Otto Bock B400 Service Manual
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Otto Bock B400 Service Manual

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B400 Power Wheelchair
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  • Page 1 B400 Power Wheelchair Service Manual...
  • Page 2 The dissemination and duplication of the service manual and all accompanying documents as well as the utilization and com- munication of its content is prohibited unless explicitly authorized in writing by Otto Bock HealthCare GmbH. Failure to comply results in liability for compensation.

  • Page 3: Table Of Contents

    Service Manual for the B400 Power Wheelchair Contents Page 1 General Information ......................6 1.1 Preface ........................6 1.2 Intended Use ......................6 2 Safety Instructions ......................7 2.1 Explanation of Symbols...................7 2.2 Standards and Directives..................7 2.3 General Safety Instructions ..................7 2.4 Safety Instructions Regarding the Use of Tools and Auxiliary Means ....8 2.5 Safety Instructions for Maintenance Works ............9...
  • Page 4 6.7 Wheels ........................29 6.7.1 Inspecting the General Condition ................29 6.7.2 Replacing the Casing or Inner Tube of Pneumatic Tyres ........29 6.7.3 Replacing the Drive Wheel ..................30 6.7.4 Replacing the Wheel Flange ..................31 6.7.5 Mounting Splash Guards for Drive Wheels (option) ..........32 6.7.6 Replacing the Caster ....................32 6.7.7 Replacing the Caster Fork ..................33 6.7.8 Mounting Splash Guards for Caster Forks (option) ..........34...
  • Page 5 8.3.1 Hand Programming Device..................62 8.3.2 PC Programming Device ..................62 8.4 Programmable Parameters ..................63 8.4.1 Speed Settings ......................63 8.4.2 Setting of General Parameters ................66 8.4.3 Programming of the Light Module ................67 8.4.4 Log Functions ......................67 9 Maintenance and Service Plan B400 ................68...

  • Page 6: General Information

    This service manual describes all regularly required maintenance work as well as all repair and replacement work on the B00 from Otto Bock HealthCare GmbH. It provides the authorized dealer with all the knowledge required to eliminate malfunctions and mechanical defects on components of the B00.

  • Page 7: Safety Instructions

    Only original spare parts may be used for all service and maintenance. NOTICE Damage as a result of non-compliance with maintenance intervals. Otto Bock HealthCare GmbH recommends to have the B00 power wheelchair serviced and inspected by authorized personnel for functional reliability and driving safety once a year.

  • Page 8: Safety Instructions Regarding The Use Of Tools And Auxiliary Means

    The instructions for use can be requested from the manufacturer (see the overview of all Otto Bock branches "Otto Bock Worldwide”). Other documents can be downloaded from the homepage of Otto Bock HealthCare GmbH at www.ottobock.de or www. ottobock.com.

  • Page 9: Safety Instructions For Maintenance Works

    CAUTION Danger caused by dangerous substances. Dangerous substances at the workplace are allowed only in quantities needed for the progress of the work. Regularly and safely remove waste and residues. Immediately scavange any spilled substances. 2.5 Safety Instructions for Maintenance Works CAUTION Risk of injury caused by pinch points.

  • Page 10: Safety Instructions For Maintenance Works On Electrical Components

    Risk of injury when working on the battery. Only use battery chargers from Otto Bock that have been tested and approved by Otto Bock HealthCare GmbH for the batteries used (see information on the battery charger). Non-observance can result in battery explosion and health risk due to contact with acid.

  • Page 11: Safety Instructions For Disposal

    NOTICE Risk of damage if the B400 falls down. The maximum empty weight of the B00 power wheelchair is 9 kg / 209 lbs. The means of transportation and hoisting devices used for transportation must have...

  • Page 12: Storage

    If the B00 power wheelchair is not moved for several days, permanent colour changes might result on the ground where the wheelchair comes into contact with it. Otto Bock HealthCare GmbH therefore recommends using a suitable mat when parking the wheelchair for extended periods of time.

