FIOR & GENTZ NEURO FLEX MAX Tutorial

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09-12-18 1/55 Joint Assembly NEURO FLEX MAX

Joint Assembly NEURO FLEX MAX

This online tutorial describes the joint assembly for locked system knee joints using the

example of the NEURO FLEX MAX in its basic function. The basic function includes a lock lever

and a locating pin that are used to activate the permanent unlock function. Due to the

constructional diﬀerences, the NEURO FLEX MAX system knee joint is assembled a little

diﬀerently than the NEURO LOCK and the NEURO LOCK MAX.

For example, the NEURO LOCK has, in contrast to the NEURO LOCK MAX and the NEURO FLEX

MAX, no permanent unlock function. Furthermore, a ﬂexion stop disc is already integrated into

the joint's lower part of the NEURO LOCK MAX system knee joint, whereas, in the case of the

NEURO FLEX MAX, it still needs to be mounted.

Consult the manual (chapter 11 “Assembly Instructions”) of the corresponding system joint to

learn about the diﬀerences regarding

mounting the extension stop,

mounting the spring unit and the locking pawl,

mounting the cover plate and

checking the lock function.

Besides, this online tutorial shows in detail the four alternative functions of the NEURO FLEX

MAX system knee joint.

Note: You will ﬁnd information regarding torque (Nm) and locking pawls for all system widths in

the manual of the corresponding system joint.

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Basic Function

Step 1/23

Clean the system joint.

Step 2/23

If you are using a supporting joint, shorten the extension stop damper with a

sharp knife. Now, the system joints reach the extension stop at the same

time and the locking pawl should lock without diﬃculty.

Step 3/23

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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.

Step 4/23

Place the ﬂexion stop disc on the joint's lower part and press both by using a

vice.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

Step 5/23

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Mount the extension stop to the joint's upper part.

Step 6/23

If you have to demount the extension stop, screw it out of the joint's upper

part by using the pan head screw delivered with the system joint. If it is

mounted correctly, you do not have to demount the extension stop.

Step 7/23

Insert the pressure spring by pushing it from below into the spring duct of

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the joint's upper part.

Step 8/23

Grease the axle bore of the locking pawl and the friction surfaces of the

bearing nut with the delivered orthosis joint grease.

Step 9/23

Put the bearing nut into the intended opening of the joint's upper part and

make sure that it is in the correct position. Fix the bearing nut with one

ﬁnger. Mount the locking pawl.

Step 10/23

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Place the ball and push the locking pawl to the top. Insert the pressure

spring and the locating pin for adjusting the permanent unlock function in

the locking pawl.

Step 11/23

Push the locating pin against the spring force into the system joint until it

locks in the joint's upper part. The locking pawl is now secured, which

facilitates the following assembly of the system joint.

Step 12/23

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Grease the axle bore of the joint axis and the friction surfaces of the bearing

nut with the delivered orthosis joint grease.

Step 13/23

Put the joint axis’ bearing nut into the intended opening of the joint's upper

part and make sure that it is in the correct position. Fix the bearing nut with

one ﬁnger.

Step 14/23

Grease the second sliding washer slightly with the delivered orthosis joint

grease.

Step 15/23

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While still ﬁxing the bearing nut, place the second sliding washer onto the

joint's upper part and mount the joint's lower part.

Step 16/23

Mount the cover plate. Turn in the ﬁrst countersunk ﬂat head screw (axle

screw). Continue with the second countersunk ﬂat head screw while still

ﬁxing the bearing nut.

Step 17/23

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If the sliding washer has been damaged during the assembly of the cover

plate (audible cracking), remove the particles and place a new sliding

washer.

Step 18/23

Check if the bearing nuts are placed completely in the intended openings.

Note: The delivered screws are always matching the system joint. Even if the

screws are not as long as the thread of the bearing nuts, that does not aﬀect

the system joint’s load capacity.

Step 19/23

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 femoral shell. The femoral shell should smoothly fall

downward until it has reached the maximum possible ﬂexion grade. If the

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system joint does not move freely, mount the next thinner sliding washers,

repeat all steps from step 12 onwards and check again.

Note: With a bilateral orthosis, only check one system joint at a time.

