Joint Assembly

NEURO VARIO-SPRING System Ankle Joint

The system ankle joint NEURO VARIO-SPRING is a joint with foot lifter. It has a pressure spring. Using the so-called assembly aid for cover plate, the pressure spring can be mounted easily. This facilitates mounting the cover plate to the system ankle joint. The use of this tool as well as all required steps for the joint assembly are described and illustrated in this online tutorial.

The NEURO VARIO-SPRING is, alongside with the NEURO SWING, a system ankle joint, which can be used in combination with the automatic knee joint system NEURO MATIC. A mechanical connection between system ankle and system knee joint controls locking and unlocking of the system knee joint. In the online tutorial Joint Assembly NEURO MATIC, you can find instructions on the assembly of the NEURO MATIC system knee joint in combination with the NEURO VARIO-SPRING system ankle joint.

 Joint Assembly NEURO VARIO-SPRING

Step 1/21

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

Step 2/21

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

Step 3/21

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

Step 4/21

Put the bearing nut into the intended opening of the joint's upper part. Ensure that the bearing nut is in the correct position. Fix it from the backside with one finger.  

Step 5/21

Slightly grease the second sliding washer on both sides with the delivered orthosis joint grease.

Step 6/21

Place the second sliding washer onto the joint's upper part and mount the system stirrup while still fixing the bearing nut.

Step 7/21

Mount the cover plate. Turn in the first countersunk flat head screw (axle screw). Continue with the second countersunk head screw using the corresponding torque while still fixing the bearing nut.

Step 8/21

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

Step 9/21

Check if the bearing nut is placed completely in the intended opening.

Step 10/21

Bring the system joint in plantar flexion/dorsiflexion. If the system joint does not move freely (it jams), you need to mount the next thinner sliding washers and repeat all steps starting at the 5th. Check again.
Note: Check if the system joint moves freely before mounting the spring. At a bilateral orthosis, only check one system joint at a time.

Step 11/21

Fix the tibial shell and try to move the foot shell in pronation-supination direction. If the system joint runs with lateral play, you need to mount the next thicker sliding washers and repeat all steps starting at the 5th. Check again.
Note: Check if the system joint runs with lateral play before mounting the spring. At a bilateral orthosis, only check one system joint at a time.

Step 12/21

At a 14mm system joint, 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 the ball, the pin and the spring into the spring duct and turn in the pressure screw as far as possible.
Note: You will find information about the torque in the manual of the corresponding system joint.
Note: Mind the safety data sheet when using
LOCTITE® 243 medium strength.

Step 13/21

At 16 and 20mm system joints, we recommend using the assembly aid for cover plate. To do so, demount the cover plate. Insert the ball, the pin and the spring into the spring duct and turn in the pressure screw as far as possible.

Step 14/21

Clamp the assembly aid for cover plate into a vice. Place the cover plate with the ball on the pin of the assembly aid for cover plate. Compress the spring by pulling the cover plate in your direction (right arrow). Simultaneously, press with the thumb against the assembly aid for cover plate (left arrow) until the cover plate fits in. 

Step 15/21

Remove the assembly aid for cover plate with the cover plate from the vice.

Step 16/21

Mount the cover plate with the adhered sliding washer while fixing the bearing nut in the correct position.

Step 17/21

Secure both screws with LOCTITE® 243 medium strength and the torque corresponding to the system width. Turn in the first countersunk flat head screw (axle screw). Continue with the second countersunk flat head screw while still fixing the bearing nut. Let the adhesive harden (final strength after approx. 24 hours).
Note: You will find information about the torque in the manual of the corresponding system joint.
Note: Mind the safety data sheet when using
LOCTITE® 243 medium strength.

Step 18/21

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

Step 19/21

Bring the foot piece in plantar flexion to remove the assembly aid for cover plate. Thus, you compress the spring and the plastic-sheathed side of the assembly aid for cover plate can be removed from the spring duct.

Step 20/21

Bring the foot piece in dorsiflexion to decompress the spring as much as possible. Pull out the narrow end of the assembly aid for cover plate.

Step 21/21

When the adjusting screw turns or loosens, it must be secured again with the securing pin. Please follow the instructions in the manual.