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FIOR & GENTZ NEURO FLEX MAX Tutorial

Joint assembly
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09-12-18
Joint Assembly NEURO FLEX MAX
This online tutorial describes the joint assembly for locked system knee joints using the
example of the NEURO FLEX MAX in its basic function. The basic function includes a lock lever
and a locating pin that are used to activate the permanent unlock function. Due to the
constructional differences, the NEURO FLEX MAX system knee joint is assembled a little
differently than the NEURO LOCK and the NEURO LOCK MAX.
For example, the NEURO LOCK has, in contrast to the NEURO LOCK MAX and the NEURO FLEX
MAX, no permanent unlock function. Furthermore, a flexion stop disc is already integrated into
the joint's lower part of the NEURO LOCK MAX system knee joint, whereas, in the case of the
NEURO FLEX MAX, it still needs to be mounted.
Consult the manual (chapter 11 "Assembly Instructions") of the corresponding system joint to
learn about the differences regarding
mounting the extension stop,
mounting the spring unit and the locking pawl,
mounting the cover plate and
checking the lock function.
Besides, this online tutorial shows in detail the four alternative functions of the NEURO FLEX
MAX system knee joint.
Note: You will find information regarding torque (Nm) and locking pawls for all system widths in
the manual of the corresponding system joint.
09-12-18
1/55
1/55
Joint Assembly NEURO FLEX MAX
Joint Assembly NEURO FLEX MAX

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Summary of Contents for FIOR & GENTZ NEURO FLEX MAX

  • Page 1 This online tutorial describes the joint assembly for locked system knee joints using the example of the NEURO FLEX MAX in its basic function. The basic function includes a lock lever and a locating pin that are used to activate the permanent unlock function. Due to the constructional differences, the NEURO FLEX MAX system knee joint is assembled a little...
  • Page 2 09-12-18 2/55 Joint Assembly NEURO FLEX MAX Basic Function Step 1/23 Clean the system joint. Step 2/23 If you are using a supporting joint, shorten the extension stop damper with a sharp knife. Now, the system joints reach the extension stop at the same time and the locking pawl should lock without difficulty.
  • Page 3 09-12-18 3/55 Joint Assembly NEURO FLEX MAX Apply spray adhesive to one side of the first sliding washer and adhere it to the cover plate. Grease the other side of the sliding washer slightly with the delivered orthosis joint grease.
  • Page 4 09-12-18 4/55 Joint Assembly NEURO FLEX MAX Mount the extension stop to the joint's upper part. Step 6/23 If you have to demount the extension stop, screw it out of the joint's upper part by using the pan head screw delivered with the system joint. If it is mounted correctly, you do not have to demount the extension stop.
  • Page 5 09-12-18 5/55 Joint Assembly NEURO FLEX MAX the joint's upper part. Step 8/23 Grease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 9/23 Put the bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 6 09-12-18 6/55 Joint Assembly NEURO FLEX MAX Place the ball and push the locking pawl to the top. Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl. Step 11/23 Push the locating pin against the spring force into the system joint until it locks in the joint's upper part.
  • Page 7 09-12-18 7/55 Joint Assembly NEURO FLEX MAX Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 13/23 Put the joint axis’ bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 8 09-12-18 8/55 Joint Assembly NEURO FLEX MAX While still fixing the bearing nut, place the second sliding washer onto the joint's upper part and mount the joint's lower part. Step 16/23 Mount the cover plate. Turn in the first countersunk flat head screw (axle screw).
  • Page 9 09-12-18 9/55 Joint Assembly NEURO FLEX MAX If the sliding washer has been damaged during the assembly of the cover plate (audible cracking), remove the particles and place a new sliding washer. Step 18/23 Check if the bearing nuts are placed completely in the intended openings.
  • Page 10 09-12-18 10/55 Joint Assembly NEURO FLEX MAX system joint does not move freely, mount the next thinner sliding washers, repeat all steps from step 12 onwards and check again. Note: With a bilateral orthosis, only check one system joint at a time.
