Otto Bock B400 Service Manual Download Page 2

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Edition 7.08/1
Editorial date: 23.07.2008
© Otto Bock HealthCare

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.
We reserve the right to file for patents, utility models, and designs.

Summary of Contents for B400

Page 1: ...B400 Power Wheelchair Service Manual ...

Page 2: ...ice 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 We reserve the right to file for patents utility models and designs ...

Page 3: ...nsportation and Storage 11 3 1 Transportation 11 3 2 Storage 12 4 Required Tools and Auxiliary Means 13 5 Information Display 14 6 Service Works 15 6 1 Inspecting the General Condition 15 6 2 Replacing the Fuse 15 6 3 Batteries 16 6 3 1 Checking the Liquid Level and Filling Up only with lead acid batteries 16 6 3 2 Charging the Batteries 18 6 3 3 Replacing the Batteries 19 6 3 4 Removing the Batte...

Page 4: ...at Frame 43 6 10 4 Standard Seat Replacing the Seat Plate 44 6 10 5 Standard Seat Changing the Seat Height 45 6 10 6 Standard Seat Setting the Seat Inclination 45 6 10 7 Standard Seat Replacing Setting the Side Panel Attachment Devices 46 6 11 Replacing the Drive Unit Sustainer 47 6 12 Replacing the Drive Motor 48 6 13 Brakes and Brake Release 48 6 14 Accessories 49 6 14 1 Retrofitting Mechanical ...

Page 5: ... Wiring 61 8 3 Programming Tools 62 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: ... basis of DIN EN 62079 Preparation of instruc tions Structuring content and presentation It is divided into 9 chapters The service manual also contains cross references that make it easier to use e g See Chapter 6 2 1 2 Intended Use The B400 power wheelchair is intended for individual self transportation by persons with limited mobility indoors and outdoors The B400 power wheelchair may only be us...

Page 7: ...mes without restrictions The B400 power wheelchair has been constructed in accordance with the currently valid techni cal rules and is safe to operate The safety of the B400 power wheelchair has been confirmed by CE certification and the declaration of conformity 2 3 General Safety Instructions Information Regular maintenance is important it improves the safety and increases the lifespan of the pr...

Page 8: ...oaded from the homepage of Otto Bock HealthCare GmbH at www ottobock de or www ottobock com 2 4 Safety Instructions Regarding the Use of Tools and Auxiliary Means CAUTION Health risk as a result of using inappropriate tools For carrying out the works only use tools which are suitable for the conditions prevailing at the workplace and which ensure safety and health protec tion if used properly Test...

Page 9: ...ct to prevent it from tipping over or falling off the workbench Some components of the power wheelchair are very heavy such as the batteries frame seat and motors If the use of hoisting devices is required they must have a sufficient capacity Clean or disinfect the product before you start the inspection Consult the instructions for use regard ing product care or product specific inspection inform...

Page 10: ...ry 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 When working on the batteries smoking and open flames are not permitted Sparks must be avoided Explosive gases can develop while the batteries...

Page 11: ... national regulations If a wheelchair is to be disposed of all components and materials of the power wheelchair must be recycled or disposed of properly CAUTION There is a risk of polluting the environment with battery acid The batteries of the power wheelchair contain a toxic acid They must not be disposed of with regular domestic waste and the battery acid must not enter the sewage water system ...

Page 12: ... 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 The B400 power wheelchair must be stored in an enclosed area Remove the main fuse to pre vent the risk of deep discharge The storage location must be dry and sufficient air circulation must be provided There must not be any bu...

Page 13: ...ps screwdriver Ring wrench or open end wrench sizes 8 to 24 mm Allen wrench sizes 2 3 4 5 6 7 mm Torque wrench Wrench socket size 19 mm Pull off tool Pin punch Ø 3 mm Plastic hammer Drill bit size 4 6 mm hand drill Plastic tyre mounting levers Inner tube repair kit Side cutting pliers Water pump pliers gripping width up to 32 mm Liquid thread lock medium strength Fig 2 Tools ...

Page 14: ...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 Battery capacity The LEDs show the battery capacity see instructions for use 647G485 Speed levels The LEDs show the currently selected speed level from 1 to 5 Table 1 LED display fields on the control panel ...

Page 15: ...eplace the screws Check cables for breaks wear and tear and proper attachment in case of defects replace the cables in accordance with the cable plan Check the cable connections plug connections 6 2 Replacing the Fuse The fuse is located in a small yellow box with folding cover in front of the battery case Steps Open the cover of the fuse box Pull out the fuse and replace if necessary Properly rea...

