Introduction1 6............................................................................................................................................................
Foreword 1.1 6....................................................................................................................................................
Support1.2 6........................................................................................................................................................
Product overview1.3 7.........................................................................................................................................
Safety2 9......................................................................................................................................................................
Explanation of warning symbols2.1 9.................................................................................................................
General Safety Instructions2.2 10.......................................................................................................................
Service Work3 10.........................................................................................................................................................
Instructions for Adjustment3.1 10.......................................................................................................................
Required Tools and Accessories3.2 11...............................................................................................................
Special features of the Avantgarde CLT3.3 11...................................................................................................
Maintenance Schedule3.4 11..............................................................................................................................
Assembly A: Frame3.5 12...................................................................................................................................
Replacement Work on the Frame3.5.1 12...................................................................................................
Replacing the Front Frame Part3.5.1.1 12.......................................................................................
Replacing the Rear Frame Part3.5.1.2 13........................................................................................
Replacing the Cross-Brace/Cross-Brace Bracket3.5.1.3 14............................................................
Replacing the Joint Tubes3.5.1.4 15.................................................................................................
Replacing the Seat Tube Supports3.5.1.5 15...................................................................................
Retrofitting the Vertical Accessory Mount3.5.2 16........................................................................................
Installation / adjustment of the anti-tipper3.5.3 17........................................................................................
Installing the anti-tipper3.5.3.1 17....................................................................................................
Adjustment of the anti-tipper3.5.3.2 18.............................................................................................
Replacing the Pivot Arm3.5.3.3 18...................................................................................................
Replacing Anti-Tipper Rollers3.5.3.4 19...........................................................................................
Retrofitting the Transport Wheels3.5.4 19...................................................................................................
Retrofitting the Horizontal Accessory Mount3.5.5 19....................................................................................
Retrofitting the Tip-Assist3.5.6 20................................................................................................................
Retrofitting the Crutch Holder3.5.7 20.........................................................................................................
Retrofitting the Frame Pads (CS/CLT only)3.5.8 20....................................................................................
Assembly B: Footrest3.6 21................................................................................................................................
Adjusting the Foot Rests/Tube Foot Rest/Foot Plates3.6.1 21.....................................................................
Replacement Work on the CV Model3.6.2 21..............................................................................................
Replacing the Foot Rest3.6.2.1 21...................................................................................................
Replacing the Foot Rest Bar/Swivel Segment3.6.2.2 21..................................................................
Replacing the Foot Plate3.6.2.3 22..................................................................................................
Replacing the Pivot Bearing3.6.2.4 22.............................................................................................
Replacing the Locking Device3.6.2.5 23..........................................................................................
Retrofitting the Heel Strap3.6.2.6 23................................................................................................
Elevating Foot Rest with Automatic Length Adjustment3.6.2.7 23.....................................................
Retrofitting the Elevating Foot Rest3.6.2.7.1 23.................................................................
Replacing the Foot Rest Bar3.6.2.7.2 23...........................................................................
Replacing the Calf Pads3.6.2.7.3 24.................................................................................
Replacing the Retaining Plate3.6.2.7.4 24.........................................................................
Replacement Work on the CS/CLT Model3.6.3 25.....................................................................................
Replacing the Foot Rest Bar3.6.3.1 25............................................................................................
Replacing the Foot Plate3.6.3.2 25..................................................................................................
Replacing the Foot Plate3.6.3.3 25..................................................................................................
Replacing the Tube Foot Rest3.6.3.4 25..........................................................................................
Table of contents
302/2011
Table of contents
Table of contents
Replacing the Tube Foot Rest Mounting3.6.3.5 26...........................................................................
Assembly C: Seat3.7 26......................................................................................................................................
Replacing the Standard/Business Seat Upholstery3.7.1 26.........................................................................
Replacing the Seat Upholstery, Adaptable3.7.2 27.....................................................................................
Cleaning the Seat Upholstery3.7.3 28.........................................................................................................
Cleaning the Standard Seat Cushion3.7.4 28.............................................................................................
Assembly D: Back/Push Handle3.8 28...............................................................................................................
Replacement Work on the Push Handles3.8.1 28........................................................................................
Replacing the Push Handles, Standard3.8.1.1 28............................................................................
