes Tocompletelyreplacethebacktubes,pleaseproceedasdescribedunderSection4.4.3“Height setting/Replacementofthebacktubes“. Toreplacethefold-downmechanism,loosenthetwoscrewsbelowaswellasthetwoscrews abovethehinge(Fig.45)andpullthehingeoutofthetwotubeends. Forassembly,pleaseproceedinreverseorder. 4.4.8 Retrofitting with the back system “The Back“ Pleaseobservetheinformationgivenintheproduct‘sInstructionsforUse647H491(nofigure). 4.5  Component Group E: Side Panels 4.5.1 Replacement / Retrofit / Setting the side panels a) Desk side panels Releasethesidepanelfromtheanteriorguideusingthelockinglever(Fig.46).Swingtheside panelbackuptoa45°angle.
  • Page 30 Settings / Replacement / Retrofit b) Plug-on side panels Firstremovetheoldsidepanel. Loosentheanteriorscrewontheuppersideofthecentralunit.Attachtheholderfortheplug- onsidepanelandtightenthescrewconnection(Fig.48).Inserttheplug-onsidepanelfrom aboveintotheholder. CaUTIon Risk of pinching. Thelockingbuttoniscounter-sunktopreventaccidentaloperation.Alwaysusean objecttopressthelockingbutton;neveruseyourfingers(Fig.49). c) Clothing protector (M5; version until June 2008) First,removethedesksidepanels.Thenloosenthefrontscrewfromthecentralunitandscrew theadapteroftheclothingprotectorwiththetwoscrewsprovidedtothetwoanteriorholesof thecentralunit(Fig.50). Inserttheclothingprotectorintotheadapter‘sguidesandfixitatthedesiredheightwiththe clampingscrewinfrontoftheadapter(Fig.51). Tofurtherchangethepositionoftheclothingprotectorinrelationtotherearwheel,loosenthe screwconnectionsontheinnersideoftheclothingprotector,positionitinthedesirednewpo- sitionandretightenthescrewconnections. 30 | Ottobock Start Series | Service Manual...

  • Page 31: Adjusting The Height Of The Armrest

    Settings / Replacement / Retrofit 4.5.2 adjusting the height of the armrest a) Desk side panel (standard/stepped) Loosenandremovethetwoscrewsunderneaththearmrestandremovethearmrest(Fig.52). Bychangingthetwospacers–thetwounderneath,underneathandaboveorthetwoabovethe sidepaneltube-youwillachievetheheightsettingofthearmrestinthreeincrements(Fig.53). Thepositionofthearmrestpadcanbechangedbyremovingthepadandusingotherboreho- lesbeneaththepad(Fig.54). Forassembly,pleaseproceedinreverseorder. b) Height-adjustable desk side panel Whilepressingthebuttonontheplasticelementoftheslide,pullthearmrestpadintothedesired position.Theslidecontainsdifferentlockingpositionsinwhichthearmrestwillengage(Fig.55). c) Plug-on side panel Forheightadjustmentofthesidepanel,pressthecounter-sunklockingbuttonusingaballpoint pen/key/screwdriver,etc.(Fig.49).Movethesidepanelintothedesiredposition. CaUTIon Risk of pinching. Thelockingbuttoniscounter-sunktopreventaccidentaloperation.Alwaysusean objecttopressthelockingbutton;neveruseyourfingers.

  • Page 32: Replacing The Armrest

    Settings / Replacement / Retrofit 4.5.3 Replacing the armrest a) Desk side panel (standard/stepped) Loosenandremovethetwoscrewsunderthearmrestpadandremovethepad. Forassembly,pleaseproceedinreverseorder(Fig.52/54). b) Height-adjustable desk side panel/Plug-on side panel Forbetteraccessibilityofthescrewsbringthearmrestintothehighestpossibleposition.Loosen thetwoscrewsontheundersideofthearmrestandremovethearmrestpad(Fig.56). Forassembly,pleaseproceedinreverseorder. 4.5.4 Replacing the locking lever (desksidepanels) Loosenandremovetheattachmentscrewtogetherwiththespringandremovethelockingle- ver(Fig.57). Forassembly,pleaseproceedinreverseorder. 32 | Ottobock Start Series | Service Manual...

