Otto Bock C1000 DS Service Instructions Manual Download

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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.

NOTICE

Risk of upholstery damage.

During any work on the seat, the upholstery must be adequately protected

against mechanical and chemical damage. The seat and back rest cushions are flame retardant but

nevertheless flammable. They must not come into contact with open flame or embers.

NOTICE

Risk of damage due to improper cleaning after the completion of maintenance tasks.

Never use

a water jet or high-pressure cleaning apparatus for cleaning the power wheelchair. A cloth or sponge

may be used for cleaning. Water must not come into direct contact with the motors under any circum-

stances. Check the operating performance of the power wheelchair after cleaning.

INfORMATION

Prior to using the power wheelchair, all the necessary mechanical adaptations (e. g. mounting special

controls) and software settings (e. g. programming the control unit) must be made to comply with the

individual requirements and abilities of the user. Settings may only be made by personnel that has been

authorised and trained by Otto Bock.

INfORMATION

The tyres of the power wheelchair contain chemical substances that may react with other chemical

substances (e.g. cleaning agents, acids etc.).

INfORMATION

Piston rods do not require lubrication. They are maintenance-free.

2.5 Safety standards for maintenance tasks on electrical components

CAUTION

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 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.

• Smoking and open flame are prohibited while working on the battery. Sparks must be avoided.

• Explosive gases can develop while the batteries are charging. Observe the safety information provided

by the battery manufacturer. Wear protective goggles. Ensure sufficient ventilation when charging

the batteries in an enclosed room.

• The air vents in the trim must not be covered.

• Drive batteries can supply very large amounts of energy and may arc if they are short-circuited. There-

fore, always disconnect the batteries when working on the motor control or wiring.

Summary of Contents for C1000 DS

Page 1: ...C1000 DS Service Instructions ...

Page 2: ......

Page 3: ...ansportation 14 3 1 1 Folding for transportation 15 3 1 2 Folding the back rest 15 3 1 3 Folding the back rest with electric back angle adjustment 16 3 2 Storage 17 4 Required Tools and Accessories 18 5 Information Display 19 6 Service and Maintenance 21 6 1 Inspecting the general condition 21 6 2 Fuse replacement 21 6 3 Batteries 22 6 3 1 Charging the batteries 22 6 3 2 Removing the battery cover...

Page 4: ...lock release 50 6 12 3 Performing a function check of the wheel lock settings 52 6 13 Anti tipper 53 6 13 1 Removing the anti tipper holder 53 6 13 2 Removing the anti tipper wheel 53 6 14 Lighting 54 6 14 1 Removing the front lights 54 6 14 2 Removing the rear lights 55 6 15 Seat 56 6 15 1 Standard seat Removing the seat cushion and back pad 57 6 15 2 Standard seat Replacing adjusting the back up...

Page 5: ...nk 84 6 19 Removing the drive unit sustainer 85 6 20 Replacing retrofitting control elements 85 6 20 1 Mounting an LCD monitor 85 6 20 2 Replacing the control panel 87 6 20 3 Replacing the control panel holder 87 6 20 4 Retrofitting the removable or swing away control panel 88 6 20 5 Retrofitting the height adjustable control panel holder 89 6 20 6 Retrofitting attendant controls 90 6 20 7 Install...

Page 6: ...06 8 3 2 Electrical specifications 107 8 4 Programming device 108 8 4 1 Handheld programming device 108 8 4 2 PC Programming Station PCPS 110 8 5 Programmable parameters 110 8 5 1 Main parameters 111 8 5 2 Driving parameter settings 115 8 5 3 Joystick parameter settings 119 9 Maintenance and Service Plan C1000 DS 121 ...

Page 7: ... chapters The service instructions also contain cross references that make them easier to use e g see Section 6 2 1 2 Support Your national Otto Bock Team will be pleased to answer your technical questions Contact addresses and telephone numbers are listed on the last two pages of this manual 2 Safety 2 1 Explanation of symbols WARNING Warnings regarding possible risks of severe accident or injury...

Page 8: ...strain The maximum load capacity for the standard version of the C1000 DS power wheelchair is 140 kg It is possible to have the power wheelchair ret rofitted for a maximum load capacity of 200 kg If the power wheelchair is equipped with a seat height adjustment unit the maximum load capacity is 130 kg optional 200 kg Information Only use original options supplied by the manufacturer The optional c...

Page 9: ...e construction All at tendants must be informed about this In order to prevent injuries ensure that body parts such as the hands and feet are always kept out of the danger zone that no interfering objects such as clothing or obstacles are in the danger zone and that no unauthorised persons are present there WARNING Risk of accidents and injury due to loosening plug and screw connections Screw and ...

Page 10: ...tests of the electrical components Secure the product to prevent it from tipping over or falling Some components of the power wheelchair e g the batteries frame seat and motors are very heavy Observe ergonomically correct practices when lifting these components or use sufficient hoist ing equipment Clean disinfect the product before you start the inspection Consult the instructions for use regard ...

Page 11: ...nts and abilities of the user Settings may only be made by personnel that has been authorised and trained by Otto Bock Information The tyres of the power wheelchair contain chemical substances that may react with other chemical substances e g cleaning agents acids etc Information Piston rods do not require lubrication They are maintenance free 2 5 Safety standards for maintenance tasks on electric...

Page 12: ...any work on the batteries Only use insulated tools in or der to prevent short circuits Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery damage Ensure correct polarity is used when connecting the batteries The black cable must be connected to the negative pole and the red cable to the positive pole NOTICE Risk of damage to the battery charger Pre...

