Otto Bock Discovery User manual

Discovery
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 Discovery – Maintenance Plan ................................................................................ 6
5 Discovery – Settings, Retrofit, Replacement .................................................... 7
5.1 Main Frame ............................................................................................................................. 7
5.2 Seat Bar .................................................................................................................................. 7
5.3 Interface Adapter ..................................................................................................................... 8
5.4 Push Handles and Pushbar ..................................................................................................... 9
5.5 Back Frame ........................................................................................................................... 12
5.6 Seat Tilt ................................................................................................................................. 13
5.7 Rear Wheels and Brakes/ Wheel Locks ................................................................................ 16
5.8 Front Wheels ......................................................................................................................... 20
5.9 Storage Bag .......................................................................................................................... 21
5.10 Tip-assist ............................................................................................................................... 21
5.11 Armrests ................................................................................................................................ 21
5.12.1 Footrest Assemblies – models from 11/2003 ......................................................................... 23
5.12.2 Footrest Assemblies – models until 10/2003 .......................................................................... 28
5.13 Footrest Assembly and Seating Shell Interface ...................................................................... 29
5.14 Anti-tipper .............................................................................................................................. 31
5.15 Back Guide for Seating Shell Back ....................................................................................... 33
5.16 Tray ....................................................................................................................................... 33

2
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
Discovery 647H427 / 647G162 646K48
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.

3
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!

4
3 Required Tools
The following photos show you the tools and auxiliaries mentioned in the text.
Reversible ratchet handle wrench
and sockets, sizes 8 mm - 24 mm
Torque wrench,
measurement range 8 Nm to 65 Nm
Wrenches,
sizes 8 mm - 24 mm
Allen wrenches,
sizes 4 mm - 8 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

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

6
4 Maintenance Plan
Maintenance Plan
for regular service
Discovery
Mobility Base for Seating Shells
Customer:
Item Component (group) Inspection (check list)
Serial no.: 1.)
Function / setting
2.)
Inspected for damages
/ deformations
3.)
Screw connections
inspected
1 Main frame
2 Seat bar
3 Interface adapter - Universal adapter
- Type "Parallel"
- Type "Trapezoid"
- Type "Dräger"
- Type "R82/Atoform"
- Type "InterCo"
- Type "Ortho-Seat 2"
- Type "Shape / Moss"
4 Push handles / pushbar - Push handles
- Rubber hand grips (strength)
- Pushbar
- Pushbar with ratchet joint
5 Back frame - Height adjustment of the push
handles/pushbar
- Angle adjustment
- Folding mechanism
6 Seat tilt - Cables
- Cable pull divider
- Tilting mechanism
7 Rear wheels - Wheel lock
- Drum brake
- Tires (wear)
- Air pressure
- Running behavior of the wheels
- Spokes
- Quick-release axles
8 Front wheels - Tires (wear)
- Air pressure
- Screw connection to the frame
- Running behavior of the wheels
- Swiveling of the caster forks
9 Storage bag - Loading capacity, snap fasteners
10 Tip-assist
11 Armrests - Height adjustment
- Angle adjustment
12 Footrest assemblies - Angle adjustment
- Lower leg length
- Folding mechanism
13 Seating shell interface and
footrest for seating shell
interface
- Locking mechanism
- Angle adjustment
14 Anti-tipper - Swiveling and engaging
15 Back guide for seating shell
back
- Locking mechanism
16 Tray
Notes:
Do the settings of the mobility
base comply with the user's
requirements?
Maintenance performed by: on:

7
Replacing the main frame
To disassemble the main frame, separate the seat bars
and the seat tilt mechanism from the main frame.
Then remove the rear wheels and brakes (refer to
section 5.7) and the front wheels with the wheel forks
(refer to section 5.8).
Caution!
Unscrewed elements can slip and lead
to injuries.
Support the backrest before removing
the screw connections on the left and
right attachment device for the back.
Also remove all accessories which are attached to the
main frame such as
storage bag (refer to section 5.9)
tip-assist (refer to section 5.10)
anti-tipper (refer to section 5.14)
5.2 Seat Bars
C
A
B
5 Discovery – Settings, Retrofit, Replacement
5.1 Main Frame
Replacing/Shifting the seat bars
First disassemble any interface adapters (A) and arm-
rest attachments (B). Undo and remove the screw con-
nections to the attachment device for the back (C).
Undo and remove the screw connection between seat
bar and main frame (D). Move the seat bar towards
the attachment device for the backrest until the tilting
bearings are free and you can turn the seat bar 90°
and pull the seat bar out of the attachment device for
the backrest.