Retrofitting the Telescoping Push Handles3.8.1.2 29........................................................................
Retrofitting the Height-Adjustable Push Handles3.8.1.3 29...............................................................
Retrofitting the Folding Push Handles3.8.1.4 30...............................................................................
Replacing the Rubber Hand Grips3.8.1.5 30....................................................................................
Replacing the Back Upholstery3.8.2 30.......................................................................................................
Replacing the Back Upholstery, Standard3.8.2.1 30........................................................................
Replacing the Back Upholstery, Adaptable3.8.2.2 31......................................................................
Replacing the Back Tubes3.8.3 31..............................................................................................................
Replacing the Angle-Adjustable Back Tubes3.8.4 32..................................................................................
Assembly E: Side Panels3.9 33...........................................................................................................................
Replacement Work on the Standard Side Panel/Clothing Protector3.9.1 33...............................................
Replacing the Standard Side Panel/Clothing Protector3.9.1.1 33....................................................
Replacing the Side Panel Mounting3.9.1.2 34..................................................................................
Replacement Work on the Desk Side Panel3.9.2 34....................................................................................
Replacing the Desk Side Panels3.9.2.1 34.......................................................................................
Replacing the Side Panel Mounting3.9.2.2 35..................................................................................
Replacing the Seat Tube Support3.9.2.3 35....................................................................................
Replacing the Retaining Clip3.9.2.4 35............................................................................................
Replacing the Pivot Pin3.9.2.5 36.....................................................................................................
Replacing the Strut3.9.2.6 36..........................................................................................................
Replacing the Arm Rest Pad3.9.2.7 36............................................................................................
Assembly F: Caster Wheels3.10 36.......................................................................................................................
Replacing/Changing the Installation Position of the Caster Head3.10.1 36...................................................
Adjusting the Caster Wheel Journal Angle3.10.2 37......................................................................................
Replacing/Changing the Installation Position of the Caster Wheels3.10.3 38................................................
Replacing the Caster Fork3.10.4 39..............................................................................................................
Replacing the Eccentric Disc3.10.5 39..........................................................................................................
Retrofitting the Caster Fork System Frog Legs (spring-mounted)3.10.6 39....................................................
Retrofitting the Caster Wheel Adapter for High/Low Seat Heights in the Front3.10.7 40...............................
Assembly G: Rear Wheels3.11 41.........................................................................................................................
Adjusting the Rear Wheels/Rear Wheel Adapters3.11.1 41...........................................................................
Rear Wheel Adapter, Standard3.11.2 41......................................................................................................
Replacing the Rear Wheel Adapter, Standard3.11.2.1 41..................................................................
Installing the Fitting3.11.2.2 42..........................................................................................................
Shock Absorber System3.11.3 43.................................................................................................................
Retrofitting the Shock Absorber3.11.3.1 43........................................................................................
Installing the Fitting3.11.3.2 44..........................................................................................................
Wheelbase extension3.11.4 44......................................................................................................................
Retrofitting the Wheelbase Extension3.11.4.1 44................................................................................
Installing the Fitting3.11.4.2 45..........................................................................................................
Changing the Rear Wheel Camber3.11.5 45................................................................................................
Maintenance Work on the Rear Wheel3.11.6 45...........................................................................................
Replacing the Tyres3.11.6.1 45..........................................................................................................
Replacing the Push Rings/Adjusting the Installation Position "narrow/wide"3.11.6.2 45.....................
Tensioning the Spokes/Adjusting the Out-of-Round3.11.6.3 46..........................................................
4 02/2011
Table of contents
Adjusting the Quick-Release Axle3.11.6.4 46.....................................................................................
Retrofitting the Tetra Axle3.11.6.5 46.................................................................................................
Assembly H: Wheel Lock/Brake3.12 47................................................................................................................
Adjusting the Knee Lever Wheel Lock/Drum Brake3.12.1 47.........................................................................
Replacing the Knee Lever Wheel Lock3.12.2 47...........................................................................................
Replacing the Brake Block3.12.3 48.............................................................................................................
Retrofitting the Wheel Lock Lever Extension3.12.4 48...................................................................................
Retrofitting the Drum Brake3.12.5 48............................................................................................................
Adjusting the Drum Brake3.12.6 49...............................................................................................................