Page 13: ...iving characteristics In particular changes to the speed acceleration braking or joystick settings can lead to unexpected and therefore uncontrollable operat ing performance with a risk of accidents Always test the driving characteristics of the power wheel chair after configuration programming is complete Programming must only be completed by author ised personnel Neither Otto Bock nor the contro...

Page 14: ... CAUTION Risk of crushing or pinching in the pivot range of the footrests Ensure limbs are clear of the danger zone when folding the footrests up or down NOTICE Risk of damage due to falling The maximum net weight of the power wheelchair is 129 kg Only use hoisting devices and transportation vehicles with sufficient capacity for transportation The eyebolts at the font and back of the power wheelch...

Page 15: ...d down the back rest back rest with electrical back angle adjustment see Section 3 1 2 3 1 3 Fig 2 Folding the footrests up 3 1 2 Folding the back rest 1 Remove the side panels see Section 6 15 9 2 Pull the release strap to the rear 3 With your hand fold the back rest down onto the seat bottom Fig 3 Folding the back rest ...

Page 16: ...ent 1 Remove the side panels see Section 6 15 9 2 Push the lever up and unlock the cross bolt at the lower end of the drive unit 3 Remove the cross bolt from the holder 4 Fold the back rest down onto the seat bottom Fig 4 Removing the cross bolt Fig 5 Folding size ...

Page 17: ... pieces break out of the tread Information Avoid parking the wheelchair outdoors whenever possible Regardless of wear and tear replace the tyres every 2 years Information Remove the fuse for shipping or when the power wheelchair is not being used for an extended period of time The C1000 DS power wheelchair must be stored in an enclosed room Remove the main fuse otherwise there is a risk of deep di...

Page 18: ...rench and sockets sizes 8 20 Open end or combination wrenches sizes 8 24 Allen wrenches size 2 8 Torque wrench Puller Pin punch Ø 3 mm Rubber hammer Hand drill Drill bit Ø 4 mm Plastic tyre mounting lever Tyre lever Inner tube repair kit Side cutting pliers Water pump pliers gripping width up to 32 mm Liquid thread lock medium strength Handheld programming device Hoisting devices of sufficient cap...

Page 19: ...using the control panel display LCD monitor or the handheld programming device PC software Messages are shown on the control panel display or LCD monitor Display symbol s LCD monitor display Function Driving menu with speed level and battery ca pacity Low battery capacity Charging process with drive stop Electric back adjustment Electric seat tilt ...

Page 20: ... 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 ...

Page 21: ...g in case of corrosion Check cables for ruptures signs of wear and proper attachment replace defective com ponents Check cable connections and plug connections 6 2 Fuse replacement The 80 A fuse is located in a fuse housing to the left rear of the battery case Preparation Turn the control unit off Steps 1 Open the flip cover of the fuse housing 2 Pull out the fuse and replace if required Properly ...

Page 22: ...ry damage due to falling Hoisting devices used for transportation must have a sufficient capacity Secure the batteries against falling NOTICE Risk of battery damage In order to prevent short circuits always use insulated tools when working on the batteries Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery damage Ensure correct polarity is used wh...

Page 23: ...pply network Only use the battery charger within the specified ranges of temperature and humidity Place the rubber feet of the battery charger on a level surface When setting the charger up close to a window protect it against direct sunlight Keep the charger from overheating The vent openings on the back of the charger must not be covered Turn off the control unit during the charging process so t...

Page 24: ...9 Connecting the charger to charging receptacle 1 Charging receptacle 2 Battery charger plug Fig 10 Otto Bock 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 25: ...defective or missing or charging time has been exceeded Table 2 Battery capacity indicator on the battery charger If none of the LEDs are lit there is no power supply The battery capacity is displayed by the Battery Capacity LEDs in 7 segments Each segment represents approximately 14 of the total capacity 6 3 2 Removing the battery cover Steps 1 Loosen the two knurled head screws on the left and r...

Page 26: ... pole Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the battery cover see Section 6 3 2 Tools Open end or combination wrench size 11 Steps 1 Unlock the release bolt and remove the track Fig 12 Unlocking the battery drawer and removing the track 2 Disconnect all battery cables 3 Lift out the batteries by the handles and replace if required Fig 13 Removing the batterie...

Page 27: ...ing casters may loose ground con tact and the front anti tipper may engage Test the effects of the centre of gravity shift on the behaviour of the power wheelchair with the support of an attendant WARNING Risk of tipping due to changing the battery position Ensure that the batteries are up against the stop during installation and that there is no play between the batteries and track when installin...

Page 28: ...compartment according to the mount ing bores and attach it Properly reassemble all components upon completion of the work 1 2 3 Fig 15 Battery stop 1 Mounting holes 2 Allen head screws 3 Battery stop 6 3 5 Reinstalling the battery cable Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the battery cover see Section 6 3 2 Remove the batteries see Section 6 3 3 Tools Screw...

Page 29: ...sure correct assignment Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the battery cover see Section 6 3 2 Remove the batteries see Section 6 3 3 Tools Open end or combination wrench size 11 Small Phillips screwdriver Side cutting pliers Steps 1 Loosen the charging receptacle cables on the controller 2 Loosen the charging receptacle cables on the batteries 3 Open all ...

Page 30: ...gage carrier 6 5 1 Replacing the luggage carrier Tools Open end or combination wrench size 13 Allen wrench size 5 Steps 1 Loosen and remove one Allen head screw from the right and left underneath the luggage carrier respectively 2 Remove the luggage carrier and replace if required Properly reassemble all components upon completion of the work 2 1 Fig 18 Removing the luggage carrier 1 Notch 2 Allen...