  • Page 33: Component Group F: Caster

    Settings / Replacement / Retrofit 4.6  Component Group F: Caster InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. 4.6.1 Setting the caster wheel journal angle Loosenthelockingscrew(Fig.58,itemA)andmovethecasterwheeljournaluntilitisperpen- dicular.Usethelevelprovided. 4.6.2 Replacing the caster journal bearings Afterlooseningandremovingthescrewconnection(Fig.58,itemA)thecasterjournalbearing canberemovedfromtheframe. Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingnuts. 4.6.3 Replacing / Setting the caster fork Afterlooseningandremovingthetwoscrewconnectionsthecompletecomponentgroupcan beremovedfromtheframe(Fig.59). Forassembly,pleaseproceedinreverseorder.Usenew,self-lockingnuts.Tightenthescrew connectionwithatorqueof23 nm. Toadjusttheanteriorseatheight,alsoloosenthescrewconnectionasshown(Fig.59)and changethepositionofthespacersleeve.

  • Page 34: Replacing / Setting The Casters

    Settings / Replacement / Retrofit 4.6.4 Replacing / Setting the casters Theanteriorseatheightissetviatherowofholesintheforkandviathecasterwheeldiameter (Fig.60/61).Todothis,pleaserefertotheseatheighttableintheinstructionsforusemanual. Loosenthescrewconnectiononthecastersandremovethewheelsfromthefork. Forassembly,pleaseproceedinreverseorder.Firmlyretightenthescrewconnection.Usenew screwswiththreadlock. InfoRMaTIon Thecastersmustbereplaced,ifthematerialshowssignsofcrackingordamageandwhenthetread becomesworndowntosuchanextentthatthereisonly5 mm ofradiusleftontheouteredgesofthetire. InfoRMaTIon ReplacethecasingofwheelswithpneumaticTiresifitisbaldorshowssignsofcrackingorother damage. 4.7  Component Group G: Rear wheel InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. 4.7.1 Replacing the tires (Fig. 62) Forreplacingthetire,innertubeandrimband,pleaseobservetheinformationgiveninthein- structionsforusemanual. InfoRMaTIon Replacethecasingifitisbaldorshowscrackingorotherdamage. 34 | Ottobock Start Series | Service Manual...

  • Page 35: Re-Tightening / Adjusting The Spokes

    Settings / Replacement / Retrofit 4.7.2 Re-tightening / adjusting the Spokes (Fig. 63) InfoRMaTIon Theradialexcursionshouldnotexceed±1mm. Checktoseeifspokesarebrokenandthattheyarestilltightbytryingtomovethem. Adjustmentoftheradialexcursionrequiresspecialdevicesandexpertise.Pleasehavethead- justmentcarriedoutbyabicycleworkshop. 4.7.3 Replacing the push rings Loosenandremovethescrewconnectionofthepushrings(Fig.64)withtherimandremove thepushring.Forassembly,pleaseproceedinreverseorder. 4.7.4 adjusting the quick-release axle Thequick-releaseaxle(Fig.65)shouldbesetsothewheelisproperlyengaged,withnoplay ontheaxle.Useawrenchtoholdthequick-releaseaxleontheinside,andadjusttheplayby turningthenutontheendofthequick-releaseaxleinorout(Fig.65,itemA). InfoRMaTIon Pleasealsoobservetheinformationregardingmaintenance,cleaningandcaregivenintheinstruc- tionsforusemanual. Withsomerearwheelsthequick-releaseaxlesaresecuredwithretainingringstoprotectthem fromfallingoutofthewheelhub.Removetheretainingringsusingcirclippliersandpullthe quick-releaseaxleoutofthehub. Repositiontheretainingringintothehubonlyafterhavingsetthequick-releaseaxle. Start Series | Service Manual Ottobock | 35...