Other Accessories3.13 50.....................................................................................................................................
Retrofitting a Lap Belt3.13.1 50.....................................................................................................................
Retrofitting a Tray3.13.2 50...........................................................................................................................
Appendices4 50...........................................................................................................................................................
Technical Data4.1 50..........................................................................................................................................
502/2011 502/2011
1 Introduction
1.1 Foreword
Regular maintenance is important – it improves safety and increases the lifespan of the product.
All Mobility products should be inspected and serviced once a year.
However, we recommend inspecting, readjusting, and if necessary servicing the product every 6 months if the product
is used frequently, by growing children, or by patients with changing clinical pictures.
Only use original spare parts for all service and maintenance work. The service and maintenance tasks described here
should only be completed by trained, qualified personnel and not by the user of the device.
This service and maintenance manual refers to the respective spare parts catalogues and the instructions for use of
the described products. Please use these documents together.
Use the maintenance schedule (checklist) as a template for making copies. Retain completed maintenance schedules
and provide the customer with a copy.
Instructions for Use (qualified person
nel)
Instructions for Use (User)
Avantgarde CV/CS/CLT 647G568=* 647G689=*
1.2 Support
Your national Otto Bock team will be happy to answer any technical questions. The contact addresses and telephone
numbers can be found on the back of the service manual.
6 02/2011
Introduction
1.3 Product overview
1
Avantgarde CS
Maximum load (in combination with double cross-brace): 140 kg
Thanks to its closed frame geometry, the Avantgarde CS allows very rigid and sporting use.
1 Seat/seat pad 9 Rear wheel with push ring
2 Side panel 10 Quick-release axle release button
3 Back/back upholstery 11 Double cross-brace
4 Push handle 12 Caster wheel
5 Back tube 13 Caster fork
6 Rear frame 14 Foot plate
7 Front frame 15 Knee lever wheel lock
8 Rear wheel adapter
702/2011
Introduction
2
Avantgarde CV
Maximum load (in combination with double cross-brace): 140 kg
Thanks to its frame geometry, the Avantgarde CV offers precise leg guidance with the possibility of swinging away and
removing the foot rests. When the foot rests are removed, the upright frame front section allows the wheelchair to be
manoeuvred close to objects.
1 Seat/seat pad 9 Rear wheel with push ring
2 Side panel 10 Quick-release axle release button
3 Back/back upholstery 11 Double cross-brace
4 Push handle 12 Caster wheel
5 Back tube 13 Caster fork
6 Rear frame 14 Foot plate (foot rest removable)
7 Front frame 15 Knee lever wheel lock
8 Rear wheel adapter
8 02/2011
Introduction
3
Avantgarde CLT
Maximum load (in combination with double cross-brace): 100 kg
The Avantgarde CLT is the weight-optimised sports version for particularly active users. In the version CLT "welded",
subsequent modification of the wheel position and back height was sacrificed in favour of saving additional weight.
1 Seat/seat pad 9 Rear wheel with push ring
2 Side panel 10 Quick-release axle release button
3 Back/back upholstery 11 Double cross-brace
4 Back tube 12 Caster wheel
5 Push handle 13 Caster fork
6 Rear frame 14 Foot rest
7 Front frame 15 Knee lever wheel lock
8 Rear wheel attachment device (here welded)
2 Safety
2.1 Explanation of warning symbols
WARNING Warnings regarding possible risks of severe accident or injury.
CAUTION Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
902/2011
Safety
2.2 General Safety Instructions
INFORMATION
Read the service manual before starting work. Familiarise yourself with the product's functions before use. If you are
not familiar with the product, read the service manual before performing the inspection. If a service manual is not
available, request it from the manufacturer (see the overview of all Otto Bock branches "Otto Bock Worldwide"). You
can also download documents from our home page at www.ottobock.de or www.ottobock.com.
CAUTION
Wearing unsuitable work clothing
Risk of pinching, crushing, being pulled in
►Wear suitable work clothing and, for example, gloves and protective eyewear as necessary when working on the
product.
CAUTION
Use of unsuitable tools
Risk of pinching/crushing or damage to the product.
►When completing the tasks, only use tools that are suitable for the conditions at the place of work and for which
safety and the protection of health are assured with proper use.