Page 31: ... cables ensure correct assignment The longer cable must be connected on the right in the direction of travel Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the luggage carrier see Section 6 5 Tools Allen wrench size 3 Allen wrench size 4 Steps 1 Remove the controller cover In order to do so loosen and remove two Allen head screws 2 Tip the controller cover forward at ...

Page 32: ...nections on the controller 1 Connector for steering motor left behind that connection for steering potentiometer left 2 Connector for steering motor right behind that connection for steering potentiometer right 3 Lighting connector 4 Connector for battery capacity indicator cable 5 Motor connector left 6 Battery cable connector 7 Motor connector right ...

Page 33: ...t assignment Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the luggage carrier see Section 6 5 Tools Allen wrench size 2 5 Steps 1 Loosen all cables on the seat module 2 Loosen and remove two Allen head screws 3 Remove the seat module and replace if required Properly reassemble all components upon completion of the work Fig 22 Removing the seat module ...

Page 34: ...ardless of wear and tear the tyres should be replaced every 2 years If the wheelchair is parked for an extended period of time or the tyres overheat e g in the vicinity of radiators or in case of exposure to strong sunlight behind glass the tyres may become permanently deformed Therefore sufficient clearance should always be maintained from sources of heat and the power wheelchair should be moved ...

Page 35: ...the drive unit sustainer Information When installing the steering caster ensure that the steering caster and drive wheel are aligned Preparation Switch off the control unit Raise the power wheelchair so that the wheel being replaced can turn freely Tools Socket wrench size 17 Screwdriver for pan head screws Torque wrench Steps 1 Remove the cover cap 2 Loosen and remove the hexagon head screw 3 Pul...

Page 36: ...t all the air out of the tyre 2 Using the tyre lever remove the casing from the wheel rim and replace if required Properly reassemble all components upon completion of the work 6 8 5 Replacing the casing and or tube The wheel rims are in two parts and can be separated by removing the Allen head screws Preparation Remove the wheel see Section 6 8 2 or 6 8 3 Tools Plastic tyre mounting lever Inner t...

Page 37: ... sections of the wheel rim 9 For pneumatic tyres Inflate the tyre observe the allowable tyre pressure 10 Install the wheel Fig 25 Removing the casing 6 8 6 Removing the splash guard for the drive wheel Preparation Remove the drive wheel see Section 6 8 2 Remove the wheel lock release on the right side see Section 6 12 1 Tools Allen wrench size 4 Open end or combination wrench size 10 Steps 1 Loose...

Page 38: ...e Section 6 8 2 Remove the splash guard for the drive wheel see Section 6 8 6 Tools Allen wrench size 6 Steps 1 Loosen and remove two Allen head screws on the holder 2 Remove the holder for the splash guard and replace if required Properly reassemble all components upon completion of the work Fig 27 Removing the holder for the drive wheel splash guard ...

Page 39: ...and injury due to improper completion of work on the wheel flange The removal and installation of the wheel flange may only be completed in the plant of Otto Bock Manufacturing Königsee GmbH 6 9 Removing the spring adjusting the spring power NOTICE Risk of damage due to improper preparation of maintenance tasks Use suitable objects such as wooden blocks to secure the power wheelchair against slidi...

Page 40: ...holder Preparation Remove the drive wheel see Section 6 8 2 Remove the splash guard for the drive wheel see Section 6 8 6 Tools Allen wrench size 6 Steps 1 Loosen and remove the top Allen head screw that holds the spring to the drive unit sustainer 2 Loosen and remove the bottom Allen head screw that holds the spring to the oscillating crank 3 Remove the spring and replace if required Properly rea...

Page 41: ...he steering rocker 3 Remove the steering rocker spring and replace if required Properly reassemble all components upon completion of the work 1 2 Fig 30 Removing the steering rocker spring 1 Rear screw connection 2 Front screw connection 6 9 3 Adjusting the spring power Adjusting the spring power on the drive axle and steering axle is done in the same manner 1 Manually turn the plate up or down a ...

Page 42: ... Replacing the steering potentiometer Tools Allen wrench size 2 5 Side cutting pliers Steps 1 Loosen and remove two Allen head screws on the cover Fig 32 Remove the cover 2 Remove the cover 3 Loosen and remove two Allen head screws on the cover for the steering potentiometer 4 Remove the cover for the steering potentiometer ...

Page 43: ...le ties 7 Disconnect the cables to the steering motor and controller 8 Remove the steering potentiometer and replace if required Properly reassemble all components upon completion of the work 6 10 2 Replacing the steering motor Preparation Replacing the steering potentiometer see Section 6 10 1 Tools Allen wrench size 4 Allen wrench size 5 Retaining ring pliers Rubber mallet Puller ...

Page 44: ...remove two Allen head screws on the small mounting plate Fig 35 Removing the small mounting plate 2 Remove the small mounting plate 3 Lift and remove the larger mounting plate below Fig 36 Removing the larger mounting plate ...

Page 45: ...1 Fig 37 Removing the spacers 1 Spacers 5 Open and remove the retaining ring Fig 38 Removing the retaining ring 6 With counter support on the oscillating crank remove the toothed wheel upwards Fig 39 Removing the toothed wheel ...

Page 46: ...spring washers 8 Secure the oscillating crank against falling with one hand and gently tap it out towards the floor Fig 41 Tapping out the oscillating crank 9 Gently tap out the bearing towards the floor 1 Fig 42 Bearing installed and removed 1 Bearing ...