  • Page 11 09-12-18 11/55 Joint Assembly NEURO FLEX MAX system joint. Note: Mind the information on the locking pawls in the manual. Step 22/23 Check the position of the locking pawl. You can see the correct position on the left picture. If the locking pawl does not fit well, exchange it.
  • Page 12 09-12-18 12/55 Joint Assembly NEURO FLEX MAX Step 1/28 The locked system joint can be used for locking in different flexed positions (alternative function 1) by exchanging the locking parts. To do so, exchange the extension stop according to the intended extension position by choosing a degree.
  • Page 13 09-12-18 13/55 Joint Assembly NEURO FLEX MAX Demount the flexion stop disc. To do so, clamp the flexion stop disc in a vice and carefully lever it of the joint's upper part. Note: Use a vice with plain or soft jaws in order not to affect the joint function.
  • Page 14 09-12-18 14/55 Joint Assembly NEURO FLEX MAX Demount all further system components. Clean the system joint. Check all system components and exchange them if there are signs of wear. Note: Follow the maintenance instructions in the manual of the system joint.
  • Page 15 09-12-18 15/55 Joint Assembly NEURO FLEX MAX extension stop. The line should remain visible! Make sure that the stop face remains even and is not inclined to the sides. Step 8/28 Place the flexion stop disc on the joint's lower part and press both by using a vice.
  • Page 16 09-12-18 16/55 Joint Assembly NEURO FLEX MAX Mount the extension stop to the joint's upper part. Step 11/28 Insert the pressure spring by pushing it from below into the spring duct of the joint's upper part. Step 12/28 If you exchange the delivered locking pawl with another, choose the smallest possible locking pawl that still fits.
  • Page 17 09-12-18 17/55 Joint Assembly NEURO FLEX MAX and wear out, you can then mount the next bigger locking pawl, if necessary. Note: Mind the information on the locking pawls in the manual. Step 13/28 Grease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease.
  • Page 18 09-12-18 18/55 Joint Assembly NEURO FLEX MAX Place the ball and push the locking pawl to the top. Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl. Step 16/28 Push the locating pin against the spring force into the system joint until it snaps in the joint's upper part.
  • Page 19 09-12-18 19/55 Joint Assembly NEURO FLEX MAX Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 18/28 Put the joint axis’ bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 20 09-12-18 20/55 Joint Assembly NEURO FLEX MAX While still fixing the bearing nut, place the second sliding washer onto the joint's upper part and mount the joint's lower part. Step 21/28 Mount the cover plate. Turn in the first countersunk flat head screw (axle screw).
  • Page 21 09-12-18 21/55 Joint Assembly NEURO FLEX MAX If the sliding washer has been damaged during the assembly of the cover plate (audible cracking), remove the particles and place a new sliding washer. Step 23/28 Check if the bearing nuts are placed completely in the intended openings.
  • Page 22 09-12-18 22/55 Joint Assembly NEURO FLEX MAX does not move freely, mount the next thinner sliding washers, repeat all steps from step 18 onwards and check again. Note: With a bilateral orthosis, only check one system joint at a time.
  • Page 23 09-12-18 23/55 Joint Assembly NEURO FLEX MAX system joint. Note: Mind the information on the locking pawls in the manual. Step 27/28 Check the position of the locking pawl. You can see the correct position on the left picture. If the locking pawl does not fit well, exchange it.
  • Page 24 09-12-18 24/55 Joint Assembly NEURO FLEX MAX Step 1/16 The locked system joint can be used as a free moving, monocentric joint with integrated posterior offset (alternative function 2) by removing the locking parts. Note the next work steps for the removal of the locking parts.
  • Page 25 09-12-18 25/55 Joint Assembly NEURO FLEX MAX If you have to demount the extension stop, screw it out of the joint's upper part by using the pan head screw delivered with the system joint. If the extension stop is mounted correctly, you do not have to demount it.