  • Page 13: Required Tools And Auxiliary Means

    4 Required Tools and Auxiliary Means The following list includes appropriate tools and auxiliary means for the execution of the service works: Flathead screwdriver und Phillips screwdriver ❒ Ring wrench or open-end wrench; sizes: 8 to 2 mm ❒ Allen wrench; sizes: 2, 3, , , , 7 mm ❒...

  • Page 14: Information Display

    fig. 3 Hand programming device 5 Information Display INfORMATION For error indication information with the LED display "Battery capacity” or with the aid of the hand programming device (Fig. 3)/PC software, please refer to section 7 "Error Diagnosis”. The wheelchair functions are displayed on the LED display fields of the control panel: LED display function The LEDs show the battery capacity (see instructions for use 7G8).

  • Page 15: Service Works

    6 Service Works 6.1 Inspecting the General Condition Check safety-relevant components for corrosion, repair if necessary, and restore corrosion ❒ protection. Check weld seams. ❒ Check screw connections for strength; reapply thread-locking compound, if necessary; observe ❒ defined tightening torque values; in case of defects (e.g. corrosion), replace the screws. Check cables for breaks, wear and tear, and proper attachment;...

  • Page 16: Batteries

    6.3 Batteries CAUTION Risk of injury when working on the battery. When working on the batteries, smoking and open flames are not permitted. Sparks must be avoided. Explosive gases can develop while the batteries are charging. Observe the safety instructions of the manufacturer of the battery.
  • Page 17 Top up with distilled water until the liquid level is between the "min” and "max” marks. Properly reassemble all components upon termination of the work. fig. 5 Opening the battery case, disconnecting the connections 1 Opening the battery case 2 Disconneting the battery cables fig.

  • Page 18: Charging The Batteries

    • Do not charge, if green LEDs are lit. • When the B00 power wheelchair is not used over extended periods of time, charge the wheelchair once a week. • The guarantee of Otto Bock HealthCare GmbH does not cover damages resulting from deep dis- charge. NOTICE Risk of damage to the battery charger/ Risk of damage caused by the battery charger.

  • Page 19: Replacing The Batteries

    Steps: Turn off the control of the power wheelchair. Connect the plug of the battery charger to the charging receptacle on the underside of the control panel. Connect the battery charger to a wall socket. The batteries will start charging automatically, and the current charge status is indicated by the LEDs of the battery charger (see Table 2).

  • Page 20: Removing The Battery Case

    Steps: Disconnect all connection cables from the batteries. Remove the batteries and replace them, if necessary. Properly reassemble all components upon termination of the work. 6.3.4 Removing the Battery Case NOTICE Risk of battery damage. When connecting the batteries, ensure correct pole assignment. Preparation: Remove the battery cover (see Section .3.1).

  • Page 21: Replacing The Controller

    Properly connect the battery cable to the battery. Properly reassemble all components upon termination of the work. fig. 7 Controller with connector plugs 1 Battery main cable 2 Motor plugs 6.4 Replacing the Controller INfORMATION When connecting the cables, ensure correct assignment. INfORMATION For information about the assembly of the light module refer to Section .8.3.

  • Page 22: Side Panels

    fig. 8 Disassembling the protective cover / Connections on the controller 1 Connection for control panel 2 Connection for motor 1 3 Connection for motor 2  Connection for lights  Connection for battery 6.5 Side Panels 6.5.1 Adapting/Replacing the Side Panels A side panel attachment device is located on the left and right sides of the seat frame.
  • Page 23 fig. 9 Adapting the side panel to the forearm length b) Adapting to upper arm length Steps: Loosen the set screw at the top of the side panel attachment device. Move the armrest to the required height. Tighten the set screw. fig.

  • Page 24: Replacing The Clothing Protectors

    fig. 11 Replacing the side panel 6.5.2 Replacing the Clothing Protectors Preparation: Remove the side panel. ❒ Tools: Allen wrench, size 3 mm ❒ Steps: Loosen the two Allen head screws on the side panel. Change the position of the closing protector or remove and remplace it, if necessary. Properly reassemble all components upon termination of the work.