  • Page 36: Setting The Rear Wheel Position

    Settings / Replacement / Retrofit 4.7.5 Setting the rear wheel position InfoRMaTIon Whentherearwheelpositionischanged,theangleofthecasteraxleinrelationtothegroundalso changes.Ensurethatthisangleisalwaysapprox.90°wide(refertoSection4.6.1).Thewheellock mustbere-adjustedaswell(refertoSection4.8.1). InfoRMaTIon Thedistancebetweenrearwheelandsidepanelcanbecontinuouslyadjustedbyadjustingthecoun- ternutontheoutersideofthefitting. a) for M1, M2, M3, M6 versions Vertical position adjustment:Loosenthetwoscrewsoftherearwheeladapter(Fig.66,item A)andrepositiontheadapterupwards/downwardsasdesired.Thesettingmustalwaysbe equalonbothsides. Forfineadjustment,loosenthenutofthefittingontheinsideofrearwheeladapter(Fig.66,item B)andmovetheadapterintheslottedhole.Thesettingmustalwaysbeequalonbothsides. Horizontal position adjustment:Loosenthetwoscrewsoftherearwheeladapter,rotateand mounttheadapterforwards/rearwardsasdesired(Fig.67).Thesettingmustalwaysbeequal onbothsides. Makesuretofirmlyretightenallscrewsandnutsaftermakingadjustments.Thepropertorque forthescrewconnectionoftherearwheeladapteris10 nm.Thepropertorqueforthescrew connectionofthefittingis50 nm.
  • Page 37 Settings / Replacement / Retrofit b) for M4, M5 versions Verticalpositionadjustment:Loosenthefourscrewconnectionsconnectingthereadwheelad- aptertothecentralunit(Fig.68).Therearwheeladaptercanthenbeshiftedupwards/down- wards.Thesettingmustalwaysbeequalonbothsides. Horizontalpositionadjustment:Loosenthenutofthefittingontheinsideoftherearwheelad- apterandshifttheadapterforwards/rearwards(Fig.69).Thesettingmustalwaysbeequalon bothsides. Makesuretofirmlyretightenallscrewsandnutsaftermakingadjustments.Thepropertorque forthescrewconnectionoftherearwheeladapteris8 nm.Thepropertorqueforthescrew connectionofthefittingis50 nm. Start Series | Service Manual Ottobock | 37...

  • Page 38: Setting The Wheel Camber

    Settings / Replacement / Retrofit 4.7.6 Setting the wheel camber (M5) Firstunscrewthenutsoftherearwheelfitting. Setting the rear wheel camber to 0°:Ifnecessary,removethecamberwasherfromtheinside oftherearwheeladapterandplaceitagainstthewasherontheoutsideoftheadaptersothat thethinnersideofonewasherisincontactwiththethickersideoftheotherwasher(Fig.70). Setting the rear wheel camber to 2.5°:Positionthecamberwasherwiththethinnersideup- wardintothedesiredlockingposition(Fig.43)ontheoutsideoftherearwheeladapter.Position thesecondcamberwasherwiththethickersideupwardsintotherespectivelockingpositionon theinsideoftherearwheeladapter. further proceeding:Slightlytightenthenutsontherearwheelfittingonceyouhaveappliedthe retainingwasherfromtheinside(Fig.72).Checkthespacebetweentherearwheelandthe sidepanel.Youcanadjustthespacebyrotatingthefitting. Finally,tightenthenutsoftherearwheelfittingwith50 nm. 38 | Ottobock Start Series | Service Manual...

