Otto Bock Dino 3 User manual

Dino® 3
Service Manual

1
Table of Contents
1 General Information................................................................................................ 2
1.1 Preface.................................................................................................................................... 2
1.2 Symbol Legend........................................................................................................................ 2
1.3 Warranty ................................................................................................................................. 2
2 Safety Instructions.................................................................................................. 3
3 Required Tools ........................................................................................................ 4
4 Dino 3 – Maintenance Plan ..................................................................................... 6
5 Dino 3 – Settings, Retrot, Replacement
5.1 Frame...................................................................................................................................... 7
5.2 Footrests ................................................................................................................................. 8
5.3 Seat ...................................................................................................................................... 15
5.4 Back / Push Handle............................................................................................................... 21
5.5 Side Panel............................................................................................................................. 24
5.6 Caster ................................................................................................................................... 25
5.7 Rear Wheel ........................................................................................................................... 27
5.8 Wheel Lock ........................................................................................................................... 30
5.9 Accessories........................................................................................................................... 32

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1 General Information
1.1 Preface
Regular maintenance is important. It increases safety and prolongs the service life of the product.
All Mobility products should be inspected and serviced once a year. If the product is used frequently, or if it is
used by growing children or patients with changing clinical conditions, it should be readjusted and serviced
every 6 months.
The service and maintenance described in this manual should be performed by skilled specialists only and
not by the user. This service and maintenance manual refers to the spare parts catalogs and instructions for
use manuals for the products described. For this reason, it is important to use these documents together.
Use the maintenance plan (see section 4) as a template for making copies. Retain completed maintenance
plans and provide the customer with a copy.
Instructions for Use Spare Parts Catalog
Dino 3 647H470 646K54
1.2 Symbol Legend
Caution!
Warning messages regarding possible risks of accident or injury.
Attention!
Warning messages regarding possible technical damages.
Note!
Information for service staff.
Note!
Please read the Instructions for Use first!
1.3 Warranty
• Use only original spare parts for all service and maintenance to maintain the warranty!
• 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).
• Clean and disinfect the product before starting inspection. Please observe the maintenance
and cleaning instructions contained in the Instructions for Use!
• These service instructions will explain, among other things, how to dismantle individual compo-
nents. For reassembly, please proceed in reverse order. If other or additional steps are required
for reassembly, we will point out them separately in the corresponding section.

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2 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.
This can lead to accidents, resulting in a risk of injury to the person being transported in the
product!
Always secure screws and nuts. If you have to undo secured screw fastenings, replace self-lock-
ing nuts and screws exclusively with new ones. To secure screws, you can also use a medium-
strength liquid thread lock substance (such as Loctite 241 or Euro Lock A24.20).
Caution!
Bald tires can lead to accidents.
This results in a risk of injuries for the person transported in the product!
For this reason, wheels with solid material tires such as PU or EVA foam must be replaced if the
material shows signs of cracking or damage, or when the tread becomes worn down to such an
extent that there is only 5 mm of radius left on the outer edges of the tire.
For this reason, the casing of pneumatic tires must be replaced if it is bald or shows signs of
cracking or other damage.
Caution!
Always observe the following guidelines:
• Times needed for adhesives to set,
• Torque indications for screw connections!
Non-compliance with these instructions can lead to malfunctioning of the product and accidents.
In such cases, there is a risk of injury to the person being transported in the product!

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5
3 Required Tools
The following photos show you the tools and auxiliaries mentioned in the text.
Reversible ratchet handle wrench
and sockets, sizes 8 - 24 mm
Torque wrench,
measurement range 8 Nm to 65 Nm
Wrenches,
sizes 8 - 24 mm
Allen wrenches,
sizes 4 - 6 mm
Screwdrivers,
blade widths 2.5/3.5/5.5 mm
Phillips head screwdriver, size 2 mm
Plastic hammer Hammer, approx. 300 g Stanley knife with sickle hooked
blade and standard blade
Water pump pliers DIN 8976,
gripping width up to 32 mm
Side cutting pliers Pop rivet gun for rivets up to
Ø 5 mm

