Otto Bock B400 Service Manual
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Otto Bock B400 Service Manual

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  • Page 1 B400 Service Manual...

  • Page 3: Table Of Contents

    Tabel of contents Service Instructions for the B400 Wheelchair Page Tabel of contents 1 General information ......................6 1.1 Foreword ........................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 for the use of tools and accessories ........8...
  • Page 4 6.15.7 Installing the bracket for headrest mounting (option) ..........55 6.15.8 Retrofitting with a lap belt (option) .................55 6.15.9 Installing a luggage carrier (option) ...............56 6.15.10 Retrofitting with a crutch holder ................56 6.15.11 Retrofitting with a bag ...................57 4 | Ottobock B400 Family...
  • Page 5 8.3.2 PC programming device ................... 74 8.4 Programmable parameters .................. 74 8.4.1 Speed settings ......................74 8.4.2 Setting general parameters ..................77 8.4.3 Programming the light module ................78 8.4.4 Reporting functions ....................78 9 B400 maintenance and service plan ................79 B400 Family Ottobock | 5...

  • Page 6: General Information

    B400. The information in this service manual is essential in order to work on the B400 correctly and safely. This is why this document, in particular the section "Safety instructions", must be read carefully by all persons working on the B400.

  • Page 7: Safety Instructions

    The B400 power wheelchair has been constructed in accordance with state-of-the-art technol- ogy and is safe to operate. The safety of the B400 power wheelchair has been confirmed by CE certification and the declaration of conformity.

  • Page 8: Safety Instructions For The Use Of Tools And Accessories

    They must be available to service and maintenance personnel at all times. NOTICE Risk of damage due to excessive heat or cold. The B400 may only be operated in the temperature range from -25°C to +50°C. It must not be operated at temperatures outside this range.

  • Page 9: Safety Instructions For Maintenance Work

    Risk of damage due to improper preparation for maintenance work. • The B400 power wheelchair must be turned off and the fuse must be removed for all maintenance tasks. Functional tests of the electrical components are excepted from this rule.

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

    Safety instructions InfoRmaTIon The tyres of the B400 power wheelchair contain chemical substances that may react with other chemi- cal substances (e.g. cleaning agents, acids, etc.). 2.6 Safety instructions for maintenance work on electrical components NOTICE Risk of damage due to improper preparation for maintenance work.

  • Page 11: Safety Instructions For Disposal

    NOTICE Risk of damage due to falling. The maximum net weight of the B400 power wheelchair is 95 kg (with seat height adjustment option: + 20 kg). Only use hoists and transport means of sufficient capacity for transport.

  • Page 12: Storage

    3.2 Storage InfoRmaTIon If the B400 power wheelchair is not moved for several days, permanent colour changes may occur in the regions where the wheelchair is in contact with the support surface. The manufacturer thus rec- ommends ensuring that a suitable surface is provided if the wheelchair is to be parked for extended periods of time.

  • Page 13: Required Tools And Accessories

    ❒ Plastic tyre lever ❒ Inner tube repair kit ❒ Side cutting pliers ❒ Water pump pliers, gripping width up to 32 mm ❒ Liquid thread lock "medium strength" fig. 2 Tools fig. 3 Hand-held programming device B400 Family Ottobock | 13...

  • Page 14: Information Display

    The fuse is in a fuse enclosure with hinged cover in front of the battery cover beside the control unit. Steps: 1. Flip open the cover of the fuse enclosure. 2. Pull out the fuse and replace it if necessary. Properly reassemble all components upon completion of the work. 14 | Ottobock B400 Family...

  • Page 15: Batteries

    • Charge the batteries as soon as possible if only one LED is flashing on the "battery capacity" LED indicator. • Charge the batteries weekly if the B400 power wheelchair is not used for an extended period of time. • The manufacturer does not assume any liability for damage due to deep discharge.
  • Page 16 Prolonged driving at the lower end of the battery indicator results in deep discharge which causes battery damage. In addition, there is the risk that the B400 power wheelchair will stop when the battery is fully discharged and put the user in a dangerous situation.