8
Replacing/Retrofitting/Shifting the interface
adapter
READ: Please observe the information
given in the instructions for use manual.
For the interface adapters "Shape/Moss" (A) and "Uni-
versal crossbars" (B), please proceed as follows:
First disassemble the seat bars as described in sec-
tion 5.2 Seat Bars. Now slide the interface adapters
onto the seat bars and fasten them with screws. Reas-
semble the seat bars.
5.3 Interface Adapter
B
A
B
A
A
D
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.

9
5.4 Push Handles / Pushbar
Replacing/Retrofitting push handles/pushbar
Disassemble the operating lever of the seat tilt mecha-
nism (refer to section 5.6).
Open the clamping levers on the left and right side of
the back frame. Loosen and remove the screw con-
nections between bearing plates and back frame (A)
to free the loops of the pull cable.
For reassembly, please proceed in reverse order. Use
new, self-locking nuts.
A
Caution!
Risk of injury.
Unscrewed elements can slip.
Support the back frame before removing
the screws.
Remove the operating lever of the seat tilt
mechanism (refer to section 5.6).
Open the clamping levers on both sides
of the back frame.
Loosen the screws between the bearing
plates and back frame (A) until the loops
of the pull cable are free.
Use new, self-locking nuts for reassem-
bly.

10
Replacing the rubber hand grips on push handles
Use the HR32042490 Repair Kit (refer to the spare
parts catalog).
Carefully cut open the rubber hand grip using a stanley
knife. Remove the old rubber hand grip.
Using a knife remove the residue of the old glue or
rubber from the handle surface and from inside the
tube. Using a clean cloth and solvent, fully degrease
the ends of the push handle tubes. This will make it
easier to push the new hand grips onto the tubes.
Attaching rubber hand grips onto push handles
Note:
Ensure you work effectively after mixing,
since the adhesive sets quickly. Also ob-
serve the instructions given by the manu-
facturer of the adhesive. The quantity of
adhesive is sufficient for fixing two rubber
hand grips.
Open the two part adhesive sachet. Use the spatula
to squeeze out all the contents of the sachet into the
center of the mixing card and thoroughly mix. Apply
half of the adhesive into the rubber hand grip using the
spatula. Evenly distribute the adhesive in the rubber
hand grip up to a depth of approx. 4-5 cm.
Attention!
Now wait for at least 24 hours so as to
allow full curing of the adhesive and to
achieve the desired strength.
Slide the rubber hand grip onto the push handle rotat-
ing it through 180° as it is pushed on.

11
Replacing the rubber hand grips on pushbars
First disassemble the operating lever of the seat tilt
mechanism (refer to section 5.6) and then the push-
bar from the back frame (refer to section 5.4).
Carefully cut open the older rubber hand grips using
a blade and remove the old rubber hand grips from
the pushbar.
Disassembling a ratchet joint half
To mount new rubber hand grips on pushbars with
ratchet joints it is necessary to loosen one half of the
ratchet joint.
To do this, drill out the rivets with a sharp drill bit
(ø 4.0 mm). Drive out any rivet residues that may
have remained in the ratchet joint using a pin punch
(ø 3.0 mm).
Clamp the upper part of the pushbar in a vise.
Spray the mixture of washing-up liquid and water
into the first new rubber hand grip and pull it onto the
pushbar.
After mounting of the rubber hand grips, reassemble
the ratchet joint halves and fasten with rivets.
Finally reassemble the pushbar to the frame.
B
B
In case of pushbars with ratchet joints first remove
the operating lever (refer to section 5.6). Then loosen
and remove the clamping levers (B) and remove the
upper part of the pushbar from the lower parts of the
pushbar.
To replace the lower part of the pushbar, please pro-
ceed as described in section 5.4.

