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Otto Bock C2000 Service Instructions Manual

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Summary of Contents for Otto Bock C2000

  • Page 1 Front-wheel drive Rear-wheel drive C2000 Service Instructions...

  • Page 2: Table Of Contents

    C2000 Service Instructions Contents Page 1 General Information ......................6 1.1  Preface  ........................6 1.2  Support  ........................6 2 Safety ..........................6 2.1  Symbol Legend  .......................6 2.2  General Safety Instructions ...................6 2.3    S afety Requirements for the Use of Tools and Aids  ..........7 2.4  Safety Requirements for Service and Maintenance Tasks  ........8 2.5    S afety Requirements for Maintenance Tasks on Electrical Components ...10 2.6 ...
  • Page 3 6.8.5  Removing the Drive Wheel Splash Guard ...............33 6.8.6  Removing the Steering Caster Splash Guard ............33 6.8.7  Caster Fork ......................34 6.9  Removing Springs, Changing the Spring Tension ..........34 6.9.1  Removing the Drive Axle Spring ................34 6.9.2  Removing the Steering Axle Spring  .................35 6.10  Steering ......................36 6.10.1  Adjusting the Chain Tension...................36 6.10.2  Steering motor .......................38 6.10.3  Steering Potentiometer  ..................38 6.11  Wheel Lock and Wheel Lock Release ..............39 6.11.1  Replacing the Wheel Lock Release and Bowden Cables  ........39 6.11.2  Setting / Adjusting the Wheel Lock Release............40 6.11.3  Performing a Brake Setting Function Check ............42 6.12  Lighting .......................43 6.12.1  Front lights  ......................43 6.12.2 ...
  • Page 4 6.14.4  Retrofitting the Seat Module .................. 74 6.14.5  Removing the Seat Tilt Actuator ................75 6.14.6  Removing the Back Angle Adjustment Actuator ........... 76 6.14.7  Removing the Seat Height Adjustment Actuator  ........... 77 6.15  Replacing the Side Tube  ..................78 6.16  Removing the Drive Motor ..................78 6.17  Removing the Drive Axle  ..................80 6.18  Replacing the Steering Axle / Drive Axle Rubber Oscillating Crank Mount  ..81 6.19  Replacing / Retrofitting Control Elements ............83 6.19.1  Mounting an LCD Monitor  ..................83 6.19.2  Replacing the Control Panel ..................85 6.19.3  Replacing the Control Panel Holder ..............85 6.19.4  Retrofitting the Detachable and Swing-Away Control Panel  .........86 6.19.5 ...
  • Page 5 8.5  Programmable Parameters  ................109 8.5.1  Main Parameters  ....................110 8.5.2  "Driving" Parameter Settings ................114 8.5.3  “Joystick” Parameter Settings ................119 9 C2000 Maintenance and Service Plan ................. 120...

  • Page 6: General Information

    These service instructions describe all regular maintenance tasks as well as repair and re- placement tasks for the C2000 power wheelchair from Otto Bock. They include all information required by authorised personnel to correct functional and mechanical defects on components of the power wheelchair.

  • Page 7: S Afety Requirements For The Use Of Tools And Aids

    NOTICE Risk of damage caused by failure to comply with maintenance intervals. Otto Bock recommends having the power wheelchair inspected and maintained for functionality and operational safety by au- thorised personnel at least once a year. In case of frequent user changes (growing children or youths) or users with changing clinical pictures, the wheelchair should be inspected, adjusted and maintained twice a year.

  • Page 8: Safety Requirements For Service And Maintenance Tasks

    CAUTION Risk of health impairment due to the use of improper work clothing. Ensure legally prescribed pro- tective work clothing is worn. CAUTION Risk of injury during tasks that involve lifting. When repair and maintenance tasks must be completed under raised parts or equipment, ensure suitable precautions are taken to secure the applicable com- ponents against falling.
  • Page 9 Hazards while working on the brake system. All repairs and adjustments to the wheel lock may only be made by personnel that has been authorised by Otto Bock. Incorrect settings can lead to a loss of brake functionality, and therefore to serious bodily injuries and even death.

  • Page 10: S Afety Requirements For Maintenance Tasks On Electrical Components

    Risk of injury while working on the battery. • Only use a battery charger supplied by Otto Bock which has been tested and approved for the re- spective batteries used by Otto Bock (observe information on the charger). Failure to do so can result in a battery explosion and possible impairment of health due to contact with battery acid.
  • Page 11 Ensure that the cooling ribs on the back of the device are not covered. INfORMATION For the purpose of shipping or when the C2000 power wheelchair is not being used for an extended period of time, remove the fuse from the battery case in order to prevent deep discharge of the batteries due to standby current.

  • Page 12: Safety Functions

    / programming is complete. Programming must only be completed by author- ised personnel. Neither Otto Bock nor the control unit manufacturer are liable for damages (especially in combination with special controls) caused by programming that was not properly / professionally adapted to the abilities of the wheelchair user.