Step 20/23

Check if the system joint moves without lateral play. Hold the tibial shell and

try to move the femoral shell in varus-valgus direction. If the system joint

runs with lateral play, mount the next thicker sliding washers, repeat all

steps from step 12 onwards and check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 21/23

Bring the system joint as far as possible in extension. Then, disable the

permanent unlock function by pressing the locking pawl against the joint's

upper part. Check if the locking pawl is locked. Fix the tibial shell and try to

move the femoral shell against it. There should be no movement in the

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Alternative Function 1

system joint.

Note: Mind the information on the locking pawls in the manual.

Step 22/23

Check the position of the locking pawl. You can see the correct position on

the left picture. If the locking pawl does not ﬁt well, exchange it.

Step 23/23

Secure both screws with LOCTITE 243 medium strength and the torque

corresponding to the system width.

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Step 1/28

The locked system joint can be used for locking in diﬀerent ﬂexed positions

(alternative function 1) by exchanging the locking parts. To do so, exchange

the extension stop according to the intended extension position by choosing

a degree.

Note: You will ﬁnd the article numbers of the extension stops in our product

catalogue System Joints and Articulated System Side Bars.

Step 2/28

Secure the locking pawl (permanent unlock function). Disassemble the

system joint.

Step 3/28

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Demount the ﬂexion stop disc. To do so, clamp the ﬂexion stop disc in a vice

and carefully lever it of the joint's upper part.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

Step 4/28

Demount the extension stop. To do so, screw it out of the joint's upper part

by using the pan head screw delivered with the system joint.

Step 5/28

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Demount all further system components. Clean the system joint. Check all

system components and exchange them if there are signs of wear.

Note: Follow the maintenance instructions in the manual of the system joint.

Step 6/28

The ﬂexion stop disc is marked with lines that serve as a guide when ﬁling

the desired ﬂexion and thus enable an accurate locking of the pawl at the

lock area (R1). The marked lines are not straight but slightly bent! Do not

use a ﬂat ﬁle and ensure a smooth transition from lock area to lock disc

(R2).

Note: Mount the system joint in order to check the proper locking function

and to be able to readjust the ﬂexion degree, if required.

Step 7/28

File the ﬂexion stop disc according to the ﬂexion grade corresponding to the

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extension stop. The line should remain visible! Make sure that the stop face

remains even and is not inclined to the sides.

Step 8/28

Place the ﬂexion stop disc on the joint's lower part and press both by using a

vice.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

Step 9/28

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.

Step 10/28

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Mount the extension stop to the joint's upper part.

Step 11/28

Insert the pressure spring by pushing it from below into the spring duct of

the joint's upper part.

Step 12/28

If you exchange the delivered locking pawl with another, choose the

smallest possible locking pawl that still ﬁts. As locking pawls are wear parts

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and wear out, you can then mount the next bigger locking pawl, if

necessary.

Note: Mind the information on the locking pawls in the manual.

Step 13/28

Grease the axle bore of the locking pawl and the friction surfaces of the

bearing nut with the delivered orthosis joint grease.

Step 14/28

Put the bearing nut into the intended opening of the joint's upper part and

make sure that it is in the correct position. Fix the bearing nut with one

ﬁnger. Mount the locking pawl.

Step 15/28

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Place the ball and push the locking pawl to the top. Insert the pressure

spring and the locating pin for adjusting the permanent unlock function in

the locking pawl.

Step 16/28

Push the locating pin against the spring force into the system joint until it

snaps in the joint's upper part. The locking pawl is now secured, which

facilitates the further assembly of the system joint.

Step 17/28

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Grease the axle bore of the joint axis and the friction surfaces of the bearing

nut with the delivered orthosis joint grease.

Step 18/28

Put the joint axis’ bearing nut into the intended opening of the joint's upper

part and make sure that it is in the correct position. Fix the bearing nut with

one ﬁnger.

Step 19/28

Grease the second sliding washer slightly with the delivered orthosis joint

grease.

Step 20/28

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While still ﬁxing the bearing nut, place the second sliding washer onto the

joint's upper part and mount the joint's lower part.

Step 21/28

Mount the cover plate. Turn in the ﬁrst countersunk ﬂat head screw (axle

screw). Continue with the second countersunk ﬂat head screw while still

ﬁxing the bearing nut.

