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Summary of Contents for Otto Bock Start M1 Intro
- Page 1 Start Series Service Manual Intro • M Effect • M Hemi • M XXL • M Comfort • M Junior...
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Page 2: Table Of Contents
Table of Contents 1 Preface ..........................2 2 Safety ..........................2 3 Required Tools and Maintenance Plan ................3 - 8 Start M Intro / M2 Effect ..................5 Start M3 Hemi ......................6 Start M4 XXL / M5 Comfort ................... 7 Start M6 Junior ....................... 8 4 Settings / Replacement / Retrofit ..................... 9 4.A Frame ........................ -
Page 3: Preface
1 Preface Regular maintenance is important. It increases safety and prolongs the service life of the product. All Mobility products should be inspected and serviced once a year. However, if the product is used frequently, or if it is used by growing children or patients with changing clinical conditions, we recommend readjusting and servicing the product every 6 months. Use only original spare parts for all service and maintenance. The service and maintenance described in this manual should be performed by skilled specialists only and not by the user. This service and maintenance manual refers to the spare parts catalogs and instructions for use manuals for the products described. For this reason, it is important to use these documents together. Use the maintenance plans (check list) as a template for making copies. Retain completed maintenance plans and provide the customer with a copy. Instructions for Use Spare Parts Catalog Start Series 647G324=D/GB 646K84=GB 2 Safety For all maintenance and repair works, there are a few points you should always observe: Use appropriate tools (refer to pages 3 & 4). Wear appropriate clothing, including gloves and safety glasses, if necessary. Secure the product to prevent it from tipping over or falling off the workbench. Read the service and maintenance instructions before starting. Familiarize yourself with the functions of the product. If you are not familiar with the product, read the instructions for use manual before inspecting the product. If you do not have an instructions for use manual, you can order one from the manufacturer (see the overview of all Otto Bock Branches "Otto Bock Worldwide"). Alternatively, you can download documents from our home page at www.ottobock.de or www.ottobock.com. -
Page 4: Required Tools And Maintenance Plan
3 Required Tools and Maintenance Plan The following list shows you the tools and auxiliaries required for the service. Reversible ratchet handle wrench Torque wrench, Wrenches, and sockets, sizes 8 - 24 measurement range 5 Nm to 50 Nm sizes 8 - 24* Allen wrenches, Screwdrivers, blade widths Phillips head screwdriver, sizes 3 - 6* 2.5, 3.5, and 5.5 mm size 2 Hammer, approx. 300 g Stanley knife with sickle hooked Plastic hammer blade and standard blade Side cutting pliers Liquid thread lock "medium strength" Pop rivet gun for rivets up to ø 5 mm * Contained in 48C08=ST00 Tool Set... - Page 5 Workbench as well as a vise with Hand drill Tire mounting levers*, plastic jaws and rubber insert inner tube repair kit* * Contained in 48C08=ST00 Tool Set...