  • Page 13: Transportation And Storage

    3 Transportation and Storage The following environmental conditions apply to transportation and storage: Ambient temperature -40 °C to +65 °C 3.1  Transportation CAUTION Risk of injury due to insufficient restraints. Secure the power wheelchair during transportation in another vehicle by tightening the tensioning straps properly. Only attach the tensioning straps to the corresponding eyebolts and mounting points.

  • Page 14: Folding For Transportation

    3.1.1 folding for Transportation 1. Flip up the footrests. 2. Remove the side panels (see Section 6.13.10). 3. Fold down the back rest (see Section 3.1.2). figure 2 flipping up the footrests 3.1.2 folding the back rest 1. Remove the side panels (see Section 6.13.10). 2.

  • Page 15: Folding The Back Rest With Electric Back Angle Adjustment

    2. Push up the lever and release the cross bolt at the lower end of the drive unit. 3. Remove the cross bolt from the holder. 4. Fold the back rest forward and lay it down onto the seat bottom. figure 4 Removing the cross bolt figure 5 C2000 power wheelchair folded for transportation...

  • Page 16: Storage

    The power wheelchair must not be subjected to any damaging exterior influences, e.g. rain, snow, or strong solar radiation during storage. Otto Bock recommends storing the power wheelchair with slightly elevated tyre pressure and using assembly stands or wooden blocks in order to raise the tyres (completely) off the ground...

  • Page 17: Required Tools And Accessories

    4 Required Tools and Accessories Suitable tools and aids for the completion of service tasks are listed below: ❒ Flat screwdrivers, blade widths: 2.5/3.5/5.5 mm ❒ Phillips head screwdriver, size 2 mm ❒ Reversible ratchet handle wrench and sockets, sizes 8 – 20 mm ❒...

  • Page 18: Information Display

    figure 7 Handheld programming device 5 Information Display INfORMATION For information on the display of errors with the help of the control panel display / LCD monitor or with the help of the handheld programming device / PC software, please see Section 7 and 8. Messages are shown on the control panel display or LCD monitor: Display Symbol(s) LCD Monitor Display...
  • Page 19 Coupled electric seat adjustment – (back rest and seat tilt) Special functions, e.g. coupled electric seat ‘ – adjustment (back adjustment and seat tilt) Seat height adjustment Electric footrests, coupled Electric footrest, left Electric footrest, right Drive-away lock Creep speed Attendant control Table 1 Information Display on the Control Panel / LCD Monitor...

  • Page 20: Service Tasks

    6 Service Tasks 6.1  Inspecting the General Condition ❒ Check all safety-related components for corrosion, repair if required and reapply corro- sion protection. ❒ Check weld seams. ❒ Check tightness of screw connections; replace thread-locking compound if required; ob- serve any defined torque specifications; replace defective screws (e. g. in case of corro- sion).

  • Page 21: Batteries

    • Ensure correct polarity is used when connecting the batteries and battery capacity meter. The standard version of the C2000 power wheelchair includes two low-maintenance 12 V gel batter- ies. The batteries are located under the seat of the power wheelchair.
  • Page 22 • Only use a battery charger supplied by Otto Bock which has been tested and approved by Otto Bock for the respective batteries (observe information on the charger). Failure to do so can result in a battery explosion and possible impairment of health due to contact with battery acid.
  • Page 23 1 Charging receptacle 2 Metal pin figure 10 Otto Bock battery charger The battery charger features a programmed recharging phase. Once a discharged battery is completely charged (after approximately 8 hours), the battery charger can remain connected with no risk of overcharging or damaging the battery.

  • Page 24: Battery Replacement

    If none of the LEDs are lit, there is no power supply. The battery capacity is indicated by the "Battery Capacity" LEDs in 7 segments. Each segment represents approximately 14 % of the total capacity. 6.3.2 Battery Replacement NOTICE Risk of battery damage. Ensure correct polarity is used when connecting the batteries. The black ca- ble must be connected to the negative pole and the red cable to the positive pole.

  • Page 25: Reinstalling The Battery Cable

    6.4  Reinstalling the Battery Cable Preparation: ❒ Remove the seat including seat frame (see Section 6.13.1 and 6.13.5). ❒ Remove the batteries (see Section 6.3.2). Tools: ❒ Flat screwdriver ❒ Ring or open-end wrench, size 8 ❒ Side cutting pliers Steps: 1. Remove the controller cover. 2.

  • Page 26: Replacing The Charging Receptacle

    6.5  Replacing the Charging Receptacle INfORMATION When connecting the cables, ensure correct assignment. Preparation: ❒ Turn the control unit off. ❒ Remove the fuse (see Section 6.2). ❒ Remove the seat including seat frame (see Section 6.13.1 and 6.13.5). ❒ Remove the batteries (see Section 6.3.2). Tools: ❒...

  • Page 27: Replacing The Controller

    6.6  Replacing the Controller The controller on the C2000 is attached above the drive axle (on the outside of the battery case). INfORMATION When connecting the cables, ensure correct assignment. Preparation: ❒ Remove the fuse (see Section 6.2). Tools: ❒ Flat screwdriver ❒...