  • Page 25: Footrests

    6.6 Footrests 6.6.1 Adapting/Replacing the Footrests Different footrest systems are available for the B00 power wheelchair, all offering the same setting and attachment options. The length and position of the footrests can be individually ad- justed to the wheelchair user. As an alternative to the standard version, elevating footrests with calf and knee pads can option- ally be installed.
  • Page 26 fig. 14 Adjusting the lower leg length 1 Set screw b) Adapting to thigh length This adjustment is made on footrest holder, which is attached to the seat frame. Steps: Pull the footrest release rearwards and pull out the footrest upwards (see Fig. 13). Loosen the two Allen head screws on the rear side of the receiver.
  • Page 27 Steps: Disassemble the standard footrest holder. Mount the footrest holder for elevating footrests. Loosen the Allen head screws. Remove and replace the standard footrests. d) Replacing the knee pads Steps: Remove the footrest. Loosen the Allen head screw (Fig. 1). Remove or replace the knee pad, if necessary.

  • Page 28: Replacing The Footplates

    fig. 17 Replacing the calf pad 6.6.2 Replacing the Footplates Different footplates are available for the B00 power wheelchair. As an alternative to the standard version with individual footplates, a continuous aluminium footplate can optionally be installed. Tools: Allen wrench, size  mm ❒...

  • Page 29: Wheels

    6.7 Wheels CAUTION Risk of accident as a result of bald or defective tyres. Wheels with PU tyres 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  mm of radius left on the outer edges of the tyre.

  • Page 30: Replacing The Drive Wheel

    Properly reassemble all components upon termination of the work. fig. 19 Removing the casing 6.7.3 Replacing the Drive Wheel NOTICE Damage as a result of improperly prepared maintenance. Secure the B00 power wheelchair with suitable objects, e.g. pieces of wood, to prevent it from slipping or tipping over. The drive wheels must be able to rotate freely.

  • Page 31: Replacing The Wheel Flange

    6.7.4 Replacing the Wheel Flange Preparation: Remove the wheel. ❒ Tools: Wrench socket, size 18 mm ❒ Pull-off tool ❒ Steps: Loosen the wheel flange screw (see Fig. 21). Remove the wheel flange using the pull-off tool and replace, if necessary (see Fig. 22). Properly reassemble all components upon termination of the work.

  • Page 32: Mounting Splash Guards For Drive Wheels (Option)

    6.7.5 Mounting Splash Guards for Drive Wheels (option) NOTICE Damage as a result of improperly prepared maintenance. Secure the B00 power wheelchair with suitable objects, e.g. pieces of wood, to prevent it from slipping or tipping over. The drive wheels must be able to rotate freely.

  • Page 33: Replacing The Caster Fork

    Steps: Loosen the Allen head screw. Remove and replace the caster, if necessary. Properly reassemble all components upon termination of the work. When reassembling, tighten the Allen head screw with a torque of 55 Nm. INfORMATION fig. 24 Disassembling the caster 6.7.7 Replacing the Caster Fork INfORMATION Do not tighten the fork to snugly, the fork must be able to turn by approximately 180°...

  • Page 34: Mounting Splash Guards For Caster Forks (Option)

    fig. 25 Standard caster fork 6.7.8 Mounting Splash Guards for Caster Forks (option) INfORMATION When mounting the caster, make sure that the caster and drive wheel are in line. The splash guard for casters must be attached to the caster fork. Preparation: Disassemble the caster.

  • Page 35: Control Panel / Light Module

    6.8 Control Panel / Light Module 6.8.1 Replacing the VR2/VR2-L Control Panel The control panel must be dis- and reassembled not only in case of replacement but also for mounting of the VR2-L control panel for control of the optional lights. Tools: Phillips screwdriver ❒...

