Fabtech Crossover Extensible Knee Owner's Manual
Text of the manual
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Crossover™ Extensible Knee
“Infinite Possibilities”
Congratulations on your decision to purchase a Crossover™ Extensible Knee! We have taken our original
Bartlett Tendon Knee (BTK) design and made it even better! The new Crossover™ is an ambulatory Extensi-
ble knee that transforms into a sports knee in less than three minutes!
This state-of-the-art prosthetic knee system will be very gratifying if you service and maintain it accordingly.
Please enter the serial numbers of your knee below. You will provide this number if the knee unit requires
servicing. Serial numbers are located on the knee frame under the protective cover.
This owner's manual contains the latest information for this model (as of June 2016). Future minor differ-
ences due to developments in the knee design cannot be ruled out completely.
All specifications are non-binding. LEFTSIDE Industries (Leftside) specifically reserves the right to modify or
delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without
prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of
a particular model without prior notice. Leftside accepts no liability for delivery options, deviations from illus-
trations and descriptions, as well as misprints and other errors. The models portrayed (via included illustra-
tions) partly contain special equipment that does not form part of the regular scope of delivery.
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permis-
sion of the copyright owner.
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
1. Multidurometer impact/kneeling pads
2. ABS protective cover
3. ABS protective X/CAM™ covers
4. Rubber socket flexion limiters
5. Urethane lower frame bumpers
6. Easy to access “On Demand” shock controls
7. RT3 pneumatic/hydraulic shock
Crossover™ Knee Walking Configuration
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
1. X/CLIP™ removable composite tendon connectors
2. Urethane tendons
3. X/CAM™ 3 position guide wheels
4. Urethane lower tendon guide wheels
5. Lower tendon retaining clamp
6. Multidurometer impact/kneeling pads
7. ABS protective cover system
8. SS removable X/CAM™ locking pin
9. Rubber socket flexion limiters
10. RT3 pneumatic/hydraulic shock
11. Tendon lock plate
Crossover™ Knee Sport Configuration
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Crossover ™ Knee Parts
1. Multidurometer impact/kneeling pads
2. Urethane lower tendon guide wheels
3. Urethane lower frame bumpers
4. X/CAM™ 3 position guide wheels
5. Lower tendon retaining clamp
6. Urethane tendons
7. X/CLIP™ removable composite tendon connectors
8. RT3 shock pump
9. ABS X/CAM™ cover
10. ABS protective cover, knee frame
11. RT3 pneumatic/hydraulic shock
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Crossflex™ Preflexion Wedges
1. 20° Crossflex™ wedge
2. 30° Crossflex™ wedge
3. 40° Crossflex™ wedge
When installing Crossflex™ preflexion wedges, take care as to not tear the foam
section that locks into the knee unit.
Note: For instructional video visit www.leftsideindustries.com
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Lower Tendon Connector
1. Placement of tendons into lower connector
2. Back locking plate attached to connector
3. Lower tendon connector
4. Lower tendon connector in open position
5. Lower tendon connector in closed position with locking plate
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
General Knee Description
1
Design Features & Function
1
Crossover™ Knee Kit Contents
2
Compatible Activities, Sports and Rehabilitation 3
New Features and Benefits
4
Technical Specifications
4
Understanding the Crossover™ Knee System
5
Ambulation Configuration
5
Sport Configuration
5
How the Systems Work Together
6-8
Tendons
6
Upper Tendon Connectors
6
Lower Tendon Connector
7
X/CAM™ Guide Wheels
7
RT3 Shock
8
Crossflex™ Preflexion Wedges
8
“VED” Variable Extension Dampening System
8
Alignment and Initial Ambulation Settings
9-14
Alignment and First Time Knee Set Up
10
Understanding Shock Controls
11-12
Walking the Patient and Adjusting the Shock
13-14
Sports Set Up
15-17
X/CAMs™
15
Lower Tendon Guide Rollers
15
Lower Tendon Retaining Connector
16
X/CLIP™ Upper Tendon Connectors
16
Tendons Set Up
17
Crossflex™ Preflexion Wedges Set Up
17
Baseline Activity Recommendations Chart
18-20
Knee Maintenance
20-22
Warranty
23-24
Service Contact Information
25
Technical Support Contact
25
L-Code Information
25
Component Options and Creative Solutions 25
Set Up Reference Notes
26
Parts List
26
X/CLIP™ Mounting Template
27
Table of Contents
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
General Knee Description
Designed exclusively for lower limb prosthetic fittings, the Crossover™ knee is a monocentric (single axis)
articulated Extensible knee that can be used for general ambulation or—with simple additions/adjustments—
can be used for high activity sports. Designed similar to the Mauch S-N-S knee unit, the Crossover™ knee
has the advantage of having the ability to add a patented highly adjustable Tendon and Three-Position X/
CAM™ system when the user wants to participate in high activity sports or other activities.