  • Page 39: Retrofitting Rear Wheels With Drum Brakes

    Settings / Replacement / Retrofit 4.7.7 Retrofitting rear wheels with drum brakes InfoRMaTIon FormountingthedrumbrakepleaserefertoSection4.8.2. Thewheelswithdrumbrakes(Fig.73)areattachedontotherearwheeladapterinsteadofthe standardrearwheelsusingthequick-releaseaxle. Forsettingthedrumbrakes,pleaseobservetheinformationgivenintheinstructionsforuse manual. 4.7.8 Retrofitting rear wheels with one-arm drive (M3) Theone-armdriveisdeliveredwithspecialfittingsthatmustfirstbeattachedtotherearwheel adapter(Fig.74,item1).Positionthefittingsontheadapterinthedesiredpositionandfixthe fittingswiththenutontheinnerside. Thenattachtherearwheelstothefittings(itdoesnotmatterwhichwheelisattachedtowhich side). 481G53=ST097,longtelescopingbar Boltinhole8 45,5 50,5 45,5 Boltinhole4 40,5 35,5 481G53=ST096,shorttelescopingbar Start Series | Service Manual Ottobock | 39...

  • Page 40: Attaching A Spoke Protector To The Standard Wheel

    Settings / Replacement / Retrofit AdjustthetelescopingbartotherequiredwidthaccordingtoFig.75byobservingthevalues inthefollowingtable. Thelaststepistomountthetelescopingaxle.Putoneendoftheaxleontothewheelpivotpro- trudingfromtheinnersideofthefitting(Fig.74,item2).Thenpresstogetherthetelescoping axle(featuresspringbearings)andputtheotherendontotheotherwheelpivot. Seat width Telescoping Telescoping article number Hole for Hole for bar length the screw the bolt short 481G53=ST098 30.5 short 481G53=ST098 short 481G53=ST096 35.5 short 481G53=ST096 short 481G53=ST096 40.5 long 481G53=ST097 long 481G53=ST097...

  • Page 41: Attaching Z50

    Settings / Replacement / Retrofit 4.7.11 attaching z50 Removethestandardrearwheeladaptersfromthecentralunit.Attachthez50rearwheelad- aptertothecentralunitasshowninthephotoandfixitattheindicatedpositions(Fig.78). Forfurtherassembly,pleaseproceedasdescribedinthez50instructionsforusemanual (647H315). 4.8  Component Group H: Brake CaUTIon Risk of accident. Thewheellocksareonlyeffectivewithsufficientairpressureandproperadjustment. Theproperairpressureisindicatedonthesidewallofthetire.Itshouldbeatleast3.5bar(350kPa). Toensuresufficientbrakingeffect,useonlyoriginalrearwheelswithanapprovedradialexcursionof maximally±1mm. InfoRMaTIon Usenewscrewscoatedwiththreadlockorapplyaliquidthreadlocktotheexistingscrews. InfoRMaTIon Thewheellockshouldthenberemountedsuchthatthedistancebetweenthetyreandbrakeblockis max.4 mm whenthewheellockisnotactivated(subjecttotechnicalchanges). 4.8.1 Wheel lock a) Replacing / Setting a wheel lock Removetherearwheel.Forreplacing,removethescrewtobeabletoremovethewheellock (Fig.79).Replacethewheellockifnecessary.Reattachtherearwheel.
  • Page 42 Settings / Replacement / Retrofit b) attaching the plug-on wheel lock lever extension First,screwthecordofthewheellockleverextensiontothepre-drilledholeinthewheellock housingusingthescrewprovided(Fig.81). Pullthewheellockleverhandlecoveroffthewheellocklever.Ifnecessarycutopenthehandle cover(Fig.82).Removeanyresiduesofoldglueorrubberfromthewheellocklever. Plugthewheellockleverextensionontothewheellocklever(Fig.83). 42 | Ottobock Start Series | Service Manual...