  • Page 36: Replacing The Control Panel Holder

    The VR2-L control panel features additional keys to control the light function: function Light key Turns the front/rear lights on and off Warning flasher key Turns the warning flasher on and off (all four direction indicators flash simultaneously) Direction indicator right/left Turns the direction indicators on and off (indicators automatically stop flashing after 20 seconds) Table 3...

  • Page 37: Mounting The Light Module

    6.8.3 Mounting the Light Module CAUTION Risk of injury as a result of incorrect positioning. The housing of the light module can heat up to more than 0 °C. The light module must therefore be mounted in a place where the wheelchair user will not get in touch with it.
  • Page 38 fig. 30 Mounting the light module DETAIL VIEW FOR CABLING OF THE LIGHT MODULE VR2-L LIGHT MODULE 1 2 3 Earth Earth Lamps Lamps Direction Direction To the electric module indicators indicators 1 2 3 VIEW ON THE LIGHT MODULE Connector Function Pin 1...

  • Page 39: Lights

    6.9 Lights 6.9.1 Retrofitting Lights The lights for the B00 power wheelchair, which are optionally available, can be retrofitted at any time. a) front lights The front lights must be attached to the side panel. Preparation: Mount the VR2-L control panel and light module (see Sections .8.1/.8.3). ❒...

  • Page 40: Replacing Defective Lamps

    fig. 33 Retrofitting rear lights 6.9.2 Replacing Defective Lamps Tools: Allen wrench, size 3 mm ❒ Flathead screwdriver, small ❒ a) front light Steps: Push the black engaging lever at the lower end of the lamp to fold the halogen lamp along with pane forward.
  • Page 41 b) front direction indicator Steps: Slightly press into the notch on top of the housing until the nose jumps out. Fold down the cover. Turn the bulb a quarter turn counter-clockwise and remove it. Properly reassemble all components upon termination of the work. When installing the lamp, make sure that the nose of the bulb engages in the notch INfORMATION on the socket.

  • Page 42: Seats

    fig. 36 Replacing the bulbs of rear direction indicator and rear light 1 Direction indicator bulb 2 Rear light bulb 6.10 Seats CAUTION Risk of burns when near to fire. The backrest and seat of the B00 power wheelchair are flame retardant but nevertheless flammable.

  • Page 43: Standard Seat: Replacing/Adjusting The Back Upholstery

    fig. 37 Replacing the bearing plate 6.10.2 Standard Seat: Replacing/Adjusting the Back Upholstery Steps: Completely pull off the back upholstery and individually readjust, remove, or replace the hook and loop straps in accordance with the user‘s requirements. fig. 38 Standard seat: back upholstery 6.10.3 Standard Seat: Replacing the Seat Frame NOTICE Risk of cable damage.

  • Page 44: Standard Seat: Replacing The Seat Plate

    Steps: Loosen all cables fastened to the seat frame with cable ties. Loosen the two Allen head screws of the anterior seat brackets. Loosen the two Allen head screws of the posterior seat brackets. Remove and replace the seat frame, if necessary. Properly reassemble all components upon termination of the work.

  • Page 45: Standard Seat: Changing The Seat Height

    6.10.5 Standard Seat: Changing the Seat Height NOTICE Risk of cable damage. Make sure not to damage the cables that are fastened to the frame with cable ties. To change the seat height of the B00 power wheelchair, the seat brackets must be replaced. The seat brackets are screwed directly to the frame, at the front.

  • Page 46: Standard Seat: Replacing/Setting The Side Panel Attachment Devices

    Tools: Allen wrench, size  mm ❒ Ring wrench or open-end wrench, size 13 mm ❒ Steps: Loosen the lower screw connections of the anterior seat brackets. Push the seat unit up or down to the desired seat inclination. Retighten the screw connections of the seat brackets. Properly reassemble all components upon termination of the work.