Step 22/28

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09-12-18 21/55 Joint Assembly NEURO FLEX MAX

If the sliding washer has been damaged during the assembly of the cover

plate (audible cracking), remove the particles and place a new sliding

washer.

Step 23/28

Check if the bearing nuts are placed completely in the intended openings.

Note: The delivered screws are always matching the system joint. Even if the

screws are not as long as the thread of the bearing nuts, that does not aﬀect

the joint’s load capacity.

Step 24/28

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 femoral shell. The femoral shell should smoothly fall

downward up to the maximum possible ﬂexion grade. If the system joint

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does not move freely, mount the next thinner sliding washers, repeat all

steps from step 18 onwards and check again.

Note: With a bilateral orthosis, only check one system joint at a time.

Step 25/28

Check if the system joint moves without lateral play. Hold the tibial shell and

try to move the femoral shell in varus-valgus direction. If the system joint

runs with lateral play, you need to mount the next thicker sliding washers

and repeat all steps starting at step 18. Check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 26/28

Bring the system joint as far as possible in extension. Then, disable the

permanent unlock function by pressing the locking pawl against the joint's

upper part. Check if the locking pawl is locked. Fix the tibial shell and try to

move the femoral shell against it. There should be no movement in the

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09-12-18 23/55 Joint Assembly NEURO FLEX MAX

Alternative Function 2

system joint.

Note: Mind the information on the locking pawls in the manual.

Step 27/28

Check the position of the locking pawl. You can see the correct position on

the left picture. If the locking pawl does not ﬁt well, exchange it.

Step 28/28

Secure both screws with LOCTITE 243 medium strength and the torque

corresponding to the system width.

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Step 1/16

The locked system joint can be used as a free moving, monocentric joint

with integrated posterior oﬀset (alternative function 2) by removing the

locking parts. Note the next work steps for the removal of the locking parts.

Note: You will ﬁnd further information on alternative function 2 in the

manual

Step 2/16

Secure the locking pawl (permanent unlock function). Disassemble the

system joint.

Step 3/16

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If you have to demount the extension stop, screw it out of the joint's upper

part by using the pan head screw delivered with the system joint. If the

extension stop is mounted correctly, you do not have to demount it.

Step 4/16

Demount all system components. Clean the system joint. Check all system

components and exchange them if there are signs of wear.

Note: Follow the maintenance instructions in the manual of the system joint.

Step 5/16

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09-12-18 26/55 Joint Assembly NEURO FLEX MAX

If you have demounted the extension stop before, place it correctly on the

joint's upper part now.

Step 6/16

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.

Step 7/16

Grease the friction surfaces of both bearing nuts with the delivered orthosis

joint grease.

Step 8/16

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09-12-18 27/55 Joint Assembly NEURO FLEX MAX

Put the bearing nuts into the intended openings of the joint's upper part and

make sure that they are in the correct position. Fix the bearing nut of the

locking pawl with one ﬁnger. The locking pawl is not mounted again.

Step 9/16

Grease the second sliding washer slightly with the delivered orthosis joint

grease.

Step 10/16

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09-12-18 28/55 Joint Assembly NEURO FLEX MAX

While still ﬁxing the bearing nut, place the second sliding washer onto the

joint's upper part and mount the joint's lower part.

Step 11/16

Mount the cover plate. Turn in the ﬁrst countersunk ﬂat head screw (axle

screw). Continue with the second countersunk ﬂat head screw while still

ﬁxing the bearing nut.

Step 12/16

If the sliding washer has been damaged during the assembly of the cover

plate (audible cracking), remove the particles and place a new sliding

washer.

Step 13/16

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09-12-18 29/55 Joint Assembly NEURO FLEX MAX

Check if the bearing nuts are placed completely in the intended openings.

Note: The delivered screws are always matching the system joint. Even if the

screws are not as long as the thread of the bearing nuts, that does not aﬀect

the system joint’s load capacity.

Step 14/16

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 femoral shell. The femoral shell should smoothly fall

downward until it reaches the maximum possible ﬂexion grade. 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: With a bilateral orthosis, only check one system joint at a time.

