Joint Assembly Articulated Side Bars for Knee Orthoses

Clean the articulated side bar and all screw drives (e.g. with LOCTITE^® 7063 Super Clean) in order for the screws to be effectively fixed later on.
Note: Mind the safety data sheet when using the Super Clean LOCTITE^® 7063.

Mount the extension stop (A) and, if required, the flexion stop (B) as well. Make sure that the stops fit properly.
Tighten the slotted pan head screws.

Screw the countersunk flat head screws (1) into the base plate from behind. Place the bronze bushings (2) onto the screw threads.
Note: The bronze bushings serve as positioning aid for the sliding washers.

Apply spray adhesive to one side of two sliding washers and adhere them to the base plate.
Remove the screws and bronze bushings again.

Put the countersunk flat head screws (1) into the bores of the cover plate. Place the bronze bushings (2) onto the screw threads. Make sure that the notch of each bronze bushing faces the cover plate.
Apply spray adhesive to two sliding washers and adhere them to the cover plate. Remove the screws and bronze bushings again.

Grease the sliding washers slightly with orthosis joint grease (tube with the orange stripe; 1). Grease the sliding washers of the base plate (2) and the cover plate (3).

Slightly grease the bronze bushings’ exterior with orthosis joint grease (tube with the orange stripe) as well.

Place the femoral side bar wing onto the base plate (1). Make sure that it is in touch with the extension stop. Insert the first bronze bushing (2).
Note: At a bilateral orthosis, the height of both bronze bushings in one joint is the same, but it can differ from one joint to another. The height is engraved in the bronze bushings. Take care to find the right match.

Place the tibial side bar wing onto the base plate. Make sure that both side bar wings are in touch with the extension stop (arrow). The gear segments must mesh.

Insert the second bronze bushing.
Note: At a bilateral orthosis, take care to correctly match the bronze bushings. The height is engraved in the bronze bushings.

Place the cover plate (1). Tighten the countersunk flat head screws (2).
Note: You will find information about the torque (Nm) on the cover plate of the articulated side bar or in the instructions for use.

Check if the joint moves freely. Bring the articulated side bar in extension. In order to check the flexion, hold the orthosis in a horizontal position and then let go of the tibial shell. The tibial shell should smoothly fall downward up to the maximum possible flexion angle. If the articulated side bar does not move freely, mount the next higher bronze bushings, repeat all steps from step 7 onwards and check again.
Note: At a bilateral orthosis, only check one articulated side bar at a time.

Check if the articulated side bar moves without lateral play. Hold the tibial shell and try to move the femoral shell in varus-valgus direction. If there is lateral play, mount the next lower bronze bushings, repeat all steps from step 7 onwards and check again.

Demount the cover plate. Grease the gear segments of the side bar wings with the orthosis joint grease for joints with gear segments (tube with the green stripe).

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).
Note: Mind the safety data sheet when using LOCTITE^® 243 medium strength.