Page 16: ...ated tools when working on the batteries in order to prevent short circuits Avoid deep discharge of the batteries in order to prevent function failure and permanent damage to the batteries When connecting the batteries and the device for measuring the battery s capacity ensure correct pole assignment The standard version of the B400 power wheelchair includes two 12 V lead acid batteries with a cap...

Page 17: ...assemble all components upon termination of the work 1 2 Fig 5 Opening the battery case disconnecting the connections 1 Opening the battery case 2 Disconneting the battery cables 1 2 Fig 6 Liquid level marks battery cell 1 Min max marks for the liquid level 2 Closures of an individual battery cell 7 ...

Page 18: ...on and health risk due to contact with acid The indications on the type plate of the battery charger must be identical to the voltage of the mains supply of your country Only use the battery charger within the indicated ranges of temperature and humidity Place the rubber feet of the battery charger on a level surface When the battery charger is in use protect it from direct sunlight Avoid overheat...

Page 19: ...is lit Battery is fully charged battery charger has changed to trickle charge Red LED is lit Incorrect pole assignment immediately unplug the battery charger from the wall outlet and reconnect the cables with correct pole assignment Red LED flashes Error in the course of the characteristic curve charging time has been exceeded Table 2 LED display on the battery charger The battery charger features...

Page 20: ...all components upon termination of the work 6 3 5 Laying New Battery Cables NOTICE Risk of battery damage When connecting the batteries ensure correct pole assignment Preparation Remove the battery cover see Section 6 3 1 Pull out the fuse see Section 6 2 Disconnect and remove the batteries see Section 6 3 3 Remove the battery case Tools Allen wrench size 3 mm Ring wrench or open end wrench size 1...

Page 21: ...nformation For information about the assembly of the light module refer to Section 6 8 3 Preparation Remove the batteries see Section 6 3 3 Remove the battery case see Section 6 3 1 Pull out the fuse see Section 6 2 Tools Allen wrench size 3 mm Steps Disassemble the protective cover see Fig 8 Disconnect all connections from the controller Loosen the two Allen head screws remove the controller and ...

Page 22: ...th armrest are plugged into these attachment devices The height and position of the side panels can be individually adapted to the arm length of the wheelchair user Tools Allen wrench size 2 mm a Adapting to the forearm length Side panel without control panel Steps Loosen the two Allen head screws Fig 9 item 1 Change the position of the armrests by moving them to the front or rear or remove and re...

Page 23: ...vice Move the armrest to the required height Tighten the set screw Fig 10 Adapting the side panel to the upper arm length c Replacing the side panel Steps Loosen the thumb screw at the bottom of the side panel attachment device Pull out the side panel upwards and replace it if necessary Properly reassemble all components upon termination of the work 1 2 3 1 2 ...

Page 24: ...e 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 Fig 12 Replacing the clothing protector 1 2 ...

Page 25: ...ndard version elevating footrests with calf and knee pads can option ally be installed Tools Allen wrench size 5 mm Allen wrench size 6 mm Ring wrench or open end wrench size 10 mm a Adapting to the lower leg length Steps Pull the footrest release rearwards and pull out the footrest upwards see Fig 13 Loosen the two set screws see Fig 14 Adjust the length by pulling out or pushing in the footrest ...

Page 26: ...he two Allen head screws on the rear side of the receiver Loosen the two Allen head screws on the left and right sides of the seat frame Separate the footrest tube from the receiver or adjust it to another length Properly reassemble all components upon termination of the work Fig 15 Adapting the footrest to the thigh length c Mounting elevating footrests with calf and knee pads Tools Allen wrench ...

Page 27: ...Loosen the Allen head screw Fig 16 Remove or replace the knee pad if necessary Properly reassemble all components upon termination of the work Fig 16 Replacing the knee pad e Replacing the calf pads The calf pad is attached to the footrest tube Steps Remove the footrest Loosen the Allen head screw Remove or replace the calf pad if necessary Properly reassemble all components upon termination of th...

Page 28: ...tandard version with individual footplates a continuous aluminium footplate can optionally be installed Tools Allen wrench size 6 mm Steps Loosen the Allen head screw that connects the footplate and mounting kit Remove and replace the footplate if necessary Properly reassemble all components upon termination of the work Fig 18 Replacing the footplate 1 2 ...

Page 29: ...ar and tear the tyres should be replaced every 2 years When the wheelchair is not used for extended periods of time or if the tyres are heated strongly e g near radiators or by sunlight shining through a window permanent deformation of the tyres will result Therefore always make sure that the wheelchair has sufficient distance from sources of heat move your wheelchair from time to time or jack up ...

