Joint Assembly NEURO TRONIC

Clean the system joint. In order to clean the threads in the cover plate, use the Super Clean LOCTITE^® 7063 to remove any insulating wax residues.
Note: Mind the safety data sheet when using the Super Clean LOCTITE^® 7063.

Apply spray adhesive to one side of the first sliding washer and adhere it to the big cover plate. Grease the other side of the sliding washer slightly with orthosis joint grease.

Mount the toothed ring with sliding bushing to the joint’s upper part.

Grease the axle bore of the locking pawl and of the toothed ring as well as the friction surfaces of the bearing nut with orthosis joint grease.
Note: Make sure that no grease enters the toothing of the locking pawl and the toothed ring.

Put the bearing nut for the locking pawl into the intended opening on the joint’s lower part. Ensure that the bearing nut is in the correct position. Mount the locking pawl.

Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with orthosis joint grease.

Put the bearing nut for the joint axis into the intended opening on the joint’s lower part. Ensure that the bearing nut is in the correct position.

Slightly grease the second sliding washer on both sides with orthosis joint grease.

Place the second sliding washer on the bearing nut while fixing the bearing nut from the backside with one finger. Mount the joint’s upper part with the toothed ring.

Mount the cover plate without the solenoid and tighten the screws with the corresponding torque.
Note: You will find the appropriate torque (Nm) on the cover plate of the system joint or in the instructions for use.

If you have damaged a sliding washer during the assembly of the cover plate (you would hear a soft cracking), remove the particles and place a new sliding washer.

Make sure that the bearing nuts are placed completely in the intended openings.
Note: The delivered screws are always matching the system joint. Even when the screws are not as long as the thread of the bearing nuts, it does not affect the joint’s load capacity.

Check if the system joint moves freely. Bring the system joint in extension. In order to check the flexion, hold the orthosis in a horizontal position and then let go of the femoral shell. The femoral shell should smoothly fall downward up to the maximum possible flexion grade. If the system joint does not move freely, mount the next thinner sliding washers, repeat all steps from step 8 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Check if the system joint moves without lateral play. Hold the tibial shell and try to move the femoral shell in varus-valgus. If the system joint has lateral play, mount the next thicker sliding washers, repeat all steps from step 8 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Check the mobility of the locking pawl. To do so, set the lever to the dot. Turn the orthosis until the foot piece points upwards. By doing so, the locking pawl falls into the toothing. Now, it should no longer be possible to flex the system knee joint. If the system knee joint can still be flexed, check the joint assembly and remove, if there are any, remaining resin residues and surplus grease from the system knee joint. Check again.
Note: During the following steps, the lever remains set to the dot.

Secure the axle screw and the screw of the locking pawl with LOCTITE^® 243 medium strength and the corresponding torque. Let the adhesive harden (final strength after approx. 24 hours).
Note: Mind the safety data sheet when using LOCTITE^® 243 medium strength.

Mount the solenoid. Place the pressure spring and then the washer onto the plunger. Put the plunger with pressure spring and washer in the solenoid and mount the solenoid into the cover plate.

Connect the connector of the solenoid cable with the solenoid. It does not matter to which pole of the solenoid the cable is connected. Afterwards, place the solenoid with connector in the big cover plate.

Mount the small cover plate and fix it by tightening the screw.

Press the extension stop damper into the predetermined bore.

Prepare the retainer for the controller. To do so, cut in the pre-milled grooves with a knife. Break out the piece and smooth the edges with sandpaper.

Apply CA-Activator Spray to the lower surface of the retainer for the controller and allow it to flash off briefly. Adhere the retainer for the controller with the arrow pointing upwards to the tibial shell of the orthosis by using a small amount of fast-acting adhesive.
Note: Mind the safety data sheet when using the fast-acting adhesive.

Please note that the lamination dummy for the connection cable determines the route of the connection cable. It corresponds to the length of the connection cable. If you have shortened the lamination dummy, the connection cable must also be shortened and subsequently stripped and tinned.

Place the solenoid connection cable in the depression created by the lamination dummy until it reaches the retainer for the controller. If you have to shorten the connection cable or are using the longer connection cable, which is an accessory part and not included in the scope of delivery, mark the position of the opening through which the cable is inserted into the retainer for the controller. Make a second marking at a distance of 5 to 7cm from the first marking in the direction of the end of the cable. Cut the cable at this marking with pliers. Use the FIOR & GENTZ stripping tool to strip the cable up to the first mark. You can now see two exposed cable wires. Strip the ends of the cable wires again. Twist and tin the braids. Then, adhere the cable as described in the previous step.

If you need to shorten the connection cable, first follow the instructions in the next step. Adhere the cable to the tibial shell of the orthosis by using a small amount of fast-acting adhesive. Start close to the system joint and work your way up to the retainer for the controller.
Note: Mind the safety data sheet when using the fast-acting adhesive.

Establish a cable connection to the controller. On a controller with exchangeable batteries, the four connections are marked with numbers from 1 to 4. Put the braids into the cable connections 3 and 4. It does not matter to which pole the cables of the solenoid are connected.
Note: For a bilateral construction with two NEURO TRONIC system knee joints, two cable wires are each plugged into the cable connections 3 and 4.

On a controller with integrated lithium-ion battery, the numbers can be found on the cable connecting aid. Put the braids into the cable connections 3 and 4 with the aid of the cable connecting aid. It does not matter to which pole the cables of the solenoid are connected.
Note: For a bilateral construction with two NEURO TRONIC system knee joints, two cable wires are each plugged into the cable connections 3 and 4.

Then, place the controller with the cable connections facing downwards into the retainer for the controller.

Secure the controller by tightening the four screws of the retainer for the controller.

If you have a controller with exchangeable batteries without Bluetooth, place the supplied batteries in the battery compartment of the controller according to the plus and minus poles and press the MODE button (e.g. with a paper clip). The LEDs will then blink. This indicates that you can now connect the controller with the multi-purpose device within 30 seconds. Slide the lid onto the controller to close the battery compartment.

If you have a controller with exchangeable batteries with Bluetooth, place the supplied batteries in the battery compartment of the controller according to the plus and minus poles and press the MODE button (e.g. with a paper clip). A short beep is emitted. Keep the button pressed until a second, longer beep is emitted after about 6-10 seconds. This indicates that you can now connect the controller with the multi-purpose device or the patient remote control within 30 seconds. Slide the lid onto the controller to close the battery compartment.

If you have a controller with integrated lithium-ion battery, press the MODE button. A short beep is emitted. Keep the button pressed until a second, longer beep is emitted after about 6-10 seconds. This indicates that you can now connect the controller with the multi-purpose device or the patient remote control within 30 seconds. To finish, slide the cover over the Micro-USB port.