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Page 6: Start M Intro / M2 Effect
Customer: Maintenance Plan Start M1 Intro / M2 Effect for regular service - Lightweight Wheelchair - Item Inspection (check list) Component (group) Serial no.: Function / setting Damages / Screw connections (see 647G324 Instructions for Use) deformations M Intro M2 Effect Frame - Frame - Central unit Frame accessories - Anti-tipper - Transport wheels (only M2) - Crutch holder Footrests - Flip-up mechanism - Lower leg length setting - Angle adjustment Seat - Crossbrace - Seat upholstery - Seat cushion Back / push handle - Back upholstery... -
Page 7: Start M3 Hemi
Customer: Maintenance Plan Start M3 Hemi for regular service - Lightweight Wheelchair - Item Component (group) Inspection (check list) Serial no.: Function / setting Damages / Screw connections (see 647G324 Instructions for Use) deformations M3 Hemi Frame - Frame - Central unit Frame accessories - Anti-tipper - Transport wheels - Crutch holder Footrests - Flip-up mechanism - Lower leg length setting - Angle adjustment Seat - Crossbrace - Seat upholstery - Seat cushion Back / push handle - Back upholstery - Back tubes - Angle adjustment - Fold-down mechanism - Push handles Back accessories... -
Page 8: Start M4 Xxl/ M5 Comfort
Customer: Maintenance Plan Start M4 XXL/ M5 Comfort for regular service - Lightweight Wheelchair - Item Inspection (check list) Component (group) Serial no.: Function / setting Damages / Screw connections (see 647G324 Instructions for Use) deformations M4 XXL M5 Comfort Frame - Frame - Central unit Frame accessories - Anti-tipper - Transport wheels - Crutch holder Footrests - Flip-up mechanism - Lower leg length setting - Angle adjustment Seat - Crossbrace - Seat upholstery - Seat cushion Back / push handle - Back upholstery - Back tubes - Angle adjustment (M5) - Fold-down mechanism (M5) - Push handles... -
Page 9: Start M6 Junior
Customer: Maintenance Plan Start M6 Junior for regular service - Lightweight Wheelchair - Item Inspection (check list) Component (group) Serial no.: Function / setting Damages / Screw connections (see 647G324 Instructions for Use) deformations M6 Junior Frame - Frame - Central unit Frame accessories - Anti-tipper - Transport wheels - Crutch holder Footrests - Flip-up mechanism - Lower leg length setting - Angle adjustment Seat - Crossbrace - Seat upholstery - Seat cushion Back / push handle - Back upholstery - Back tubes - Angle adjustment - Fold-down mechanism - Push handles Back accessories - Side thoracic support... -
Page 10: Settings / Replacement / Retrofit
4 Settings / Replacement / Retrofit 4.A - Frame It is advisable to start with disassembling the acces- Replacing the frames sories which are attached to the frame, i.e. anti-tipper, In order to replace one or both frames, you first have to transport wheels or crutch holder. All parts mounted to remove all component groups and accessories which the frame are attached with screws. are connected to the frame. - Central unit according to drawing, - footrests (refer to section 4.B), Replacing the cap - crossbrace (refer to section 4.C), There is a cap a the tube end, which can be cut open - back/upholstery/push handles (refer to section 4.D), when damaged using a blade and pulled off the tube - side panels (refer to section 4.E), end. Put the new cap on the tube end (arrowed). - casters and caster journal bearings (refer to section 4.F), - rear wheels and rear wheel adapters (refer to sec tion 4.G), - and brakes / wheel locks (refer to section 4.H). Replacement / Retrofit / Setting of the swinging Replacing the support brackets anti-tipper Loosen and remove the screw connections (arrowed) - Page 11 Replacing the central unit Replacing the reinforcement sheet First disassemble the rear wheel adapter as described In order to remove but the reinforcement sheet the in section 4.G. standard rear wheel adapter must be removed. Then Also remove all frame accessories as described in the loosen all screws on the reinforcement sheet and preceding section. Loosen all screws of the central remove the sheet. unit, remove the back tubes by pulling them up and For reassembly, please proceed in reverse order. then remove the central unit from the frame by pulling it to the back. For reassembly, please proceed in reverse order.
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Page 12: B Footrests
4.B - Footrests Replacing the footrests with footrest holders Replacing the footrest receiver Insert the footrest holders – in outwards turned Loosen and remove the two screws and remove the position (approx. 30°) – from above into the footrest footrest receiver from the frame. receivers. Turn the footrest holders to the front until the swivel For reassembly, please proceed in reverse order. segment engages with the lock. Use new screws with thread lock. For disassembly, please proceed in reverse order. All footrests fit into the receiver without having to ex- change any parts. Replacing the pivot bearing Replacing the swivel segment Loosen and remove the screw and remove the pivot Remove the footrest holder from the frame. bearing. Loosen the set screw on the inner side of the swivel For reassembly, please proceed in reverse order. segment and remove the footrest bar by pulling it downwards. Use new screws coated with thread lock. - Page 13 Now you can also pull off the swivel segment and put For reassembly, please proceed in reverse order. down the parts as shown in the photo. Before putting the parts together, lay the clamp piece into the opening of the frame tube as shown in the Pay attention to the clamp piece, which is only photo. laid in. Use new set screws coated with thread lock.
