Joint Assembly NEURO TRONIC

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.

Drill a hole (diameter 3.4mm) where the screws of the lamination dummy for the controller were and press in the securing pins.

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.

Grease the axle bore of the toothed ring with orthosis joint grease. Mount the toothed ring with sliding bushing to the joint’s upper part.
Note: make sure that no grease enters the toothing of 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 sliding 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.

Grease the second sliding washer slightly 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 information about the torque on the system joint’s cover plate or in the instructions for use.

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.

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

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 thigh shell. The thigh shell should smoothly fall downward up to the maximum possible flexion angle. 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. 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.

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. Slide the coil spring and then the washer onto the plunger. Place the plunger with coil spring and washer into the solenoid. Afterwards, mount the solenoid to the cover plate.

Connect the connector of the solenoid connection cable with the solenoid. It does not matter to which pole of the solenoid the cable is connected. 

Put the end cap over the connector of the solenoid, then place the connector into the big cover plate.

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

Press the extension stop damper into the intended bore.

At both a unilateral and a bilateral construction, plug the connector of the solenoid connection cable into the connection of the controller and tighten the knurled threaded bushing.  

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

Adhere the solenoid connection 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 solenoid connection cable and the lamination dummy for the cable length compensation. Any excess cable length can also be fixed to the area created by the lamination dummy for the cable length compensation. 
Note: mind the safety data sheet when using fast-acting adhesive.

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.