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5
Pin punch,
Ø 3 mm, Ø 5 mm, Ø 8 mm
Hand drill Twist drills,
Ø 4 mm, Ø 5.2 mm, 6 mm
PVC tube and wire loop (e.g.
HR11590005 and HR11190031)
Tire mounting levers / inner tube
repair kit (e.g. 481C08=ST010)
Liquid thread lock "medium
strength"
Brush and standard grease Workbench as well as a vise with
plastic jaws or rubber insert (e.g.
HR11290048)
Washing-up liquid and water mixed
at a ratio of 1:4 in a spray bottle
Spray oil WD40

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Maintenance Plan
for regular service
Dino 3
Mobility Base for Seating Shells
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
2.)
Damages /
deformations
3.)
Screw connections
1 Frame - Frame
Frame accessories - Anti-tipper
- Tip-assist
2 Footrests - Flip-up mechanism
- Lower leg length setting
- Angle adjustment
Footrest accessories - Locking device for single-panel
footrest
- Heel band for individual footrests
3 Seat - Seat
- Seat tilt
- Back angle adjustment
Interface adapters - Type "Parallel"
- Type "Trapezoid"
- Type "Ortho-Seat 2"
- Type "Shape / Moss"
- Type "Dräger"
- Type "R82/Atoform"
- Type "InterCo"
Seat accessories - Adapter for pre-tilt of the seat
4 Back / push handle - Back
- Height adjustment of the push
handles/ push bar
- Push handles
- Rubber hand grips (strength)
- Pushbar
- Pushbar with ratchet joint
Back accessories - Back guide for seating shell back
5 Side panel - Wheel cover
- Clothing protector
- Height adjustment of the
armrests
6 Caster - Tires (wear)
- Air pressure
- Screw connection to the frame
- Running behavior of the wheels
- Swiveling of the caster forks
7 Rear wheel - Tires (wear)
- Air pressure
- Running behavior of the wheels
- Spokes
- Quick-release axles
Rear wheel accessories - Spoke protectors
8 Wheel lock - Wheel lock
- Reverse-roll lock
Wheel lock accessories - Wheel lock lever extension
9 Accessories - Seating shell interface
- Footrest at seating shell interface
- Trapezoid adaption for seating
shells
Do the settings of the mobility
base comply with the user's
requirements?
Maintenance performed by: on:
4 Maintenance Plan

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Replacing the frame
In order to replace the frame, first remove all compo-
nent groups and accessories which are connected
to the frame.
- Anti-tipper (refer to section 5.1)
- Tip-assist (refer to section 5.1)
- Seat with back (refer to section 5.3)
- Side panels (refer to section 5.5)
- Casters (refer to section 5.6)
- Rear wheels (refer to section 5.7)
- Wheel locks (refer to section 5.8)
Replacing/Retrotting/Setting an anti-tipper
READ: For mounting and setting
the anti-tipper please observe the
information given in the instructions
for use manual and in the spare parts
catalog.
Replacing/Retrotting a tip-assist
The tip-assist may be attached on the left or the right
side.
With the spring button of the tripod spring pressed
down insert the tip-assist from underneath into the
receiver tube for accessories or into the frame's
vertical end tube and let the tripod spring engage in
the lowest bore hole.
5 DINO 3
5.1 Frame
Replacing/Retrotting the receiver tube for acces-
sories
For the attachment of an anti-tipper or tip-assist to
models equipped with 12" rear wheels, a receiver
tube for accessories is required. Receiver tubes for
accessories must be mounted before mounting the
wheel attachments.
Screw the receiver tube for accessories to the
frame's vertical end tube as shown in the photo.
Use new, self-locking nuts.

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9
5.2 Footrests
Replacing/Retrotting the footrest assembly
All footrest assemblies are attached to the seat tube
with the seat depth adjuster/holder.
READ: For operation and setting
please refer to the information given in
the instructions for use manual.
Replacing/Setting the seat depth adjuster/holder
Loosen and remove the screw connections on the
seat tube (A) and either change the seat depth set-
ting or completely pull the tubes of the seat depth
adjuster out of the seat tubes.
Next, loosen and remove the screw connection
between the seat depth adjuster and footrest hold-
er (B) and replace the seat depth adjuster.
A
B
Replacing/Retrotting/Shifting the footrest re-
ceiver with angle adjustment
First remove the stopper plugs from the seat tube
ends. Insert the footrest receiver into the seat bar
and fasten the footrest receiver (A) with the four
screws to the seat bar. The row of holes in the seat
bar allows depth adjustment of the footrest receiver.
For disassembly, please proceed in reverse order.
Use new screws with thread lock.
A
Replacing the footrest holder
Remove the calf band.
Undo the lock as shown in the photo, swing the
footrest holder outwards and pull it upwards off the
footrest receiver.
For reassembly, please proceed in reverse order.