  • Page 43: Drum Brake

    Settings / Replacement / Retrofit 4.8.2 Drum brake a) Mounting the break unit with rear wheel adapter M1 / M2 / M3 / M6 Removethestandardfittingandattachthebrakecomponentgroupwiththelongfittingtothe rearwheeladapterinthedesiredposition(Fig.84). Screwthelockagainstrotationtothecentralunitbymeansofadrilledtongue(Fig.85).Insert thespacersleevebetweenthepartsduringscrewing(Fig.86). Finallyfixthefittingtotheinsideoftherearwheeladapterwithwasherandnut(Fig.87). ConnecttheBowdencabletothedrumbrake.Inserttherearwheelwithdrumbrakeintothe fitting. Start Series | Service Manual Ottobock | 43...
  • Page 44 Settings / Replacement / Retrofit Mounting the break unit with rear wheel adapter M4 / M5 (FormountingprocedurepleaserefertoSection4.8.2a). Pleaseobservethefollowingdeviation:DuringtheuseoftherearwheeladapterM4/M5thenose oflockagainstrotationistobescrewedwithoutdrilledtonguedirectlytothecentralunit(Fig. 88).Insertthespacersleevebetweenthelockagainstrotationandcentralunitinthiscase,too. b) Mounting the brake handles Forattachmentofthebrakehandlesleft/right,thepushhandlesmustbeequippedwithanex- tension. Todothis,firstremovetherubberhandgripsasdescribedundersection4.4.4“Replacingthe rubberhandgrips”andmountthebrakeleverunitusingtheclamp,whichisscrewedtothe pushhandle(Fig.89). Next,mountthehandleextensiontothepushhandle.Todothis,inserttheextensionintothe pushhandleandfixitwitharivet(Fig.90).Finallyattachnewrubberhandgrips. c) adjusting the brake handles Aftercorrectpositioningofthebrakecables,adjustthetensionofthecablessuchthatthebra- ke/wheellockisopenwithreleasedbrakehandleandthatitsafelyblockswhenthehandleis manipulated(Fig.91). 44 | Ottobock Start Series | Service Manual...
  • Page 45 Settings / Replacement / Retrofit Pleasealsoobservetheinformationgivenintheinstructionsforusemanual. d) Laying the brake cables NOTICE Risk of pinching. Takecarenottopinchthebrakecablesduringfolding. Feedthebrakecablesfrominsidethroughbetweenthesidepanelandcentralunit(Fig.92). Makesurethatthewheelchaircanstillbefoldedwithouttrappingthebrakecables. e) Setting the drum brake Thebrakeforceofthedrumbrakecanbeadjustedwiththeadjustingnut(Fig.93,itemA).To dothis,pleaseobservetheinformationgiveninSection6.6oftheinstructionsforusemanual. Afterfinishingtheadjustment,fastentheadjustmentscrewbytighteningthecounternut(Fig. 93,itemB). Start Series | Service Manual Ottobock | 45...

  • Page 46: Attaching The Wheel Lock For One-Handed Operation

    Settings / Replacement / Retrofit 4.8.3 attaching the wheel lock for one-handed operation (M3) a) attaching / Setting the wheel lock for one-handed operation (M3) NOTICE Risk of pinching. Takecarenottopinchthebrakecablesduringfolding. DisassemblethestandardwheellocksasdescribedunderSection4.8.1a)andinsteadmount thecomponentgroupsprovided(Fig.94). Positioningofthebrakecablemusttakeplacewithframeunfolded.Routethebrakecableas showninthephoto,underneathandalongtheframeandacrosstotheoppositeside.Thenrou- tethebrakecableforwardstotheoppositewheellock(Fig.95). Locatethenippleendofthebrakecableintothewheellockwiththewheellocklever(Fig.96). Insertthebrakecablethroughtheholeinthecableattachmentpin(Fig.97). Routethebrakecableasshowninthephoto,underneathandalongtheframeandtotheother side.Pulltheprotectivecoveroverthebrakecable. Insertthebrakecablethroughtheholeinthecableattachmentpinoftheoppositeside(Fig. 98).Pullthepartsprovided(attachablesleeves+spring)overthebrakecable(Fig.99).
  • Page 47 Settings / Replacement / Retrofit Firstlightlyclampthebrakecablebytighteningthenut(Fig.100). Setthebrakefunctionbyadjustingthebrakecable(byfurtherpullingoutthecable)soasto obtainanevenbrakingeffectonbothsides. Cutoffthebrakecabletoapprox.1 cmonlyafterallsettingshavebeenmade.Puttheprovided cableendsleeveontotheendofthebrakecable(Fig.102)andclampthecableendsleeve usingsidecuttingpliers. b) Replacing the brake block Withdisassembledwheellockloosenthescrewofthebrakeblockandremovetheblock(Fig. 102).Forassembly,pleaseproceedinreverseorder. Start Series | Service Manual Ottobock | 47...

