Whirlwind Cargo Tricycle Assembly Instructions

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Whirlwind Cargo Tricycle Assembly

Assembly instructions for the Whirlwind Cargo handcycle Tricycle

For videos on assembly and adjustment visit http://www.whirlwindwheelchair.org/tech-support

Ralf Hotchkiss riding the Cargo Handcycle Tricycle

2 4 3 5 9 8 6,7

CARGO TRIKE ADJUSTMENTS

SEAT HEIGHT UP AND DOWN SEAT POSITION FRONT-BACK

CRANK HEIGHT UP AND DOWN BACKREST HEIGHT

SEAT ANGLE TENSION ADJUSTABLE BACKREST

SCI SEATING KIT:LATERAL

BACKREST ANGLE

WEDGES, CHEST STRAP, AND PRESSURE RELIEF CUSHION

Accessories

Additional Accessories not pictured:

SCI Kit

Cargo Canopy/ Overhead storage and shelter

Sun Canopy

Identify all components, from front to back

1) Front wheel

2) Fork

3) Crank Boom

4) Chain Idler assembly

5) Chain

6) Left Crank

7) Right Crank with Chainring

8) Crank handles

9) Optional Front Brake

10) Steering Centering Spring

11) Front Frame

12) Frame attachment location with bolts

13) Rear Frame

14) Brakes

15) Brake Mount Clamp

16) Brake Lock Assembly

17 Seat Frame

18) Seat base/cushion

19) Optional Pressure relief cushion with separate seat base (not shown)

20) Backrest Frame

21) Backrest posts

22) Tension adjustable backrest straps

23) Backrest cover

24) Rear wheel, Left

25) Rear wheel, right

The following components are pre-assembled:

• Bottom bearing cone “crown race” installed on fork steerer tube

• Top and bottom bearing cups are installed in head tube on front of mainframe

• Chain idler wheels (2) installed on rotating bar of chain idler, with torsion spring installed.

• Tensioned chain idler pulley with bearings is installed securely.

• Rear wheel clamp bolt and lock bolt are installed on rear main frame.

• Center spring clamp is installed on front main frame

• Bolt and wedge are installed on stem quill.

• Chain Idler brace is installed on crank boom

• Bottom bracket is installed on Crank Boom, with the long side of the bottom bracket spindle on

the right side when viewed from the back of the trike.

• Handrims, rim strip, tube, and tire are installed on rear wheels. Refer to the RoughRider

wheelchair assembly materials available from Whirlwind. Note: There are different left and right wheels. The right wheel has the adjustable cup of the hub on the same side as the handrim, and the left wheel has the fixed cup on of the hub on the same side as the handrim.

• The crank chain ring has chain guards discs installed on both sides of the cog.

• Hand grips are installed onto “pedals”/ crank arms.

• The TAB tension adjustable backrest straps are installed on the backrest posts.

• Brake lock parts are attached to brake arm.

• Brake plastic bushings are installed on brake pivot tubes.

• Foot guards are installed.

• Centering spring clamp protector is installed.

• Fenders are installed on seat.

• Quick release bolts installed on crank boom and idler brace.

Assembly Instructions:

GREASE

1. Apply grease to the bearing cups on the headtube.

2. Apply grease to the bearing on the “crown race” of the fork. The bearing should be installed

with the ball retaining ring on the bottom side.

3. Insert the fork steerer tube through the head tube.

4. Install the centering spring (this is easier to install before the headset is tightened).

5. Install the top bearing with the ball retaining ring on the top side.

6. Install the threaded headset cone and lockring. Tighten the lockring against the cone, so that the

bearings spin freely but there is no wiggle in the bearings. This is a standard bicycle assembly.

7. Install the chain idler with the idler wheels on the same side as the chain rings (right side when

viewed from the rear).

8. Install the crank boom with the crank facing backwards.

9. The bottom bracket / crank spindle is the same as a bicycle. Make sure that the longest side of

the spindle is on the right side with the gears, when viewed from the back of the trike. Note: the left side may be “left-hand threaded” and tighten counter-clockwise (opposite from most bolts).

The left side cup may also be welded to the frame, depending on manufacturer. This part is preinstalled.

10. During maintenance of the crank / “bottom bracket”, the Right side /adjustable cup should be

tightened last, with the lockring tightened against the right side cup so that the spindle can spin freely, but there is no wiggle. This should be secured quite tight, and is a standard bicycle assembly.