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9
Removing the footrest bar and footplate
Unscrew the Allen head screw (A) and pull the
footrest bar with the mounted footplate out of the
footrest holder.
For reassembly, please proceed in reverse order.
A
Replacing the lock piece (counterpart to the foot-
rest holder)
Loosen and remove the screw and remove the lock
piece.
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
section 3).
Replacing the pivot bearing (on the footrest holder)
Loosen and remove the screw and remove the pivot
bearing.
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
section 3).
Replacing the swivel segment
Remove the footrest holder from the frame. Loosen
the set screw (A) and pull the footrest bar out of
the footrest holder. Loosen and remove the set
screw (B).
Pull the frame tube of the footrest holder out of the
swivel unit. Pay attention to the clamp piece which is
only laid in.
For reassembly, please proceed in reverse order.
A
B

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Before putting the parts together, lay the clamp
piece into the opening of the frame tube as shown in
the photo.
Use new set screws coated with thread lock or
apply a liquid thread lock to the existing set screws
(refer to section 3).
Replacing the footrest bar
First pull the footrest bars out of the footrest holders.
Undo the screw connection for the angle adjustment
of the footplates and pull the receivers off the bear-
ings.
For later reassembly, please proceed in reverse
order.
Attention! Please pay attention to the
tapered shape of the half length taper-
grooved dowel pins. For driving out the
pins hit the thin beginning of the pins;
for driving in hit the thick end of the pins.
The side with the notches (right photo) is
the thick end of the pin. The side without
notches is the thin beginning of the pin
(left photo).
If you use the wrong direction for driving
the pins in or out, you will enlarge the bore
hole resulting in that the pins can fall out
and no longer provide sufficient securing
function.
Hit the thin beginning (no notches) of the half
length taper-grooved dowel pins using a pin punch
(Ø 5 mm) to drive the pins out of the receivers and
then pull the footrest bar out of the receiver.

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Insert the new footrest bar into the receiver and
fasten it with the dowel pins. Use a plastic hammer
for driving in the dowel pins.
Ensure that the dowel pins are seated equally deep
in the bore holes on both sides. If necessary, drive
the dowel pin deeper into the hole using a pin punch
(ø 5 mm).
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
section 3).
Replacing the locking clip and the cover
First loosen and remove the screw connections (ar-
rowed) of the cover and remove the cover.
Take the locking clip out of the bearing segment and
replace it with a new one.
In case of bearing segments up to size 2, the locking
clip can only be removed after the screw connection
of the footplate has been opened slightly.
Retighten the screw connection of the cover. Use
new screws coated with thread lock or apply a liquid
thread lock to the existing screws (refer to section 3).

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13
Retrotting the locking device for single-panel
footrest
Flip up the footplate of the single-panel footrest.
Undo the screw connection for the angle adjustment
of the footplate.
Retrotting heel bands for individual footrests
The footplates must first be provided with two bore
holes each with a diameter of 5.2 mm.
The mounting hole on the rear edge of the footplate
is center marked (A). The drill hole besides the foot-
rest screw connection (B) should be 17 mm above
the existing drill hole.
Fasten the heel band holders from underneath with
the screws provided.
B
A
Replace the standard bearing (A) with the bearing
with locking device (B).
Fold down the footplate and let the support segment
engage in the locking device. Now tighten the screw
connection for the angle adjustment of the footplate.
Attach the heel band halves to the holders and ad-
apt the length to the patient's foot.
Cut off excessive strap ends using scissors.
A
B

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13
Replacing footrest bar, footplate and spring ele-
ment (models until 11/2003)
First pull the footrest bars out of the footrest holders.
Undo the screw connection for the angle adjustment
of the footplates as shown in the photo and pull the
footplate off the bearing.
For reassembly, please proceed in reverse order.
Loosen and remove the screw connection in the
joints (A) and pull out the joint bolt.
Put aside the fork part and pull the cover off the
footrest bar.
The cover (B) at the same time is the spring ele-
ment that holds the footplate in flipped-up position.
For reassembly, please proceed in reverse order.
A
B
Setting the lower leg length/Replacing the foot-
rest bar in case of elevating footrests
Loosen the screw (arrowed) to adjust the footrest
bar in length.
To replace the footrest bar loosen and remove the
screw (arrowed) and completely pull out the footrest
bar.
For reassembly, please proceed in reverse order.
Models until 11/03:
In case of single-panel footrests one side is de-
signed as receiver (fork part).
Open the screw connection for the angle adjustment
of the footplate and pull the clamp out of the foot-
plate.
Drive the half length taper-grooved dowel pin out of
the receiver using a pin punch (Ø 4 mm) and pull out
the footrest bar.
For reassembly, please proceed in reverse order.

