Otto Bock BRAVO Racer Service Manual
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Otto Bock BRAVO Racer Service Manual

Otto Bock BRAVO Racer Service Manual

Active wheelchair
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Summary of Contents for Otto Bock BRAVO Racer

  • Page 1 BRAVOracer Service Manual...

  • Page 3: Table Of Contents

    Service Manual for the BRAVO Racer Active Wheelchair Table of contents Page 1 Introduction ........................3 1.1 Foreword ........................3 1.2 Technical support .......................3 1.3 Explanation of symbols ....................3 2 General safety instructions ....................4 3 Required tools, maintenance schedule ................5 3.1 Required tools ......................5 3.2 Maintenance schedule ....................7 4 Adjustments / replacement / retrofitting ................8 4.1 Assembly A: Frame ....................8...
  • Page 4 4.4 Assembly D: Back / push handles ................23 4.4.1 Replacing the back release ................... 23 4.4.2 Replacing the back release spring ................23 4.4.3 Replacing the push handles: Standard / folding version ..........24 4.4.4 Replacing the push handles: Height-adjustable version ..........24 4.4.5 Retrofitting the push bar ....................

  • Page 5: Introduction

    Spare Parts Catalogue BRAVO Racer 647G447=D/GB 1.2 Technical support Your national Otto Bock Team will be pleased to answer your technical questions. Contact ad- dresses and telephone numbers are listed on the last page of this manual. 1.3 Explanation of symbols Caution! Personal injury warning.

  • Page 6: General Safety Instructions

    If you do not have a copy of the instructions for use, you can order one from the manufacturer (see the overview of all Otto Bock branches “Otto Bock Worldwide”). You can also download documents from our homepage: www.ottobock.de or www.ottobock.com.

  • Page 7: Required Tools, Maintenance Schedule

    3 Required tools, maintenance schedule 3.1 Required tools The following list shows the tools and accessories required for service. Ratchet wrench and socket set, Torque wrench, Wrenches, sizes 8 – 4 measurement range 5 – 50 Nm sizes 0 – 4 Allen wrenches, Screwdrivers, blade widths Phillips screwdriver,...
  • Page 8 Workbench and vice with plastic Hand drill Tyre mounting levers and inner tube repair kit jaws and rubber insert...

  • Page 9: Maintenance Schedule

    3.2 Maintenance schedule Customer: Maintenance schedule BRAVO Racer for regular inspections - active wheelchair - Item Inspection (checklist) Component (assembly) Serial number: Function / setting Damage / Screw connections (refer to 647G447GB Instructions for Use) deformation Frame - Base frame Frame accessories - Anti-tipper - Transport wheels...

  • Page 10: Adjustments / Replacement / Retrofitting

    4 Adjustments / replacement / retrofitting 4.1 Assembly A: Frame 4.1.1 Retrofitting the multi-function adapter for frame accessories Before mounting frame accessories (tip-assist, crutch holder, and transport wheels), a multi- function adapter must be installed. Please proceed as follows: First remove the rear wheels by pressing the button on the quick-release axle with your thumb and pulling off the wheel (Figure ).

  • Page 11: Retrofitting / Replacing / Adjusting The Tip-Assist

    Now push the hexagonal multi-function adapter past the loosened adjustment tube onto the exposed hexagon nut on the rear wheel axle (Figure 5). Secure the multi-function adapter using the clamping screw (Figure 6). Reinstall the adjustment tube, rear wheel attachment, and wheels. Repeat the steps described above in reverse order.

  • Page 12: Retrofitting / Replacing / Adjusting The Transport Wheels

    Note! Subject to technical changes. 4.1.4 Retrofitting / replacing / adjusting the transport wheels First, proceed as described in Section 4... Follow the same process to install a second multi- function adapter across from the rear wheel attachment in order to attach the transport wheels on both sides.