12
Replacing the back frame
First disassemble the push handles or pushbar (refer
to section 5.4).
Pull the release strap (A) and remove the back
frame.
For reassembly, please proceed in reverse order. Use
new nuts with thread lock.
Replacing the bearing plates
Caution!
Unscrewed components can slip and
lead to injuries. Support the back
frame before removing the screw
connections.
Loosen and remove the screw connections to the at-
tachment device for the backrest (A) and to the back
frame (B). Pay attention to the flute washers and bush-
ings when removing the bearing plate. For reassembly,
please proceed in reverse order. Use new nuts with
thread lock.
5.5 Back Frame
B
A
Replacing/Shifting the attachment device for the
backrest (to change the seat depth)
Loosen and remove the screw connections (A) and (B).
Slide the attachment device to the required position on
the seat bar or completely remove it.
For reassembly, please proceed in reverse order. Use
new nuts with thread lock. Screws which are secured
with a nylon thread (B) can be used once again.
Replacing the release strap
Loosen and remove the two retaining screws (A) and
pull off the release strap.
For reassembly, please proceed in reverse order.
A
B
A
A

13
Replacing the gas compression springs
Caution!
Unscrewed frame elements can slip and
lead to injuries.
Secure the seat bars and backrest before removing
the screw connections.
Loosen and remove the screw connections to the at-
tachment device for the backrest (A) and to the main
frame (B).
For reassembly, please proceed in reverse order.
5.6 Seat Tilt
Replacing the release head
Carefully lever the bowden cable (sheathed 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)
using a wrench.
Completely unscrew the release head from the piston
of the gas compression spring.
For reassembly, please proceed in reverse order.
Setting the release heads
Attention!
Scratches on the pistons would make
the damping function ineffective.
Protect the piston with leather or with
a piece of PVC flexible tubing when
making adjustments.
For reassembly of the release heads, screw the pis-
ton (A) of the gas compression spring into the release
head (B) until the release pin (C) contacts the release
A
C
B
A
B
lever (D). Screw up the lock nut (E) until it is in contact
with the release head but do not tighten it any further.
Reassemble the gas compression spring and relocate
the cables in the release heads.
For setting the gas compression springs:
• Use the release heads for Discovery models until
10/2003.
• Use the cable pull divider for Discovery models
from 11/2003.
D
E
C
B
A

14
Replacing the bearing axle
Loosen and remove the screw connection on the left
and right (A) between the attachment devices for the
backrest and the bearing axle and between the gas
compression springs and the main frame. Pull the gas
compression springs from the bearing axle.
For reassembly, please proceed in reverse order.
Screws which are secured with a nylon thread can
be used once again.
Replacing the operating lever (until 06/2005)
Loosen the clamping screw (A) holding the cable and
pull the cable out of the operating lever.
Loosen and remove the screw connection on the push
handle (B) and remove the operating lever. Finally pull
the collar bush (C) off the push handle.
For reassembly, please proceed in reverse order.
A
A
B
C
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.
Finally tighten the lock nuts against the release heads.
Use a liquid thread lock substance.

15
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. Finally pull the collar bush off the push
handle.
For reassembly, please proceed in reverse order.
Replacing/Setting the cable pull divider
Release the two cable ends from the gas compres-
sion springs (refer to ‘Replacing the release heads’).
Loosen the cable end from the operating lever (refer
to ‘Replacing the Operating Lever’). Pull the cables
out of the cable tie loops and reuse them later. The
individual adjustment screw is used to adjust the ten-
sion of the upper release cable. The pair of adjustment
screws are used to adjust the point of release of the
gas compression spring. All adjustment screws are
secured with lock nuts.