  • Page 28: Replacing The Seat Module

    figure 15 Connections on the controller, disconnecting 1 Actuator, steering motor, steering potentiometer connector 2 Left motor connector (493E62=LK00x) 3 Battery cable connector 4 Right motor connector (493E62=RK00x) 6.7  Replacing the Seat Module The seat module is attached on the seat frame underneath the seat. INfORMATION When connecting the cables, ensure correct assignment.

  • Page 29: Wheels

    figure 16 Removing the seat module 6.8  Wheels CAUTION Risk of accidents due to worn or defective tyres. Replace wheels with PU tyres if the material is cracking or damaged, 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 tyre.

  • Page 30: Removing The Drive Wheel

    6.8.2 Removing the Drive Wheel NOTICE Risk of damage due to uncontrolled movements. When raising the power wheelchair, e.g. with a jack, secure it against slipping and tipping sideways by using a suitable block under the drive unit sustainer. Preparation: ❒...

  • Page 31: Removing The Steering Caster

    6.8.3 Removing the Steering Caster NOTICE Risk of damage due to uncontrolled movements. When raising the power wheelchair, e.g. with a jack, secure it against slipping and tipping sideways by using a suitable block under the drive unit sustainer. Preparation: ❒...

  • Page 32: Replacing The Casing And / Or Inner Tube

    The wheels on the drive and steering end have rims consisting of 2 sections. Therefore, this step is not possible / required. 6.8.4 Replacing the Casing and / or Inner Tube The wheel rims are in two parts and can be separated by removing the Allen head screws. Preparation: ❒...

  • Page 33: Removing The Drive Wheel Splash Guard

    6.8.5 Removing the Drive Wheel Splash Guard Preparation: ❒ Remove the drive wheel (see Section 6.8.2). Tools: ❒ Allen wrench, size 4 ❒ Open-end or combination wrench, size 10 Steps: 1. Loosen and remove the six Allen head screws. 2. Remove the splash guard and replace if required. Properly reassemble all components upon completion of the work.

  • Page 34: Caster Fork

    Risk of accidents and injury due to improper completion of work on the steering system. In order to avoid damage or incorrect settings on the chain steering system, the removal and installation of the caster forks may only be completed at the plant of Otto Bock Manufacturing Königsee GmbH. 6.9  Removing Springs, Changing the Spring Tension NOTICE Risk of damage due to improper preparation of maintenance tasks.

  • Page 35: Removing The Steering Axle Spring

    figure 22 Removing the drive axle spring 6.9.2 Removing the Steering Axle Spring The springs on the steering axle are attached to the drive unit sustainer at two points. Preparation: ❒ Remove the steering caster (see Section 6.8.3). ❒ Remove the splash guard (see Section 6.8.7). Tools: ❒...

  • Page 36: Steering

    NOTICE Risk of damage due to the improper completion of maintenance tasks. The removal and instal- lation of the chain may only be completed at the plant of Otto Bock Manufacturing Königsee GmbH. NOTICE Risk of tyre damage. Incorrect chain settings may lead to uneven tyre wear, which can have a nega-...
  • Page 37 The chain tension is adjusted using two adjustment screws on the side opposite the steering motor. Preparation: ❒ Align the steering casters and drive wheels: They must be parallel and in line with each other. Tools: ❒ Allen wrench, size 3 ❒...

  • Page 38: Steering Motor

    Risk of accidents and injury due to improper completion of work on the steering potentiometer. An incorrectly installed and / or adjusted steering potentiometer can lead to steering system malfunction. The removal and installation of the steering potentiometer, including all adjustment tasks, may only be completed at the plant of Otto Bock Manufacturing Königsee GmbH.

  • Page 39: Wheel Lock And Wheel Lock Release

    Both drive motors of the C2000 power wheelchair are braked simultaneously by the control unit via a motor brake. In case of braking unit defects, the motor brake can only be replaced as a unit with the drive motor.

  • Page 40: Setting / Adjusting The Wheel Lock Release

    Repairs and settings must only be made by authorised personnel. Replace damaged Bowden cables with new ones immediately. Correct wheel lock settings are essential for safe driving. This is why Otto Bock recommends inspecting the wheel lock every three months.
  • Page 41 (e.g. cable replacement), the Bowden cable should have very little play before adjusting it. INfORMATION Lock the adjustment screw every time the setting is changed. Otto Bock recommends making adjust- ments in small increments (½ turn). Tools: ❒...

  • Page 42: Performing A Brake Setting Function Check

    figure 31 Attachment of the Bowden cables on the drive motors 1 Threaded rod for readjustment 6.11.3 Performing a Brake Setting function Check During the functional test of the brake settings, please observe the following points and com- plete the tasks described below: Steps: 1.

  • Page 43: Lighting

    6.12  Lighting The C2000 power wheelchair is equipped with front and rear lighting as standard equipment. The lighting functions are activated and deactivated via the controller. The warning flashers and right / left direction indicator lights are activated using the control panel.
  • Page 44 b) Replacing the halogen lamp, front lighting: 1. Fold the pane forward with slight pressure on the black locking lever at the lower end of the lamp. 2. Remove the pane with the attached halogen lamp. 3. Replace the defective halogen lamp with a new one. 4.