11. Attach the left crank to the spindle; make sure that the bolt touches the flat face in the spindle

securely and is very tight.

12. Attach the right crank with the gear to the spindle; make sure that the bolt touches the flat face

in the spindle and is very tight. Note: The cranks can be installed with handles together or opposite, depending on user preference. Use the flat faces in the spindle to set this position.

Cranks Opposed configuration, left Cranks together configuration, right

13. Tighten the crank boom with 2 quick release bolts or 2 regular bolts; make sure that the crank

gears are aligned and parallel on the top and bottom.

14. Check that the centering spring is installed correctly.

15. Install the stem quill into the fork steerer tube. Tighten. The height of the exposed tube should

be approximately 50mm above the top of the fork steerer tube.

16. Slide the chain idler down over the stem quill. Position the chain idler such that the idler wheels

can rotate freely without touching the crank boom quick release bolts. Tighten the chain idler with the quick release bolt.

17. Install the chain. First install the chain on the Top chainring. Second install the chain on the

TENSION FROM SPRING KEEPS CHAIN TIGHT

SPRING EXHERTS FORCE THIS DIRECTION

bottom cassette on the wheel. Third, rotate the Chain idler 1 (one) full revolution or until the torsion spring is wound enough to hold the chain tight. Install the chain as shown. Make sure that the chain is guided over the tensioned idler wheel.

18. Install the front wheel. If the wheel has a drum brake, the brake should clamp to the left side of

the fork, and the cog for the cassette will be on the right side, when viewed from the back of the trike. Tighten the front wheel securely with a 15mm wrench. Make sure that the tire is centered in the fork and is vertical when viewed from the front or rear.

19. Install the chain guard on the axle of the front wheel. This chain guard helps keep the chain on

the lower gear (cassette) if the chain tension is too loose, and on very rough terrain.

20. Attach the front and back chassis/main frame pieces together with four (4) M12 bolts. The bolt

heads should be on the outside of the trike frame, and the nuts and washers on the inside. If it is difficult to align the holes, install one at a time and do not tighten fully until they are all installed. Tighten fully with two 19mm wrenches/socket wrenches. Note: If required, a screwdriver or other flat metal tool can be inserted between the locknut and the trike frame to prevent rotation. Tighten securely with large wrenches if possible. It is unlikely that these bolts will need to be removed.

21. Identify the RIGHT REAR WHEEL. This wheel has the Adjustable cup of the hub (with lockring) on

the same side as the handrim. Install the right wheel onto the right side of the main frame chassis, when viewed from the rear. Inflate the right rear wheel.

22. Insert the axle with the slot / flat part facing up, and position the axle so the M8 bolt on the top

BOLT TIGHTENS INTO

BOLT

of the axle clamp can be tightened into that slot. Tighten the axle security bolt and locknut with a 13mm wrench. Next, tighten the M12 axle clamp bolt with two (2) 19mm wrenches.

AXLE SLOT WHICH FACES UP TO MEET

ABOVE: LEFT WHEEL VIEWED FROM UNDER SEAT LOOKING OUT.

RIGHT WHEEL. ( AXLE SLOT FACES UP FOR INSTALLATION ON BOTH WHEELS)

23. Repeat for the LEFT REAR WHEEL. Inflate the left rear wheel. The left wheel has the Fixed cup of

the hub on the same side as the handrim.

24. Install the Left rear wheel (same method as right side).

25. Identify the holes on the seat which will be used for the seat clamps and seat rail guides.

FRONT: SEAT RAIL GUIDE REAR: SEAT CLAMP

Example: Seat mounting

Different riders require different seating positions. The seat can be adjusted forward and backwards after it is installed.

for 46cm seat height at 12 degree seating angle

(Shown with bolt above tube, and can be installed with bolt below tube for low seats for riders with short legs)

LOCK NUT TRAPPED INSIDE

CHANNEL

BOLT HEADS CAN BE ABOVE OR

SEAT CLAMP

ABOVE: BRAKE CLAMP

BELOW SEAT RAIL, IN ANY ONE OF THE 6 HOLES TO SET SEAT HEIGHT AND SEAT ANGLE

SEE SEAT HEIGHT ASJUSTMENT SECTION OF THIS GUIDE AND VIDEO FOR MORE INFORMATION

26. Note on seat height: the bolts on the seat clamp and seat rail guide are usually installed above

the seat rail but can also be installed below in order to lower the seat.