NOTICE
Tipping or falling of the product
Risk of damage to the product
►When you work on the product, secure it so that it cannot tip over or fall down.
►Use a clamping fixture to secure the product whenever you work on it at a workbench.
NOTICE
Re-use of self-locking nuts
Unintended loosening of the screw connections
►Always replace self-locking nuts with new self-locking nuts after disassembly.
INFORMATION
Many screw connections utilise screws and nuts equipped with thread lock. If you loosen screw connections, be sure
to replace the respective nut or screw with one having a new thread lock. If new screws or nuts with thread lock are
not available, apply a medium-strength liquid thread locker (such as Loctite 241® or Euro Lock A24.20) to the existing
screws.
INFORMATION
Clean and disinfect the wheelchair before commencing service work. Observe the applicable care instructions and
product-specific inspection instructions in the instructions for use.
3 Service Work
3.1 Instructions for Adjustment
The following section describes the replacement and retrofitting of standard and option parts on the CV / CS / CLT
wheelchairs.
10 02/2011
Service Work
All instructions concerning the adjustment of the parts installed are included in the Instructions for Use (qualified per
sonnel) – order number 647G585.
3.2 Required Tools and Accessories
The following tools are required in order to perform the service work:
• Reversible ratchet handle wrench and sockets (sizes: 8 – 24)
• Torque wrench (measurement range: 5 – 50 Nm)
• Wrench (size: 8 – 24)*
• Allen wrench (size: 2.5 – 6)**
• Screwdriver (blade width: 2.5/3.5/5 mm)
• Phillips head screwdriver (size: 2)
• Hammer (approx. 300 g); plastic hammer
• Pliers: cutting pliers, combination pliers, snap ring pliers
• Pin punch, ø 3/4/5/6 mm
• Drill/twist drill ø 3.2/5/5.2/6 mm
• Stanley knife with sickle hooked blade and standard blade
• Tyre mounting levers and inner tube repair kit*
• Workbench and vice with plastic jaws and rubber insert
• Measurement equipment: rule, spirit level
• Liquid thread locker, "medium" and "strong"
* Included in the tool set 481C08=ST010
** Size 3 – 6 included in the tool set 481C08=ST010
3.3 Special features of the Avantgarde CLT
Lightweight construction was strictly applied in the design of the Avantgarde CLT ultra-light active wheelchair. This
necessitates the greatest possible care during adjustment.
In particular the tightening torques for the bolts of high-strength aluminium alloy must be strictly observed (see table).
Bolt diameter (mm) Maximum torque for aluminium bolts (Nm)
6 5.5
8 13
Before re-assembly and re-use of the aluminium bolts, inspect the threads for damage. We recommend that new alu
minium bolts are used at each (re-)assembly.
Use a liquid bolt locking compound on the aluminium bolts (e.g. Loctite 241®).
3.4 Maintenance Schedule
Maintenance schedule Type of wheelchair: Customer:
Item Area Inspection (checklist)
SN: 1. Function/setting
(depending on equipment)
2. Inspected for dam
age/deformation
3. Screw connections
inspected
Frame Frame x x
Anti-tipper x x
Crutch holder x x
Tip-assist x x
Crutch holder x x
A
Frame accessories
Frame pad x
Folding mechanism x x
Lower leg length setting x x
Foot rests
Angle adjustment x x
Plastic plate x x
B
Foot rest accessories
Lateral heel blocks x x
1102/2011
Service Work
SN: 1. Function/setting
(depending on equipment)
2. Inspected for dam
age/deformation
3. Screw connections
inspected
BFoot rest accessories Heel strap x x
Cross-brace x x
Seat upholstery x x
CSeat
Seat cushion x
Back upholstery x
Back tubes x x
Angle adjustment x x
DBack / push handles
Push handles x x
Height setting x x
Swivel mechanism x x
Side panels
Removability x
Arm rest padded, swing-away x x
E
Side panel accessor
ies Tray x x
Tyres (wear) x x
Air pressure x x
Caster wheel journal angle x x
Screw connections on the frame x x
Swivelling of the caster forks x x
FCaster wheel
Running behaviour of the wheels x x
Swivelling of the caster forks x x
Tyres (wear) x x
Running behaviour of the wheels x x
Spokes / push rings x x
Quick-release axles x x
Wheel camber x x
Rear wheel
Rear wheel attachment device x x
Drum brake x x
Hub brake x x
One-arm drive x x
Wheelbase extension x x
Spoke protectors x x
G
Rear wheel accessor
ies
Shock absorber x x
Braking function x xWheel locks / brakes
Swing-away mechanism x x
H
Wheel lock accessor
ies
Wheel lock lever extension x x
Tray x xAccessories
Lap belt x x
Do the wheelchair settings match the user's requirements?
