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Whirlwind Cargo Assembly Instructions Manual

Handcycle tricycle
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Whirlwind Cargo Tricycle Assembly
Assembly instructions for the Whirlwind Cargo handcycle Tricycle
For videos on assembly and adjustment visit
http://www.whirlwindwheelchair.org/tech-support
Ralf Hotchkiss riding the Cargo Handcycle Tricycle
1

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Summary of Contents for Whirlwind Cargo

  • Page 1 Whirlwind Cargo Tricycle Assembly Assembly instructions for the Whirlwind Cargo handcycle Tricycle For videos on assembly and adjustment visit http://www.whirlwindwheelchair.org/tech-support Ralf Hotchkiss riding the Cargo Handcycle Tricycle...
  • Page 3 CARGO TRIKE ADJUSTMENTS SEAT HEIGHT UP AND DOWN SEAT POSITION FRONT-BACK CRANK HEIGHT UP AND DOWN BACKREST HEIGHT SEAT ANGLE TENSION ADJUSTABLE BACKREST...

  • Page 4: Backrest Angle

    SCI SEATING KIT:LATERAL BACKREST ANGLE WEDGES, CHEST STRAP, AND PRESSURE RELIEF CUSHION...
  • Page 5 Accessories Additional Accessories not pictured: SCI Kit Cargo Canopy/ Overhead storage and shelter Sun Canopy...
  • Page 6 Identify all components, from front to back 1) Front wheel 2) Fork 3) Crank Boom 4) Chain Idler assembly 5) Chain 6) Left Crank 7) Right Crank with Chainring 8) Crank handles 9) Optional Front Brake 10) Steering Centering Spring 11) Front Frame 12) Frame attachment location with bolts 13) Rear Frame...
  • Page 7 Handrims, rim strip, tube, and tire are installed on rear wheels. Refer to the RoughRider wheelchair assembly materials available from Whirlwind. Note: There are different left and right wheels. The right wheel has the adjustable cup of the hub on the same side as the handrim, and the left wheel has the fixed cup on of the hub on the same side as the handrim.
  • Page 8 Assembly Instructions: 1. Apply grease to the bearing cups on the headtube. GREASE 2. Apply grease to the bearing on the “crown race” of the fork. The bearing should be installed with the ball retaining ring on the bottom side. 3.
  • Page 9 4. Install the centering spring (this is easier to install before the headset is tightened). 5. Install the top bearing with the ball retaining ring on the top side.
  • Page 10 6. Install the threaded headset cone and lockring. Tighten the lockring against the cone, so that the bearings spin freely but there is no wiggle in the bearings. This is a standard bicycle assembly. 7. Install the chain idler with the idler wheels on the same side as the chain rings (right side when viewed from the rear).
  • Page 11 The left side cup may also be welded to the frame, depending on manufacturer. This part is pre- installed. 10. During maintenance of the crank / “bottom bracket”, the Right side /adjustable cup should be tightened last, with the lockring tightened against the right side cup so that the spindle can spin freely, but there is no wiggle.
  • Page 12 13. Tighten the crank boom with 2 quick release bolts or 2 regular bolts; make sure that the crank gears are aligned and parallel on the top and bottom. 14. Check that the centering spring is installed correctly. 15. Install the stem quill into the fork steerer tube. Tighten. The height of the exposed tube should be approximately 50mm above the top of the fork steerer tube.
  • Page 13 16. Slide the chain idler down over the stem quill. Position the chain idler such that the idler wheels can rotate freely without touching the crank boom quick release bolts. Tighten the chain idler with the quick release bolt.
  • Page 14 17. Install the chain. First install the chain on the Top chainring. Second install the chain on the bottom cassette on the wheel. Third, rotate the Chain idler 1 (one) full revolution or until the torsion spring is wound enough to hold the chain tight. Install the chain as shown. Make sure that the chain is guided over the tensioned idler wheel.
  • Page 15 18. Install the front wheel. If the wheel has a drum brake, the brake should clamp to the left side of the fork, and the cog for the cassette will be on the right side, when viewed from the back of the trike.
  • Page 16 20. Attach the front and back chassis/main frame pieces together with four (4) M12 bolts. The bolt heads should be on the outside of the trike frame, and the nuts and washers on the inside. If it is difficult to align the holes, install one at a time and do not tighten fully until they are all installed.
  • Page 17 21. Identify the RIGHT REAR WHEEL. This wheel has the Adjustable cup of the hub (with lockring) on the same side as the handrim. Install the right wheel onto the right side of the main frame chassis, when viewed from the rear. Inflate the right rear wheel.
  • Page 18 22. Insert the axle with the slot / flat part facing up, and position the axle so the M8 bolt on the top of the axle clamp can be tightened into that slot. Tighten the axle security bolt and locknut with a 13mm wrench.
  • Page 19 25. Identify the holes on the seat which will be used for the seat clamps and seat rail guides. Different riders require different seating positions. The seat can be adjusted forward and backwards after it is installed. Example: Seat mounting for 46cm seat height at 12 degree seating angle FRONT: SEAT RAIL GUIDE...
  • Page 20 BOLT HEADS CAN BE ABOVE OR BELOW SEAT RAIL, IN ANY ONE OF THE 6 HOLES TO SET SEAT HEIGHT AND SEAT ANGLE LOCK NUT TRAPPED INSIDE CHANNEL ABOVE: BRAKE CLAMP PARTS, (THIN MATERIAL), SEAT CLAMP NOT FOR SEAT SEE SEAT HEIGHT ASJUSTMENT SECTION OF THIS GUIDE AND VIDEO FOR MORE INFORMATION 26.
  • Page 21 Put the seat on the tricycle. It is easiest to install the seat rail guides onto the rails at the front corner of the seat rails. SEE SEAT HEIGHT ASJUSTMENT SECTION OF THIS GUIDE AND VIDEO FOR MORE INFORMATION More information at http://www.whirlwindwheelchair.org/provider-resources 28.