27. With the seat off of the tricycle: Install the front seat rail guides with M8 bolts to the front

ladder of the seat as shown. The bolt head should be outside the seat, and the M8 locknut is trapped inside the channel. Align the faces of the nut so that it is secured inside the channel.

PARTS, (THIN MATERIAL), NOT FOR SEAT

Put the seat on the tricycle. It is easiest to install the seat rail guides onto the rails at the front corner of the seat rails. SEE SEAT HEIGHT ASJUSTMENT SECTION OF THIS GUIDE AND VIDEO FOR MORE INFORMATION

More information at http://www.whirlwindwheelchair.org/provider-resources

28. Position the seat at the desired seat angle, and install one of the rear seat clamps. Note that the

bolt head is facing out and the nut is trapped inside the channel. Do not tighten fully yet. Install the opposite side seat clamp into the matching hole.

29. Tighten 2 two rear clamps and two front seat rail guides securely with a 13mm wrench. Note:

The seat can be adjusted front-back by simply loosening the two rear seat clamp bolts and sliding the seat. These clamps must be removed in order to adjust the seat height or seat angle.

30. Install the backrest to the seat with the M8 bolts. The bolt heads should be on the outside.

Ensure that the backrest can pivot up and down freely. Note: The cross bar on the backrest must be in the back (away from the riders’ back).

31. Install the backrest adjustment ladder though the slots in the backrest, and attach to the seat

using M8 bolts.

32. Attach the springs between the adjustment ladder and the seat, pulling securely. Check to make

sure that the backrest ladder falls into every set of notches evenly and easily (For rider safety).

view from center of trike looking outward.

33. Lay out the backrest TAB and posts to be ready for installation. The wide Velcro is on the front of

the TAB. Each strap should wrap around each backrest cane without tangle. Refer to the

RoughRider backrest installation and fitting guides for information about installing the backrest.

http://www.whirlwindwheelchair.org/backrest-and-tab

34. Attach remaining backrest straps through the trike backrest, avoiding the adjustment

mechanism as much as possible. The number of straps below the backrest ladder will change depending on the backrest cane height, which will be selected in a seating assessment. One strap will be below for the tall backrest height, two straps for the medium backrest height, and three straps for the low backrest height.

35. Install the backrest cover with the reflector facing back, with the wings wrapped around the

backrest from the front to the back. Refer to the RoughRider backrest installation information. Note: If this trike will be set up with the SCI Kit, lateral support wedges will be installed between the backrest cover and the TAB straps, to be comfortable for the rider.

36. Install the cushion onto the seat. The cushion should be installed with the cut out relief position

matching the tubes on the seat. (The front edge is square, the rear edge has notches.) Note: If this trike will be set up with the SCI Kit, a different seat base is used that is thinner)

37. Attach the left and right brakes together, if required. Washers should be used to space the

components, and can be adjusted if needed later. (Some trikes might not have this feature).

38. Identify the right side of the brake. This side has the brake lock, which should be attached at this

point. Refer to photograph for correct installation.

39. Position the brake assembly on the trike. This is easily done if the trike is tipped vertical or

upside down. Ensure that the brake curve follows the curve of the wheel.

40. Install the brakes using the clamp plates with M6 bolts. Use threadlocking compound such as

medium strength Loctite® for security. These plates should be positioned over the plastic bushing. The bushing should have the wide flange on the outside edge. When tightened, they must allow the brake cross tube to rotate inside.

41. Press the brake clamp over the seat rail and bend the clamp together as needed to secure with

the bolt. Attach the clamp the seat rail at a position so that the Brake does (1) not touch the tire when the lock is released and (2) holds the tire securely when the lock is engaged. The lock is operated by moving the front end up to lock and down to release. The clamp is attached to the seat rail between the front seat guide and the rear seat clamp.