Page 47: ...ace if required Fig 44 Removing the steering motor Properly reassemble all components upon completion of the work Information Upon installation of the steering motor the wheel axle must face out Information The spring on the steering motor must be under pressure As a result the number of spring washers may vary 2 to 3 When slight pressure is exerted on the toothed wheel the groove must be visible ...

Page 48: ...teering caster see Section 6 8 3 Remove the steering see Section 6 10 Remove the steering rocker spring see Section 6 9 2 Remove the rear lighting see Section 6 14 2 Tools Allen wrench size 10 Steps 1 Loosen and remove the Allen head screw 2 Remove the steering rocker and replace if required Fig 46 Removing the steering rocker ...

Page 49: ...simultaneously braked by the control unit via a motor brake In case of defects in the brake system the motor brake can only be re placed as a unit with the drive motor In case of control unit failure or insufficient battery capacity the power wheelchair can be pushed To do so the wheel lock is released by the mechanical wheel lock release The wheel lock release is located on the same side as the c...

Page 50: ...cluding the Bowden cables and replace if required Properly reassemble all components upon completion of the work 6 12 2 Setting adjusting the wheel lock release CAUTION Risk of accidents and injury due to a lack of brake functionality Incorrect wheel lock settings can lead to a loss of braking power Repairs and settings must only be made by authorised personnel Re place damaged Bowden cables with ...

Page 51: ...ld have very little play before adjusting it Information Lock the adjustment screw every time the setting is changed Otto Bock recommends changing the setting in small increments turn Tools Open end or combination wrench size 8 a Adjusting an over tightened Bowden cable Steps 1 Loosen the M5 counter nut SW 8 and turn the adjustment screw clockwise on the wheel lock release housing 2 Commence funct...

Page 52: ...djustment process is described in Section 6 12 2a under Adjusting an over tightened Bowden cable 5 If the wheelchair tracks properly in both cases conduct the following test on an even surface a Pull the release bolt on the brake housing The lever automatically moves forward into position 2 You should not be able to push the wheelchair with the lever in this position If the drive wheels do not loc...

Page 53: ...ombination wrench size 13 Steps 1 Loosen the Allen head screw on the holder 2 Remove the anti tipper holder and replace if required Properly reassemble all components upon completion of the work Fig 51 Removing the anti tipper holder 6 13 2 Removing the anti tipper wheel Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 Loosen the Allen head screw on the wheel 2 Remove the w...

Page 54: ... drive wheels respectively Information Only the complete front light can be replaced on each side The front lights can be ordered from the specialist dealer Preparation Remove the drive wheel see Section 6 8 2 Remove the splash guard for the drive wheel see Section 6 8 6 Tools Phillips screwdriver Side cutting pliers Steps 1 Disconnect the front lighting plug connections to the controller next to ...

Page 55: ... the rear of the power wheelchair Information Only the complete rear light can be replaced on each side The rear lights can be ordered from the specialist dealer Tools Allen wrench size 4 Steps 1 Loosen and remove the Allen head screw on the steering rocker Fig 54 Attachment of the rear light to the steering rocker 2 Pull the mounting plate with the rear light out towards the front ...

Page 56: ...w connections Screw and plug con nections must be loosened for all adjustments This can cause uncontrolled movements of wheelchair components To avoid injuries at pinch and shear points carry out such tasks with the support of another person Ensure that body parts such as the hands or head are kept out of the danger zone at all times CAUTION Risk of accidents due to unsecured screw connections Whe...

Page 57: ...on and back pad are attached to the seat plate and back rest upholstery with hook and loop connectors and can be removed by simply pulling them off 6 15 2 Standard seat Replacing adjusting the back upholstery 1 Remove the back pad 2 Remove the entire back upholstery 3 Individually readjust the hook and loop straps according to the needs of the user or remove them and replace if required Properly r...

Page 58: ... plate 6 15 4 Standard seat Replacing the seat plate Only standard seats have a seat plate Steps 1 Remove the seat cushion 2 Unlock the back rest and fold it forward 3 Pull the seat plate up with a sharp tug and replace if required Properly reassemble all components upon completion of the work Fig 59 Seat plate standard seat ...

Page 59: ...eat cushion Remove the side panels see Section 6 15 9 Unscrew the back pad Remove the footrest see Section 6 15 18 Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 In case of a seat with electrical seat adjustment Disconnect the electrical seat adjustment cables on the controller 2 Loosen all cables connected to the seat frame by cable ties 3 Loosen and remove the two Allen...

Page 60: ...ged The seat brackets must be replaced in order to change the seat height The seat brackets are attached to the front of the frame with clamping brackets 1 2 Fig 62 Front and rear seat brackets 1 Front seat bracket 2 Rear seat bracket Preparation Remove the seat plate see Section 6 15 4 Remove the footrest see Section 6 15 18 Tools Allen wrench size 5 Open end or combination wrench size 13 ...

Page 61: ... ties are not damaged The two front seat brackets are used to adjust the seat angle These brackets have several bore holes on their lower end The angle of the seating unit is changed by using a different bore hole e g Upper bore hole 0 middle bore hole 3 lower bore hole 6 Preparation Remove the seat plate see Section 6 15 4 Remove the footrest see Section 6 15 18 Tools Allen wrench size 5 Open end...

Page 62: ...t until the corresponding screws are freely accessible Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 Loosen and remove two Allen head screws on the bearing plate 2 Move the bearing plate according to the mounting bore grid 3 Move the footrest according to the mounting bore grid see Section 6 15 18 Properly reassemble all components upon completion of the work Fig 65 Adju...