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15
Setting or replacing the calf pads of the elevating
footrests
After loosening the screw (A) in the clamping unit the
calf pad can be adjusted in height.
After loosening and removing the screw connection
(B) the calf pad can be adjusted in depth along the
row of holes.
For reassembly, snugly retighten the screw
connections.
AB
Replacing the calf pad
Loosen and remove the screw and remove the calf
pad.
For reassembly, please proceed in reverse order.
The slotted holes in the calf pad retainer plate allow
for sideways adjustments of the calf pad.

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15
Replacing the seat
Open the quick-release lock of the back angle ad-
justment (A) and fold the back down onto the seat.
Disassemble the back (refer to section 5.4) and the
footrest assemblies (refer to section 5.2).
Loosen and remove the screw connection (A) be-
tween the seat and frame.
Manually unscrew the gas comression spring from
the cross tube (B) and slowly put down the seat tilt
mechanism and seat.
Carefully push out the bushings using a pin punch.
For reassembly, please proceed in reverse order.
Use new, self-locking nuts.
5.3 Seat
B
A
A

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17
Retrotting the adapters for pre-tilt of the seat
First loosen and remove the screw connection be-
tween the seat and frame.
Then screw the adapters to the frame and firmly
tighten the set screws.
Next, screw the seat to the adapters.
Replacing the seat tilt mechanism
Manually unscrew the gas comression spring from
the cross tube and slowly put down the seat tilt
mechanism and seat.
Loosen and remove the screw connection between
the release head and the frame.
For reassembly, please proceed in reverse order.
Use new, self-locking nuts.
Replacing the release head
Carefully lever the cable (A) out of the receiver on
the release head using a screwdriver and release
the cable end (B) from the release lever. Insert a
screwdriver through the bore hole in the release
head and loosen the lock nut (C).
Completely unscrew the release head from the pis-
ton of the gas compression spring.
For reassembly, please proceed in reverse order.
A
C
B

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17
Replacing the bowden cable (sheathed cable)
Release the cable from the release head (refer to
'Replacing the release head').
Loosen the screw connection of the cable holder
until you can release the cable.
Setting the release head
For reassembly of the release head, screw the
piston of the gas compression spring into the release
head until the release pin contacts the release lever.
Screw up the lock nut until it is in contact with the
release head but do not tighten it any further.
Reassemble the gas compression spring and reloca-
te the cable in the release head.
Release the cable from the release lever.
For reassembly, please proceed in reverse order.
Attention!
Take care not to scratch the piston,
since this would make it unusable.
Protect the piston with leather or with a
piece of PVC flexible tubing.
Setting:
To decelerate the release function unscrew the
piston rod from the release head a bit. To accelerate
the release function screw in the piston rod. Finally
tighten the lock nuts against the release heads. Use
a liquid thread lock substance.

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19
Setting the back angle with xed adjustment
segment
READ: Please observe the information
given in the instructions for use manual.
Retrotting the back angle adjustment with loop
spring mechanism
Open the quick-release lock of the back angle ad-
justment (A) and fold the back down onto the seat.
Loosen and remove the screw connection be-
tween the angle adjustment mechanism and back
frame (B) and remove the adjustment segment.
Now screw the back angle adjustment with loop
spring mechanism to the back frame.
Mount the release lever to the free side of the push
handle/pushbar.
Hang the cable into the release lever.
A
B

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19
Insert the cable through the barrel-shaped guide
of the loop spring mechanism and thread on the
compression spring between the two arms of the
loop spring mechanism.
Move the clamp piece on the inner cable up to the
release arm and tighten the clamp.
Cut off the excessive inner cable length to approx.
3 cm.
Loosen the screw connection of the cable holder
until you can hang in the cable.