  • Page 13: Assembly B: Footrest

    4.2 Assembly B: Footrest 4.2.1 Adjusting / replacing the footplate If the footplate is too small or has become damaged, or if the leg length needs to be adjusted due to the growth of a child, proceed as follows: First, completely loosen all screws on the clamps on the top of the footplate and remove them (Figure ).

  • Page 14: Adjusting The Lower Leg Length

    4.2.2 Adjusting the lower leg length The lower leg length can be adjusted as follows: a) Fine adjustment of the lower leg length: Loosen the outer screws on the clamps that guide the footrest bars (Figure 5) and adjust the footplate to the desired height. b) Changing the lower leg length (from long to short or short to long): Remove the footplate, and then remove the exposed footrest bars.

  • Page 15: Adjusting The Footplate Angle

    4.2.3 Adjusting the footplate angle First, loosen the set screws on the clamps that hold the T-shaped crossbrace (Figure 8). Loosen the centre Allen screws on the same clamps so you can open the rotation joint (Figure ). Then open the screw connections located on the frame tube between the clamps (Figure 0). Now loosen the crossbrace screw connection on the seat tube (Figure ), so that the nuts can move freely in the guide groove.

  • Page 16: Replacing / Retrofitting The Lateral Heel Blocks On The Footplate

    Move the crossbrace back along the seat tube until the footplate reaches the desired angle (Figure ). Use the scale on the bottom of the seat tube (Figure ) in order to make sure the footplate is positioned evenly on both sides. Retighten all screws.

  • Page 17: Assembly C: Seat

    4.3 Assembly C: Seat 4.3.1 Replacing the seat upholstery / upholstery bars First remove the seat cushion. Remove the front tube end caps (Figure 6). Loosen the hook-and-loop connections on the tension-adjustable upholstery in order to slacken it (Figure 7). Evenly pull the seat upholstery and upholstery bars out of the guides towards the front (Figure 8) (use pliers if required).

  • Page 18: Replacing / Removing The Adjustment Tube

    4.3.2 Replacing / removing the adjustment tube Remove the rear wheels, rear wheel attachment, and U-shaped component as described under 4... Loosen the counter nut on the top of the adjustment tube (Figure 0) and remove it. Replace the adjustment tube, counter nut, or guide bushings with new parts as required (Figure ). Remove the guide bushings from the adjustment tube and insert them in the desired position (Figure ).

  • Page 19: Horizontal Seat Adjustment

    4.3.4 Horizontal seat adjustment Remove the rear wheels. Loosen the counter nuts on the top end of the adjustment tubes. Loosen the screw connections on both sides of the crossbrace in the guide grooves of the seat tubes (Figure 7). Move the seat tubes lengthwise until they reach the desired position (Figure 8).

  • Page 20: Adjusting The Seat Angle

    4.3.5 Adjusting the seat angle Slightly loosen the two cap nuts on the front of the adjustment tube. Follow this procedure on both sides. Then loosen the two inner screws on the front of the footrest clamps (Figure ; for narrow seats, loosen the outer screws) and the countersunk centre screws (Figure 40) until the crossbrace moves easily inside the clamp.

  • Page 21: Fine Adjustments To The Back Unit

    4.3.7 Fine adjustments to the back unit If a solid back is used in place of the back upholstery, the back unit can be adjusted separately in order to optimise the seating position. Remove the rear wheels. Loosen the four seat tube screw connections / nuts of the back unit on the seat tubes so that you can move it freely later.

  • Page 22: Adjusting The Seat Width

    4.3.8 Adjusting the seat width Adjusting the seat width requires a conversion kit (consult the spare parts catalogue) and a new seat cushion. The conversion kit includes a crossbrace and back unit in the new seat width, and an installation kit. We recommend replacing the upholstery as well. a) Removing the seat: First remove the seat cushion, seat upholstery, and front tube end caps.
  • Page 23 Remove the back plate screw connections on both sides of the back part (Figure 4). Now you can remove the back part. Replace the back part with the new unit. Loosen and remove the crossbrace screw connections on the seat tube (Figure 50) and the crossbrace screw connections on the footrest clamps (Figure 5).
  • Page 24 b) Widening the seat surface: Loosen and remove the rear wheel attachment (Figure 5). Move the U-shaped component into the outer notches of the camber adapters on both sides (Figure 54). Proceed in the reverse sequence in order to install the rear wheel attachment. Now insert the new crossbrace into the footrest clamps and screw them back onto the seat tubes.