Page 63: ...pletion of the work Fig 66 Loosening the thumb screw for removal of the side panel with arm rest 6 15 10 Adjusting replacing the arm rest Adapting the arm rests to the upper arm length Tools Allen wrench size 3 Steps 1 Loosen the Allen head screw 2 Move the side panel with arm rest up or down along the rail into the desired position Properly reassemble all components upon completion of the work Fi...

Page 64: ...ired position along the attachment rail Properly reassemble all components upon completion of the work Fig 68 Adapting the arm rests to the forearm length 6 15 11 Adapting replacing the clothing protector Preparation Remove the side panel see Section 6 15 9 Tools Allen wrench size 3 Steps 1 Loosen two Allen head screws on the side panel 2 Change the position of the clothing protector or remove and...

Page 65: ...e is located on either side on the rear cross brace under the seat Tools Allen wrench size 4 Steps 1 Loosen the two set screws 2 Remove the side panel attachment device and replace or readjust as required Properly reassemble all components upon completion of the work 1 Fig 70 Adjusting the side panel attachment device 1 Side panel attachment device ...

Page 66: ...r this tube b Insert the screw through the eyelets and bore hole in the centre of the tube and tighten the screw 3 Remove the protective cap from the button 4 Remove the back adjustment button from the back rest 5 Press out the three small plastic nipples from the rear 6 Remove the rest of the covering 7 Bore out the topmost of the two holes in the metal plate for the strap mounting screws 8 Attac...

Page 67: ...13 Steps 1 Attach the mounting set for installation of the lap belt to the seat frame using Allen head screws right and left respectively Fig 72 Attaching the lap belt b Changing 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 var...

Page 68: ... be anchored in the arm rest rail Tools Allen wrench size 4 Steps 1 Insert lock cams into the track and position them as desired 2 Place both strap ends with eyelets onto the set screw and secure with nuts Properly reassemble all components upon completion of the work Fig 74 Arm strap ...

Page 69: ... into place 2 Remove the back upholstery 3 Slip three mounting clamps for the back of the contour seat onto the right and left of the frame respectively 4 Put the seat back in place and mount it with six Allen head screws Properly reassemble all components upon completion of the work 1 2 3 Fig 75 Contour seat with clamp fittings 1 Frame for back rest 2 Contour seat back rest 3 Mounting clamps 6 6 ...

Page 70: ...on of the work b Replacing the seat attachment device The seat attachment device of the Recaro seat is screwed to the bottom of the seat Tools Allen wrench size 4 Steps 1 Unlock and remove the seat 2 Lay down the seat and loosen the three Allen head screws on each side of the seat attach ment device 3 Remove the seat attachment device and replace if required Properly reassemble all components upon...

Page 71: ... back rest onto the seat bottom 3 Attach the front locking mechanism to the rear adapter Properly reassemble all components upon completion of the work 6 15 18 Adapting replacing the footrests CAUTION Risk of pinching Ensure limbs are clear of the danger zone when folding the footrests up or down Various footrest systems with the same adjustment and mounting options are available for the C1000 DS ...

Page 72: ...eps 1 Pull the footrest lock lever back and pull the footrest up and out Fig 79 Unlocking the footrest 2 Loosen the two set screws see Figure 80 3 Adjust the length by pulling out or pushing in the footrest tube Properly reassemble all components upon completion of the work Fig 80 Adapting the footrest to the lower leg length ...

Page 73: ...e all components upon completion of the work Fig 81 Adapting the footrest to the thigh length d Elevating footrests with calf and knee pads Tools Allen wrench size 3 Open end or combination wrench size 10 Steps 1 Remove the standard footrest holder 2 Install the footrest holder for elevating footrests 3 Loosen the Allen head screws 4 Remove and replace the standard footrests Properly reassemble al...

Page 74: ...lf pad or replace if required Properly reassemble all components upon completion of the work Fig 83 Replacing the calf pad 6 15 19 Replacing the footplate Tools Allen wrench size 6 Steps 1 Loosen the Allen head screw that connects the footplate to the installation kit 2 Remove the footplate and replace if required Properly reassemble all components upon completion of the work ...

Page 75: ...actuator are required to install the electric back angle adjustment option The electric back angle adjustment option is delivered as a pre assembled unit Preparation Turn the control unit off Remove the fuse see Section 6 2 Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 Remove the back frame from the bearing plate seat frame see Section 6 15 3 2 Install the bearing plate ...

Page 76: ...e seat tilt is delivered as a pre assembled unit Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the footrest see Section 6 15 18 Remove the seat frame see Section 6 15 5 Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 Mount the pre assembled unit consisting of the seat frame seat brackets and actuator on the wheelchair frame 2 Connect the actu...

Page 77: ...ion Turn the control unit off Remove the fuse see Section 6 2 Remove the footrest see Section 6 15 18 Remove the seat frame see Section 6 15 5 Tools Allen wrench size 5 Open end or combination wrench size 13 Steps 1 Mount the pre assembled unit consisting of the seat frame seat brackets and actuator on the wheelchair frame 2 Connect the actuator to the controller or seat module AAM 3 Install the s...

Page 78: ...eat height adjustment and seat tilt is delivered as a pre assembled unit The installation process is the same as for a unit with seat height adjustment only see Section 6 16 3 Fig 88 Pre assembled seat height seat tilt adjustment unit 6 16 5 Retrofitting electric footrests option The electric footrests are delivered as a pre assembled unit The footrests of the power wheel chair are self contacting...