  • Page 26 09-12-18 26/55 Joint Assembly NEURO FLEX MAX If you have demounted the extension stop before, place it correctly on the joint's upper part now. Step 6/16 Apply spray adhesive to one side of the first sliding washer and adhere it to the cover plate.
  • Page 27 09-12-18 27/55 Joint Assembly NEURO FLEX MAX Put the bearing nuts into the intended openings of the joint's upper part and make sure that they are in the correct position. Fix the bearing nut of the locking pawl with one finger. The locking pawl is not mounted again.
  • Page 28 09-12-18 28/55 Joint Assembly NEURO FLEX MAX While still fixing the bearing nut, place the second sliding washer onto the joint's upper part and mount the joint's lower part. Step 11/16 Mount the cover plate. Turn in the first countersunk flat head screw (axle screw).
  • Page 29 09-12-18 29/55 Joint Assembly NEURO FLEX MAX Check if the bearing nuts are placed completely in the intended openings. Note: The delivered screws are always matching the system joint. Even if the screws are not as long as the thread of the bearing nuts, that does not affect the system joint’s load capacity.
  • Page 30 09-12-18 30/55 Joint Assembly NEURO FLEX MAX Check if the system joint moves without lateral play. Hold the tibial shell and try to move the femoral shell in varus-valgus direction. If the system joint runs with lateral play, mount the next thicker sliding washers, repeat all steps from step 8 onwards and check again.
  • Page 31 31/55 Joint Assembly NEURO FLEX MAX The locked system joint NEURO FLEX MAX can be used with a step lock function with locked flexion. For this purpose, you can use the NEURO FLEX MAX with premounted alternative function 3 or, in case you are already using the NFM with a different function and want to convert it,...
  • Page 32 09-12-18 32/55 Joint Assembly NEURO FLEX MAX Step 3/26 If you want to use the NFM with a different flexed position than the premounted 5°, exchange the mounted extension stop with a 10°, 20° or 30° extension stop and choose a corresponding step lock stop disc AF3 with 0°, 10°, 20°...
  • Page 33 09-12-18 33/55 Joint Assembly NEURO FLEX MAX Step 5/26 Then, place the step lock stop disc AF3 on the joint's lower part and press both by using a vice. Note: Use a vice with plain or soft jaws in order not to affect the joint function.
  • Page 34 09-12-18 34/55 Joint Assembly NEURO FLEX MAX Demount all system components. Clean the system joint. Check all system components and exchange them if there are signs of wear. Note: Follow the maintenance instructions in the manual of the system joint.
  • Page 35 09-12-18 35/55 Joint Assembly NEURO FLEX MAX Apply spray adhesive to one side of the first sliding washer and adhere it to the cover plate. Grease the other side of the sliding washer slightly with the delivered orthosis joint grease.
  • Page 36 09-12-18 36/55 Joint Assembly NEURO FLEX MAX Step 12/26 Grease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 13/26 Put the bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 37 09-12-18 37/55 Joint Assembly NEURO FLEX MAX Place the ball and push the locking pawl to the top. Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl. Step 15/26 Push the locating pin against the spring force into the system joint until it snaps in the joint's upper part.
  • Page 38 09-12-18 38/55 Joint Assembly NEURO FLEX MAX Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 17/26 Put the joint axis’ bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 39 09-12-18 39/55 Joint Assembly NEURO FLEX MAX While still fixing the bearing nut, place the second sliding washer onto the joint's upper part and mount the joint's lower part. Step 20/26 Mount the cover plate. Turn in the first countersunk flat head screw (axle screw).
  • Page 40 09-12-18 40/55 Joint Assembly NEURO FLEX MAX If the sliding washer has been damaged during the assembly of the cover plate (audible cracking), remove the particles and place a new sliding washer. Step 22/26 Check if the bearing nuts are placed completely in the intended openings.