  • Page 45: Rear Lights

    figure 34 Replacing the front direction indicator lamp 6.12.2 Rear lights NOTICE Risk of damage due to moisture. Do not expose the lamps to moisture. When reinserting the protec- tive pane, make sure it sits correctly in the housing and that the screws are firmly tightened. INfORMATION When ordering spare parts for the rear lighting, note that the rear lighting mount differs between power wheelchairs with front and rear-wheel drive.
  • Page 46 figure 35 Removing the rear lights, rear-wheel drive b) Removing the rear lights, front-wheel drive Preparation: ❒ Remove the battery case cover (see Section 6.3.2). Tools: ❒ Allen wrench, size 5 ❒ Open-end or combination wrench, size 10 Steps: 1. Disconnect the connection between the rear lighting and the controller in the battery case. 2.

  • Page 47: Seat

    c) Replacing defective rear direction indicator lights and rear lights: 1. Loosen the screws with a narrow flat screwdriver and remove the protective pane. 2. Remove the defective bulb from the socket and replace it. Properly reassemble all components upon completion of the work. figure 37 Removing the rear lights 1 Direction indicator bulb...

  • Page 48: Standard Seat: Removing The Seat Cushion And Back Pad

    CAUTION Risk of accidents due to unsecured screw connections. When screw connections with thread locks are loosened, they must be equipped with new thread locks or secured with a medium-strength thread lock compound (e.g. Loctite 241®. CAUTION Risk of burns in the proximity of fire. The back rest and seat bottom of the power wheelchair are flame retardant but nevertheless flammable.

  • Page 49: Replacing The Bearing Plate (Standard And Contour Seat)

    6.13.3 Replacing the Bearing Plate (Standard and Contour Seat) Tools: ❒ Allen wrench, size 5 ❒ Open-end or combination wrench, size 13 Steps: 1. Loosen the three Allen head screws. 2. Remove the bearing plate and replace if required. Properly reassemble all components upon completion of the work. INfORMATION The screw in the middle of the plate serves as stop for the back angle adjustment.

  • Page 50: Standard And Contour Seat: Replacing The Seat Frame

    figure 41 Standard seat: Seat plate 6.13.5 Standard and Contour Seat: Replacing the Seat frame NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process! Preparation, standard seat: ❒...

  • Page 51: Standard Seat And Contour Seat: Adjusting The Seat Depth

    figure 42 Removing the seat frame figure 43 Removing the seat frame with seat tilt 6.13.6 Standard seat and contour seat: Adjusting the seat depth INfORMATION The seat depth can be adjusted in increments of 20 mm. Use both hands to move the tubes in the seat frame evenly in order to prevent them from jamming.

  • Page 52: Standard Seat And Contour Seat: Adjusting The Seat Height

    figure 44 Adjusting the seat depth: Repositioning the bearing plate and footrest 6.13.7 Standard seat and contour seat: Adjusting the seat height NOTICE Risk of cable damage. Ensure the cables attached to the frame with cable ties are not damaged. Changing the seat height requires replacement of the seat brackets.
  • Page 53 Tools: ❒ Allen wrench, size 5 ❒ Open-end or combination wrench, size 13 Steps: 1. Loosen and remove the screw connection on the connecting bracket. 2. Select the corresponding bore in the connecting bracket according to Figure 45 and attach the connecting bracket.

  • Page 54: Seat Brackets

    6.13.9 Seat Brackets The following seat brackets are available to adjust the seat angle and seat height: a) front-wheel drive "Regular" Seat Setup Electric Reference Lift Unit with Tilt Standard / Contour / Recaro Seat) Seat Tilt Seat inclination 0° 3°...
  • Page 55 b) Rear-wheel drive "Regular" Seat Setup Electric Reference Lift Unit with Tilt Standard / Contour / Recaro Seat) Seat Tilt Seat inclination 0° 3° 6° 0° 0° Bracket 491C62=SS038 491C62=SS038 491C62=SS038 491C62=SS007 491C62-SS012 – front – Bracket 491C62=SS037 491C62=SS037 491C62=SS037 491C62=SS007 491C62=SS012 –...
  • Page 56 figure 47 Installation example: SH45 – 6° figure 48 Installation example: SH50 – 0° figure 49 Installation example: SH50 – 3°...
  • Page 57 figure 50 Installation example: SH50 – 6° figure 51 Installation example: Seat brackets, standard seat with seat height adjustment and seat tilt figure 52 Installation example: Seat brackets, standard seat with seat tilt...
  • Page 58 figure 53 Seat brackets, Recaro® seat with seat tilt figure 54 Installation example: Seat brackets SH50 – 0° with rear-wheel drive...

  • Page 59: Removing The Side Panel

    6.13.10 Removing the Side Panel The side panel can be removed along with the arm rest. Steps: 1. Loosen the thumb screw at the lower end of the side panel holder. 2. Pull the side panel with arm rest up and out. Properly reassemble all components upon completion of the work.

