Joint Assembly System Ankle Joints with plug + go Modularity

Disassemble the system joint.

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

Note: a NEURO CLASSIC cover plate can be demounted by just unscrewing the countersunk flat head screws, without causing any damage to the feather keys with pin or their bores.

NEURO SWING 24mm
The NEURO SWING system ankle joint in the 24mm system width has design differences which affect the following component parts: joint’s upper part without feather keys, cover plate and system stirrup. However, the assembly of the system joint is exactly performed as described in the next work steps.

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 required.

Note: mind the safety data sheet when using Super Clean LOCTITE^® 7063.

A = system joint with feather keys
B = system joint without feather keys

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.

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

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.

Make sure that there is no contact between the laminate and the cover plate to prevent developing noises under dynamic load.
If required, rework the laminate edges.
Do not grind the side-surfaces of the joint’s upper part to prevent developing noises or damages to the feather keys with pin.

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

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

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

Grease the second sliding washer slightly with orthosis joint grease.

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

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.

Check the position of the sliding washer.

Slightly grease the sliding surfaces of the bearing nut with orthosis joint grease.

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

Turn in the second countersunk flat head screw (axle screw) with a torque corresponding to the system width. Still secure the bearing nut with one finger.

If a sliding washer should be damaged during the assembly of the cover plate (it is jammed), remove the washer particles and place a new sliding washer.

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 10 onwards and check again.

Note: check if the joint moves freely before mounting the spring units. A bilateral orthosis, only check one system joint at a time.

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 10 onwards and check again.

Note: check if the joint runs with lateral play before mounting the spring units. At a bilateral orthosis, only check one system joint at a time.

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.

NEURO SWING, NEURO VARIO 2, NEURO VARIO-CLASSIC 2, NEURO VARIO-SPRING 2, NEURO VARIO-SWING 2, NEURO SWING 2

Place the stop dampers, screw units, O-ring dampers and/or spring units at hand.

Place the orthosis on its forefoot and put weight on the system joint in dorsiflexion. Screw in the spring unit for dorsiflexion until the aimed orthosis alignment is achieved.

NEURO SWING 2
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.

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

Hold the foot piece. Screw in the spring unit for plantar flexion until the aimed orthosis alignment is achieved.

Note: you will find information about the assembly of the spring units in the instructions for use.

NEURO SWING 2
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.

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