- Page 14 Setting the lower leg length / Replacing the footrest Setting the lower leg length / Replacing the footrest bar in case of footrests with footrest holder bar in case of elevating footrests After loosening the set screw the footrest bar can After loosening the screw (arrowed) the footrest bar can be adjusted or completely pulled out of the footrest be adjusted in length. After loosening and removing the holder. screw the footrest bar can be pulled out completely. Adjusting the angle of the plastic footplate Setting or replacing the calf pads of the elevating footrests Loosen the lower screw of the two screws on the...
- Page 15 Replacing the pad of the amputation legrest Replacing the plastic footplates Loosen and remove the screws on the clamp piece Loosen and remove the screw and remove the foot- and remove the calf pad. plate. In order to also remove the joint piece from the footrest For reassembly, please proceed in reverse order. bar, the two screws on the outside must be loosened, refer to "Adjusting the angle". The clamp connection can also be used to change the For reassembly, please proceed in reverse order. pad's mounting height. Use new, self-locking screws and nuts. Replacing / Setting the aluminum footplates (M4) Attaching an amputation legrest After loosenging the screw connection the footplate The amputation legrest is inserted from above into the footrest receiver in the place of a footrest.
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Page 16: C Seat
4.C - Seat Replacing the center crossbrace mounting kit Scale on the crossbrace bracket Loosen and remove the screws as shown in the The crossbrace brackets are provided with a scale photo and pull the plastic half-shells out from be- showing the appropriate setting for the correspond- tween the crossbrace tubes. ing seat width. For reassembly, please proceed in reverse order. Use new, self-locking nuts. Attention: With removal of the central screw connection of the mounting kit, the stability of the crossbrace and frame gets lost. Attach a new mounting kit before moving the chair. Replacing the crossbrace brackets Replacing the seat upholstery After loosening and removing the screw connection you First remove the front end stoppers using a (not too can unclip the crossbrace bracket from the frame and sharp-edged) screwdriver. replace it. If the wheelchair is unfolded, slightly fold it to reduce the tension on the seat upholstery and then pull the seat upholstery out of the crossbrace's profile tubes. Please pay attention to the scale as decribed above. - Page 17 Adjusting the seat depth The Start crossbrace allows you setting of the seat depth in three positions in increments of 2.5 cm. To change the seat depth remove the two plastic clips on the lower frame tube and move the crossbrace on the frame. Insert the plastic clip into the next bore hole so that the foot of the crossbrace is limited by the two plastic clips. Be sure to properly engage the plastic clips in the bore holes provided for this after all adjustments. Cleaning the seat cushion (example: Evolight) Retrofitting with the seating system "Adjustable Seat" Open the zipper and remove the foam core and the Please observe the information given in the product's spacer fabric. Clean the cushion cover according to instructions for use manual 647H450. the sewn in care instructions label. Cleaning the nylon seat upholstery Clean the seat upholstery with regular mild household cleaner.
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Page 18: D Back / Push Handles
4.D - Back / Push Handles Height setting/Replacement of the back tubes Setting the back upholstery The back tube which is integrated into the posterior frame Please observe the information given in the instructions for use manual. allows for the adjustment of the back height in increments of 2.5 cm. Remove the uppermost screw in the central unit After adjusting the back height the straps must be and move the back tube to the desired position. redistributed. The space between the straps should In this way, the back tube can also be removed completely not be larger than one strap width (approx. 40 mm). from the holding device. If necessary, another strap must be added. Attention: Be sure that the back tube is seated properly. It is of utmost importance to firmly retighten the screws of this safety-relevant part! Ensure you work effectively after mixing, since the Replacing the rubber hand grips adhesive sets quite quickly. Apply half of the adhesive... - Page 19 Replacing the standard back upholstery Replacing the back angle adjustment mechanism Remove the back tubes as described in the preceding To replace the release cable, loosen the spring bolt section. with your hand or using an open-end wrench and pull the bolt out of the eyelet. Loosen and remove the screw connections at the top If you only want to replace the cable, remove the O-ring of the back tubes. from the device by turning (key ring principle). Pull the upholstery downwards off the back tubes. For reassembly, please proceed in reverse order. To completely replace the back angle adjustment To replace the frame element with the different locking mechanism, unlock the back and fold it down onto positions, loosen the screw on the inner side of the back the seat surface as for transporting. Loosen the tube and completely remove the element. three screw connections which connect the back angle adjustment mechanism to the frame and re- For reassembly, please proceed in reverse order. move the adjustment mechanism. For reassembly, please proceed in reverse order.