16
Replacing 12" rear wheels
Remove the hub cover as shown in the photo. Loosen
and remove the screw and remove the wheel.
Use a new, self-locking screw for mounting.
Tighten the screw with a torque of 40 Nm (30 lbf.ft./
354 lbf.in.).
Reattach the hub cover by pressing it over the head
of the screw.
5.7 Rear Wheels and Brakes / Wheel Locks
Caution!
Risk of injury.
Bald tires can lead to accidents. Re-
place the tires if the material shows
signs fo cracking or damage. Replace
solid material tires even without visible
damages, 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.
Replacing the casing or inner tube
First let the air out of the tire. Using plastic tire levers,
insert them under the wall of the tire and lever it over
the wheel rim. Continue all the way around the tire wall
until it is fully off the wheel rim. Pull the inner tube out
of the tire and repair it with a standard bicycle repair
kit or replace the tube with a new one.
For reassembly, please proceed in reverse order.
5 mm 5 mm
Fill the inner tube with a small amount of air before
mounting in order to avoid damages and pinching.
Tire pressure:
Always ensure that all tires are fully inflated to the maxi-
mum pressure indicated on the sidewall of the tire.

17
Replacing the rubber brake blocks of the wheel
lock and the expansion spring
Pull the worn rubber brake blocks off the brake rods
using pliers.
If necessary pull the expansion spring off the grooved
pin and put on a new expansion spring.
The expansion spring must be positioned in the groove
of the grooved pin.
Replacing/Retrofitting/Setting the wheel locks
READ: Please observe the information
given in the instructions for use manual.
Tighten the screws in the clamping block with a torque
of 15 Nm (11 lbf.ft./132.8 lbf.in.).
Replacing the O-ring
Replace worn out or porous O-rings.
Stretch and apply the new O-ring as shown here from
the abutment to the brake block.
Replacing/Retrofitting/Lubricating the foot-oper-
ated wheel locks
Loosen and remove the screw connections to the
main frame and remove the wheel lock.
The pivot axle is guided within a sleeve. Lubricate the
sleeve regularly with each maintenance.
For reassembly, please proceed in reverse order.
Use new nuts with thread lock.
A
B

18
Replacing the brake anchor
After removal of the rear wheel, it is only the rotation
protection (A) that holds the brake anchor in place.
Undo and remove this screw connection and remove
the brake anchor from the rear wheel.
Note: When replacing the main frame
it is not necessary to disassemble the
cable.
Reassemble the screw of the rotation protection of the
brake anchor but do not fully tighten.
Screw on the rear wheel and now tighten the screw of
the rotation protection.
Replacing the inner cable
Cut off the cable end crimp (A) using side cutting pliers.
Undo the adjustment die (B) and pull the inner cable
out of the adjustment screw (C).
Pull the brake handle up fully to the stop. Undo the
set screw in the brass insert (D). Next, using pliers
grip the nipple of the inner cable and pull it through
the brake lever.
For reassembly, please proceed in reverse order.
Setting the drum brakes
The brake force must be checked from time to time
and readjusted if need be.
Uncrew the adjustment screw (C) to increase the
tension and thereby the brake force. Adjust the brake
so that no rotation of the rear wheels is possible with
the brake lever pulled fully up and secured using the
locking lever and that the wheels run freely when the
brake lever is released.
Finally secure the adjustment screw (C) with the lock
nut.
BA
C
D
A

19
Retrofitting the rear axle for 20", 22" and 24"
wheels
First disassemble the 12" wheels. Fix the rear axle
plate assembly to the main frame using the screws
provided. The M12 bolts fasten the assembly to the
main frame rear axle (A).
In vertical orientation, the hole matrix is designed
as follows: for 20“ wheels (upper row), 22“ wheels
(center row) and 24“ wheels (bottom row).
In horizontal orientation you can choose from three
different wheelbase positions.
Now fasten the main frame with the axle plates (B)
with screws.
Mount the brake handles to the push handles/pushbar
and fit the cables as shown in the photo.
READ: For additional information,
please refer to the instructions for use
manual.
Setting the quick-release axle
The quick-release axle should be set so the wheel is
fully engaged but has the minimum amount of lateral
axle play:
Using a wrench hold the inner end of the axle still, whilst
the outer nut of the axle is adjusted so as to give the
correct lateral axle distance.
Regularly clean the quick-release axle and lubricate
with spray oil.
Rear wheels with quick-release axles
READ: Please observe the information
given in the instructions for use manual.
Also check the air pressure, as described in the instruc-
tions for use manual.
A
B