  • Page 17: Replacing The Batteries

    2. Open the battery cover and remove the cover (see fig. 5). 3. Disconnect all connection cables from the battery. 4. Remove the batteries and replace them if necessary. Properly reassemble all components upon completion of the work. B400 Family Ottobock | 17...

  • Page 18: Reinstalling The Battery Cable

    ❒ Ring or open-end spanner, size 11 Steps: 1. Disconnect the old main battery cable from the controller (for connections on the controller, see fig. 7). 2. Unscrew the fuse holder of the old fuse cable from the frame. 18 | Ottobock B400 Family...

  • Page 19: Replacing The Controller

    For information about the assembly of the lighting module refer to section 6.8.3. Preparation: ❒ Remove the battery cover (see section 6.3.2). ❒ Remove the batteries (see section 6.3.3). ❒ Remove the fuse (see section 6.2). Tools: ❒ Allen wrench, size 3 B400 Family Ottobock | 19...

  • Page 20: Side Panels

    Side panel without control panel: Steps: 1. Loosen the two Allen head screws (fig. 9, item 1). 2. Change the positions of the armrests by moving them forward or backward, or remove and replace them if required. 20 | Ottobock B400 Family...
  • Page 21 1. Loosen the wing nut laterally at the bottom of the side panel mounting bracket. 2. Pull the side panel up to remove and replace it if required. Properly reassemble all components upon completion of the work. B400 Family Ottobock | 21...

  • Page 22: Replacing The Clothing Protector

    1. Loosen two Allen head screws on the side panel. 2. Change the position of the clothing protector, or remove and replace it if required. Properly reassemble all components upon completion of the work. fig. 12 Replacing the clothing protector 22 | Ottobock B400 Family...

  • Page 23: Footrests

    Service work 6.6 Footrests 6.6.1 Adapting/replacing the footrests Different footrest systems are available for the B400 power wheelchair, all offering the same setting and attachment options. The lengths and positions of the footrests can be individually adjusted to the wheelchair user.
  • Page 24 Properly reassemble all components upon completion of the work. fig. 15 adapting the footrest to the thigh length c) Installing elevating footrests with calf and knee pads Tools: ❒ Allen wrench, size 3 ❒ Ring or open-end spanner, size 10 24 | Ottobock B400 Family...
  • Page 25 The calf pad is attached to the footrest tube. Steps: 1. Remove the footrest. 2. Loosen the Allen head screw. 3. Remove the calf pad or replace it if required. Properly reassemble all components upon completion of the work. B400 Family Ottobock | 25...

  • Page 26: Replacing The Footplate

    17 Replacing the calf pad 6.6.2 Replacing the footplate Different footplates are available for the B400 power wheelchair. As an alternative to the standard version with individual footplates, a continuous aluminium footplate may be installed. Tools: ❒ Allen wrench, size 6 Steps: 1.

  • Page 27: Wheels

    Replace the casing of pneumatic tyres if it is bald or shows signs of cracking or other damage. The B400 power wheelchair is propelled by two 14" drive wheels (optional: 12.5"). Two 9" castor wheels are used for steering (optional: 8").

  • Page 28: Replacing The Drive Wheel

    6.7.3 Replacing the drive wheel NOTICE Risk of damage due to improper preparation for maintenance work. Use suitable objects such as wooden blocks to secure the B400 power wheelchair against sliding or tipping. The drive wheels must rotate freely. Steps: 1.

  • Page 29: Replacing/Retrofitting With The Drive Wheel Splash Guards

    NOTICE Risk of damage due to improper preparation for maintenance work. Use suitable objects such as wooden blocks to secure the B400 power wheelchair against sliding or tipping. The drive wheels must rotate freely. The splash guard is screwed on above the wheel flange.