- Page 20 Replacing the fold-down back tubes Retrofitting with the back system "The Back" To completely replace the back tubes, please proceed Please observe the information given in the product's as described under "Height setting/Replacement of the instructions for use manual 647H49. back tubes" beschrieben. To replace the fold-down mechanism, loosen the two screws below as well as the two screws above the hinge and pull the hinge out of the two tube ends. For reassembly, please proceed in reverse order.
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Page 21: E Side Panel
4.E - Side Panels Attaching / Setting the clothing protector First remove the desk side panels. Then loosen the foremost 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 as shown in the photo. Insert the clothing protector into the adapter's guides and fix it at the desired height with the clamping screw in front of the adapter as shown in the photo. To further change the position of the clothing protector in relation to the rear wheel, loosen the screw connec- tions on the inner side of the clothing protector, position it in the desired new position and retighten the screw connections. Replacing the side panels Release the side panel from the anterior guide using the locking lever and swing it to the back up to a 45° angle. Then pull it upwards to the back out of the rear anchorage. For reassembly, please proceed in reverse order. - Page 22 Replacing / Changing the position of the armrest, height adjustment Loosen and remove the two screws under the armrest pad and remove the pad. For reassembly, please proceed in reverse order. By changing the two spacers the height setting of the armrest pad can be changed. The position of the armrest pad can be changed by removing the pad and using other bore holes beneath the pad. Adjusting the height of the armrest pad 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. Replacing the locking lever Replacing the arm pad of the height-adjustable armrest For better accessibility of the screws bring the Loosen and remove the attachment screw together amrest into the highest possible position. Loosen with the spring and remove the locking lever. the two screws on the underside of the armrest and remove the armrest pad.
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Page 23: F Caster
4.F - Caster Setting the caster wheel journal angle Loosen the locking screw as shown in the photo and move the caster wheel journal until it is per- pendicular. Use the level provided as shown in the photo. Replacing the caster journal bearings After loosening and removing the screw connection the caster journal bearing can be removed from the frame. For reassembly, please proceed in reverse order. Use new, self-locking nuts. -
Page 24: G Rear Wheel
Replacing / Setting the caster fork After loosening and removing the two screw connections the complete component group can be removed from the frame. For reassembly, please proceed in reverse order. Use new, self-locking nuts. Tighten the screw connection with a torque of 23 Nm. To adjust the anterior seat height, also loosen the screw connection as shown in the photo and change the position of the spacer sleeve. Upon delivery, the spacer sleeve is always mounted in the lower position. Replacing / Setting the casters The anterior seat height is set via the row of holes in the fork and via the caster wheel diameter. To do this, please refer to the seat height table in the instructions for use manual. Loosen the screw connection on the casters and remove the wheels from the fork. For reassembly, please proceed in reverse order. Firmly retighten the screw connection. Use new screws with thread lock. Attention: 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. Replace the casing of weels with pneumatic tires if it is bald or shows signs of cracking or other damage. - Page 25 4.G - Rear Wheel Replacing the tires Retightening the spokes and adjusting to a radial excursion with a maximum of ±1 mm For replacing the casing, inner tube and rim band, Check to see if spokes are broken and that they are please observe the information given in the instruc- still tight by trying to move them. tions for use manual. Adjustment of the radial excursion requires special devices and expertise. Please have the adjustment carried out by a bicycle workshop. Attention: Replace the casing if it is bald or shows cracking or other damage. Replacing the push rings Setting the quick-release axle Loosen and remove the screw connection of the The quick-release axle should be set so the wheel is push rings with the rim and remove the push ring.