Design Features & Function
Single-axis pneumatic/hydraulic knee system with swing and stance control adjustments
Designed for multispeed ambulation and sport activities
Adjustable Variable Extension Dampening “VED” bumper system (kneeling and impact)
Multi-faceted mode selector to control flexion and extension
Patented urethane tendon and Three (3) Position X/CAM™ system, offering infinite tunable resistance
and return in a removable Extensible format
Crossflex™ preflexion foam wedges for sport activities. Three pack kit comes in 20°, 30° and 40° degree
wedge settings
Removable ABS protective impact cover
Ultra lightweight CNC machined 6061-T aircraft aluminum frame with stainless steel inserts
Oilite™ self-lubricating bushings:
No maintenance with increased durability
Smooth motion in light use or heavy impact situations
Reduced play
All parts serviceable
Water and salt water resistant
1
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Crossover™ Kit Contents
The Crossover knee kit comes with everything you will need to get your patient up and walking and participat-
ing in sports or other high activities.
Kit Contents: (PN: 1001-3)
Crossover™ Knee with 75 durometer Variable Extension Dampening “VED” bumpers (upper/
lower)
Protective ABS impact covers with X/CAM™ covers
Shock pump
2 pair urethane tendons
X/CLIPs™ with removable hardware
Easy hinged lower tendon clamp with locking system
6061-T CNC three (3) position X/CAMs™ with removable hardware
2 pair urethane lower frame tendon guide wheels for sport configuration
2 pair urethane lower frame bumper stops for ambulation configuration
Tendon connector placement template
User manual
Note: Consumable Products: The following items are classified as “Consumable Products” and will require
replacement when visual wear, cracks or tears are present. See “Periodic Maintenance Table” (Pages 20-22)
Urethane tendons
“VED” dampening bumpers
Protective cover
Crossflex™ inter-changeable preflexion wedges
Note: Available additional items NOT included in the Crossover™ kit:
Crossflex™ adjustable preflexion wedges are available for purchase in a three (3) pack kit
(PN: C113)
85 durometer “VED” bumper set
2
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Ambulation
Walking and community ambulation.
Winter Sports
Alpine skiing
Telemark skiing
Cross country skiing
Snowboarding
Snow shoeing
Ice Skating
Hockey
Snow kiting
Water Sports
Water skiing
Wakeboarding
Wind surfing
Surfing
SUP
Kite boarding
Scuba diving
Rowing / crewing
Swimming
Summer Sports
Mountain biking
Road cycling
Skate boarding
Inline skating
Backpacking
Fighting sports
Hiking
Golf
Beach days
Moto Sports
Moto-cross
Enduro and trail
Motorcycle ADV
Snowmobile
Rehabilitation
Build muscle
Weight lifting / squatting
Promote general fitness
Increase active, quality time with family
Compatible Activities, Sports and Rehabilitation
3
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
New Features and Benefits
8° - 140° expanded range of USABLE flexion
No fade after 90° degrees flexion
New compact, lighter, stronger and 5cm (2”) shorter frame
Easy removable hinged lower tendon connector with lock (no need to remove feet)
ABS impact covers for sport and ambulation
Multi-durometer Variable Extension Dampening “VED” bumper system
Kneeling pad
3ea Crossflex™ adjustable pre-flexion position wedges
Oilite™ bushings that require no service
Demo/trial program
Technical Specifications
Maximum weight 125kg (275lbs)
Net weight 908g (2lbs)
Frame size 20cm (8 inches)
8° to 150° knee flexion available range
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Understanding the Crossover™ Knee System
Ambulation Configuration
In the ambulation configuration the Crossover™ knee functions like a monocentric (single axis) S-N-S
knee unit, with a free swing feature utilizing a pneumatic/hydraulic shock with micro adjustment capabili-
ties and a unique “VED” impact multi-durometer inter-changeable bumper system to address swing and
stance gait phases.
Under normal ambulation conditions no tendons and X/CAMs™ are used. However, the tendon and X/
CAM™ system may be used for highly active walking situations like—for example—back packing or hik-
ing.
The Crossover™ knee utilizes a highly adjustable pneumatic/hydraulic cylinder to control flexion and ex-
tension adjustments.
Variable Extension Dampening “VED” bumper system is also used to address stance phase.
Sport Configuration
In the sport configuration the Crossover™ knee functions the same as in the ambulation noted above.
But, when combined with the relatively linear spring rate of the tendons and X/CAM™ system the Crosso-
ver™ delivers a smooth even energy absorption and return. It is this smooth isotonic stability that makes
the Crossover™ knee such a good choice for rehab and sport applications.
Under sporting conditions, the tendon and X/CAM™ system are generally used. This system takes a user
about 3 minutes to add to the knee.
Crossflex™ adjustable preflexion wedges may also be used to position the user into a more preflexed po-
sition. For example, snowboarding uses a 30° preflexion position.
In general more air is added to the shock during heavy sport activities in combination with the tendon and
X/CAM™ system.
Ambulation
Sport
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Tendons
The tendon system is the heart of the Crossover™ knee, offering a highly var-
iable and infinitely tunable resistance and return mechanism. This relatively
linear spring rate of tendons and X/CAM™ system delivers a smooth, even
energy absorption and return. This patented tendon and X/CAM™ system is
what makes it possible for the user to get extension/resistance moments that
provide the needed assistance to enable exiting and absorbing the extreme
flexion moments associated with sport activities.
This system is comprised of four primary components: tendons, tendon
connectors, three (3) position X/CAM™ guide wheels, and lower tendon
connector.