Page 79: ...ing a seat module Information A seat module is required if an electric seat function is installed A seat module can cover up to 5 func tions on the power wheelchair additional functions require a second seat module After new electric seat functions are installed and connected the control unit has to be reprogrammed For more information see the instructions for use for the enAble50 control unit 647...

Page 80: ...re that you do not damage the cables during this process Preparation Remove the seat cushion see Section 6 15 1 Remove the seat plate see Section 6 15 4 Raise or tilt the seat until the actuator mounts are freely accessible Turn the control unit off Remove the fuse see Section 6 2 Tools Screwdriver for pan head screws Retaining ring pliers Rubber mallet Side cutting pliers Steps 1 Disconnect the s...

Page 81: ...ure that you do not damage the cables during this process Preparation Turn the control unit off Remove the fuse see Section 6 2 Tools Allen wrench size 3 Allen wrench size 4 Retaining ring pliers Rubber mallet Side cutting pliers Steps 1 Disconnect the seat function cables on the controller or seat module AAM 2 Open the cable ties 3 Loosen two retaining rings on the mounting points at the top and ...

Page 82: ...eat plate see Section 6 15 4 Raise or tilt the seat until the actuator mounts are freely accessible Turn the control unit off Remove the fuse see Section 6 2 Tools Screwdriver for pan head screws Retaining ring pliers Rubber mallet Side cutting pliers Steps 1 Disconnect the seat height adjustment plug connections on the controller or AAM 2 Open the cable ties 3 Loosen two retaining rings on the mo...

Page 83: ...see Section 6 2 Remove the drive wheel see Section 6 8 2 Remove the splash guard for the drive wheel see Section 6 8 6 Remove the wheel lock release right side see Section 6 12 1 Remove the holder for the drive wheel splash guard see Section 6 8 7 Tools Allen wrench size 6 Open end or combination wrench size 6 Open end or combination wrench size 8 Side cutting pliers Steps 1 Loosen the Bowden cabl...

Page 84: ...ming any work on the drive motors Preparation Turn the control unit off Remove the fuse see Section 6 2 Remove the drive wheel see Section 6 8 2 Remove the splash guard for the drive wheel see Section 6 8 6 Remove the wheel lock release right side see Section 6 12 1 Remove the holder for the drive wheel splash guard see Section 6 8 7 Remove the drive motor see Section 6 17 Tools Allen wrench size ...

Page 85: ...lation of the drive unit sustainer may only be completed in the plant of Otto Bock Manufacturing Königsee GmbH 6 20 Replacing retrofitting control elements 6 20 1 Mounting an LCD monitor Information For more information and operating instructions for the LCD monitor consult the instructions for use for the enAble50 control unit 647G490 D GB A separate LCD monitor with infrared and Bluetooth option...

Page 86: ...le holder holder with swan neck onto the attachment rail below the arm rest and secure it with two set screws 2 Slide the holder onto the square tube and secure it with set screws 3 Secure the square tube 4 Attach the LCD monitor to the holder 5 Connect the LCD monitor to the controller 6 Function test Fig 97 LCD monitor with standard holder ...

Page 87: ... plugs ensure that they are firmly connected to each other Tools Allen wrench size 3 Steps 1 Disconnect the plug connection on the controller 2 Loosen all cable ties attaching the cable to arm rest 3 Loosen three set screws on the bottom of the arm rest 4 Pull the control panel with control panel holder forward out of the track 5 Attach the control panel with control panel holder on the opposite s...

Page 88: ... pushed into the adapter to the stop Preparation Remove the control panel with control panel holder see Section 6 20 2 Tools Phillips screwdriver Allen wrench size 3 Steps 1 Disconnect the control panel plug connections on the controller 2 Separate the control panel and control panel holder in order to do so loosen four Phillips head screws on the bottom of the control panel holder 3 Attach the sw...

Page 89: ...an be mounted on the power wheelchair allowing the height of the control panel to be adjusted Tools Allen wrench size 3 Allen wrench size 5 Steps 1 Attach the swing away control panel holder to the bottom of the arm rest with three set screws 2 Loosen two mounting screws and adjust the height of the control panel Fig 100 Control panel holder height adjustable ...

Page 90: ...the back rest Two bore holes are provided for this purpose on the left and right of the back tube respectively Tools Allen wrench size 4 Steps 1 Hold the bracket for the attendant controls against the back tube 2 Attach with two Allen head screws 3 Attach the control panel Fig 102 Attaching attendant controls to the standard contour seat b Assembly on the Recaro seat On the power wheelchair with t...

Page 91: ...st to the seat 4 Adjust the width of the holder with the two set screws Fig 103 Attendant control on the Recaro seat 6 20 7 Installing joystick accessories Tools Allen wrench size 6 Steps 1 Slide off the top of the joystick 2 Slide an accessory such as the fork for tetraplegics golf ball stick etc onto the metal pin 3 Mount the accessory by tightening the set screw Fig 104 Installing joystick acce...

Page 92: ...for use 647G490 D GB and send it to Otto Bock via e mail with a specification for the desired configuration Here the configuration file is amended modified accordingly The file sent back by Otto Bock is then uploaded to the control unit by the service technician The push button module is delivered as an installation kit 6 21 1 Preparing the push button module attaching the icons The service techni...

Page 93: ...sequence is 1 2 3 4 5 1 2 The switches can be turned on or off depending on the needs of the user If for example switches 4 and 5 are turned off the new switching sequence is 1 2 3 1 2 Preparation Turn the control unit off Remove the fuse see Section 6 2 Tools Torx screwdriver Steps 1 Remove the push button module from the holder and lay it down with the back facing up 2 Loosen and remove three To...