- Page 26 With some rear wheels the quick-release axles are Setting the rear wheel position secured with retaining rings to protect them from fall- M1, M2, M3, M6 ing out of the wheel hub. Remove the retaining rings using circlip pliers and pull the quick-release axle out Loosen the two screws of the rear wheel adapter and of the hub. reposition the adapter as desired. The setting must always be equal on both sides. Be sure that the screw Reposition the retaining ring into the hub only after connections are firmly tightened. having set the quick-release axle. Please note that adjustments of the rear wheel adapter always require readjustment of the wheel lock position! The position of the fitting within the adapter can be Setting the rear wheel position changed after loosening the two main nuts. Loosen one M4, M5 nut completely and change the position of the fitting. Loosen the screw connections on the lower frame tube The setting must always be equal on both sides. Be and on the central unit. Move or turn the adapter to sure that the screw connections are firmly tightened. the desired position and retighten the screw connec- Please note that adjustments of the rear wheel adapter tions. always require readjustment of the wheel lock posi- tion! Please observe the torque moments mentioned in the...
- Page 27 Setting the wheel camber (M5) Open the nuts of the rear wheel fitting as described in Always turn both washers to ensure that the set camber the preceding section and remove the camber wash- is secured on the inside of the rear wheel adapter and ers. Turn the camber washers to get a wheel camber that the fitting is firmly seated. of 0° or 2.5°. Retighten the screw connections of the fitting (torque moment of 50 Nm). Attaching rear wheels with drum brakes The wheels with drum brakes are screwed to the rear wheel adapter instead of the standard rear wheels. For attachment of the brake handle the push handle must be equipped with an extension. For setting the drum brakes please observe the informa- tion given in the instructions for use manual.
- Page 28 Mounting brake handles for the attendant for drum brake / for wheel lock for user and attendant One brake handle must be mounted to the left and right push handle each. To do this, first remove the rubber hand grips as described under section 4.D Replacing the rubber hand grips and mount the brake lever unit using the clamp, which is screwed to the push handle. Next, mount the handle extension to the push handle. To do this, insert the extension into the the push handle and fix it with a rivet. Finally attach new rubber hand grips. Attaching rear wheels with one-arm drive (M3) The one-arm drive is delivered with special fittings which must first be attached to the rear wheel adapter. Posi- tion the fittings on the adapter in the desired position and fix the fittings with the nut on the inner side as shown in the photo. Then attach the rear wheels to the fittings (it does not matter which wheel is attached to which side). The last step is to mount the telescoping axle. Put one end of the axle onto the wheel pivot protruding from the fitting as shown in the photo. Then press together the telescoping axle (features spring bearings) and put the other end onto the other wheel pivot.
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Page 29: H Brake / Wheel Lock
Attaching a spoke protector to the standard wheel Attaching a spoke protector to a wheel with drum Lay the spoke protector onto the wheel such that the brake notches match the screw connections of the push ring. Lay the spoke protector onto the wheel such that the Starting with a round hole press on the spoke protector notches match the screw connections of the push ring. with an attachment nipple. We recommend to use a Starting with a slotted hole keep the respective spokes in hammer shaft for this work step. Press all nipples onto mind and mount screw clamps to the spokes as shown the spokes, one after the other. in the photo. Screw the spoke protector to these screw clamps using the set of screws provided. Attaching e-support Attaching z50 Remove the standard rear wheel adapters from the Remove the standard rear wheel adapters from the central unit. Attach the e-support rear wheel adapter central unit. Attach the z50 rear wheel adapter to the to the central unit as shown in the photo and fix it at central unit as shown in the photo and fix it at the the four indicated positions. - Page 30 4.H - Wheel Lock / Brake Setting / Replacing a wheel lock Remove the two screws in order to remove the wheel lock. After loosening the two screws on the clamp element (right photo) the distance between the wheel lock and rear wheels can be changed. For setting the wheel lock, please observe the information given in the instructions for use manual and observe the correct distance to the rear wheel. Replacing the wheel lock lever Replacing the brake block Disassemble the wheel lock as described above. Loosen With disassembled wheel lock loosen the screw of the the screw in the wheel lock housing and remove the brake block and remove the block. For reassembly, wheel lock lever. For reassembly, please proceed in please proceed in reverse order. reverse order.