Page 30: ...le objects e g pieces of wood to prevent it from slipping or tipping over The drive wheels must be able to rotate freely Steps Jack up the drive wheels Loosen all four Allen head screws remove the wheel and replace it if necessary Properly reassemble all components upon termination of the work Information When reassembling the wheel tighten all four Allen head screws with a torque of 25 Nm Fig 20 ...

Page 31: ...eel 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 Information When reassembling tighten the wheel flange with a torque of 55 Nm Fig 21 Loosening the wheel flange screw Fig 22 Applying the pull off tool 1 2 ...

Page 32: ...wrench or open end wrench size 10 mm Steps Apply the splash guard to the motor suspension so that the attachment holes coincide Insert two carriage screws and fasten with self locking nuts Fig 23 Mounting splash guards for drive wheels 6 7 6 Replacing the Caster NOTICE Damage as a result of improperly prepared maintenance Secure the B400 power wheelchair with suitable objects e g pieces of wood to...

Page 33: ...isassembling 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 with a jerk The caster forks of the B400 power wheelchair are supplied complete Tools Wrench socket size 19 mm Steps Remove the black plastic cap Loosen the nut Remove and replace the caster fork if necessary Properly reassemble all components upo...

Page 34: ... are in line The splash guard for casters must be attached to the caster fork Preparation Disassemble the caster Tools Allen wrench size 3 mm Steps Apply the splash guard to the caster fork so that the attachment holes coincide Insert two Allen head screws from inside to outside through the holes and tighten Fig 26 Mounting the splash guard for caster forks 1 2 ...

Page 35: ...he optional lights Tools Phillips screwdriver Steps Loosen the two Phillips head screws on the holder Remove the control panel and replace it with a new one or with the VR2 L control panel Properly reassemble all components upon termination of the work Fig 27 Replacing the control panel 1 3 2 Fig 28 Additional functions of the VR2 L control panel 1 Light key 2 Warning flasher key 3 Direction indic...

Page 36: ...hing after 20 seconds Table 3 Function of the additional keys of the VR2 L control panel 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 profile rail Preparation Remove the side panel Remove and deposit the control panel Tools Allen wrench size 3 mm Steps Remove the side panel from the holder Loosen t...

Page 37: ...le is pre programmed It can be adapted to the respective lights see Section 8 4 by programming with the hand programming device see Section 8 3 Connector sockets Function Connector socket 1 3 pole plug for control of the lamps on the left side Connector socket 2 3 pole plug for control of the lamps on the right side Connector socket 3 Socket for connection to the electric module control panel of t...

Page 38: ...arth Lamps Direction indicators VIEW ON THE LIGHT MODULE Connector Function Pin 1 Earth Pin 2 Lamps Pin 3 Direction indicators Earth Lamps Direction indicators 1 2 To the electric module LIGHT MODULE VR2 L Fig 31 Connecting the light module to the control panel electric module cabling of the light module ...

Page 39: ...the light holders into the outer slots and retighten the screw connections Fig 32 Lead the light cable along the seat frame and fasten it with cable ties Connect the light cable to the corresponding connector of the controller beneath the seat Properly reassemble all components upon termination of the work Fig 32 Retrofitting front lights b Rear lights The rear lights must be attached at the rear ...

Page 40: ...o fold the halogen lamp along with pane forward Pull the retaining ring to the rear Pull the halogen lamp to the rear remove and replace it if necessary Properly reassemble all components upon termination of the work Information When installing the lamp make sure that the notch on the socket of the halogen lamp is positioned correctly and engages Fig 34 Replacing the halogen lamp of a front light ...

Page 41: ...screws and remove the protective glass Remove the bulb from the holder to the front and replace it Properly reassemble all components upon termination of the work d Rear light Steps Loosen the two screws and remove the protective glass Pull the bulb downward out of the holder and replace it Properly reassemble all components upon termination of the work Information When installing the lamp make su...

Page 42: ...me or sparks especially lit cigarettes is required NOTICE Risk of damage to the seat padding When working on the seat the padding must be sufficiently protected against mechanical and chemical stresses 6 10 1 Replacing the Bearing Plate Tools Allen wrench size 5 mm Ring wrench or open end wrench size 13 mm Steps Loosen the three Allen head screws marked with an arrow Remove and replace the bearing...

Page 43: ...ance 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 Pay attention to the cables fastened to the seat frame with cable ties Carefully cut the cable ties using side cutting pliers or a knife Make sure not to damage the cables Preparation Remove the side panels Tools Allen wrench size 5 mm Ring wrench or open...