  • Page 60: Adjusting / Replacing The Clothing Protector

    Adapting the arm rests to the forearm length Tools: ❒ Allen wrench, size 3 Steps: 1. Loosen the two set screws (three set screws on the control panel side) underneath the arm rest. 2. Move the arm rest (with the control panel holder or the replacement tube) forward or back along the attachment rail into the desired position.

  • Page 61: S Tandard And Contour Seat: Replacing

    figure 58 Adjusting the clothing protector 6.13.13 Standard and Contour Seat: Replacing / Adjusting the Side Panel Attachment Device The attachment device is located on either side on the rear cross brace under the seat. Tools: ❒ Allen wrench, size 4 Steps: 1.

  • Page 62: Retrofitting The Four-Way Chest Strap (Option For Recaro® Seat Only)

    6.13.14 Retrofitting the four-Way Chest Strap (Option for Recaro® Seat Only) The attachment device is located on either side on the rear cross brace under the seat. Tools: ❒ Screwdriver ❒ Allen wrench, size 4 ❒ Hand drill ❒ 4 mm drill bit Steps: 1.

  • Page 63: Lap Belt

    6.13.15 Lap Belt The power wheelchair can be retrofitted with a lap belt as an option. a) Installing the lap belt Preparation: ❒ Move the seat up until the corresponding mounting points are freely accessible. Tools: ❒ Allen wrench, size 5 ❒...

  • Page 64: Retrofitting The Arm Strap

    b) Adjusting the belt length The belt length can be adjusted on both sides. 1. Position the buckle halves in the middle of the body. 2. After positioning the buckle halves at a right angle in relation to the belt, their position can be varied.

  • Page 65: Installing The Contour Seat (Optional)

    Properly reassemble all components upon completion of the work. figure 64 Contour seat with clamp fittings 1 Frame for back rest 2 Contour seat back rest 3 Mounting clamp (6 pieces) 6.13.18 Installing the Recaro® Seat (Optional) figure 65 C2000 power wheelchair with Recaro® seat...
  • Page 66 a) Replacing the mobility base Tools: ❒ Allen wrench, size 5 Steps: 1. Pull the latch underneath the seat, slightly lift the seat and push it back. 2. Remove the seat. 3. Unscrew the seat brackets from the front and rear of the frame. 4.
  • Page 67 figure 67 Unlocking and mounting the Recaro® seat c) Retrofitting seat modules (optional) The seat bottom of the Recaro® seat module is attached to the seat frame and removed in the same manner as the complete Recaro® seat. The modular back rest is hooked into the seat bottom.

  • Page 68: Adapting / Replacing The Footrests

    They are mounted to the C2000 power wheelchair with an adapter at- tached to rails that are already adapted in their length to the user. The C2000 power wheel- chair in the rear-wheel drive version is only available with the narrow footrests. All versions of the footrests can be flipped up.

  • Page 69: Removing The Footrest Including Adapter

    figure 69 Removing the footrest connecting tube 6.13.21 Removing the footrest Including Adapter Tools: ❒ Allen wrench, size 5 ❒ Open-end or combination wrench, size 13 Steps: 1. Loosen and remove the two Allen head screws on the left and right of the anterior seat frame, respectively.

  • Page 70: Electric Seat Functions

    Please see the EnAble50 instructions for use for more information (647G490=D/GB). 6.14.1 Retrofitting the Electric Seat Tilt (Optional) The C2000 power wheelchair may be retrofitted with a seat tilt option. It is integrated into the seat frame and operated by an actuator.
  • Page 71 Steps: 1. Install the pre-assembled unit on the wheelchair frame with the help of the seat brackets. Observe the correct position of the four seat brackets for correct traction. Consult the in- formation / installation examples in Section 6.13.9. 2. Connect the actuator to the controller or seat module. 3.

  • Page 72: Retrofitting The Electric Back Angle Adjustment (Optional)

    6.14.2 Retrofitting the Electric Back Angle Adjustment (Optional) A back frame with crossbrace, new upholstery and a back rest actuator are required to install the electric back angle adjustment option. The electric back angle adjustment option is delivered as a preassembled unit. Preparation: ❒...

  • Page 73: Retrofitting The Seat Height Adjustment Function (Optional)

    (see Section 6.9.1). The C2000 power wheelchair can be retrofitted with one of two versions of the seat height ad- justment function (up to 130 kg or up to 200 kg).

  • Page 74: Retrofitting The Seat Module

    6.14.4 Retrofitting the Seat Module INfORMATION For information on connecting the seat module, please see Section 6.2. After new electric seat functions are installed and connected, the control unit has to be reprogrammed. Please see the EnAble50 instructions for use for more information (647G490=D/GB). Controlling more than one electric seat function requires the installation of a seat module.

  • Page 75: Removing The Seat Tilt Actuator

    6.14.5 Removing the Seat Tilt Actuator NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process! Preparation: ❒...

  • Page 76: Removing The Back Angle Adjustment Actuator

    6.14.6 Removing the Back Angle Adjustment Actuator NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process! Preparation: ❒...

  • Page 77: Removing The Seat Height Adjustment Actuator

    6.14.7 Removing the Seat Height Adjustment Actuator NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process! Preparation: ❒...