ACCESSORIES

a. SCI Kit (Spinal Cord Injury Kit): This accessory supports riders wanting additional seating

support, including those with spinal cord injuries, with a pressure relief cushion, lateral support wedges for the backrest, and a chest strap. Refer to WHO wheelchair seating materials for information about appropriate seating for riders with varying seating needs. The seat base for the SCI kit has thin foam on a plastic base. This replaces the standard seat + cushion on the tricycle. The Pressure Relief Cushion (PRC) attaches with Velcro to the seat base. Refer to Whirlwind and WHO information about seating assessment and pressure relief cushion fitting. The lateral support wedges are inserted between the front of the TAB backrest straps and the backrest cover. Refer to the information in the “Provision” Section of the tricycle guide for more information. The chest strap attaches around the rider’s chest and seat backrest, wherever feels safe and comfortable for the rider.

b. Rear Cargo bag: Attach the Velcro straps to the frame, using cord as needed to secure

the bag at 6 points.

c. Rear Cargo Box: This accessory is an alternative to the Rear Cargo Bag (and cannot be

used at the same time). Secure the box to the floor of the cargo trike with bolts. The cargo box can be locked with a padlock (not provided) to secure valuables and other cargo.

d. Front Cargo Rack: Insert the angled tubes into the receivers on the cargo trike frame.

The front cargo rack should be secured to the receiver tube to prevent accidental removal while lifting on the front rack to move the trike (with or without rider). The rack can be fitted with a Front Cargo Box accessory, or a basket, bin, box, crate, or other container of a riders’ preference. Please note that while this rack is strong and attached to the tricycle frame (instead of the fork+wheel), it is not designed to carry passengers, and that steering will be difficult with heavy cargo on the Front Cargo Rack.

e. Front Cargo Box: This box is installed on the front cargo rack, with bolts installed

through the tube frame of the Front Cargo Rack. This box can also be locked with padlocks (not provided).

f. Under seat Cargo Box: This box attaches with screws from the inside of the box into a

custom frame. Currently, the tricycle needs to be built with a custom mounting bracket if you want to install this box into the trike. Note that the box is a sliding drawer, and can be opened either from its position under the seat, or it can be slid forward into the footrest area for improved access to the box. There is a latch to prevent the box from sliding into the footrest area during riding.

PROVISION:

The Whirlwind Cargo Handcycle Tricycle is a mobility device, and should be provided similarly to a wheelchair following best-practices for service provision for seating and mobility. Refer to the World Health Organization (WHO) Basic Wheelchair provision training and guides. The following information describes adjustments and seating options specific to this tricycle, and should be used as a reference for experienced wheelchair providers .

The Whirlwind Cargo Tricycle may be an appropriate product for riders who can maintain an upright seated position and have good head control. With the optional “SCI Kit” the tricycle may be appropriate for riders without trunk control, if determined to be appropriate by the rider and an experienced service provider. Refer to the Whirlwind RoughRider service provision “quickstart” for more information.

The cargo tricycle large, and may not be appropriate for use indoors.

Refer to the Trike Spec sheet for information regarding the range of adjustment for people with different body sizes.

Size Adjustments:

Trike/Hip Width:

The Whirlwind Cargo tricycle is available in one width only: 18 1/8”. Riders with narrower hip widths may prefer to place foam between their hips and the frame.

Backrest Height + Tension Adjustable Backrest

The backrest can be adjusted for the highest support of the backrest to be 14”, 16”, or 18” above the seat surface. The Tension Adjustable backrest straps can be adjusted to fit each rider.

Refer to the RoughRider backrest adjustment information.

From http://whirlwindwheelchair.squarespace.com/backrest-and-tab/

Video of backrest strap adjustment for changing backrest height: http://vimeo.com/60119609

Tension Adjustable Backrest Setup

(By the rider and a service provider)

Whirlwind recommends that riders consult with service providers who have experience with wheelchair seating to promote comfort and posture. The following notes are provided as a reference for riders and service providers and are not a replacement for a skilled service provider.

The RoughRider (and Cargo Tricycle) backrest supports comfort for riders with good head and trunk control, who have the ability to maintain an upright seated position.

Remove the backrest cover, and loosen the buckles to release tension on the all of the straps.

The rider should transfers into the wheelchair/tricycle.

If the rider cannot maintain the upright posture independently, the service provider supports the rider in the upright postur e and guides a helper to tighten the straps.

It is usually best if the service provider supports the rider to ensure that the posture is maintained in the correct alignment.

First tighten the straps at the top of the pelvis and the lumbar spine. Quite a bit of force is required to give the correct tension.

The straps over the upper trunk area are tightened next. They are tightened lightly only. Check with the rider to make sure they feel balanced and that the strap is not pushing them forward.

The straps over the buttocks area are tightened last. These are also done up very lightly t o prevent pushing the bottom forward. For riders with lots of soft tissue in this area, ensure that the straps are sufficiently loose.