Page 44: ...ll components upon termination of the work Fig 39 Standard seat replacing the seat frame 6 10 4 Standard Seat Replacing the Seat Plate Only standard seats have a seat plate Steps Remove the seat cushion Unlock the backrest and fold it ahead Pull the seat plate up with a sharp tug and replace if necessary Properly reassemble all components upon termination of the work 1 2 Fig 40 Replacing the seat ...

Page 45: ...r Allen head screws Loosen the Allen head screws of the posterior seat brackets Loosen the Allen head screws of the two anterior seat brackets see Fig 41 Loosen the seat brackets from the seat frame and replace as needed Properly reassemble all components upon termination of the work Fig 41 Anterior seat brackets 6 10 6 Standard Seat Setting the Seat Inclination Without mechanical seat tilt The tw...

Page 46: ...rly reassemble all components upon termination of the work Fig 42 Setting the seat inclination 6 10 7 Standard Seat Replacing Setting the Side Panel Attachment Devices The attachment is located on both sides on the posterior crossbrace beneath the seat Tools Allen wrench size 3 mm Steps Loosen the two set screws Remove the side panel attachment device and replace or readjust it as necessary Proper...

Page 47: ...e components are very heavy such as the batteries frame seat and motors When installing or removing such components lift them safely to avoid injury Only use hoisting devices that have a sufficient capacity Tools Allen wrench size 5 mm Allen wrench size 6 mm Steps Disassemble the seat including the seat frame Disassemble the lights Disassemble all components attached to the frame and drive unit su...

Page 48: ...wer wheelchair and disconnect all plug connections to the control electric module Preparation Disassemble the drive wheel see Section 6 7 3 Tools Open end wrench size 13 mm Steps Disconnect the motor from the controller Loosen the four self locking nuts Remove and replace the motor if necessary Properly reassemble all components upon termination of the work Fig 44 Replacing the drive motor 6 13 Br...

Page 49: ...pacer bushings to prevent the frame from warping 4 Insert an Allen head screw at the third attachment point of the lower gas compression spring receiver into the existing bore hole beneath the drive unit sustainer and tighten Fig 45 4 5 Remove the anterior seat bracket 6 Mount the crossbrace for the upper gas compression spring receiver Fig 45 5 7 Move the upper end of the gas compression spring b...

Page 50: ...move the side panel Tools Allen wrench sizes 2 5 mm Steps Mount the C profile for the Bowden cable attachment beneath the armrest Mount the clamp piece and sliding nut Position the release lever with the sliding nut and tighten the Allen head screw Mount the side panel making sure to correctly position the Bowden cable Fig 46 Attaching the Bowden cable 1 2 3 ...

Page 51: ... Slide on the supplied spacer bushings from underneath and secure them with nuts Fig 47 3 Information It is very important to use spacer bushings to prevent the frame from warping 1 2 3 Fig 47 Mounting a curb climbing assist 6 14 4 Retrofitting a Rearview Mirror Tools Allen wrench size 3 mm Steps Mount the rearview mirror on the opposite side of the control panel holder to the C profile of the arm...

Page 52: ...Allen head screws Fig 49 2 Secure the plastic locking lever with lock washers above below Fig 49 3A Screw the locking screws into the frame Fig 49 3B Properly reassemble all components upon termination of the work 1 2 3 A B Fig 49 Mounting the caster swivel lock 6 14 6 Assembling the Holding Device for Headrest Attachment option The holding device for the headrest must be attached to the back fram...

Page 53: ...r 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 Fig 51 Retrofitting a lap belt 6 14 8 Mounting a Luggage Carrier option Preparation First disassemble the rear lights if present Tools Allen wrench size 6 mm Steps Mount the luggage carrier to the prefabricated bore holes in the rear frame s...

Page 54: ...g connections and cabling They should be inspected first for this reason Errors are displayed either by flashing signals on the LED display Battery capacity see Sec tion 7 2 or with the aid of the hand programming device see Section 7 3 The hand programming device offers the possibility of describing errors more precisely with the aid of error codes With this manual you will be able to assign disp...

Page 55: ...device read the error code see Table 7 and find out the type of error see Table 8 Slow flashing There is no error release in the control system but maybe an er ror has been released earlier Information The less LEDs are flashing the less battery capac ity remains Read the control system s error diagnostic log and find out the type of error see Section 7 3 Charge the batteries Display is perma nent...

Page 56: ... right motor Defective motor E g faulty plug con nection Check the connections to the right motor Check the motor Short circuit on the bat tery connection to the right motor E g broken cable Check the battery connec tion to the right motor Driving function is blocked due to external influences Maybe the battery charger is connected Disconnect the battery charger Joystick error Joystick not in zero...