Only one tendon durometer is needed with the Crossover™ knee.
One OR two tendons may be used at a time.
The primary goal in setting selections is to find the winning combination
that provides the optimal flexion resistance and extension assistance that
will balance forces like a natural leg for the activity the user is doing. The
idea is: “helping, but not hindering.”
Upper Tendon Connectors
The carbon tendon connectors form the proximal connection between the
socket and the tendon system. These connectors form the pocket that the flat-
tened ball end of the tendon slips into.
They are connected with removable hardware or they can be bonded to
the socket.
Optimal location is between 5” to 9” proximal of knee center.
Ensure the tendon has a clear path on the socket to the tendon guide
wheel.
How the Systems Work Together
6
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Lower Tendon Connector
The lower tendon connector is the distal attachment point for the ball
end of the tendon.
This connector can slide up or down the pylon, and is used as addition-
al adjustment for the tendons sliding distally to increase tension and
proximally to reduce tension. The lower connector that comes in the kit
is a designed to fit a 30mm pylon and is hinged for easy on and off.
X/CAM™ Guide Wheels
To enhance the fluid dynamic feel of the tendons a three (3) position
tendon X/CAM™ Guide Wheel system is used in conjunction with the
tendons at the knee axis. These X/CAMs™ allow the highest tuning of
tendon response within further progression of knee flexion.
Having a tendon resistance properly tuned within a specific range of
flexion is very important as it means the user can tune specific points
in flexion for the tendon to CAM into action, offering additional support
where it’s need it, or X/CAM™ out the energy for explosive returns.
Because of this X/CAM™ action Crossover™ users also achieve
much lower preflexion resistance allowing them to conserve much
needed energy while still providing the power and support needed
flexing 25 degrees and beyond.
Each X/CAM™ offers three levels of progression and an additional 4th
non-pinned option on each side, and can be used with the Crosso-
ver™ tendons in singles or pairs. These selections offer an unsur-
passed series of options within the full range of flexion that can all be
done on-the-fly without tools. The X/CAMs™ can also be utilized in
reverse (4th option) or in a non-pinned free movement position deliver-
ing the identical performance of the previous BTK model with a round
guide wheel.
Pos.1 (single dot): This position is suggested for the least amount of X/
CAM™ effect with knee flexion (least amount of resistance).
Pos.2 (two dots): This position is suggested for a mid-range of X/CAM™
effect with knee flexion (middle range of resistance).
Pos.3 (three dots): This position is suggested for a maximum X/CAM™
effect with knee flexion (maximum range of resistance).
Pos.4 (no locking pin): In this position the X/CAM™ is in a FREE motion
state with no increased resistance. This position is suggested if the
amount of flexion tension with the tendon is desired in the very least
amount of tension as the X/CAM™ will not engage during knee flexion.
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
RT3 Shock
The Crossover™ knee utilizes a pneumatic/hydraulic shock. This
shock uses a combination of air, oil and valving to control and change
flexion and extension moments. Air pressure is user adjustable and
the regulated air spring/air pressure will dictate how firm that spring is.
The user controls will regulate flexion and extension rates.
Similar in function to the S-N-S Mauch units this pneumatic/hydraulic
shock provides the ability to manage average ambulation require-
ments, and when combined with the tendon, X/CAM™ and Cross-
flex™ wedges (see below), provides the additional dampening and
rebound for high activity sports.
Crossflex™ Wedges
Crossflex™ preflexion wedges are a mid-durometer foam wedge sys-
tem that is user added to change the preflexion angle/position per
sport activity. Different sports require different preflexion settings.
Snowboarding for example may require 30° whereas mountain biking
may do better at 10°.
Crossflex™ wedges are designed to act like knee cartilage and pro-
vide a small amount of compression absorption. This feature absorbs
a small percentage of impact energy keeping it from directly translating
into the prosthetic limb. The net result is a less stressed prosthetic
limb.
Crossflex™ wedges require no tools to add to the knee and are insert-
ed at the knee axis.
20, 30 and 40 degree angle/positions are available. Note: When
standing forces are placed on the wedges, there is an average com-
pression rate of 5 to 10% to the wedges.
Variable Extension Dampening “VED” Bumper System
VED bumpers come in 75° and 85° durometer ratings and can be in-
terchanged to address knee performance during stance phase. 85 du-
rometer VED pads can be ordered separately. ( Page 26)
8
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Alignment and Initial Ambulation Settings
This procedure addresses both ambulation and sport
When setting up the Crossover™ knee for the first time on a new patient, the goal is to align the knee in a sta-
ble condition for ambulation. All adjustments to tune the knee are after the patient is set in a stable alignment.
Make sure the patient is in parallel bars for safety as the knee will be in free swing with no or very little re-
sistance in the initial set up phase.
1. Unpack the box and make sure all items are in the package.
2. Remove air cap on shock and remove any residual air pressure. Depress valve to remove air.
(Figure 1)
3. Set all shock settings to the zero position. (Page 11-12)
4. Remove protective covers for easy adjustments.
5. Attach Crossover™ to prosthetic.
6. For recommended beginning alignment. (Figure 2)
Warning! If the patient is not stable they can fall at this stage of the fitting.
Figure 1
Figure 2
9
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Alignment & First Time Set-Up
The alignment reference line is equal to the weight line
1.
Alignment Reference Line (Socket Bisection)
2.
Knee Axis Reference Point
•
Establish a vertical pylon.
•
Establish the knee center height.
•
Establish the appropriate socket angles. 5 degrees of socket flexion is
recommended.
•
Position the socket so that the alignment reference line bisects the
lateral wall at the ischial level of the socket and falls through or
slightly posterior to the knee axis.
•
Establish the correct length of the prosthesis.
If the weight line is too far anterior to the knee axis, the knee may require much more effort to create a
hyperextension moment that will engage the knee axis and allow for fluid initiation of the knee flexion.
Premature knee flexion may result from a weight line position too posterior to the knee axis and will
make the knee unstable.
10
Figure 2
Figure 2/A
Figure 2/A displays alignment with a
socket flexed at10 degrees.
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Understanding Shock Controls
Flexion Resistance—Blue Lever
This lever controls flexion, also known as “dampening” on this shock. The flexion lever has three positions.
Looking at the shock in the knee frame, these positions are 10, 2 and 6 O’clock.
On the shock these positions are labeled as the following: (Figure 3)
10 O’clock = Unlock
2 O’clock = Pedal
6 O’clock = Lock
Figure 3
Most common setting for ambulation:
10 O’clock position = Lowest flexion resistance. “Unlock”
(Figure 4)
Additional settings most commonly used to address ambulation on un-
even terrain, stairs and steep declines:
2 O’clock position = Medium flexion resistance. “Pedal” (Figure 5)
6 O’clock position = Highest flexion resistance. “Lock”
(Figure 6)
Figure 4
Figure 6
Figure 5
Note: With higher air pressures the 6 O’clock setting can act as an on demand extension lock.
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Extension Resistance—Red Dial
This red dial controls extension, also known as “rebound” on this shock. The red dial is located directly be-
hind the blue flexion lever. The red extension dial has a BLACK notch on it to indicate its position.(Figure
7)
The dial rebound adjuster has ten positions with audible/tactile clicks
Clockwise rotation = slow extension (rebound)
Counter-clockwise rotation = faster extension (rebound)
Air Pressure:
Air pressure influences flexion and extension based on the amount of air pressure added to the shock.
High air pressures create more resistance and are better for heavy impact sport.
Lower air pressures create less resistance and are better for walking.
You can run 1psi to 275psi depending on the user’s requirements and the activity.
Figure 7
12
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Walking the Patient and Adjusting the Shock
Step 1.
Set the shock to the zero set point.
Set the Blue Lever to the 10 O’ Clock position.
Turn the Red Dial in a clockwise rotation until it stops.
Remove all the air from the shock.
Remove air cap and depress the valve with a tool.
Step 2.
Set shock to “Recommended Home Position.” This is your starting position for each change in air pres-
sure.
Blue Lever set to the 10 O’ Clock position.
Turn Red Dial (4) clicks counter clockwise. The black notch should be at the 7 O’ Clock posi-
tion.
Add 10 psi to the shock using the supplied shock pump.
Step 3.
With the knee set at “Home Position” have the patient walk a few times in the parallel bars.
They should feel a slight resistance in the shock. This is a good starting point for ambulation
tuning.
The first adjustment to address is extension. Adjust the red dial either COUNTER-
CLOCKWISE (faster extension) or CLOCKWISE (slower extension) from the original 7 O’clock
home position. Find the desired extension speed of the knee while walking the patient in the
parallel bars. Move the dial one click at a time faster or slower as it may only take one click
either way to find the desired settings.
The second adjustment should be to flexion by adjusting the Blue Lever into one of three posi-
tion options on the shock.
The patient should be at an air pressure range that they can walk with while the Blue Lever is
in the 10 O’clock position. (labeled as “Unlock”
on the shock)
Warning! If the patient is not stable they can fall at this stage of the fitting.
Note: Keep notes on settings while working through adjustments. (Page 26)
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Walking the Patient and Adjusting the Shock
Additional Information:
As noted in the previous “Understanding Shock Controls” section, the additional two blue lever settings
are commonly used to address ambulation on uneven terrain, stairs and steep declines as they can be
adjusted quickly “ on-the-fly” by the patient when on-demand flexion resistance is needed. These two set-
tings provide the on-demand flexion resistance that deliver additional security when desired without the
need to add more air to the shock.
Step 4.
While walking the patient and changing adjustments as needed, determine whether or not 10 psi is a
good air pressure for your patient’s ambulation needs. If more air pressure is required, add more air with
the air pump.
When adding air go up at a scale of 5-10psi if you are close to where you’d like the patient to
be. If not, close jump up 10-20psi at a time.
Repeat adjustment process as in Step 3 until desired ambulation is met.
Warning! When adding or changing air pressure keep the knee fully extended.
Note: If air pressure is added or reduced, always reset the knee to the home position dial and lever set-
tings, and start the tuning process again.
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Sports Set-Up
There are two common sport mode applications for this knee:
1. Low Impact: SUP, hiking, golfing, snorkeling, snow shoeing, etc.
2. High Impact: downhill skiing, alpine skiing, snowboarding, moto, skydiving, etc.
Low Impact Sport
For low impact applications the Crossover™ can be utilized in the “Walk Mode” with the addition of more
air pressure to get desired resistance levels while adjusting the shock adjustments to fit the ideal 3 posi-
tion (Blue Lever) operating range.
High Impact Sport
For high impact applications the Crossover™ will need to be converted to the X/CAM™ sport mode con-
figuration.
This conversion can be done in just minutes while the patient is wearing the knee with a rotator device
(this is suggested) in the knee or simply by removing the leg and making these changes.
Required Tools: 3, 4, 5mm Allen wrench & Phillips screwdriver
Step 1. X/CAMs™
Using a 3mm Allen tool, remove the screws on both side covers. Place in bag
for safe keeping.
Using a 4mm Allen tool, attach the X/CAMs™ to the sides of the Crosso-
ver™. Torque to 8nm.
Step 2. Lower Tendon Guide Rollers
Using a 5mm Allen wrench remove the rubber caps on the lower part of
Crossover™, replace with rubber tendon rollers and re-install. NOTE: all
screws/ bolts are pre-Loctite but with frequent removal and re-install you may
want to re-Loctite with Blue 242. Hand tighten.
Installing X/CLIPs™ and Lower Tendon Mounts and X/CAM™
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Step 3. Lower Tendon Retaining Connector
Remove the two screws holding the rear “Tendon Locking Plate” on, and
remove from the connector.
Remove the 5mm SS clamping screw from the connector and pull apart.
Place the lower tendon connector on the 30mm pylon facing posterior.
Normal starting position is just under the tube clamp adaptor.
Check build height of prosthesis and knee position before moving onto the
next step: mounting carbon X/CLIP™ connectors to socket.
Step 4. X/CLIPs™ Upper Tendon Connectors
Utilizing the X/CLIPs™ tendon template, cut out the inside of the square
boxes on the template paper with a bladed tool to use as your placement
template on the patient’s existing socket or new test socket.
Check the placement of template by taking a tendon and placing the half
ball end flush on the socket at bottom half of the cut out window to check
the placement. Look for the tendon to line up with a tendon X/CAM™ guide
wheel on the knee (Note: no need to stretch into place, you are only looking
to see that the tendon lines up with the drive groove in the guide wheel).
Placement of the X/CLIP™ connectors on the socket is recommended to
be 5” (12.7cm) to 9” (22.86cm) from knee center. Keep this in consideration
if you are building a new socket. If this is not possible, lower is better if you
have room to slide the lower tendon connector down to increase tension.
Once placement of template has been checked horizontally and vertically
and lines up well with the guide wheels, use a marker to mark the X/
CLIPs™ outline on the socket utilizing the cut out square box on template
then remove paper from the socket. At this point (if applicable) remove the
inner flexible socket from the carbon socket to easily access the socket
wall.
Place the X/CLIP™ carbon clip on the corresponding template space and
mark the area to be drilled. Using a sharp (#1/.228) drill bit, drill the two
mounting holes.
Remove the template. Large and small SS removable mounting hardware
is included in the package. Use the best fitting hardware and mount the
carbon clips.
Note: If the socket shape or design does not allow for good placement, see
our “Creative Solutions” section at www.leftsideindustries.com.
Note: The lower tendon connector can be adjusted up and down the pylon to in-
crease/ decrease tension on the tendon. This is dependent on available space.
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Remove the template. Large and small SS removable mounting hardware
is included in the package. Use the best fitting hardware and mount the
carbon clips.
Tendons Set Up
Once the Crossover™ knee build has been completed and the X/CLIP™
connectors have been secured to the socket you can apply the tendons by
simply slipping the tendon half ball end from the top of the connector
(tendon may be tight when brand new, use of small amount of lubricant or
rubbing alcohol can ease placement and removal of the tendon into con-
nector) and sliding it down in locking into place.
Next, flex the assembled prosthetic and knee allowing the tendon ball end
to hang down so as you can easily secure the ball end into the lower ten-
don connector (best to do one side at a time), making sure that the ball is
completely secured into the recessed position of the lower connector. Reat-
tach the locking back plate and torque screws to 8mm.
Finally, extend the prosthesis to full extension. Now stretch the tendon “Lift
and Set” onto the tendon guide wheel groove, making sure that tendon is
not “rolled” into the groove as it will want to twist out of groove. Also, check
that the tendon is seated behind the small guide wheel on the lower knee
frame, allowing for a straight pull from the lower connector.
Crossflex™ Wedges Set Up
Crossflex™ preflexion wedges are easy for the user to install and require
NO
tools. Crossflex™ wedges are only used during sport activities.
While the leg is on, simply flex the leg so the upper knee opening is at its
widest point.
Insert the narrow end of the Crossflex™ wedge into the open knee cavity.
The foam hook will create a lock on the inside of the knee holding the
wedge in place.
Remove in reverse, being careful not to tear or damage the foam.
Note: See video at www.leftsideindustries.com for example.
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Baseline Activity Recommendations Chart
All baseline settings are provided as a guideline for initial setup. The final settings will vary from user to user
based on user preferences and conditions.
*N/A indicates no use of the Crossflex™ Wedges or X/CAM™ and
tendons necessary for particular application
*(10) Unlock =
, (2) Pedal, (6) Lock =
- indicate the position of the Flexion Lever (Blue Lever) on
the shock body
*Fast, Medium, Slow – indicates the Extension Speed (Red Dial) of the Knee
Ambulation
Crossflex™
Wedge
Flexion
Resistance
Extension Speed
X/CAM™
Position
Air Pres-
sure
Walking & Community
ambulation
N/A
Unlock (10) / Pedal
(2)
Medium to Slow
N/A
5-30psi
Winter Sports
Alpine Skiing
20º / 30º
Pedal (2) / Lock (6)
Medium to Slow
1st & 2nd
15-60psi
Telemark Skiing
30º / 40º
Pedal (2) / Lock (6)
Medium to Slow
2nd & 3rd
15-80psi
Cross Country Skiing
20º
Unlock (10) / Pedal
(2)
Medium to Fast
4th & 1st
15-60psi
Snowboarding
30º / 40º
Pedal (2) / Lock (6)
Medium to Slow
3rd & 3rd
25-165psi
Snow Shoeing
N/A
Pedal (2) / Lock (6)
Medium to Fast
N/A
5-35psi
Ice Skating
None to 20º
Pedal (2) / Lock (6)
Medium to Fast
N/A
15-80psi
Hockey
20º / 30º
Pedal (2) / Lock (6)
Medium to Fast
1st & 2nd
15-60psi
Snow Kiting
20º / 30º
Pedal (2) / Lock (6)
Medium to Slow
3rd & 3rd
15-140psi
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Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Baseline Activity Recommendations Chart
Water Sports
Water Skiing
None to 20º
Pedal (2) / Lock
(6)
Medium to Fast
N/A
15-140psi
Wakeboarding
20º / 30º
Pedal (2) / Lock
(6)
Medium to Slow
3rd & 3rd
25-165psi
Wind Surfing
20º / 30º
Pedal (2) / Lock
(6)
Medium to Slow
2nd & 3rd
15-65psi
Surfing
None to 20º
Pedal (2) / Lock
(6)
Medium to Slow
N/A
35-165psi
SUP
None to 20º
Pedal (2) / Lock
(6)
Medium to Fast
N/A
30-100psi
Kite Boarding
20º / 30º
Pedal (2) / Lock
(6)
Medium to Slow
3rd & 3rd
15-140psi
Scuba Diving
N/A
Unlock (10)
Fast
4th & 1st
5-30psi
Swimming
N/A
Unlock (10)
Fast
N/A
15-60psi
Summer Sports
Mountain Biking (DH)
20º / 30º
Pedal (2) / Lock
(6)
Medium to Slow
3rd & 3rd
25-165psi
Mountain Biking (XC)
20º / 30º
Unlock (10) /
Pedal (2)
Medium to Slow
1st & 2nd
15-60psi
Road Biking
20º
Unlock (10) /
Pedal (2)
Medium to Fast
N/A
15-80psi
Skate Boarding
None to 20º
Pedal (2) / Lock
(6)
Medium to Fast
N/A
15-100psi
Inline Skating
None to 20º
Pedal (2) / Lock
(6)
Medium to Fast
N/A
15-100psi
Backpacking
N/A
Unlock (10) /
Pedal (2) / Lock
(6)
Medium to Fast
N/A
10-50psi
Fighting Sports
N/A
Pedal (2) / Lock
(6)
Medium to Fast
N/A
15-80psi
Hiking
N/A
Unlock (10) /
Pedal (2) / Lock
(6)
Medium to Slow
N/A
10-30psi
Golfing
N/A
Unlock (10) /
Pedal (2) / Lock
(6)
Medium to Slow
N/A
10-45psi
Beach Days
N/A
Unlock (10) /
Pedal (2) / Lock
(6)
Medium to Slow
N/A
10-30psi
19
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Baseline Activity Recommendations Chart
Moto Sports
Motocross
30º / 40º
Pedal (2) / Lock
(6)
Medium to Slow
3rd & 3rd
25-185psi
Enduro & Trail
20º / 30º
Pedal (2) / Lock
(6)
Medium to Slow
1st & 2nd
15-60psi
Motorcycle ADV
None to 20º
Pedal (2) / Lock
(6)
Medium to Slow
N/A
15-80psi
Snowmobile
30º / 40º
Pedal (2) / Lock
(6)
Medium to Slow
3rd & 3rd
25-185psi
Knee Maintenance
General Inspection
Before you use your Crossover™ knee, personally inspect the knee before each use. Check the knee for:
Loose or missing bolts or screws
Proper air pressure as indicated by your prosthetist determined during knee set up for the corre-
sponding activity you intend to do
Cracks or damage to protective covers
Tear or damage to a rubber tendons and rubber pads
Carbon attachments secured to socket
Periodic Maintenance Schedule
To maintain the high performance, safety, and long life of your Crossover™ knee, it is required that you peri-
odically check the knee system and perform routine maintenance on your shock. If you use the shock and
knee in extreme conditions, compliance checks and maintenance should be performed more frequently.
20
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Knee Maintenance
Normal use. Walking and occasional sports. No water.
Wear and Tear Parts
Interval (hours)
Replace
Inspect rubber tendons for excessive wear, abrasion or
tears. Replace if necessary.
8hrs or after every sport
activity
Annually
Inspect 75 durometer terminal impact pads for excessive
wear, abrasion or tears. Replace if necessary.
100hrs
Annually
Inspect 85 durometer terminal impact pads for excessive
wear, abrasion or tears. Replace if necessary.
100hrs
Annually
Inspect ABS protective cover for excessive wear, abra-
sion or cracks. Replace if necessary.
8hrs or after every sport
activity
As indicated
by damage
Inspect Crossflex™ adjustable preflexion wedges for ex-
cessive wear, abrasion or tears. Replace if necessary.
After every sport activi-
ty
As indicated
by damage or
wear.
Shock Maintenance Service Chart
Interval (hours)
Replace
Clean your shock with mild soap and a toothbrush.
8
NA
Keep mounting hardware clean and lubricated.
8
NA
Remove, clean, and grease mounting hardware.
20
NA
Clean and inspect extension/preflexion spacers. Replace
if necessary.
20
NA
Inspect eyelet bushings and mounting hardware for wear
and play. Replace if necessary
100
Annually
Replace all seals.
100
Annually
Inspect shaft, reservoir, damper body and air can for
scratches or damage (if applicable). Replace if necessary.
100
Annually
Replace damping fluid (if applicable).
100
Annually
Knee Frame and Knee Parts
Interval (hours)
Replace
Torque
Inspect X/CAM, for dings or sharp edges that
may cut into tendons. Inspect 4mm SS attachment
screws for damage. Replace if necessary.
After each sporting
activity
If damaged
8nm
Inspect carbon tendon X/CLIPS and SS mounting
hardware for damage. Replace if necessary.
After each sporting
activity
If damaged
4nm
Inspect lower tendon mount for dings or sharp
edges that my cut into tendons. Inspect 5mm SS
attachment screws for damage.
After each sporting
activity
If damaged
8mn
Knee frame. Inspect for any damage.
Annually
If damaged
NA
Inspect protective ABS cover 3mm mounting
screws.
After each removal
If damaged
Hand tight
Inspect nylon washers, rubber O-rings, and cir-
clips.
Annually
If damaged
21
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Knee Maintenance
High Use: Mostly Sports. Fresh and Saltwater.
Wear and tear parts
Interval (hours)
Replace
Inspect rubber tendons for excessive wear, abrasion or tears
replace if necessary.
After every sport activity
As indicated
by damage or
wear.
Inspect 75 durometer terminal impact pads for excessive wear,
abrasion or tears replace if necessary.
30hrs
As indicated
by damage or
wear.
Inspect 85 durometer terminal impact pads for excessive wear,
abrasion or tears replace if necessary.
30hrs
As indicated
by damage or
wear.
Inspect ABS protective cover for excessive wear, abrasion or
cracks replace if necessary.
After every sport activity
As indicated
by damage
Inspect Crossflex™ adjustable pre-flexion wedges for exces-
sive wear, abrasion or tears replace if necessary.
After every sport activity
As indicated
by damage or
wear.
Shock maintenance service chart
Interval (hours)
Replace
Clean your shock with mild soap and a toothbrush
After every sport activity
NA
Keep mounting hardware clean and lubricated
After every sport activity
NA
Remove, clean, and grease mounting hardware
After every sport activity
NA
Inspect eyelet bushings and mounting hardware for wear and
play. Replace if necessary
30
As indicated by
damage or
wear.
Replace all seals
30
Annually
Inspect shaft, reservoir, damper body and air can for
scratches or damage (if applicable). Replace if necessary
30
Annually
Replace damping fluid (if applicable)
30
30
Knee frame and knee parts
Interval (hours)
Replace
Torque
Inspect X/CAM™ for dings or sharp edges that
may cut into tendons. Inspect 5mm SS attach-
ment screws for damage. Replace if necessary.
After each sporting
activity
If damaged
8nm
Inspect carbon tendon X/CLIPs™ and SS mount-
ing hardware for damage. Replace if necessary.
After each sporting
activity
If damaged
4nm
Inspect lower tendon mount for dings or sharp
edges that my cut into tendons. Inspect SS at-
tachment screws for damage.
After each sporting
activity
If damaged
8nm
Knee frame. Inspect for any damage.
After each sporting
activity
If damaged
NA
Inspect protective ABS cover 3mm mounting
screws
After each removal
If damaged
Hand tight
Nylon washers, rubber O-rings, circlips
Annually
If damaged
22
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Warranty
Leftside Industries, Inc.
Leftside Industries Inc. warrants its products to be free from defects in materials and/or workmanship for a
period of 36 months from date of original purchase. This warranty is non-transferable and voided if the serial
number or production code has been deliberately altered, defaced or removed. Claims must be accompanied
by original proof of purchase. All shipping costs are the responsibility of the party making the warranty claim.
This warranty does not apply to products that have been modified, incorrectly installed and/or improperly ad-
justed. This warranty does not apply to normal wear and tear, crash impact, abuse or non-compliance with the
manufacturers’ specifications.
Final determination on all warranty claims is at the sole discretion of Leftside Industries Inc.