  • Page 30: Replacing The Castor Wheels

    6.7.5 Replacing the castor wheels NOTICE Risk of damage due to improper preparation for maintenance work. Use suitable objects such as wooden blocks to secure the B400 power wheelchair against sliding or tipping. The drive wheels must rotate freely. InfoRmaTIon When installing the castor wheel, ensure that the castor and drive wheels are aligned.

  • Page 31: Installing The Splash Guard For The Castor Fork (Option)

    1. Hold the splash guard up against the castor fork so that the mounting holes line up. 2. Insert two Allen head screws through the holes and tighten from the inside. fig. 24 attaching the splash guard for the castor fork B400 Family Ottobock | 31...

  • Page 32: Control Panel/Lighting Module

    3A: LED for power seat tilt/ Horn If toggle switch activated: power Lights on/off footrests (see section 7.5) On/Off button 3B: LED for power back angle adjustment LED battery capacity indicator Speed button: slow Bottom (see fig. 25) 32 | Ottobock B400 Family...

  • Page 33: Replacing The Control Panel Holder

    Table 3 Supplementary function keys on control panel – version a – 6.8.2 Replacing the control panel holder The control panel holder for the B400 power wheelchair is clamped to the underside of the armrest with a linear guide. Preparation: ❒...

  • Page 34: Mounting The Lighting Module

    3. Plug the connection cable firmly into the middle connector socket and connect the lighting module to the power module/control panel (see fig. 29). 4. The lighting module is ready to be retrofit with lights. 34 | Ottobock B400 Family...
  • Page 35 1 2 3 VIEW OF LIGHTING MODULE Connection Function Pin 1 Earth Pin 2 Lights Pin 3 Direction indicator lights fig. 29 Connecting the lighting module to the control panel/power module, wiring of the lighting module B400 Family Ottobock | 35...

  • Page 36: Lighting

    Service work 6.9 Lighting 6.9.1 Retrofitting with lighting The optionally available lighting for the B400 power wheelchair can be retrofitted at any time. a) front lights The front lights are attached to the side panel. Preparation: ❒ Mount control panel – version A – and lighting module (see section 6.8.1/6.8.3).

  • Page 37: Replacing Defective Lamps

    2. Take the front LED light out of the holder as a complete part. 3. Disconnect the cable from the front LED light. 4. Replacing the front LED light Properly reassemble all components upon completion of the work. fig. 32 Replacing the front lighting B400 Family Ottobock | 37...
  • Page 38 When carrying out the installation make sure the lug on the lamp engages in the notch InfoRmaTIon on the socket. Ensure the glass covers are seated properly in the housing when installing them. InfoRmaTIon Tighten the screws on the glass cover firmly so that moisture cannot penetrate into the lamp. 38 | Ottobock B400 Family...

  • Page 39: Seats

    6.10 Seats CaUTIon Risk of burns in the proximity of fire. The backrest and seat surface of the B400 power wheelchair are flame retardant but nevertheless flammable. Therefore utmost caution is required near any sources of open flames or sparks, especially lit cigarettes.

  • Page 40: Standard Seat: Replacing/Adjusting The Back Upholstery

    Ensure that you do not damage the cables in the process! Preparation: ❒ Remove the side panels. Tools: ❒ Allen wrench, size 5 ❒ Ring or open-end spanner, size 13 40 | Ottobock B400 Family...

  • Page 41: Standard Seat: Replacing The Seat Plate

    1. Remove the seat cushion. 2. Pull the seat plate up with a sharp tug and replace it if required. Properly reassemble all components upon completion of the work. fig. 38 Standard seat: replacing the seat plate B400 Family Ottobock | 41...

  • Page 42: Standard Seat: Changing The Seat Height

    Risk of cable damage. Make sure the cables attached to the frame with cable ties do not become damaged. Changing the seat height of the B400 power wheelchair requires replacement of the seat brack- ets. The seat brackets are screwed directly to the frame at the front.

  • Page 43: Standard Seat: Replacing/Adjusting The Side Panel Bracket

    1. Loosen the two set screws. 2. Remove the side panel bracket and replace or readjust as required (see fig. 41, item 1). Properly reassemble all components upon completion of the work. fig. 41 Side panel bracket Side panel bracket B400 Family Ottobock | 43...