  • Page 78: Replacing The Side Tube

    6.15  Replacing the Side Tube Tools: ❒ Allen wrench, size 4 Steps: 1. Loosen and remove an Allen head screw at the front and rear of the side tube, respectively. 2. Remove the side tube and replace if required. Properly reassemble all components upon completion of the work. figure 78 Removing the side tube 6.16 ...
  • Page 79 figure 79 Removing the lower cover plate 3. Open the cable ties. 4. Disconnect the drive motor connection cable on the controller: a. Right-hand plug on the controller = right-hand drive motor b. Left-hand plug on the controller = left-hand drive motor 5.

  • Page 80: Removing The Drive Axle

    Properly reassemble all components upon completion of the work. figure 81 Cable bridge 6.17  Removing the Drive Axle Preparation: ❒ Remove the drive motors (see Section 6.16). ❒ Remove the drive axle spring (see Section 6.9.1). Tools: ❒ Allen wrench, size 10 ❒ Open-end or combination wrench, size 19 Steps: 1.

  • Page 81: Replacing The Steering Axle / Drive Axle Rubber Oscillating Crank Mount

    80 –160 kg or 160 – 260 kg. INfORMATION In order to assure balanced driving characteristics, Otto Bock recommends replacing the rubber os- cillating crank mounts and / or their single components in pairs per axle only. figure 83...
  • Page 82 figure 84 Unscrewing the rubber oscillating crank mounts, steering axle 2. Tilt the steering axle / drive axle up on the corresponding spring around the pivot point. 3. Remove the rubber oscillating crank mount and replace single components if required. Properly reassemble all components upon completion of the work.

  • Page 83: Replacing / Retrofitting Control Elements

    figure 86 Installation position of rubber inserts, steering axle figure 87 Rubber cover and rubber inserts for drive axle 6.19  Replacing / Retrofitting Control Elements 6.19.1 Mounting an LCD Monitor INfORMATION For more information and operating instructions for the LCD monitor, please consult the enAble50 con- trol unit instructions for use (647G490=D/GB).
  • Page 84 figure 88 LCD monitor Tools: ❒ Allen wrench, size 2 Steps: 1. Slide the square tube for the holder adapter onto the attachment rail below the arm rest and secure it with two set screws (applies to standard holder, height and / or laterally adjustable holder, swan neck holder).

  • Page 85: Replacing The Control Panel

    6.19.2 Replacing the Control Panel The standard configuration has the control panel mounted on the right side. Depending on whether the wheelchair user is a right hander or left hander, it can be mounted to either arm rest. NOTICE Risk of cable damage. Positioning the cables incorrectly can lead to pinching and therefore damage to the cables.

  • Page 86: Retrofitting The Detachable And Swing-Away Control Panel

    figure 90 Removing the control panel holder 6.19.4 Retrofitting the Detachable and Swing-Away Control Panel The power wheelchair can be equipped with a removable control panel on a swing-away control panel holder. For this purpose, the control panel is equipped with a spring steel sheet as a holder. CAUTION Risk of injury due to uncontrolled driving characteristics.

  • Page 87: Retrofitting The Height-Adjustable Control Panel Holder

    figure 91 Installing the detachable control panel holder 6.19.5 Retrofitting the Height-Adjustable Control Panel Holder An optional special control panel holder can be mounted on the power wheelchair, allowing the height of the control panel to be adjusted. Tools: ❒ Allen wrench, size 3 ❒...

  • Page 88: Retrofitting Attendant Controls

    6.19.6 Retrofitting Attendant Controls figure 93 Attendant controls a) Installation on the standard or contour seat Attendant controls are delivered as an installation kit. On the power wheelchair with the standard or contour seat, they are attached to cross tube on the back rest. Two bore holes are provided for this purpose on the left and right of the back tube, respectively.

  • Page 89: Installing Joystick Accessories

    Recaro® Seat On the power wheelchair with the Recaro® seat, the attendant controls are attached to the headrest. Tools: ❒ Allen wrench, size 3 ❒ Open-end or combination wrench, size 10 Steps: 1. Remove the headrest. 2. Guide the metal rods of the headrest through the two loops on the control panel holder. 3.

  • Page 90: Push Button Module

    PC with the help of a PC programming station (PCPS; see the enAble50 instructions for use (647G490=D/GB)) and send it to Otto Bock by e-mail with a request for the desired configuration. Otto Bock will amend / change the configuration file accordingly.

  • Page 91: Turning Switches On / Off

    Steps: 1. Select an icon from the configuration panel, remove it from the backing and attach it in the recess provided on the front of the push button module. INfORMATION Ensure that the icons are properly aligned when they are attached in the recesses of the push button module.
  • Page 92 figure 98 Back of the push button module 1 Holes for Torx screws to mount the cover 3. Remove the cover and put it aside. 4. Turn switches on or off as required. Individual functions can be deactivated with these 5 switches (Figure 107, item 1) depending on the configuration (e.g.

  • Page 93: Installing The Push Button Module

    6.20.4 Installing the Push Button Module CAUTION Risk of health impairment due to a pinched cable. Pinching the cable while operating seat functions can impair signal transmission by the push button module, resulting in uncontrolled wheelchair behav- iour. Extreme care is therefore required when installing the cable. The push button module is attached with a magnetic holder or hook-and-loop connector.