  • Page 47: Replacing The Drive Unit Sustainer

    fig. 43 Side panel attachment device 1 Side panel attachment device 6.11 Replacing the Drive Unit Sustainer CAUTION Risk of injury due to electric current. Prior to working on the drive unit sustainers turn off the B00 power wheelchair and disconnect all plug connections between the drive unit sustainer and frame. Before removing the motors, loosen the wires of the brake release.

  • Page 48: Replacing The Drive Motor

    Electrostatic charging, caused by friction, for example, can result in discharge (high INfORMATION voltages with low current) when touching the wheelchair; however, this does not represent any health risk. This reduction of comfort can be prevented by attaching an earthing strap to the drive unit sustainer/wheelchair frame.

  • Page 49: Accessories

    6.14 Accessories 6.14.1 Retrofitting Mechanical Seat Tilt Mechanism Preparation: Remove the seat plate. ❒ Tools: Allen wrench, sizes 2, ,  mm ❒ Ring wrench or open-end wrench, sizes 10, 13 mm ❒ Steps: 1. Remove the cover stopple frame the frame. 2.

  • Page 50: Attaching The Bowden Cable (For Seat Tilt)

    fig. 45 Retrofitting the mechanical seat tilt mechanism 6.14.2 Attaching the Bowden Cable (for seat tilt) Preparation: Mount the gas compression spring. ❒ Remove the side panel. ❒ Tools: Allen wrench, sizes 2,  mm ❒ Steps: Mount the C-profile for the Bowden cable attachment beneath the armrest. Mount the clamp piece and sliding nut.

  • Page 51: Retrofitting A Curb Climbing Assist

    6.14.3 Retrofitting a Curb Climbing Assist Tools: Allen wrench, size  mm ❒ Open-end wrench, size 13 mm ❒ Steps: Insert the curb climbing assist into the frame: on the left side into the frame cutout (Fig. 7-1); on the right side into the half oval frame hole (Fig. 7-2). Insert the Allen head screw from above.

  • Page 52: Installing A Swivel Lock (Option)

    6.14.5 Installing a Swivel Lock (option) INfORMATION The swivel stops prevent the casters from turning. In addition, they counteract possible fluttering when driving straight forward for a longer time. Preparation: Disassemble the caster fork. ❒ Tools: Allen wrench, size  mm ❒...

  • Page 53: Retrofitting A Lap Belt (Option)

    fig. 50 Assembling the holding device for headrest attachment 6.14.7 Retrofitting a Lap Belt (option) The lap belt is available for both seat models and must be attached to the sides. It is not neces- sary, however, to additionally attach it to the rear side of the seat frame. The belt must be attached to the bearing plate with an attachment plate with eyelet and a screw.

  • Page 54: Error Diagnosis

    fig. 52 Mounting a luggage carrier 7 Error Diagnosis NOTICE Damage as a result of unauthorized service. An improperly or poorly executed repair can cause unsafe operation of the power wheelchair. The error diagnosis may therefore only be carried out by authorized dealers who have profound knowledge of electronic controllers from Otto Bock.

  • Page 55: Diagnostic Steps

    7.1 Diagnostic Steps For an efficient and successful error diagnosis proceed as follows: Verify, whether the error was released for a concrete reason or if the error indication has oc- ❒ curred sporadically. Find out the type of error. ❒ Refer to the table of error types (Section 7.3, Table 7) to read the possible cause and perform ❒...
  • Page 56 The following table lists the error messages/flashing signals on the LED display field "Battery capacity” as well as causes and corrective measures: flashing LED(s) Error/warning Cause Measure Low battery capacity Total battery dis- Charge the battery Battery cable malfunc- charge tioning / faulty connection Check the connection to the to the battery...