Check the rider's balance and adjustments. Usually it is the straps at the top and middle sections which require fine tuning.

The rider should now transfer out of the chair.

Check the contour of the adjusted backrest. This should be the same as the contour of the spine.

Secure the straps so that they cannot be accidently adjust ed / slide out of positi on, by ensuring that the ends of the straps are secured with the velcro. (Not e: the top strap is different from the others, requiri ng an additi onal buckl e.)

Place the cover over the straps. Ensure that you follow the contour of the straps (the cover should not be stretched tighter than the straps). Secure the tabs on the bottom of the backrest cover.

Final tip: In s ome cases, the st raps may not be able to b e reach lu mbar curve. This curve can be supported by adding s ome foam to the front of the back support. Be careful to avoid pressure on the bony part of the spine and top of the pelvis.

Seat Height (for Lower leg length) and Seat Angle

The seat angle can be adjusted by selecting holes for mounting the seat clamp. Some factors to consider when selecting seat angle, seat height, and seat position front/back include the following:

• Comfort and safety of seating position (refer to WHO Wheelchair Provision materials for

more information)

• Height of front of seat/cushion from the footrest to support riders’ feet and legs

• Distance from the backrest support to the cranks (also affected by TAB adjustment and

backrest angle relative to seat.

• Note that as the seat angle is adjusted, the backrest angle changes with the seat.

• Example: To achieve a 90-90-90 seating position (the most upright backrest angle is

approximately 86 degrees from the seat)the seat angle might be set at 12 degrees, with the backrest in the most upright position with the top straps loosened to create a 90 degree seating angle with lumbar support. The Front Seat Rail Guide will be positioned 2 holes higher than the Rear Seat Clamp. The particular configuration shown in the photo will give a seat height (from the floor to the top of the integrated cushion) of 46cm.

FRONT: SEAT RAIL GUIDE REAR: SEAT CLAMP

Example:Seat mounting for

46cm seat height at 12 degree seating angle

(Shown with bolt above tube, and can be installed with bolt below tube for low seats for riders with short legs)

Low seat positions:

2nd Hole, bolt-on-bottom

1st Hole, bolt-on-bottom Seat height = 34 cm

Image: Showing lowest seat position with 5 degree seat angle, 34cm seat height from footrest. The rear seat clamp is bolt-on-bottom in the top hole (1 of 6). The front seat guide is bolt-on-bottom in second hole, 2 of 6.

Seat Depth:

The seat on the cargo trike is 14” deep, which gives a total seat depth of approximately 15” to back of the sling backrest. If a longer seat is required, the tricycle and be fit with a seat extension from an

18.5” RoughRider wheelchair. Riders may also choose to install a seat extension without the strap to provide a handle for transfer. The seat extension can be installed following the instructions for the Roughrider Wheelchair. Note that the cushion is 14” deep only. Note: This seat extension is not included

with each tricycle, and must be ordered as an accessory. Please inform Whirlwind if your experience fitting tricycles indicates that this should be included with each tricycle.

Website: http://whirlwindwheelchair.squarespace.com/seat-extension/

Video: http://vimeo.com/60116938

Crank Height:

Many riders prefer the lowest cranks possible because there is less of a visual obstruction in front of them. The lowest position of the cranks that will be comfortable for riders will likely be set such that the riders’ hand is only slightly above their knee when propelling the trike forward. To set the crank height before the rider sits in the trike, measure from the ground or footrest where the rider’s feet are resting to the top of the knee and add 5 cm for the hand and clearance. Set the center of the handgrip at its lowest this distance from the trike footplate.

Note: A longer chain can be used for the highest chain positions. This should be available from the manufacturer, and can be lengthened or replaced by a bicycle mechanic.

Seat Position Front-back

The seat position front-back, combined with the crank height, affects the propulsion and comfort of the trike rider. Many riders are the most comfortable when the seat position is set so that their shoulder is still in contact with the backrest and the farthest part of the crank stroke. A good starting point for this setting is 3 cm shorter than the fully extended arm length from the center of a closed fist to the surface supporting the rider’s back. Remember that the trike backrest is a sling backrest, and to accommodate for the curve of the backrest when measuring riders.

For more information contact

info@whirlwindwheelchair.org

and visit

http://www.whirlwindwheelchair.org/tech-support

http://www.whirlwindwheelchair.org/provider-resources

Whirlwind Cargo Tricycle Assembly Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual