Otto Bock Discovery Service Manual
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Otto Bock Discovery Service Manual

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Discovery
Service Manual

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Summary of Contents for Otto Bock Discovery

  • Page 1 Discovery Service Manual...

  • Page 2: Table Of Contents

    Warranty ..........................2 Safety Instructions ....................3 Required Tools ......................4 Discovery – Maintenance Plan ................6 Discovery – Settings, Retrofit, Replacement ............ 7 Main Frame ..........................7 Seat Bar ..........................7 Interface Adapter ........................8 Push Handles and Pushbar ..................... 9 Back Frame ...........................

  • Page 3: General Information

    Are you familiar with the functions of the product? If not, please read the Instructions for Use first! If you do not have them, you can order the Instructions for Use from Otto Bock or down- load them from our homepage at www.ottobock.de (German version) or www.ottobock.com (other languages).

  • Page 4: Safety Instructions

    Safety Instructions Caution! Always wear adequate protective clothing (e.g. gloves, safety glasses, etc.) and use appropriate tools (refer to page 4)! Caution! You may get injured if the product tips over or falls off a work surface (e.g. workbench)! Secure the product to prevent it from tipping over or falling off any work surfaces! Caution! Unsecured screw connections can become loose while using the product.

  • Page 5: Required Tools

    3 Required Tools The following photos show you the tools and auxiliaries mentioned in the text. Wrenches, Reversible ratchet handle wrench Torque wrench, and sockets, sizes 8 mm - 24 mm measurement range 8 Nm to 65 Nm sizes 8 mm - 24 mm Allen wrenches, Screwdrivers, Phillips head screwdriver, size 2 mm...
  • Page 6 Pin punch, Hand drill Twist drills, Ø 3 mm, Ø 5 mm, Ø 8 mm Ø 4 mm, Ø 5.2 mm, 6 mm PVC tube and wire loop (e.g. Tire mounting levers / inner tube Liquid thread lock "medium HR11590005 and HR11190031) repair kit (e.g.

  • Page 7: Discovery - Maintenance Plan

    4 Maintenance Plan Customer: Maintenance Plan Discovery for regular service Mobility Base for Seating Shells Item Inspection (check list) Component (group) Serial no.: Function / setting Inspected for damages Screw connections / deformations inspected Main frame Seat bar Interface adapter - Universal adapter - Type "Parallel"...

  • Page 8: Discovery - Settings, Retrofit, Replacement

    Discovery – Settings, Retrofit, Replacement 5.1 Main Frame Replacing the main frame To disassemble the main frame, separate the seat bars Also remove all accessories which are attached to the and the seat tilt mechanism from the main frame. main frame such as Then remove the rear wheels and brakes (refer to storage bag (refer to section 5.9)

  • Page 9: Interface Adapter

    Note: Pay attention to the flute washers and bushings. For reassembly, please proceed in reverse order. Use new nuts with thread lock. The seat bar can be mounted in two positions to leave more space for footrest assemblies, if necessary. 5.3 Interface Adapter For the interface adapters "Shape/Moss"...

  • Page 10: Push Handles And Pushbar

    Push Handles / Pushbar Replacing/Retrofitting push handles/pushbar Caution! Risk of injury. Disassemble the operating lever of the seat tilt mecha- nism (refer to section 5.6). Unscrewed elements can slip. Support the back frame before removing Open the clamping levers on the left and right side of the screws.
  • Page 11 Replacing the rubber hand grips on push handles Attaching rubber hand grips onto push handles Use the HR32042490 Repair Kit (refer to the spare Note: parts catalog). Ensure you work effectively after mixing, Carefully cut open the rubber hand grip using a stanley since the adhesive sets quickly.
  • Page 12 Replacing the rubber hand grips on pushbars First disassemble the operating lever of the seat tilt In case of pushbars with ratchet joints first remove mechanism (refer to section 5.6) and then the push- the operating lever (refer to section 5.6). Then loosen and remove the clamping levers (B) and remove the bar from the back frame (refer to section 5.4).

  • Page 13: Back Frame

    5.5 Back Frame Replacing the back frame Replacing the bearing plates First disassemble the push handles or pushbar (refer Caution! Unscrewed components can slip and to section 5.4). lead to injuries. Support the back Pull the release strap (A) and remove the back frame before removing the screw frame.

  • Page 14: Seat Tilt

    PVC flexible tubing when For setting the gas compression springs: making adjustments. • Use the release heads for Discovery models until 10/2003. For reassembly of the release heads, screw the pis- • Use the cable pull divider for Discovery models ton (A) of the gas compression spring into the release from 11/2003.
  • Page 15 The gas compression springs must release simulta- neously to prevent frame distortions and premature wear. For testing, fix a weight of approx. 50 kg on the seat bars and release the seat tilt mechanism. If need be, unscrew the piston rod from the release head to decel- erate the release function and screw it in to accelerate the release function.
  • Page 16 Replacing the operating lever (from 07/2005) Loosen the bowden cables (sheathed cables) from the release heads. Release the cable from the release handle as shown in the photo. Pull the soldered end of the cable later- ally out of the release lever. Loosen and remove the screw connection on the push handle and remove the operating lever.

  • Page 17: Rear Wheels And Brakes/ Wheel Locks

    5.7 Rear Wheels and Brakes / Wheel Locks 5 mm 5 mm Replacing 12" rear wheels Caution! Risk of injury. Remove the hub cover as shown in the photo. Loosen Bald tires can lead to accidents. Re- and remove the screw and remove the wheel. place the tires if the material shows signs fo cracking or damage.
  • Page 18 Replacing/Retrofitting/Lubricating the foot-oper- Replacing the rubber brake blocks of the wheel ated wheel locks lock and the expansion spring Loosen and remove the screw connections to the Pull the worn rubber brake blocks off the brake rods main frame and remove the wheel lock. using pliers.
  • Page 19 Replacing the brake anchor After removal of the rear wheel, it is only the rotation Reassemble the screw of the rotation protection of the protection (A) that holds the brake anchor in place. brake anchor but do not fully tighten. Undo and remove this screw connection and remove Screw on the rear wheel and now tighten the screw of the brake anchor from the rear wheel.
  • Page 20 Retrofitting the rear axle for 20", 22" and 24" Now fasten the main frame with the axle plates (B) wheels with screws. First disassemble the 12" wheels. Fix the rear axle plate assembly to the main frame using the screws Mount the brake handles to the push handles/pushbar provided.

  • Page 21: Front Wheels

    Checking and retightening the spokes Attention! Adjustment of the radial excursion requires special devices and expertise. Please have the adjustment carried out by a bicycle workshop. Check to see if spokes are broken and that they are still tight by trying to move them. 5.8 Front Wheels Replacing the front wheels Replacing the caster fork...

  • Page 22: Storage Bag

    5.9 Storage Bag 5.10 Tip-assist Replacing/Retrofitting the storage bag Replacing/Retrofitting the tip-assist At the rear axle of the Discovery you will find two tube READ: Please observe the information ends which are welded to the frame. To this tube ends, given in the instructions for use manual.
  • Page 23 Mounting version with spacers Replacing the PU armrest pad Loosen and remove the two screws from the armrest For especially wide seating shells the delivery includes support. Then remove the plastic caps from the bore spacers and long screws. holes and move the armrest pad to the desired posi- tion.

  • Page 24: Footrest Assemblies - Models From 11/2003

    5.12.1 Footrest Assemblies – models from 11/2003 Replacing/Retrofitting/Shifting the footrest as- Replacing/Retrofitting/Shifting the footrest re- sembly ceiver with angle adjustment First remove the stopper plugs from the seat tube First remove the stopper plugs from the seat tube ends. ends. Insert the footrest receiver (A) into the seat bar, Insert the footrest receiver into the seat bar and fasten put the upper bolt (B) through the front bore hole in the footrest receiver (A) with the four screws to the seat...
  • Page 25 Replacing the lock piece (counterpart to the foot- Replacing the pivot bearing (on the footrest holder) rest holder) Loosen and remove the screw and remove the pivot Loosen and remove the screw and remove the lock bearing. piece. For reassembly, please proceed in reverse order. For reassembly, please proceed in reverse order.
  • Page 26 Replacing the footrest bar Attention! Please pay attention to the tapered shape of the half length taper-grooved First pull the footrest bars out of the footrest holders. dowel pins. For driving out the pins hit the thin beginning of the pins; for driving Undo the screw connection for the angle adjustment of in hit the thick end of the pins.
  • Page 27 Replacing the footplates Loosen and remove the screw connections on the sides of the footplate and remove the footplate from the bearing segments. For reassembly, please proceed in reverse order. Use new screws coated with thread lock or apply a liquid thread lock to the existing screws (refer to sec- tion 3).
  • Page 28 Retrofitting the locking device for single-panel footrest Flip up the footplate of the single-panel footrest. Replace the standard bearing (A) with the bearing with locking device (B). Undo the screw connection for the angle adjustment of the footplate. Fold down the footplate and let the support segment engage in the locking device.

  • Page 29: Footrest Assemblies - Models Until 10/2003

    5.12.2 Footrest Assemblies – models until 10/2003 Replacing/Retrofitting the footrest assembly (with Replacing the footrest holders and without angle adjustment) Remove the calf band. Before mounting, remove the stopper plugs from the Undo the lock (A), swing the footrest holder outwards seat tube ends.

  • Page 30: Footrest Assembly And Seating Shell Interface

    5.13 Footrest Assembly and Seating Shell Interface Replacing/Retrofitting/Adjusting the knee angle Loosen the set screws (A) on the seating shell inter- Loosen and remove the screw connection in the joints face (C) and pull out the knee angle (B). Now change (A) and pull out the joint bolt.
  • Page 31 Mounting the seating shell interface to the seating shell Lay the seating shell interface on the upturned seating Firmly tighten the screw connection. shell and use the seating shell interface as a pattern When mounted, the release lever of the seating shell for marking the fixing holes.

  • Page 32: Anti-Tipper

    5.14 Anti-tipper Replacing the anti-tipper At the rear axle of the Discovery you will find two tube Slide the anti-tipper body over the frame tube end. ends which are welded to the frame. To this tube ends, Pull out the expansion spring at the hooked-shaped a tip-assist or anti-tipper can be mounted.
  • Page 33 Setting the anti-tipper in case of 12" wheels Press the spring button of the tripod spring. Pull the Caution! telescoping part off the swivel arm or let engage it in another length position. The anti-tipper wheel must at least completely extend from the rear wheel READ: For function and handling of the to the back, and the distance between...

  • Page 34: Back Guide For Seating Shell Back

    5.15 Back Guide for Seating Shell Back Retrofitting a back guide Note: The package includes longer screws and spacers for mounting of the Turn the attachment block of the back guide with the attachment block. wing nut (A) to the right until it is parallel in the slot. Now separate the attachment block from the guide Hold the attachment block and unscrew the wing nut plate (B).
  • Page 35 Otto Bock HealthCare GmbH Lindenstraße 13 · 07426 Königsee/Germany Otto Bock HealthCare GmbH has been certified by the German Society for the Certification of Quality Assurance Systems (DQS) in accordance with DIN EN ISO 9001 standard, reg. no. 779 (management system)

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