  • Page 22 31. Install the backrest adjustment ladder though the slots in the backrest, and attach to the seat using M8 bolts. 32. Attach the springs between the adjustment ladder and the seat, pulling securely. Check to make sure that the backrest ladder falls into every set of notches evenly and easily (For rider safety). view from center of trike looking outward.
  • Page 23 33. Lay out the backrest TAB and posts to be ready for installation. The wide Velcro is on the front of the TAB. Each strap should wrap around each backrest cane without tangle. Refer to the RoughRider backrest installation and fitting guides for information about installing the backrest. http://www.whirlwindwheelchair.org/backrest-and-tab...
  • Page 24 34. Attach remaining backrest straps through the trike backrest, avoiding the adjustment mechanism as much as possible. The number of straps below the backrest ladder will change depending on the backrest cane height, which will be selected in a seating assessment. One strap will be below for the tall backrest height, two straps for the medium backrest height, and three straps for the low backrest height.
  • Page 25 35. Install the backrest cover with the reflector facing back, with the wings wrapped around the backrest from the front to the back. Refer to the RoughRider backrest installation information. Note: If this trike will be set up with the SCI Kit, lateral support wedges will be installed between the backrest cover and the TAB straps, to be comfortable for the rider.
  • Page 26 39. Position the brake assembly on the trike. This is easily done if the trike is tipped vertical or upside down. Ensure that the brake curve follows the curve of the wheel. 40. Install the brakes using the clamp plates with M6 bolts. Use threadlocking compound such as medium strength Loctite®...
  • Page 27 The seat base for the SCI kit has thin foam on a plastic base. This replaces the standard seat + cushion on the tricycle. The Pressure Relief Cushion (PRC) attaches with Velcro to the seat base. Refer to Whirlwind and WHO information about seating assessment and pressure relief cushion fitting. The lateral support wedges are inserted between the front of the TAB backrest straps and the backrest cover.
  • Page 28 Rear Cargo Box: This accessory is an alternative to the Rear Cargo Bag (and cannot be used at the same time). Secure the box to the floor of the cargo trike with bolts. The cargo box can be locked with a padlock (not provided) to secure valuables and other cargo.
  • Page 29 PROVISION: The Whirlwind Cargo Handcycle Tricycle is a mobility device, and should be provided similarly to a wheelchair following best-practices for service provision for seating and mobility. Refer to the World Health Organization (WHO) Basic Wheelchair provision training and guides. The following information describes adjustments and seating options specific to this tricycle, and should be used as a reference for experienced wheelchair providers .
  • Page 36 Size Adjustments: Trike/Hip Width: The Whirlwind Cargo tricycle is available in one width only: 18 1/8”. Riders with narrower hip widths may prefer to place foam between their hips and the frame.
  • Page 37 Backrest Height + Tension Adjustable Backrest The backrest can be adjusted for the highest support of the backrest to be 14”, 16”, or 18” above the seat surface. The Tension Adjustable backrest straps can be adjusted to fit each rider. Refer to the RoughRider backrest adjustment information.
  • Page 39 The following notes are provided as a reference for riders and service providers and are not a replacement for a skilled service provider. The RoughRider (and Cargo Tricycle) backrest supports comfort for riders with good head and trunk control, who have the ability to maintain an upright seated position.
  • Page 40 Seat Height (for Lower leg length) and Seat Angle The seat angle can be adjusted by selecting holes for mounting the seat clamp. Some factors to consider when selecting seat angle, seat height, and seat position front/back include the following: •...
  • Page 41 Example:Seat mounting for 46cm seat height at 12 degree seating angle FRONT: SEAT RAIL GUIDE REAR: SEAT CLAMP (Shown with bolt above tube, and can be (Shown with bolt above tube, and can be installed with bolt below tube for low seats for installed with bolt below tube for low seats for riders with short legs) riders with short legs)
  • Page 42 Low seat positions: Seat height = 34 cm Hole, bolt-on-bottom 2nd Hole, bolt-on-bottom Image: Showing lowest seat position with 5 degree seat angle, 34cm seat height from footrest. The rear seat clamp is bolt-on-bottom in the top hole (1 of 6). The front seat guide is bolt-on-bottom in second hole, 2 of 6.

  • Page 43: Seat Depth

    Seat Depth: The seat on the cargo trike is 14” deep, which gives a total seat depth of approximately 15” to back of the sling backrest. If a longer seat is required, the tricycle and be fit with a seat extension from an 18.5”...
  • Page 44 Crank Height: Many riders prefer the lowest cranks possible because there is less of a visual obstruction in front of them. The lowest position of the cranks that will be comfortable for riders will likely be set such that the riders’...
  • Page 45 Seat Position Front-back The seat position front-back, combined with the crank height, affects the propulsion and comfort of the trike rider. Many riders are the most comfortable when the seat position is set so that their shoulder is still in contact with the backrest and the farthest part of the crank stroke. A good starting point for this setting is 3 cm shorter than the fully extended arm length from the center of a closed fist to the surface supporting the rider’s back.
  • Page 46 For more information contact info@whirlwindwheelchair.org and visit http://www.whirlwindwheelchair.org/tech-support http://www.whirlwindwheelchair.org/provider-resources...