Page 94: ...nit 9 Test the functionality of the push button module 6 21 3 Installing the push button module CAUTION Hazard to health due to pinched cable Pinching the cable while operating seat functions can cause problems with the transmission of signals by the push button module which may result in uncontrolled behaviour of the wheelchair Please ensure the cable is routed with due care A magnetic holder or ...

Page 95: ...loop holder is positioned as desired Fig 108 Holder with attached push button module 3 Connect both plugs to the receptacles on the seat module see Figure 109 and Section 8 3 RSW connector 4 Insert the fuse 5 Switch on the control unit 6 Test the functionality of the push button module Properly reassemble all components upon completion of the work 2 1 Fig 109 Push button module connections on the ...

Page 96: ...ton Fig 110 Connecting an external switch e g buddy button to the push button module Information The assignment of connections for external switches is identified by corresponding symbols on the back of the push button module 6 22 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 ...

Page 97: ...for headrest installation kit 6 22 2 Retrofitting the signal panel installation kit The holder for the signal panel is mounted to the back frame 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 Hook the signal panel in place Fig 112 Installation kit with signal panel ...

Page 98: ... and in the wheelchair accessories catalogue Puncture proof tyres Solid rubber tyres Seating shell interface For the adaptation of special seating shells Control panel holders for seating shells are also available Arm rest accessories Special adapter for the arm rests in the Otto Bock wheelchair ac cessories catalogue Joystick accessories Fork for tetraplegics STICK S80 soft ball golf ball and fle...

Page 99: ...the handheld programming device The handheld programming device see Sec tion 8 4 can capture errors more precisely with the help of error codes The separate enAble50 instructions for use 647G490 D GB contain a table with error codes causes and possible steps for resolution 7 1 Diagnostic steps For troubleshooting purposes the control unit of the C1000 DS power wheelchair identifies the following c...

Page 100: ... Bring joystick to zero position be fore switching on Hand control de vice fault Defective joystick Controller error Defective controller Communication error alternating flashing signal Faulty connection be tween the hand control device and controller Defective cabling soft ware or hardware Check cabling plug connections Battery under voltage Battery deep dis charge Charge as soon as possible Batt...

Page 101: ...lectric footrest motor fault Wheel lock fault Open wheel lock re lease defective wheel lock Close wheel lock release check wheel lock e g Bowden cable Emergency stop Severe fault caused by controller hand control device and or drive motor malfunction Table 4 Error messages Information The enAble50 instructions for use 647G490 D GB include a list of error codes WARNING XXX and ERROR XXX on the LCD ...

Page 102: ...ely in order to meet the needs of users 1 2 3 4 5 Actuators Special Input Device ED LCD PB Controller AAM Seat module Input Device Batt HC SAJ AT Light Light Fig 69 Control unit elements With the enAble50 control unit the power wheelchair can indicate the causes of error mes sages on the display Error sources in the drive section and in the electric options are indicated by flashing of the cor res...

Page 103: ... screws see Section 6 4 1 2 3 4 5 6 7 8 9 10 11 12 Fig 71 Controller 1 J8 Actuator 1 2 and driver outputs 2 J9 Lighting connection 3 J1 Analogue input connector 4 J2 Analogue input connector 5 J3 Analogue input connector 6 J4 BUS connector 7 J5 BUS and charger inhibit connector 8 J6 Encoder switch connector 9 M1 Motor 1 connector 10 BATT Battery connector 11 M2 Motor 2 connector 12 J7 Encoder swit...

Page 104: ...e 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 Fig 72 Controller connection schematic 8 2 2 Technical Data Connections Wire gauge Mating force M1 M2 Motors 2 5 4 mm2 40 Nm M1 M2 Wheel lock 0 5 1 mm2 18 Nm Battery 2 5 4 mm2 40 Nm J4 bus J9 12 pin 0 5 1 mm2 1 5 kg 8 ...

Page 105: ...ve pole of the battery while the actuator is in operation may damage the out put The actuators have high impedance when they are not in operation 8 3 Seat module The controller is attached to the wheelchair with two screws and can be aligned in any position see Section 6 16 6 1 2 3 4 5 6 7 Fig 73 Seat module connection schemata 1 IN A IN B IN C IN D IN E connections 2 RSW 3 A1 A5 connections actua...

Page 106: ...has to be connected to the bus using a 2 pin bridge see Figure 75 1 or directly to the battery using the 4 pin plug see Figure 75 2 If the seat module is connected directly to the battery you may also use the battery to supply higher loads Fig 74 Seat module connection schemata Fig 75 Battery connection for power supply ...

Page 107: ...rom 0 to 100 Nominal current 1 For 1 second 25 A For 10 seconds 15 A Continuous maximum 10 A 2 1 Data apply when only one of the actuators is in operation 2 This nominal current depends on the seat module installation Up to 5 actuators may be operated simultaneously The total current is not permitted to ex ceed the maximum supply current of 18 A Each actuator is short circuit protected M to M Ther...

Page 108: ...held programming device Control and display elements 1 LCD Graphic display 128 x 64 pixels to display functions and parameters 2 Cross navigation key A control element to navigate the cursor in the menu tree Press the up down arrow to move the cursor vertically in the menu tree Press the right hand arrow at the branch points to open the corresponding sub functions and press the left hand arrow to ...

Page 109: ...enu item the parameters of individual modules can be changed Monitor allows you to display the current module status and parameters The status of the control elements battery voltage and battery capacity motor current and voltage during opera tion as well as other important module data can be used for system analysis For debugging purposes the errors are stored in fault history for the individual ...