  • Page 48: Wheel Lock For User And Attendant

    Settings / Replacement / Retrofit c) attaching the plug-on wheel lock lever extension FormountingprocedurepleaserefertoSection4.8.1b). 4.8.4 Wheel lock for user and attendant a) Replacing / Setting a wheel lock for user and attendant Removetherearwheel.Removethebrakecableonthebrakeblockbylooseningthebrakeca- bleclamp(Fig.103,itemA). Loosenbothscrewsontheclampingunitandcompletelyremovetheclampingunit+wheellock (foruserandattendant)(Fig.103,itemB). Ifnecessaryreplacethewheellockforuserandattendant.Forreassemblingthebrakecable, proceedasdescribedundertheSection4.8.3a),startingfromFig.98Wheellockforone- handedoperation. Reattachtherearwheel. Afterlooseningthetwoscrewsontheclampingunit(Fig.103,itemB)thedistancebetween thewheellockandrearwheelcanbechanged.Forsettingthewheellock,pleaseobservethe informationgivenintheinstructionsforusemanualandobservethecorrectdistancetotherear...

  • Page 49: Accessories, Accessory Products

    Settings / Replacement / Retrofit c) adjusting the brake handles FollowthestepsinSection4.8.2c). d) Laying the brake cables FollowthestepsinSection4.8.2d). e) Replacing the brake block FollowthestepsinSection4.8.3b). f) attaching the plug-on wheel lock lever extension FormountingprocedurepleaserefertoSection4.8.1b). 4.9  Accessories, Accessory Products 4.9.1 attaching a lap belt Attachthelapbeltwiththescrewsprovidedtotheboreholeshowninthephotoofthecentral unit(Fig.104).

  • Page 50: Attaching A Fold Fixation Strap

    Settings / Replacement / Retrofit 4.9.5 attaching a fold fixation strap ScrewthelooseendofthefoldfixationstrapwiththePhillipsheadscrewtotheleftsupport(in drivingdirection)(Fig.108). Thenscrewthesnapfastenertotherightsupport. 50 | Ottobock Start Series | Service Manual...

  • Page 51: Technical Data

    Technical Data 5 Technical Data Overall length (in cm) Rear wheel size 20x1 3/8“ 22x1 3/8“ 24x1 3/8“ Rearaxle Frontaxle Rearaxle Frontaxle Rearaxle Frontaxle Module position position position position position position – – – – 103.5 94.0 – – 101.0 91.0 104.0 94.0 M2, M3 –...
  • Page 52 Technical Data Start M1, M2, M4, M5, M6 Start M3 Anterior seat height (in cm)   Anterior seat height (in cm)   without wider foot space with wider foot space Caster fork, short Caster fork, short Position Settingrange Position Settingrange 5“ 40–44 5“ 38–40 5,5“ 42–44 5,5“ 39–42 Casterdiame- Casterdiame- 6“ 43–45 6“ 40–42 7“ 45–47 7“ 42–43 Caster fork, long Caster fork, long Position Settingrange...
  • Page 53 Technical Data Rear wheel adapter M1, M2, M3, M6 M4, M5 Start Series | Service Manual Ottobock | 53...
  • Page 54 54 | Ottobock Start Series | Service Manual...
  • Page 56 Ihr Fachhändler/Your specialist dealer: Versandanschrift für Rücksendungen/Address for Returns: Otto Bock Manufacturing Königsee GmbH Lindenstraße 13 · 07426 Königsee-Rottenbach/Germany Otto Bock Mobility Solutions GmbH Lindenstraße 13 · 07426 Königsee-Rottenbach/Germany T +49 (0) 69 9999 9393 · F +49 (0) 69 9999 9392 ccc@ottobock.com ·...

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