  • Page 57: Diagnosis Using The Hand Programming Device (See Also Section 8.3)

    7.3 Diagnosis Using the Hand Programming Device (see also Section 8.3) INfORMATION The programming device may only be connected to the control system, once the LED display has started flashing. If the programming device was connected before the display started flashing, the error code will not be displayed.
  • Page 58 Cause / measure Low battery voltage The control system has detected a decline of the battery voltage to below 1 V. Check the condition of the batteries and the connections to the control system. If the error per- sists, there might be a defect in the electric module. If error code 2C02 applies, the control system creates a log about the frequency of INfORMATION switch-offs caused by low battery voltage.
  • Page 59 Cause / measure Possible error in the control system The control system has detected an internal problem. The control system may only be repaired by an authorized specialist. Error in the electromagnetic brake The control system has detected a problem in the electromagnetic brakes or in the connections of the brakes.

  • Page 60: Other Errors (Not Displayed)

    7.4 Other Errors (not displayed) These are errors that are not displayed in the hand programming device or on the LED dis- play. The reasons can be: The control cannot be switched on, the error is not serious enough, or the control system cannot detect the error for any other reason.

  • Page 61: Vr 2 Wheelchair Control - Installation And Programming

    8 VR 2 Wheelchair Control – Installation and Programming 8.1 Overview The VR2 control offers the possibility to display causes of error messages. Error sources in the drive section and in the electric options are indicated by flashing of the LEDs of the control (see Section 7.2).

  • Page 62: Programming Tools

    8.3 Programming Tools WARNING Risk of injury as a result of incorrect programming. Programming may only be conducted by specialist staff with in-depth knowledge of the VR2 control. Incorrect programming could result in an unsafe set- up of a wheelchair for a user. Otto Bock or the manufacturer of the control accept no responsibility for losses of any kind if the programming of the control system is altered from the factory pre-set values.

  • Page 63: Programmable Parameters

    8.4 Programmable Parameters The following programmable parameters represent a selection. Information on other programmings is contained in the document "VR2 SERIES WHEELCHAIR CONTROL SYSTEM; OPERATION, INSTALLATION & PROGRAMMING”. 8.4.1 Speed Settings Parameter Setting range Description Acceleration Single steps Adjusts the value for forward and reverse acceleration of the from 0 to 100 wheelchair.
  • Page 64 Parameter Setting range Description Power Single steps Sets the power of the wheelchair. Power is the ability of a from 0 to 100% wheelchair to climb a hill or overcome an obstacle. If it is set to 100% then the wheelchair will provide full power. Values below 100% will result in reduced power.
  • Page 65 Parameter Setting range Description Minimum Decel- 1% increments Adjusts the minimum value for forward and reverse deceleration eration of the param- of the wheelchair. eter Decelera- This percentage of the Deceleration value occurs when the tion speed setting is at 1. Programming example: •...

  • Page 66: Setting Of General Parameters

    8.4.2 Setting of General Parameters Parameter Setting range Description Sleep Timer 1-minute incre- Sets the period of time before the control system will turn itself ments from 0 to off if the wheelchair is not driven. 30 min. If the time is set to 0 the system will never turn itself off. Joystick Throw This allows programming so that full speed can be reached with a reduced joystick movement (throw).

  • Page 67: Programming Of The Light Module

    8.4.3 Programming of the Light Module The light module is pre-programmed. By programming, the light module can be adapted to the respective lights (see Section .9). Programmable Presetting Possible adaptation function Operating voltage 2 V 12 V (the lamps must correspond to the value of lamps or must be replaced) Lamp power...

  • Page 68: Maintenance And Service Plan B400

    9 Maintenance and Service Plan B400 Customer: Re-use Year of manufacture: Serial no.: B00 general condition Driving report: Components (assemblies) Carefully check all components listed here for correct function, setting, damages, or deformations, and whether the screw connections are tightened!
  • Page 69 Maintenance and Service Plan B400 7 Seat adjustments Mechanical seat tilt 8 Side panel Attachment devices Clothing protector Attachment device for lights 9 footrests Receivers Elevating footrest 10 Options front lights Rear lights Belt Curb climbing assist Adapter for headrest...
  • Page 72 Otto Bock HealthCare GmbH Lindenstraße 13 · 072 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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