LIMITATIONS OF WARRANTY
This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result
of normal use, failure to service according to Leftside Industries recommendations and/or sports or installation
in conditions or applications other than recommended.
Wear and tear parts are identified below and are NOT covered by the 36 month warranty. Please refer to
maintenance service charts.
Urethane tendons
Variable Extension Dampening bumpers
Protective ABS cover
Crossflex™ adjustable pre-flexion wedges
Shock (See shock warranty)
Shock Warranty
SRAM LLC WARRANTY
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or work-
manship for a period of two years after original purchase. This warranty only applies to the original owner and
is not transferable. Claims under this warranty must be made through the retailer where the product or the
SRAM component was purchased. Original proof of purchase is required. Except as described herein, SRAM
makes no other warranties, guaranties, or representations of any type (express or implied), and all warranties
(including any implied warranties of reasonable care, merchantibility, or fitness for a particular purpose) are
hereby disclaimed.
LIMITATIONS OF LIABILITY
To the extent allowed by local law, except for the obligations specifically set forth in this warranty statement, in
no event shall SRAM or its third party suppliers be liable for direct, indirect, special, incidental, or consequen-
tial damages.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the
respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com,
avidbike.com, truvativ.com, or zipp.com.
23
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Warranty
Fabtech Systems, LLC
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance
with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces
or loads beyond its design.
This warranty does not apply when the product has been modified, including, but not limited to any attempt to open or
repair any electronic and electronic related components, including the motor, controller, battery packs, wiring harnesses,
switches, and chargers.
This warranty does not apply when the serial number or production code has been deliberately altered, defaced or re-
moved.
This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal
use, failure to service according to SRAM recommendations and/or riding or installation in conditions or applications oth-
er than recommended.
Wear and tear parts are identified as:
Dust seals
Bushings
Air sealing O-rings
Glide rings
Rubber moving parts
Foam rings
Rear shock mounting hardware and main seals
Snow & Water
The Crossover™ knee is designed to be used in wet conditions. To ensure a long lifespan the unit should be rinsed
with clean water after it has been used in salt water, resort snow (resort snow contains conditioning chemicals that may
corrode parts), and in other conditions in which water is questionable. Never store the unit wet. After rinsing the Crosso-
ver™ knee off with fresh clean water it should be dried, then lubricated with a lithium based lubricant to all moving parts
of the knee. Always store dry.
Prolonged submersion of the shock will void the manufacture’s warranty. Diving and snorkeling while using the Crosso-
ver™ knee are recommended without the shock unit in, using tendons only. While performing activities such as water
skiing, kite-boarding or wave running where the shock is recommended, simply follow snow and water care instructions
and don’t submerge shock for prolonged periods.
24
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Service Contact Information
Please contact:
Fabtech Systems, LLC
Phone: 1-800-322-8324
Email: [email protected]
3304 Hill Ave, Everett WA 98203
Technical Support
Call 1-800-322-8324
9:00AM -5:00PM PST
L-Code Information
Phone: 1-800-322-8324
Email: [email protected]
9:00AM -5:00PM PST
Component Options and Creative Solutions
Visit www.leftsideindustries.com for information on:
Low profile adaptors
Feet for specific activities
Mounting carbon clips on flat base with adhesive
Short sockets
HiFi strut sockets – removable bridge
Tips
25
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Set-Up Reference Notes
Parts List:
PN#:C102
75 Durometer Variable Extension Dampening Pads-2ea/Pair
PN#:C103
85 Durometer Variable Extension Dampening Pads - 2ea/Pair
PN#:C104
Urethane Tendons - 2ea/Pair
PN#:C105
Rubber Socket Flexion Limiter - 2ea/Pair
PN#:C106
Urethane Lower Frame Bumper - 2ea/Pair
PN#:C107
Urethane Lower Tendon Guide Wheel - 2ea/Pair
PN#:C108
X/CLIP™ Carbon Attachment Clip - 2ea/Pair
PN#:C109
X/CAM™ Guide Wheels & Hardware - 2ea/Pair
PN#:C110
30mm Hinged/Lock Lower Tendon Connector
PN#:C111
RT3 Hydraulic Shock
PN#:C112
Protective ABS Cover - (3 piece & hardware)
PN#:C113
Crossflex™ Preflexion wedges - (20,30,40 degree kit)
PN: C1S
PLUSeries Composite Adhesive 50ml
PN: G50
PLUSeries 50ml Dispensing Gun
Flexion Setting
Extension Setting
PSI
Result
1
2
3
4
5
Sport
X/CAM™
Setting
Crossflex™
Wedge
Flexion Setting
Extension Setting
PSI
Result
1
2
3
4
5
26
Crossover™ Manual V1/62920016 ©Fabtech Systems LLC. All Rights Reserved.
Upper X/CLIP™ Carbon Tendon Connector Placement Template
After cutting the tendon attachment boxes out, position the center line on the
anterior aspect of the socket aligned to the rotation of the knee unit.
The recommended height placement is 5” - 9” from the center of the knee.
This is the recommended position of the proximal connectors.
Center of ball
Cut out this square
Cut out this square
5” to 9” from knee center to center of tendon ball
27