  • Page 25: Assembly D: Back / Push Handles

    4.4 Assembly D: Back / push handles 4.4.1 Replacing the back release Remove the seat cushion. Unlock the back rest and fold it ahead to the stop (Figure 55). Lift the back upholstery flap. Using pincers, pinch off the release cable from both key rings (Figure 56). Open the key rings slightly and remove them from the ends of the bolts (Figure 57 –...

  • Page 26: Replacing The Push Handles: Standard / Folding Version

    4.4.3 Replacing the push handles: Standard / folding version First remove the back upholstery flap. Open the strap that covers the push handle screw con- nections and pull it off towards the bottom (Figure 60). If applicable, remove the upper upholstery strap (in case of folding push handles). Loosen the push handle screw connections on the rear of the back tubes (Figure 6) and pull the push handles up and out / off the back tubes.

  • Page 27: Retrofitting The Push Bar

    4.4.5 Retrofitting the push bar Remove the rear wheels. Remove the rear tube end caps from the seat tubes on both sides (Figure 65). Insert the supplied nuts into the seat tube grooves from the rear (Figure 66). Position the support bar against the seat tubes from below (Figure 67) and screw the support bar connectors into the nuts (Figure 68).

  • Page 28: Replacing The Back Upholstery

    Insert the tube end caps. Now the push bar can be secured using the quick clamp (Figure 6; consult the instructions for use). 4.4.6 Replacing the back upholstery Proceed as described in Section 4.4. until you have removed the push handles. Loosen all hook-and-loop straps from the old back upholstery (Figure 70).

  • Page 29: Pre-Adjusting The Back Angle

    4.4.7 Pre-adjusting the back angle First remove the rear wheels. Then loosen the screws on both sides of the side panel guides (Figure 7) and remove them. Push the side panel up and out of the way. Now you can access the back angle pre-adjustment mechanism on the back plates.

  • Page 30: Assembly E: Side Panels

    4.5 Assembly E: Side panels 4.5.1 Adjusting the side panels: Clothing protector version Loosen the screw below the lip of the clothing protector and the side panel mounting screw in the nut on the seat tube (Figure 75). Move the side panels lengthwise until they reach the desired position (Figure 76). Use the scale on the bottom of the seat tubes in order to make sure the position is even on both sides.

  • Page 31: Adjusting The Side Panels: Height-Adjustable Version

    4.5.3 Adjusting the side panels: Height-adjustable version Loosen the two side panel mounting screws in the nuts on the seat tube (Figure 7). Move the side panels lengthwise until they reach the desired position (Figure 80). Use the scale on the bottom of the seat tubes in order to make sure the position is even on both sides. Retighten all screws.

  • Page 32: Replacing The Arm Pad / Lengthwise Adjustment

    4.5.5 Replacing the arm pad / lengthwise adjustment Loosen and remove the two screws on the bottom of the arm pad (Figure 8). Replace the arm pad with a new one if required. Replace the arm pad in the desired position (Figure 84; three possible settings) and retighten the screw connections.

  • Page 33: Removing / Replacing The Casters

    4.6.2 Removing / replacing the casters Remove the two outside caster screw connections on the caster fork (Figure 88). Remove the caster and spacers. Replace the caster, ball bearing, and spacers with new parts as required (Figure 8). Insert the caster into the desired / correct bore hole on the caster fork (Figure 0;...

  • Page 34: Replacing The Caster Forks

    4.6.3 Replacing the caster forks To replace the caster forks, first proceed as described in Section 4.6.. Replace the caster fork with a new part or a different length fork if applicable. Insert the axle into the caster fork. If you changed the position of the caster or the length of the fork, you can level the frame using the spacers (Figure ).