Step 15/16

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09-12-18 30/55 Joint Assembly NEURO FLEX MAX

Alternative Function 3

Check if the system joint moves without lateral play. Hold the tibial shell and

try to move the femoral shell 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: With a bilateral orthosis, only check one system joint at a time.

Step 16/16

Secure both screws with LOCTITE 243 medium strength and the torque

corresponding to the system width.

Step 1/26

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The locked system joint NEURO FLEX MAX can be used with a step lock

function with locked ﬂexion. For this purpose, you can use the

NEURO FLEX MAX with premounted alternative function 3 or, in case you are

already using the NFM with a diﬀerent function and want to convert it,

exchange the mounted ﬂexion stop disc and the locking pawl with a step

lock stop disc and a step lock pawl. This enables a gradual locking of the

system joint from a ﬂexed position of 55° or 60° via 10° steps to the

required ﬂexed position (premounted is it at 5°).

Note: You will ﬁnd the article numbers of the step lock stop disc and the step

lock pawl in our product catalogue System Joints and Articulated

System Side Bars.

Step 2/26

Secure the locking pawl (permanent unlock function). Disassemble the

system joint.

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09-12-18 32/55 Joint Assembly NEURO FLEX MAX

Step 3/26

If you want to use the NFM with a diﬀerent ﬂexed position than the

premounted 5°, exchange the mounted extension stop with a 10°, 20° or

30° extension stop and choose a corresponding step lock stop disc AF3 with

0°, 10°, 20° or 30°. The system joint locks the ﬁrst time in a ﬂexed position

of 60° and after that in 10° steps. You do not need an extension stop for a

0° knee ﬂexion angle.

Step 4/26

If you have to demount the ﬂexion stop disc, clamp the ﬂexion stop disc in a

vice and carefully lever it of the joint's upper part.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

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09-12-18 33/55 Joint Assembly NEURO FLEX MAX

Step 5/26

Then, place the step lock stop disc AF3 on the joint's lower part and press

both by using a vice.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

Step 6/26

If you have to demount the extension stop, screw it out of the joint's upper

part by using the pan head screw delivered with the system joint. If it is

mounted correctly, you do not have to demount the extension stop.

Step 7/26

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09-12-18 34/55 Joint Assembly NEURO FLEX MAX

Demount all system components. Clean the system joint. Check all system

components and exchange them if there are signs of wear.

Note: Follow the maintenance instructions in the manual of the system joint.

Step 8/26

If you have demounted the extension stop before, place it correctly on the

joint's upper part now.

Step 9/26

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09-12-18 35/55 Joint Assembly NEURO FLEX MAX

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.

Step 10/26

Insert the pressure spring by pushing it from below into the spring duct of

the joint's upper part.

Step 11/26

If you exchange the delivered locking pawl with a step lock pawl, choose the

smallest possible ﬁtting step lock pawl. As locking pawls are wear parts and

wear out, you can then mount the next bigger locking pawl, if necessary.

Note: Mind the information on the locking pawls in the manual.

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09-12-18 36/55 Joint Assembly NEURO FLEX MAX

Step 12/26

Grease the axle bore of the locking pawl and the friction surfaces of the

bearing nut with the delivered orthosis joint grease.

Step 13/26

Put the bearing nut into the intended opening of the joint's upper part and

make sure that it is in the correct position. Fix the bearing nut with one

ﬁnger. Mount the locking pawl.

Step 14/26

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09-12-18 37/55 Joint Assembly NEURO FLEX MAX

Place the ball and push the locking pawl to the top. Insert the pressure

spring and the locating pin for adjusting the permanent unlock function in

the locking pawl.

Step 15/26

Push the locating pin against the spring force into the system joint until it

snaps in the joint's upper part. The step lock pawl is now secured, which

facilitates the further assembly of the system joint.

Step 16/26

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09-12-18 38/55 Joint Assembly NEURO FLEX MAX

Grease the axle bore of the joint axis and the friction surfaces of the bearing

nut with the delivered orthosis joint grease.

Step 17/26

Put the joint axis’ bearing nut into the intended opening of the joint's upper

part and make sure that it is in the correct position. Fix the bearing nut with

one ﬁnger.

Step 18/26

Grease the second sliding washer slightly with the delivered orthosis joint

grease.