The maintenance service was performed by: on:
3.5 Assembly A: Frame
3.5.1 Replacement Work on the Frame
3.5.1.1 Replacing the Front Frame Part
1) Remove the rear wheels and flip up the foot plates.
2) Remove the side panels (see Page 33).
3) Slightly fold the wheelchair.
4) Unscrew and remove the caster wheel assembly from the lower frame tube (see Fig. 4).
→The lower frame tube is detached from the rear part of the frame.
5) Lay the wheelchair on its back and unscrew the upper frame tube (see Fig. 5).
12 02/2011
Service Work
6) Remove the front part of the frame upward (see Fig. 6).
7) Remove all parts (knee lever brake, supports) installed on the frame.
8) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23Nm.
4 5
6
3.5.1.2 Replacing the Rear Frame Part
1) Remove the rear wheels and flip up the foot plates.
2) Remove the side panels (see Page 33).
3) Unscrew the rear wheel adapter and remove (see Page 41).
4) Slightly fold the wheelchair.
5) Remove the seat pad (see Fig. 8)
6) Open the back upholstery hook-and-loop fasteners and remove the back upholstery (see Fig. 9).
7) Remove the rear part of the frame rearward (see Fig. 10).
8) Remove all parts (back tubes, supports) installed on the frame.
9) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23Nm.
1302/2011
Service Work
7 8
9 10
3.5.1.3 Replacing the Cross-Brace/Cross-Brace Bracket
INFORMATION
The frame components are no longer connected when the crossbrace is removed. Carefully lay the frame compon
ents on the work surface one after another.
1) Remove both front parts of the frame (see Page 12).
2) Unscrew the cross-brace centre screw and remove (see Fig. 11).
3) Remove the cross-brace bracket retaining clip (see Fig. 12).
4) Remove the end caps (see Fig. 13).
5) Remove the cross-brace upward (see Fig. 14) and replace.
6) To reassemble, perform these steps in reverse order. Tighten the centre screw to the point that folding without jam
ming is possible.
11 12
14 02/2011
Service Work
13 14
3.5.1.4 Replacing the Joint Tubes
1) Remove the front part of the frame (see Page 12).
2) Unscrew the rear wheel adapter and remove (see Page 12).
3) Remove the cross-brace (see Page 14).
4) Remove/replace the joint tubes (see Fig. 15).
5) To reassemble, perform these steps in reverse order. Tighten the frame tubes with 23Nm.
15
3.5.1.5 Replacing the Seat Tube Supports
1) Slightly fold the wheelchair (see Fig. 16).
2) Unscrew the seat tube supports Allen head screws, wrench size 3 (the support with side panel attachment device
as well if necessary) (see Fig. 17).
3) Remove/replace the supports.
4) To reassemble, perform these steps in reverse order. Tighten the Allen head screws to 4Nm.
1502/2011
Service Work
16 17
3.5.2 Retrofitting the Vertical Accessory Mount
INFORMATION
The vertical accessory mount and the frame accessories cannot be installed on the welded Avantgarde CLT.
The vertical accessory mount is required for the installation of the anti-tipper and the transport wheels (see Fig. 18,
item 1).
The vertical accessory mount can be installed in two positions.
1) Remove the rear reflector from the rear frame (see Fig. 19).
2) Hold the vertical accessory mount against the inside of the frame tube with the rounded side towards the frame
tube (see Fig. 20).
3) Bolt on the accessory mount:
→Insert a screw with washer from the outside through the frame tube (see Fig. 21, item 1).
→Thread a nut from above into the profile of the vertical accessory mount (see Fig. 21, item 2).
→Hold the nut (see Fig. 21, item 3) and tighten the screw from the outside to 7Nm.