  • Page 35: Replacing The Fitting And Camber Adapter

    4.7.3 Replacing the fitting and camber adapter First proceed as described in Section 4.7. to remove the U-shaped component. Loosen the counter nut on the exposed rear wheel fitting (Figure 4). Unscrew the fitting from the camber adapter by hand. To remove the camber adapter, drill out the rivet indicated in the illustration (Figure 5).

  • Page 36: Retrofitting The Rear Wheels With Drum Brakes

    Note! Any existing frame options (tip-assist, anti-tipper, crutch holder, transport wheels) must be moved to the rear axle during installation (see Section 4.). 4.7.5 Retrofitting the rear wheels with drum brakes First proceed as described in Section 4.7.. Unscrew the fitting from the camber adapter by hand.
  • Page 37 b) Preparing for brake handle installation: In order to mount the brake handle, you first have to make room for the installation on the push handle tube. Proceed as follows: Use a knife to carefully cut open the rubber grip, and then remove it from the push handle tube (Figure 0).

  • Page 38: Adjusting The Quick-Release Axle

    c) Final assembly: Hold the brake handle of the drum brake in place in front of the rubber grip and tighten the screw on the mounting clamp (Figure 04). Adjust the pull-release cable of the drum brake using the adjustment nut (Figure 05). Follow this procedure on both sides.

  • Page 39: Changing Tyres

    4.7.7 Changing tyres To replace worn tyres, first release the air from the inner tube by opening the valve. Remove the casing from the rim using standard tools available at bicycle shops, and then remove the inner tube and inspect the rim band as well as the inner rim surface for damage. Replace the inner tube and / or casing with new parts, and / or repair the tube by following the instructions provided with the repair kit.

  • Page 40: Assembly H: Wheel Lock

    From the outside, press in the attachment nipples until you hear them lock in place on the spokes. 4.8 Assembly H: Wheel lock 4.8.1 Adjusting the wheel lock Ensure that the rear wheel tyres are inflated to the proper operating pressure. When you replace the rear wheels with a different size, the wheel lock body first needs to be adjusted on the clamp.

  • Page 41: Replacing The Wheel Lock

    4.8.2 Replacing the wheel lock a) Replacing the spring and pull-release cable: Unhook the pull-release cable from the adapters on the side panel as described in Section 4.5.4. Open the screw die in the brake block (Figure 4) and pull out the pull-release cable. You can remove the pull-release cable spring and replace it if required.

  • Page 42: Accessories

    4.9 Accessories 4.9.1 Installing the lap belt Position the lap belt on the seat upholstery. Pull the free ends of the belt through between the side panel and the back tube on both sides. Screw the grommets on the ends of the belt into one of the unused bore holes on the back plate (Figure 7).

  • Page 43: Technical Data

    5 Technical data 0 – 6 Seat width: 4 – 8 Seat depth: 0 – 40 Back height: Different settings possible from -5° to +5°, Back angle: may be locked in place at +5° 4.5 – 44.5 Lower leg length: .5 –...
  • Page 44 Wheel / camber combinations Short Fork Number of Long Fork Number of 3° camber Rear Wheel Size Position Spacers Position Spacers “ 4“ Caster 5“ 0“ 40mm 6“ “ 4“ Caster 5“ “ 40mm 6“ “ 4“ Caster 5“ 4“ 40mm 6“...
  • Page 45 Short Fork Number of Long Fork Number of 9° camber Rear Wheel Size Position Spacers Position Spacers “ 4“ Caster 5“ 0“ 40mm 6“ “ 4“ Caster 5“ “ 40mm 6“ “ 4“ Caster 5“ 4“ 40mm 6“ Colour combinations Translucent Design Orange Blue...
  • Page 48 · Internet: http://www.ottobock.com Versandanschrift für Rücksendungen/Address for Returns Otto Bock HealthCare GmbH  Lindenstraße 13 · 07426 Königsee/Germany 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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