  • Page 94: Connecting External Switches

    figure 101 Push button module connections on the seat module 1 2-pin plug for 12 V power supply 2 12-pin plug for signals 6.20.5 Connecting External Switches The push button module has 3 inputs on the underside for the connection of external switches, e.g.

  • Page 95: Accessories

    INfORMATION The connection assignment for external switches is indicated by corresponding symbols on the rear of the push button module. 6.21  Accessories INfORMATION Only use original options supplied by the manufacturer. The optional components may only be mounted as described here. Failure to comply will void the warranty. 6.21.1 Retrofitting the Headrest Adapter and Installation Kit The standard and contour can be equipped with an optional headrest.

  • Page 96: Retrofitting The Signal Panel Installation Kit

    6.21.2 Retrofitting the Signal Panel Installation Kit The signal panel holder is attached to the back frame using an adapter plate. Tools: ❒ Allen wrench, size 3 ❒ Open-end or combination wrench, size 10 Steps: 1. Attach the holder to the top of the back tube with two screws. 2.

  • Page 97: Other Optional Add-On Components

    The error diagnosis may therefore only be carried out by authorised dealers who have established knowledge of electronic controllers from Otto Bock. Otto Bock will not assume any liability for damages that are due to improperly or poorly executed repairs. INfORMATION Experience has shown that problems with the wheelchair electrical system are frequently caused by errors and defects in the plug connections and cabling.

  • Page 98: Troubleshooting Steps

    All problems that have ever occurred are saved in a list and can be retrieved, e.g. in case of a general overhaul of the C2000 power wheelchair. The saved data can be used to determine future service and maintenance intervals, for example.
  • Page 99 Display Symbol(s) LCD Monitor Error / Cause Corrective Action Display Warning / Defect Communication error Faulty connection between Check cabling / (alternating flashing the hand control device plug connections signal) and controller. Defective cabling, soft- ware or hardware Battery under volt- Battery deep discharge Charge as soon as possible...

  • Page 100: Enable50 Wheelchair Control - Installation And Programming

    INfORMATION The enAble50 instructions for use 647G490=D/GB include a list of error codes "WARNING XXX" and "ERROR XXX" on the LCD monitor as well as information on corrective actions. 8 enAble50 Wheelchair Control – Installation and Programming INfORMATION The enAble50 instructions for use 647G490=D/GB contain more detailed information about the control unit and the connection of input devices.

  • Page 101: Controller

    figure 107 Components of the enAble50 wheelchair control 1 Attendant control 2 Hand control device 3 Controller 4 Separate LCD monitor 8.2  Controller The controller is attached to the wheelchair with two screws (see Section 6.6). 3 4 5 6 7 8 10 11 12 figure 108 Controller 1 J8 - Actuator 1/2 and driver outputs...

  • Page 102: Wiring The Controller

    The housing heats up during high-current operation. Therefore, installing the controller on a metal surface with sufficient clearance for air circulation around the housing is recommended. This transfers heat away from the device, improving performance and increasing the lifespan of the controller. 8.2.1 Wiring the Controller The illustration below shows the wiring of the enAble50 controller for a system that has drive motors equipped with encoders.

  • Page 103: Technical Data, Connections

    8.2.2 Technical Data, Connections Wire gauge M1, M2: Motors 2.5 – 4 mm M1, M2: Brakes 0.5 – 1 mm Battery 2.5 – 4 mm J4 (bus), J9 (12-pin) 0.5 – 1 mm 8.2.3 Actuator Outputs The controller has two independent actuator outputs. Technical data for the first actuator output: 0…100 % V Voltage...

  • Page 104: Seat Module

    8.3  Seat module The controller is attached to the wheelchair with two screws (see Section 6.7/6.14.4). 5 6 7 figure 110 Seat module connection schemata 1 IN-A, IN-B, IN-C, IN-D, IN-E connections 2 RSW 3 A1 - A5 connections (actuators A1 - A5) 4 BUS connection 5 BUS connection 6 BATT bridge / external supply connection...

  • Page 105: Wiring The Seat Module

    8.3.1 Wiring the Seat Module The following figure shows how to wire the seat module. The battery connector either has to be connected to the bus (using a 2-pin bridge, see Figure 112-1) or directly to the battery (using the 4-pin plug, see Figure 112-2). If the seat module is connected directly to the battery, you may also use the battery to supply higher loads.

  • Page 106: Electrical Specifications

    figure 112 Battery connection for power supply 8.3.2 Electrical Specifications Power supply: 16 – 33 V Operating voltage 12 A Power supply via bus 18 A Power supply directly from the battery (continuous) 24 A Power supply directly from the battery (3 seconds) 4 mA Standby current (typical) Table 7 Power supply...