  • Page 44: Standard Seat: Replacing The Backrest

    3. Slip three mounting clamps for the back of the Contour seat on to each of the right and left sides of the frame. 4. Put the seat back in place and mount it with six Allen head screws. 44 | Ottobock B400 Family...

  • Page 45: Replacing The Drive Unit Bracket

    6.11 Replacing the drive unit bracket CaUTIon Risk of injury due to electric current. Turn off the B400 power wheelchair prior to performing any work on the drive unit brackets and disconnect all plug connections between the drive unit bracket and the frame.

  • Page 46: Replacing The Drive Motor

    6.12 Replacing the drive motor CaUTIon Risk of injury due to electric current. Turn off the control unit of the B400 power wheelchair and discon- nect all plug connections to the control unit/power module before performing any work on the drive motors.

  • Page 47: Suspension/Floating Discs/Rocker Arm

    1. Twist the adjustment ring on the spring element (see fig. 45, item 1): a. Twist the adjustment ring to the right: the spring travel is shortened. b. Twist the adjustment ring to the left: the spring travel is lengthened. B400 Family Ottobock | 47...

  • Page 48: Replacing The Floating Discs On The Rocker Arm

    8. Check the spring travel: remove the spring elements (see section 6.13.1). Depress and release the wheel suspension. The wheel suspension must be able to be moved slightly. If necessary readjust the self-locking nuts. Reinstall the spring elements. Properly reassemble all components upon completion of the work. 48 | Ottobock B400 Family...

  • Page 49: Replacing The Rocker Arm

    Floating discs (see section 6.13.3) 2. Remove and replace the rocker arm. Secure the screw in the rotary joint against rotating using the flat screwdriver (see fig. 48, arrow) and loosen the hex nut in the battery compartment. B400 Family Ottobock | 49...

  • Page 50: Brakes And Brake Release

    4. Insert an Allen head screw at the third attachment point of the lower gas spring receiver into the existing bore hole beneath the drive unit bracket and tighten (fig. 49-4). 5. Remove the front seat bracket. 6. Mount the cross-brace for the upper gas spring receiver (fig. 49-5). 50 | Ottobock B400 Family...

  • Page 51: Attaching The Bowden Cable For Seat Tilt

    2. Mount the clamp piece and sliding nut. 3. Position the release lever with the sliding nut and tighten the Allen head screw. Mount the side panel, making sure to position the Bowden cable correctly. B400 Family Ottobock | 51...

  • Page 52: Retrofitting With Mechanical Back Angle Adjustment

    7. Slide the bolt through the end of the gas spring and secure with a retaining ring. 8. Hook the bolt at the bottom of the cross tube on the back into the adapter. 9. Install the Bowden cable and mount it to the armrest on the left or right. 52 | Ottobock B400 Family...

  • Page 53: Retrofitting With Kerb Climber

    Tools: ❒ Allen wrench, size 3 Steps: 1. Mount the rearview mirror to the C-profile of the armrest. Mounting on both sides is possible. 2. Individually adjust it to user requirements by turning it manually. B400 Family Ottobock | 53...

  • Page 54: Installing Castor Swivel Lock (Option)

    4. Secure the plastic locking lever with lock washers (above/below) (fig. 54-3A). 5. Screw the locking screws into the frame (fig. 54-3B). Properly reassemble all components upon completion of the work. fig. 54 mounting the castor swivel lock 54 | Ottobock B400 Family...

  • Page 55: Installing The Bracket For Headrest Mounting (Option)

    The lap belt is available for both seat models and is attached to the bearing plates, but not also to the back of the seat frame. The belt is attached and screwed to the bearing plate with a bracket with an eyelet. fig. 56 Retrofitting with a lap belt B400 Family Ottobock | 55...