- Page 31 Attaching the plug-on wheel lock lever extension First screw the cord of the wheel lock lever extension Pull the wheel lock lever handle cover off the wheel lock to the pre-drilled hole in the wheel lock housing using lever. If necessery cut open the handle cover. the screw provided. Remove any residues of old glue or rubber from the wheel lock lever. Plug the wheel lock lever extension onto the wheel lock lever.
- Page 32 Mounting the drum brake Rear wheel adapter M / M2 / M3 / M6: Rear wheel adapter M4 / M5: First fix the triangular, black metal plate below the First remove the standard fitting. Then screw the rota- two screws of the rear wheel adapter as shown in tion protection to the adapter. Next, insert the brake the photo. Remove the standard fitting and attach component group with the long fitting into the adapter, the brake component group with the long fitting to the bring the nose of the rotation protection into the bracket rear wheel adapter in the desired position. Screw the provided for this purpose and fix the fitting with washer rotation protection to the triangular metal plate while and nut on the inside of the rear wheel adapter. placing the spacer sleeve between the parts. Finally fix the fitting to the inside of the rear wheel adapter with washer and nut. Setting the brake handle of the drum brake and Positioning of the brake cables in case of drum of the wheel lock for user and attendant brakes and wheel locks for user and attendant Feed the brake cables from inside through between After correct positioning of the brake cables, adjust the...
- Page 33 Attaching the wheel lock for one-handed opera- tion (M3) Disassemble the standard wheel locks as described above and instead mount the component group provided. Positioning of the brake cable must take place with frame unfolded. Feed the brake cable as shown in the photo, along the frame and across to the opposite side. Then feed the brake cable back forwards to the opposite wheel lock. Put the end of the brake cable into the brake with the brake handle. Insert the brake cable through the bore hole in the cable attachment pin and lightly clamp the brake cable by tightening the nut. Set the brake function by adjusting the brake cable so as to obtain an even braking effect on both sides. Cut off the brake cable to approx. cm only after all settings have been made. Put the provided cable end sleeve onto the end of the brake cable and clamp the cable end sleeve using side cutting pliers.
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Page 34: S Accessories, Accessory Products
4.S - Accessories, Accessory Products Attaching a safety belt Attaching a tray Attach the safety belt with the screws provided to A tray can be attached to all armrests. the bore hole shown in the photo of the central unit. Attaching a thoracic support Attaching a headrest mounting kit The side thoracic support is mounted to the back tubes The headrest mounting kit is pushed onto the push using the mounting kit provided. To adapt the support handles and clamped with the star grip screw. to the patiet open the three screws on the back, bring For adaptation to the wheelchair's seat width, open the support in the desired position and retighten the the Allen screws on the back side of the mounting screws. kit and move the parts within each other. Retighten the screws. All standard headrests of the Otto Bock wheelchair accessories range can be mounted to the headrest mounting kit. - Page 35 Attaching an infusion stand Mount the mounting kit provided to the inside of the A soon as the lower end rests on the counter plate central unit. The beveled clamping plate must be the tilt the stand to bring it in upright position. The upper upper one. plate now acts as a clamp. Fix the infusion stand from underneath by tightening the star grip screw. Apply the infusion stand as shown in the photo and let it glide through the beveled plate. 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). Then screw the snap fastener to the right support.
- Page 36 · Internet: http://www.ottobock.com Versandanschrift für Rücksendungen/Address for Returns Otto Bock HealthCare GmbH Lindenstraße 13 · D-07426 Königsee Otto Bock HealthCare GmbH has been certified by the German Society for the Certification of Quality Assurance Systems (DQS) in accordance with DIN EN ISO 9001 standard, reg. no. 779 (management system)
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