  • Page 107: Programming Devices

    ❒ The actuator outputs have high impedance when they are not in operation. INfORMATION The enAble50 instructions for use 647G490=D/GB contain information on the power supply and ac- tuator connectors. 8.4  Programming Devices The enAble50 control unit is programmable, i.e the settings for the various programmable pa- rameters can be set using a programming device.
  • Page 108 Initial operation: 1. Turn on the wheelchair control. 2. Ensure the cable is securely connected to the handheld programming device. 3. Connect the bus plug of the handheld programming device to a free bus receptacle (e.g. on the bottom of the display module). Operation: a) Display The interface is displayed using a so-called “menu tree”.

  • Page 109: Pc Programming Station (Pcps)

    Always test the driving characteristics of the power wheelchair after configuration / programming is complete. Programming must only be completed by authorised personnel. Neither Otto Bock nor the control unit manufacturer are liable for damages (especially in combination with special controls) caused by pro- gramming that was not properly / professionally adapted to the abilities of the wheelchair user.

  • Page 110: Main Parameters

    8.5.1 Main Parameters The menu tree is divided into the following three main parameters: ❒ Input devices ❒ System settings ❒ Configuration Main Menu Submenu Settings Parameter Input devices Hand control Basic setting 5 adaptable profiles:- Speed- Response- Mode device settings All drive parameters refer to operation with the hand control device.
  • Page 111 Main Menu Submenu Settings Parameter System General driving Max speed The maximum speed parameter forms another layer settings above the speed values that can be programmed under input devices. Example: Max. speed = 60%. Forward speed = 80%. In driving mode 1, 0.8 x 60% = 48% of the normal driving speed.
  • Page 112 Main Menu Submenu Settings Parameter Seat Actuators Parameters to adjust the seat actuators (speed, 1 to 5 current). The seat module offers a separate 12 volt output. The voltage can be turned on or off under the “Miscellane- ous” menu item. Enhanced display Sound &...
  • Page 113 Main Menu Submenu Settings Parameter Actuators & The controller actuators can be configured here. steering Very important setting that establishes the respective wheelchair model. The steering is defined. 2 addi- tional standard actuators can be programmed with normal steering, e.g. for the tilt function or back rest. Possible limitations can be programmed via limit switches.

  • Page 114: Driving" Parameter Settings

    8.5.2 "Driving" Parameter Settings Menu Tree Access Min Max Default Unit Help Text Input devices Service Maximum forward driving speed > Hand control device settings Determines the highest possible for- ward driving speed at full deflection > Driving when the position of the potentiometer >...
  • Page 115 Menu Tree Access Min Max Default Unit Help Text Service Maximum forward deceleration Input devices > Hand control device settings Specifies the forward deceleration of the wheelchair when the position of the > Driving potentiometer is set to maximum. > Profile 1 P1 A high value represents a short decel- >...
  • Page 116 Menu Tree Access Min Max Default Unit Help Text Service Maximum turning acceleration Input devices > Hand control device settings Specifies the turning acceleration of the wheelchair when the position of the > Driving potentiometer is set to maximum. > Profile 1 P1 A high value represents higher turning >...
  • Page 117 Menu Tree Access Min Max Default Unit Help Text Service Constant speed forward / reverse Input devices > Hand control device settings If ‘Constant speed’ = cruise is selected, the wheelchair accelerates to > Driving the desired speed. If the command is >...
  • Page 118 Menu Tree Access Min Max Default Unit Help Text Service Constant speed forward / reverse Input devices > Hand control device settings If ‘Constant speed’ = cruise is selected, the wheelchair accelerates to > Driving the desired speed. If the command is >...

  • Page 119: Joystick" Parameter Settings

    8.5.3 “Joystick” Parameter Settings Menu Tree Access Min Max Default Unit Help Text Input devices Service Centre deadband > Hand control device settings Centre deadband defines the joystick travel before the system recognises the > Joystick command. The value corresponds to a >...

  • Page 120: C2000 Maintenance And Service Plan

    9 C2000 Maintenance and Service Plan Customer: Re-use Year of manufacture: Serial no.: C2000 General Condition Driving report: Component (group) Carefully check all components listed here for correct function, setting, damages or deformations, and whether the screw connections are tightened!
  • Page 121 Contour seat Contoured back Recaro seat Electric seat adjustments Back adjustment (actuator; cables) Seat tilt (actuator; cables) Seat height adjust- ment (actuator; linkage; cables) Footrests (actuator; cables) Side panel Adapters Clothing protector Lighting adapter footrests Adapters Elevating footrest Lighting Front lights Rear lights Options Belt...
  • Page 123 Tel. +44 1784 744900 · Fax +44 1784 744901 Otto Bock HealthCare India Pvt. Ltd. e-mail: bockuk@ottobock.com · www.ottobock.co.uk Behind Fairlawn Housing Society Otto Bock Ortopedi ve Rehabilitasyon Tekniği Ltd. Şti. Sion Trombay Road Ali Dursun Bey Caddesi · Lati Lokum Sokak Otto Bock france SNC Chembur ·...
  • Page 124 · www.ottobock.com Otto Bock Mobility Solutions GmbH has been certifi ed by the German Society for the Certifi cation of Quality Assurance Systems (DQS) in accordance with DIN EN ISO 13 485 : 2007, reg. no. 435514 MP27 (management system)

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