  • Page 56: Installing A Luggage Carrier (Option)

    1. Unscrew the clothing protector. Hold the nuts laterally using a flat screwdriver in the process. 2. Use the longer screws supplied to remount the clothing protector. 3. Use the dome nuts/washers supplied to mount the crutch holder. 56 | Ottobock B400 Family...

  • Page 57: Retrofitting With A Bag

    2. Use the longer screws supplied to remount the clothing protector. 3. Mount the supporting plate using the supplied dome nuts/washers (fig. 59-1). 4. Mount the bracket on the supporting plate (fig. 59-2). 5. Hook on the bag (fig. 59-3). fig. 59 mounting a bag B400 Family Ottobock | 57...

  • Page 58: Power Seat Functions

    Properly reassemble all components upon completion of the work. NOTICE Risk of damage to cables due to protrusion into the adjustment area. Fasten the connection cables to the frame with cable ties to prevent them from extending into the adjustment area. 58 | Ottobock B400 Family...

  • Page 59: Retrofitting With Power Seat Tilt (Optional)

    Retrofitting with power back angle adjustment 6.16.2 Retrofitting with power seat tilt (optional) The B400 power wheelchair can be retrofitted with two seat tilt versions. a) Seat tilt to 45° The seat tilt option is delivered as a preassembled unit (fig. 61-1).
  • Page 60 ❒ Allen wrench, size 4/5 ❒ Ring or open-end spanner, size 13 Steps: 1. Remove the front seat brackets (fig. 62-1, item A). 2. Mount the axle with stop to the main frame (fig. 62-1, item B). 60 | Ottobock B400 Family...
  • Page 61 Risk of damage to cables due to protrusion into the adjustment area. Fasten the connection cables to the frame with cable ties to prevent them from extending into the adjustment area. fig. 62 Retrofitting with 20° seat tilt B400 Family Ottobock | 61...
  • Page 62 Properly reassemble all components upon completion of the work. NOTICE Risk of damage to cables due to protrusion into the adjustment area. Fasten the connection cables to the frame with cable ties to prevent them from extending into the adjustment area. 62 | Ottobock B400 Family...

  • Page 63: Retrofitting With Seat Height Adjustment (Optional)

    6. Adjust the metal tab of the microswitch (fig. 64-5). The adjustment is made by changing the length and moving the metal tab to the right or the left. Make sure the metal tab cannot crush the microswitch. B400 Family Ottobock | 63...

  • Page 64: Installing The Changeover Box

    Depending on the position of the switch on the Y-cable the first or another additional power function can be actuated via the control panel. Preparation: ❒ Remove/set aside the control panel. Tools: ❒ Allen wrench, size 3 64 | Ottobock B400 Family...

  • Page 65: Attaching The Y-Splitter

    1. Remove the upper two screws on the back upholstery. 2. Position the bracket and install with the supplied screws and washers (fig. 66-2). 3. Mount the swivel arm with clamp ring (fig. 66-3) on to the bracket. B400 Family Ottobock | 65...

  • Page 66: Diagnostics

    Troubleshooting may thus only be carried out by authorised specialist dealers possessing solid knowledge of electronic controllers from Ottobock. Ottobock assumes no liability for any damage which can be attributed to improperly or poorly carried out repairs. 66 | Ottobock B400 Family...

  • Page 67: Troubleshooting Steps

    All faults that have occurred are saved in a list and can be called, e.g., during a general overhaul of the B400 (see section 8.4.4). The saved data can be used to determine future service and maintenance intervals, for example.
  • Page 68 Check connections to con- troller Battery overvoltage Loose battery contacts Check connector contacts Communication error Defective cable; loose Check connections between control panel plug connection (joystick) and controller Table 6 LED error types, causes and remedies 68 | Ottobock B400 Family...