Step 19/26

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09-12-18 39/55 Joint Assembly NEURO FLEX MAX

While still ﬁxing the bearing nut, place the second sliding washer onto the

joint's upper part and mount the joint's lower part.

Step 20/26

Mount the cover plate. Turn in the ﬁrst countersunk ﬂat head screw (axle

screw). Continue with the second countersunk ﬂat head screw while still

ﬁxing the bearing nut.

Step 21/26

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09-12-18 40/55 Joint Assembly NEURO FLEX MAX

If the sliding washer has been damaged during the assembly of the cover

plate (audible cracking), remove the particles and place a new sliding

washer.

Step 22/26

Check if the bearing nuts are placed completely in the intended openings.

Note: The delivered screws are always matching the system joint. Even if the

screws are not as long as the thread of the bearing nuts, that does not aﬀect

the joint’s load capacity.

Step 23/26

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 femoral shell. The femoral shell should smoothly fall

downward until it reaches the maximum possible ﬂexion grade. If the system

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09-12-18 41/55 Joint Assembly NEURO FLEX MAX

joint does not move freely, mount the next thinner sliding washers, repeat

all steps from step 14 onwards and check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 24/26

Check if the system joint moves without lateral play. Fix the tibial shell and

try to move the femoral shell in varus-valgus. If the system joint runs with

lateral play, you need to mount the next thicker sliding washers and repeat

all steps starting at step 14. Check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 25/26

Bring the system joint as far as possible in extension. Then, disable the

permanent unlock function by pressing the step lock pawl against the joint's

upper part. Check if the step lock function works properly. The step lock

pawl should lock with each toothing up to the maximum set extension

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09-12-18 42/55 Joint Assembly NEURO FLEX MAX

Alternative Function 4

limitation. Then, ﬁx the tibial shell and try to move the femoral shell against

it. There should be no movement in the system joint.

Note: Mind the information on the locking pawls in the manual.

Step 26/26

Secure both screws with LOCTITE 243 medium strength and the torque

corresponding to the system width.

Step 1/29

Alternative function 4 is an expansion of alternative function 1. At AF 1, the

locked system joint can be used for locking in diﬀerent ﬂexed positions by

exchanging the locking parts. To do so, exchange the extension stop

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09-12-18 43/55 Joint Assembly NEURO FLEX MAX

according to the intended extension position by choosing a degree. When

the system joint is unlocked at AF4, it can be used as a locked system joint

with adjustable limitation of the maximum knee ﬂexion grade by ﬁling. To do

so, exchange the ﬂexion stop disc AF4 and cover plate AF4.

Note: You will ﬁnd the article numbers of the ﬂexion stop disc AF4 and cover

plate AF4 in our product catalogue System Joints and Articulated

System Side Bars.

Step 2/29

Secure the locking pawl (permanent unlock function). Disassemble the

system joint.

Step 3/29

Demount the ﬂexion stop disc. To do so, clamp the ﬂexion stop disc in a vice

and carefully lever it of the joint's upper part.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

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09-12-18 44/55 Joint Assembly NEURO FLEX MAX

function.

Step 4/29

If you have to demount the extension stop, screw it out of the joint's upper

part by using the pan head screw delivered with the system joint. If it is

mounted correctly, you do not have to demount the extension stop.

Step 5/29

Demount all other system components. Clean the system joint. Check all

system components and exchange them if there are signs of wear.

Note: Follow the maintenance instructions in the manual of the system joint.

Step 6/29

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09-12-18 45/55 Joint Assembly NEURO FLEX MAX

The ﬂexion stop disc is marked with lines that serve as a guide when ﬁling

the desired ﬂexion and thus enable an accurate locking of the pawl at the

lock area (R1). The marked lines are not straight but slightly bent! Do not

use a ﬂat ﬁle and ensure a smooth transition from lock area to lock disc

(R2).

Note: Mount the system joint in order to check the proper locking function

and to be able to readjust the ﬂexion degree, if required.

Step 7/29

If applicable, ﬁle the ﬂexion stop disc AF4 according to the ﬂexion grade

corresponding to the extension stop as well as the maximum possible ﬂexion

position when the system joint is unlocked. The lines should remain visible!

