Joint Assembly NEURO HiTRONIC

This online tutorial illustrates the joint assembly of the automatic, electrohydraulic system knee joint NEURO HiTRONIC. This includes the wiring as well as the mounting of the controller. You will find notes on the Expert app and User app in the instructions for use. Instructions for the placement of the dummies and specific aspects to be considered during reinforcement can be found in the online tutorial Special Work Steps when Producing a KAFO with a NEURO HiTRONIC.

Fase 1/24

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

Fase 2/24

Drill a hole close to the joint (diameter 6.8mm) where the lamination dummy for the connection cable ends. 
The plug of the cable is inserted through this hole. Drill a hole (diameter 3.4mm) where the screws of the lamination dummy for the controller were and press in the securing pins.
Note: use a solid carbide drill for chipping carbon or similar materials.

Fase 3/24

If you have removed the extension stop, mount it using a vice with plain or soft jaws.

Fase 4/24

Mount the extension stop damper.

Fase 5/24

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 the delivered orthosis joint grease.

Fase 6/24

Grease the axle bore of the joint’s upper part and the friction surfaces of the bearing nut with orthosis joint grease.

Fase 7/24

Mount the functional unit and tighten the screws with the fitting torque.
Note: you will find information on the torque in the instructions for use.

Fase 8/24

Set the rotary switch to the permanent unlock symbol for the following steps.

Fase 9/24

Place the flexion stop disc on the joint’s upper part.

Fase 10/24

Place the bearing nut in the intended opening on the joint’s lower part. Ensure that the bearing nut is in the correct position.

Fase 11/24

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

Fase 12/24

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.

Fase 13/24

Mount the cover plate and the functional unit. First, secure the screws of the cover plate and then those of the functional unit with the fitting torque.
Note: you will find information on the torque in the instructions for use.

Fase 14/24

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

Fase 15/24

Make sure that the bearing nut is fully inserted in the intended opening.
Note: the delivered screws always match the respective system joint. A potential discrepancy between the length of the screws and the thread of the bearing nuts has no effect on the load capacity of the system joint.

Fase 16/24

Check if the system joint moves freely. Hold the orthosis horizontally in front of you. The tip of the foot points away from you. Pull the thigh shell towards you to bring the orthosis into flexion. Then, release the thigh shell. With the aid of the hydraulic system, the system knee joint should extend smoothly. 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.

Fase 17/24

Check if the system joint moves without lateral play. Secure the lower leg shell and check whether the thigh shell can be moved in varus-valgus direction. If the system joint runs with 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.

Fase 18/24

If there is play in ap direction, loosen the small screw on the inside of the joint and adjust the plunger guide ring of the functional unit with a slotted screwdriver. Follow the directions in the instructions for use. Afterwards, tighten the small screw.

Fase 19/24

Demount the cable cover. Now, plug the connecting cable into the connection of the functional unit and tighten the knurled threaded bushing. Guide the connecting cable through the bore.

Fase 20/24

Plug the connecting cable into the connection of the controller and tighten the knurled threaded bushing.

Fase 21/24

Secure the controller to the orthosis shell using the enclosed countersunk flat head screws.

Fase 22/24

Adhere the connecting cable with a small amount of medium-viscous fast-acting adhesive to the area on the lower leg shell created by the lamination dummy for the connecting cable and the lamination dummy for the cable length compensation.
Note: mind the safety data sheet when using fast-acting adhesive.

Fase 23/24

Position the cable cover over the connecting point and fix it using the countersunk flat head screw.

Fase 24/24

Press the MODE button on the controller to establish a connection with the app and to adjust the system joint. Follow the directions in the instructions for use.

Last Update: 28 September 2022


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