  • Page 69: Troubleshooting Via Hand-Held Programming Device (Also See Section 8.3)

    Joystick error 7104 Joystick error 7147 User (11) Joystick displaced upon switch-on 7902 – (14) High temperature Other 7 or 8 (7) or (8) Possible control system error codes Table 7 List of error codes B400 Family Ottobock | 69...
  • Page 70 7102: Loss of power to joystick. Check joystick cable, ribbon cable on the joystick, connections and associated sockets. 7103/7104: Internal error trigger. Check joystick cable, ribbon cable on the joystick, connec- tions and associated sockets. Check whether the cable is connected correctly to the joystick and the PCB. 70 | Ottobock B400 Family...
  • Page 71 The control system heats up to a temperature above the defined threshold. Driving is interrupted until the controller has cooled. Each occurrence of controller overheating is recorded in the system report. Table 8 Error types, causes and remedies B400 Family Ottobock | 71...

  • Page 72: Additional Errors (Not Displayed)

    (check operation of battery charger). Use of incorrect batteries. Select an appropriate battery type by referring to the instructions for use. Motor is blocked or a brake is jammed. Replace motor. Table 9 additional errors 72 | Ottobock B400 Family...

  • Page 73: Vr 2 Wheelchair Control - Installation And Programming

    VR2 control. Faulty programming can lead to wheelchair settings that pose a risk to the safety of the user. Neither Ottobock nor the control manufacturer is liable for loss or damage due to modification of the factory-set control system program. B400 Family Ottobock | 73...

  • Page 74: Hand-Held Programming Device

    A high value enables rapid deceleration. This programmed de- celeration value appears when a speed setting of 5 has been selected. Its value for other settings depends on the value of the parameter "Minimum Turn Deceleration". 74 | Ottobock B400 Family...
  • Page 75 Although a series of driving profiles can be set to 1, InfoRmaTIon the operation of them is the same as in the case of a setting of 0. However, the maximum speed cannot be changed. B400 Family Ottobock | 75...
  • Page 76 • Speed settings 2, 3 and 4 are linearly interpolated between 20 and 80 • Turn deceleration for level 2 = 35 • Turn deceleration for level 3 = 50 • Turn deceleration for level 4 = 65 Table 10 Programming speed parameters 76 | Ottobock B400 Family...

  • Page 77: Setting General Parameters

    VR2 control. On: brake defects are detected. Off: brake defects remain undetected. This parameter should only be switched off if the InfoRmaTIon wheelchair has no power brakes. Table 11 Programming general parameters B400 Family Ottobock | 77...

  • Page 78: Programming The Light Module

    Erase System Log With this function the troubleshooting report from the VR2 control can be de- leted. This function can only be used with the PCPb and PCPc versions of the PC programming device. Table 13 Reporting functions 78 | Ottobock B400 Family...

  • Page 79: B400 Maintenance And Service Plan

    B400 maintenance and service plan 9 B400 maintenance and service plan Customer: Reuse Year of manufacture: Serial no.: General condition of the B400 Driving report: Areas For all the components listed here check the functioning, setting and screw connections and look for signs of damage or deformation!
  • Page 80 B400 maintenance and service plan In good Setting range Damaged Exchange/Replace condition Power seat adjust- ments Back adjustment (actuator, cables) Seat tilt (actuator, cables) Seat height adjust- ment (actuator, bars, cables) footrests (actua- tor, cables) 8 Side panel Brackets Clothing protector...
  • Page 81 Otto Bock Healthcare Products GmbH Kaiserstraße 39 · 1070 Wien · Austria OOO Otto Bock Service Otto Bock de Mexico S.A. de C.V. T +43 (0) 1 5269548 · F +43 (0) 1 5267985 p/o Pultikovo, Business Park „Greenwood“, Prolongación Calle 18 No. 178-A vertrieb.austria@ottobock.com ·...
  • Page 82 Ihr Fachhändler/Your specialist dealer: Versandanschrift für Rücksendungen/Address for Returns: Otto Bock Manufacturing Königsee GmbH Lindenstraße 13 · 07426 Königsee-Rottenbach/Germany Otto Bock Mobility Solutions GmbH Lindenstraße 13 · 07426 Königsee-Rottenbach/Germany T +49 69 9999 9393 · F +49 69 9999 9392 ccc@ottobock.com ·...

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