Make sure that the stop faces remain even and are not inclined to the sides.

Step 8/29

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Place the ﬂexion stop disc AF4 on the joint's lower part and press both by

using a vice.

Note: Use a vice with plain or soft jaws in order not to aﬀect the joint

function.

Step 9/29

If you demounted the extension stop before, place it correctly on the joint's

upper part now.

Step 10/29

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09-12-18 47/55 Joint Assembly NEURO FLEX MAX

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.

Step 11/29

If you exchange the delivered locking pawl with another, choose the

smallest possible locking pawl that still ﬁts. As locking pawls are wear parts

and wear out, you can then mount the next bigger locking pawl, if

necessary.

Note: Mind the information on the locking pawls in the manual.

Step 12/29

Insert the pressure spring by pushing it from below into the spring duct of

the joint's upper part.

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Step 13/29

Grease the axle bore of the locking pawl and the friction surfaces of the

bearing nut with the delivered orthosis joint grease.

Step 14/29

Put the bearing nut into the intended opening of the joint's upper part and

make sure that it is in the correct position. Fix the bearing nut with one

ﬁnger. Mount the locking pawl.

Step 15/29

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Place the ball and push the locking pawl to the top. Insert the pressure

spring and the locating pin for adjusting the permanent unlock function in

the locking pawl.

Step 16/29

Push the locating pin against the spring force into the system joint until it

snaps in the joint's upper part. The locking pawl is now secured, which

facilitates the further assembly of the system joint.

Step 17/29

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09-12-18 50/55 Joint Assembly NEURO FLEX MAX

Grease the axle bore of the joint axis and the friction surfaces of the bearing

nut with the delivered orthosis joint grease.

Step 18/29

Put the joint axis’ bearing nut into the intended opening of the joint's upper

part and make sure that it is in the correct position. Fix the bearing nut with

one ﬁnger.

Step 19/29

Grease the second sliding washer slightly with the delivered orthosis joint

grease.

Step 20/29

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09-12-18 51/55 Joint Assembly NEURO FLEX MAX

While still ﬁxing the bearing nut, place the second sliding washer onto the

joint's upper part and mount the joint's lower part.

Step 21/29

Mount the cover plate AF4. Turn in the ﬁrst countersunk ﬂat head screw

(axle screw). Continue with the second countersunk ﬂat head screw while

still ﬁxing the bearing nut.

Step 22/29

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If the sliding washer has been damaged during the assembly of the cover

plate (audible cracking), remove the particles and place a new sliding

washer.

Step 23/29

Check if the bearing nuts are placed completely in the intended openings.

Note: The delivered screws are always matching the system joint. Even if the

screws are not as long as the thread of the bearing nuts, that does not aﬀect

the joint’s load capacity.

Step 24/29

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 femoral shell. The femoral shell should smoothly fall

downward up to the maximum possible ﬂexion grade. If the system joint

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09-12-18 53/55 Joint Assembly NEURO FLEX MAX

does not move freely, mount the next thinner sliding washers, repeat all

steps from step 18 onwards and check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 25/29

Check if the system joint moves without lateral play. Fix the tibial shell and

try to move the femoral shell in varus-valgus. If the system joint runs with

lateral play, mount the next thicker sliding washers, repeat all steps from

step 18 onwards and check again.

Note: At a bilateral orthosis, only check one system joint at a time.

Step 26/29

Bring the system joint as far as possible in extension. Then, disable the

permanent unlock function by pressing the locking pawl against the joint's

upper part. Check if the locking pawl is locked. Fix the tibial shell and try to

move the femoral shell against it. There should be no movement in the

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system joint.

Note: Mind the information on the locking pawls in the manual.

Step 27/29

Check the position of the locking pawl. You can see the correct position on

the left picture (here AF1). If the locking pawl does not ﬁt well, exchange it.

Step 28/29

Check the maximum possible ﬂexion grade.

Step 29/29

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09-12-18 55/55 Joint Assembly NEURO FLEX MAX

PDF Download Online Tutorial

Secure both screws with LOCTITE 243 medium strength and the torque

corresponding to the system width.

FIOR & GENTZ NEURO FLEX MAX Tutorial

Specifications and Main Features

Frequently Asked Questions

User Manual