Page 110: ...an interface is required to connect the computer and control unit An adapter is required to programme the enAble50 wheelchair control unit Arti cle number 493U32 SK185 includes the programming software interface and adapter cable Information For more information on using the software please consult the enAble50 instructions for use 8 5 Programmable parameters WARNING Risk of accidents and injury d...

Page 111: ...ing mode 1 5 Joystick More information on the individual parameters is found in Section 8 5 3 Tone display Command tone Background light Dim delay Tone frequency Horn frequency Miscellaneous On Off switch monitor Switch monitor mode Switch delay mode Receptacle mode Navigation mode menu Menu delay Joystick module Basic setting All parameters are equivalent to those for the hand control device The ...

Page 112: ...trol unit e g the wheelchair is turned off while driving Forward tracking Compensates for speed differences between the right hand and left hand motor Directional stability can be improved Reverse tracking V steering limit Determines speed changes in curves Navigation button mode Defines whether long or short mode signals have different meanings Profile increase stop Profile change Emergency opera...

Page 113: ... seat actuators speed current The seat module offers a separate 12 volt output The voltage can be turned on or off under the Miscellane ous menu item Extended display with Bluetooth Tone display The display is needed to control external devices using infrared Bluetooth can only be used to control a computer mouse Bluetooth must be activated first Mouse Remote control Wheel lock Parameters that est...

Page 114: ...ation Save system configuration Saves the system configuration with all modules and checks whether all modules are present Remote control The menu tree for the extended display with Bluetooth LCD can be set up here The structure is customis able Seat Actuator configu ration The existing seat actuators functions are assigned to the outputs in the seat module Possible limitations can be programmed v...

Page 115: ...speed Determines the highest possible reverse driving speed at full deflection when the position of the potentiometer is set to maximum If the position of the potentiometer is between minimum and maximum the highest possible reverse driving speed is adjusted linearly Ensure the user can operate the wheel chair safely at maximum speed Input devices Hand control device settings Driving Profile 1 P1 ...

Page 116: ...delay of the wheelchair when the position of the potentiometer is set to maximum A high value represents a short delay time and a rapid stop High delay val ues result in abrupt speed changes and should only be used in special cases If the position of the potentiometer is between minimum and maximum the delay is adjusted linearly Ensure the user can operate the wheel chair safely at maximum delay I...

Page 117: ...n of the potentiometer is set to maximum A high value represents higher turning acceleration and more rapid direction changes High turning accelera tion values result in abrupt direction changes and should only be used in special cases If the position of the potentiometer is between minimum and maximum the turning acceleration is adjusted linearly Ensure the user can operate the wheel chair safely...

Page 118: ...achieved via a mode button command or an opposing command of more than 50 If Constant speed stepped is selected the wheelchair accelerates by one increment with each short com mand 33 66 and 100 up to the maximum speed Direction changes are always possible The wheelchair decelerates by one increment e g from 66 to 33 when a brief opposing command of 50 is issued A stop is achieved via a mode switc...

Page 119: ...s possible The wheelchair decelerates by one increment e g from 66 to 33 when a brief opposing command of 50 is issued A stop is achieved via a mode switch or with a permanent opposing command WARNING Risk of injury due to incor rectly installed control buttons Never select Constant speed mode cruise or stepped unless the mode button is installed so that the user can operate it quickly at any time...

Page 120: ...ettings Joystick Switch operation Service Off On Off On Off Switch function The joystick can be used like a switch If the switch function is ON the propor tional function is replaced by a switch function Moving the joystick from the centre by more than 50 generates a 100 command in the desired direction Input devices Hand control device settings Joystick Tremor suppression Service 0 100 0 Suppress...

Page 121: ... functionality settings damage or deformation and screw connections for all components listed here OK Damage Replacement 1 Control unit Control unit holder Control cable LCD monitor if applicable 2 Batteries Battery cover Wiring 3 Motors Wheel lock release 4 Tyres Drive wheels Steering casters 5 Frame Drive unit sustainer 6 Seat Back Upholstery cushion ...

Page 122: ...ring Seat height adjustment Actuator linkage wiring Footrests Actuator wiring 8 Side panel Adapters Clothing protector Lighting adapter 9 Footrests Adapters Elevating footrest 10 Options Front lights Rear lights Belt Headrest adapter Other Comments The maintenance service was carried out by Place date Signature ...

Page 123: ... Ali Dursun Bey Caddesi Lati Lokum Sokak Meriç Sitesi B Block No 6 1 TR 34387 Mecidiyeköy İstanbul Tel 90 212 3565040 Faks 90 212 3566688 e mail info ottobock com tr www ottobock com tr Otto Bock Algérie E U R L 32 rue Ahcène outalab Coopérative les Mimosas Mackle Ben Aknoun Alger DZ Algérie Tel 213 21 913863 Fax 213 21 913863 e mail information ottobock fr www ottobock fr Otto Bock Egypt S A E 11...

Page 124: ...ty Solutions GmbH has been certified by the German Society for the Certification of Quality Assurance Systems DQS in accordance with DIN EN ISO 9001 standard reg no 779 management system Hersteller Manufacturer Otto Bock Mobility Solutions GmbH Lindenstraße 13 07426 Königsee Germany Phone 49 69 9999 9393 Fax 49 69 9999 9392 ccc ottobock com www ottobock com Otto Bock 647G519 GB 01 0911 ...

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Otto Bock C1000 DS, Service Instructions Manual

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