Joint Assembly of System Ankle Joints with plug + go Modularity

Step 1/33

Demount the cover plate.
Unscrew both countersunk flat head screws. Place the washer on the cover plate and screw the pressing screw into the thread of the first screw, but not completely. Push the joint's upper part and the cover plate apart by exerting force on them as illustrated (see arrows).This can be achieved by using a vice or by controlled knocks.
Remove pressing screw and washer.

Step 2/33

Assembly Option with Spirit Level:
Clean the adhesive surfaces. Use a small amount of AGOMET^® F330 to adhere the spirit level into the cut-out shaped by the dummy.
Note: Mind the safety data sheet when using AGOMET^® F330.

Step 3/33

Clean the system joint. Clean the bearing nut, the thread of the joint’s upper part as well as the bores of the cover plate with LOCTITE^® 7063 Super Clean, if necessary.
Note: Mind the safety data sheet when using Super Clean LOCTITE^® 7063.

Step 4/33

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

Step 5/33

Grease the contact surfaces between the cover plate and joint’s upper part with orthosis joint grease to prevent mechanical noises.

Step 6/33

Use the delivered cover plate pressing aid to press the cover plate with the joint's upper part. Tighten the pressing screw with the corresponding torque.
Note: You will find information about the torque (Nm) on the system joint’s cover plate or in the instructions for use.

Step 7/33

Make sure that the laminate does not touch cover plate to prevent noise development under dynamic load.
If necessary, rework the laminate edges. Make sure that you do not grind the lateral surfaces of the joint’s upper part. That may damage the fit between the joint’s upper part and the cover plate, thus leading to mechanical noises and breaking of the feather keys with pin.

Step 8/33

Make sure there is no opening left between the cover plate and the joint's upper part.

Step 9/33

Remove pressing screw and washer.
In order to fix the cover plate for the next work steps, screw in the first countersunk flat head screw with the corresponding torque with the torque corresponding to the system width.

Step 10/33

In case the sliding bushing fell out in the previous steps, grease it slightly and place it into the bore at the system stirrup again.

Step 11/33

Grease the second sliding washer slightly with orthosis joint grease.

Step 12/33

Grease the contact surfaces of the system stirrup between system stirrup and spring units with orthosis joint grease. Place the second sliding washer onto the medial side of the system stirrup.

Step 13/33

Slide the system stirrup from below between the cover plate and the joint's upper part. Make sure that the sliding washer remains in the correct position.

Step 14/33

Check the position of the sliding washer.

Step 15/33

Grease the sliding surfaces of the bearing nut slightly with orthosis joint grease.

Step 16/33

Place the bearing nut into the intended opening of the joint's upper part and make sure that it is in the correct position. Secure the bearing nut with one finger.

Step 17/33

Turn in the second countersunk flat head screw (axle screw) with a torque which corresponds to the system width. Secure the bearing nut from the backside with one finger.

If a sliding washer is damaged (jams) while mounting the cover plate, remove the sliding washer particles and insert a new sliding washer.

Step 18/33

Bring the system joint in plantar flexion/dorsiflexion. If the system joint does not move freely, mount the next thinner sliding washer, repeat all steps from step 7 onwards and check again.
Note: Check if the joint moves freely before mounting the spring units. In the case of a bilateral orthosis, only check one system joint at a time.

Step 19/33

Hold the lower leg shell and try to move the foot piece in pronation-supination direction. If the system joint has lateral play, mount the next thicker sliding washer, repeat all steps from step 7 onwards and check again.
Note: Check for lateral play before mounting the spring units. In the case of a bilateral orthosis, only check one system joint at a time.

Step 20/33

Secure both screws with LOCTITE 243^® medium strength and the torque corresponding to the system width. Let the adhesive harden (final strength after approx. 24 hours). Insert present stop dampers/O-ring dampers and/or spring units.
Note: Mind the safety data sheet when using LOCTITE^® 243 medium strength.

Step 21/33

Insert any present spring units. Insert present stop dampers/O-ring dampers and/or spring units.

Step 22/33

Place the orthosis on its forefoot and put weight on the system joint in dorsiflexion. Screw in any present spring units until the required orthosis’ alignment is achieved.

At a bilateral orthosis with two NEURO SWING 2 system joints, mount each system joint’s anterior spring unit and make sure that both system joints are adjusted alike.

At a bilateral orthosis with a supporting joint, the range of motion of the NEURO SWING 2 system joint should be limited without being restricted by the supporting joint. You might need to file off the stops of the supporting joint’s system stirrup.

Step 23/33

Check the joint angle by reading the markings on the system stirrup and cover plate.

Step 24/33

Adjust any present spring units for the plantar flexion.
Note: You will find information about the assembly of the spring units in the instructions for use.

At a bilateral orthosis with two NEURO SWING 2 system joints, mount each system joint’s posterior spring unit and make sure that both system joints are adjusted alike.

At a bilateral orthosis with a supporting joint, the range of motion of the NEURO SWING 2 system joint should be limited without being restricted by the supporting joint. You might need to file off the stops of the supporting joint’s system stirrup.

Step 25/33

Option: NEURO HiSWING
Insert the spring units of the NEURO HiSWING. To do so loosen the body alignment screws as much as possible. Then insert the O-ring damper and the coil spring onto the plunger of the spring unit and push them into the spring duct from below. Let the damper touch down on the stirrup. The spring unit is secured

Step 26/33

Option: NEURO HiSWING
Mount the spring unit cover to close the spring ducts and secure it by tightening the screw.

Step 27/33

Option: NEURO HiSWING
With the assembly of the spring units, you only adjust the play in the system joint, but not the orthosis’ alignment as with the other system joints with plug + go modularity.
The lever must be closed while doing so.

Step 28/33

Bring the system joint in plantar flexion/dorsiflexion. Any present spring units should move by compression only. At a high spring force, it is impossible to cause any movement manually.
When the system joint still runs idle, carefully screw the posterior alignment screw further in.

Step 29/33

Option: NEURO HiSWING
To protect the spring ducts of the NEURO HiSWING from dust, mount the adjusting screw cover and secure it by tightening the screw. 

Step 30/33

Option: NEURO HiSWING
To adjust the alignment of an orthosis with a NEURO HiSWING, place the orthosis in the orthosis shoe the patient will use later and release the lever. Adjust the correct orthosis’ alignment using a plumb bob.

Step 31/33

Step 32/33

Option: NEURO HiSWING
Loosen the screws of the spirit level and adjust it until the air bubble is centred. Secure the spirit level again using the screws.

Step 33/33

Option: NEURO HiSWING
The spirit level is aligned to provide a lever reference for subsequent changes in the angle between the lower leg shell and the foot shell. When the air bladder is centred, the orthosis’ alignment is correctly adjusted to the preset tibial inclination.