  • Page 41 09-12-18 41/55 Joint Assembly NEURO FLEX MAX joint does not move freely, mount the next thinner sliding washers, repeat all steps from step 14 onwards and check again. Note: At a bilateral orthosis, only check one system joint at a time.
  • Page 42 09-12-18 42/55 Joint Assembly NEURO FLEX MAX limitation. Then, fix the tibial shell and try to move the femoral shell against it. There should be no movement in the system joint. Note: Mind the information on the locking pawls in the manual.
  • Page 43 09-12-18 43/55 Joint Assembly NEURO FLEX MAX according to the intended extension position by choosing a degree. When the system joint is unlocked at AF4, it can be used as a locked system joint with adjustable limitation of the maximum knee flexion grade by filing. To do so, exchange the flexion stop disc AF4 and cover plate AF4.
  • Page 44 09-12-18 44/55 Joint Assembly NEURO FLEX MAX function. Step 4/29 If you have to demount the extension stop, screw it out of the joint's upper part by using the pan head screw delivered with the system joint. If it is mounted correctly, you do not have to demount the extension stop.
  • Page 45 09-12-18 45/55 Joint Assembly NEURO FLEX MAX The flexion stop disc is marked with lines that serve as a guide when filing the desired flexion and thus enable an accurate locking of the pawl at the lock area (R1). The marked lines are not straight but slightly bent! Do not use a flat file and ensure a smooth transition from lock area to lock disc...
  • Page 46 09-12-18 46/55 Joint Assembly NEURO FLEX MAX Place the flexion stop disc AF4 on the joint's lower part and press both by using a vice. Note: Use a vice with plain or soft jaws in order not to affect the joint function.
  • Page 47 09-12-18 47/55 Joint Assembly NEURO FLEX MAX Apply spray adhesive to one side of the first sliding washer and adhere it to the cover plate. Grease the other side of the sliding washer slightly with the delivered orthosis joint grease.
  • Page 48 09-12-18 48/55 Joint Assembly NEURO FLEX MAX Step 13/29 Grease the axle bore of the locking pawl and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 14/29 Put the bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 49 09-12-18 49/55 Joint Assembly NEURO FLEX MAX Place the ball and push the locking pawl to the top. Insert the pressure spring and the locating pin for adjusting the permanent unlock function in the locking pawl. Step 16/29 Push the locating pin against the spring force into the system joint until it snaps in the joint's upper part.
  • Page 50 09-12-18 50/55 Joint Assembly NEURO FLEX MAX Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with the delivered orthosis joint grease. Step 18/29 Put the joint axis’ bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position.
  • Page 51 09-12-18 51/55 Joint Assembly NEURO FLEX MAX While still fixing the bearing nut, place the second sliding washer onto the joint's upper part and mount the joint's lower part. Step 21/29 Mount the cover plate AF4. Turn in the first countersunk flat head screw (axle screw).
  • Page 52 09-12-18 52/55 Joint Assembly NEURO FLEX MAX If the sliding washer has been damaged during the assembly of the cover plate (audible cracking), remove the particles and place a new sliding washer. Step 23/29 Check if the bearing nuts are placed completely in the intended openings.
  • Page 53 09-12-18 53/55 Joint Assembly NEURO FLEX MAX does not move freely, mount the next thinner sliding washers, repeat all steps from step 18 onwards and check again. Note: At a bilateral orthosis, only check one system joint at a time.
  • Page 54 09-12-18 54/55 Joint Assembly NEURO FLEX MAX system joint. Note: Mind the information on the locking pawls in the manual. Step 27/29 Check the position of the locking pawl. You can see the correct position on the left picture (here AF1). If the locking pawl does not fit well, exchange it.
  • Page 55 09-12-18 55/55 Joint Assembly NEURO FLEX MAX Secure both screws with LOCTITE 243 medium strength and the torque corresponding to the system width. PDF Download Online Tutorial 09-12-18 55/55 Joint Assembly NEURO FLEX MAX...