Page 57: ...right 1600 10 10 High battery voltage 1E03 Charging 6 Battery charger is connected 1E04 6 13 1E05 Charging 14 2C00 1 1 Low battery voltage 2C02 1 Switch off due to low battery voltage 2F00 User 7 11 Possible joystick error Joystick was moved when switching on 3B00 2 2 Left motor disconnected 3C00 4 4 Right motor disconnected 3D00 3 3 Error in the cabling of the left motor 3D01 3 3 Error in the cab...

Page 58: ...ric module Information If the outputs of the left and right motors have been inverted during programming this paragraph refers to the left motor Please contact Otto Bock if you have any questions 5 Error in the cabling of the right motor The control system detects errors in the cabling to the right motor especially if there is a short circuit in the connection between the motor and battery Check t...

Page 59: ...rsists check the items in paragraph 7 12 Communication error The most frequent cause Faulty cable between the electric module and joystick module Check the cable for damage and replace if necessary If the error persists there might be a defect in the electric module or joystick module Information Replacement of the connection cable may only be carried out by persons authorized by the manufacturer ...

Page 60: ...ug connections the modules Wheelchair moves only slowly The control system has not been properly programmed Programme the speed A speed limitation function is active Switch off the limitation function Defective motor or defective brake Check replace the motor brake The wheelchair does not prop erly drive straight forward Error in the motor or brake Check replace the motor brake The motor or one br...

Page 61: ...f the LEDs of the control see Section 7 2 The parameters can be changed with the hand programming device or using a PC software and interface cable can be ordered separately 8 2 Installation and Wiring VR2 CONTROLLER CONNECTION Motor brake ve VR2 50 70 Motor ve Motor brake ve Motor ve BATTERY Motor 1 Motor 2 Motor brake ve Motor ve Motor brake ve Motor ve 12V 24V Brake 12V 24V Brake Protect switch...

Page 62: ...hat you observe any restrictions given in your wheel chair user manual Document any changes you make for future reference The PP1a hand programming device gives access to programmable parameters in order to adjust the wheelchair to individual patient requirements and to read the Fault Log and Timer see Section 8 4 To alter the program settings the device is connected to the control system with a p...

Page 63: ...alue of acceleration occurs when speed setting 5 is selected Its value at other settings depends on the value of the Minimum Turn Acceleration parameter Turn Deceleration Single steps from 0 to 100 Adjusts the value for turning deceleration or braking of the wheelchair A higher value gives faster deceleration This programmed value of deceleration occurs when speed setting 5 is selected Its value a...

Page 64: ...s is determined by the programmable parameter Number of Drive Profiles If Number of Drive Profiles is set to 0 then there is one setting for each of the parameters listed previously and the control system s maximum speed setting can be changed with the maximum speed profile increase and decrease buttons If the values of Number of Drive Profiles is 2 to 5 there is a cor responding number of drive p...

Page 65: ...he Turn Acceleration value occurs when the speed setting is at 1 Programming example Turn Acceleration 80 and Minimum Turn Acceleration 25 Turn Acceleration at step 1 25 of 80 20 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 Turn Acceleration at step 2 35 Turn Acceleration at step 3 50 Turn Acceleration at step 4 65 Minimum Turn Deceleration 1 increments of the Turn Decelera...

Page 66: ...f while the wheelchair is being driven Soft Reverse Deceleration Single steps from 25 to 100 Adjusts the deceleration rate used while the wheelchair is stopping in reverse This rate is separately adjustable from the Deceleration parameter to prevent the wheelchair tipping when reversing down a gradient The value is a percentage of the Deceleration parameter A typical value is 70 Reverse Driving Al...

Page 67: ...dware Function Description Memory Functions The VR2 has a timer and a diagnostic log These can be read and cleared us ing the PP1a programming device or the PC programming device Read Timer The VR2 has a timer which records how long the wheelchair is in use The timer runs whenever the joystick is moved away from the centre position and stops when the joystick is returned The timer records the numb...

Page 68: ...ully check all components listed here for correct function setting damages or deformations and whether the screw connections are tightened OK Damages Replacement 1 Control Control holder Control cable Control panel 2 Battery case Batteries Cabling 3 Motors Brake release 4 Tyres Drive wheels Casters 5 Frame Drive unit sustainer 6 Seat Back Upholstery cushion ...

Page 69: ... 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 Comments The maintenance service was carried out by Place date Signature ...

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Page 72: ...e 49 5527 848 1590 Fax 49 5527 848 1676 e mail reha ottobock de Internet http www ottobock com Versandanschrift für Rücksendungen Address for Returns Otto Bock HealthCare GmbH Lindenstraße 13 07426 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 manageme...

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