18 19
16 02/2011
Service Work
20 21
3.5.3 Installation / adjustment of the anti-tipper
CAUTION
Incorrect fitting of anti-tipper / missing anti-tipper
Risk of tipping of the user to the rear
►Check correct installation and adjustment of the anti-tipper:
►Depending on the adjustment of the chassis, the wheelchair centre of gravity and the experience of the user, an
anti-tipper may be necessary.
CAUTION
Anti-tipper not intended
Risk of tipping of the user to the rear
►On the Avantgarde CLT with fixed welded fitting, installation of an anti-tipper is not intended. Therefore examine
the user intensively for suitability (adequate physiological capabilities) before supplying the user with this version.
This wheelchair version is intended only for experienced users with sporting ambitions who, thanks to their
physiological capabilities, are able to handle the wheelchair proficiently.
3.5.3.1 Installing the anti-tipper
The anti-tipper can be installed at 5 positions on the vertical accessory mount (see Fig. 22, item1).
1) Push the anti-tipper tube from below into the vertical accessory mount.
2) Tighten the anti-tipper tubes in the vertical accessory mount with the Allen head bolt to 7 Nm (see Fig. 22, item2).
22
1702/2011
Service Work
3.5.3.2 Adjustment of the anti-tipper
Height adjustment of the anti-tipper
1) Unscrew the mounting screw of the anti-tipper tube from the accessory mount (see Fig. 22, item 2).
2) Move the anti-tipper tube in the vertical accessory mount.
3) Bolt down the anti-tipper tube. The distance between the anti-tipper rollers and the ground must be 5 cm maximum
(see Fig. 23).
Angle adjustment of the pivot arm
1) Remove the pivot arm mounting screw from the anti-tipper tube (see Fig. 24, item 1).
2) Move the pivot arm to a new position (3 setting possibilities: (see Fig. 24, item 2). The distance between the anti-
tipper rollers and the ground must be 5 cm maximum.
3) Bolt down the pivot arm.
Longitudinal adjustment of the pivot arm
1) Press the button on the pivot arm (see Fig. 25).
2) Adjust the length of the pivot arm. In doing so, the rocker's outer arm should protrude beyond the largest diameter
of the tyre (see Fig. 26).
3) Allow the button to engage.
23 24
25 26
3.5.3.3 Replacing the Pivot Arm
1) Unscrew the screwed tube connection to the pivot arm (see Fig. 27) through the service opening (see Fig. 28).
2) Remove and replace the pivot arm.
3) To reassemble, perform these steps in reverse order. Tighten the pivot arm screw connection to 4Nm.
18 02/2011
Service Work
27 28
3.5.3.4 Replacing Anti-Tipper Rollers
The replacement is made without tools by pulling out the plug-in tube.
3.5.4 Retrofitting the Transport Wheels
CAUTION
Incorrect adjustment of the transport wheels
Risk of falling, tipping of the user
►Align the transport wheels to the rear while installing.
►Verify that the transport wheels have been set to the same height before using them.
1) Press the transport wheel latch pin in (see Fig. 29).
2) Insert the transport wheel true to side into the vertical accessory mount.
3) Adjust the height of the transport wheels (see Fig. 30). Adjust the height so that the transport wheels are approx.
2cm above the ground when the rear wheel is installed.
29
2 cm
30
3.5.5 Retrofitting the Horizontal Accessory Mount
The horizontal accessory mount is required for the installation of the tip-assist and the crutch holder (see Fig. 31).
►Screw the mounting screws (above/inside) into the holes on the frame to 8Nm (see Fig. 32).
1902/2011
Service Work
31 32
3.5.6 Retrofitting the Tip-Assist
1) Unscrew the mounting screw on the accessory mount clamp (see Fig. 33).
2) Insert the tip-assist true to side (see Fig. 34).
3) Tighten the clamp's mounting screw to 8Nm.
33 34
3.5.7 Retrofitting the Crutch Holder
►Set the crutch holder onto the tip-assist and screw it in place.
35 36
3.5.8 Retrofitting the Frame Pads (CS/CLT only)
1) Position the frame pad on the front frame (see Fig. 37).
2) Close the frame pad hook-and-loop fastener (see Fig. 38).
20 02/2011
Service Work
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