Otto Bock z50 Operating instructions

z50
Service Instructions

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Table of Contents
1 General View .............................................................................................................................2
2 Safety ..................................................................................................................................3
3 Preface ...................................................................................................................................5
4 Required Tools .......................................................................................................................... 5
5 Adjusting and Replacing ........................................................................................................... 6
5.1 Control Unit ................................................................................................................ 6
5.2 Battery Packs / Fuse ..................................................................................................8
5.3 Motors................................................................................................ ......................13
5.4 z50 Wheels...............................................................................................................15
5.5 Anti-tippers ...............................................................................................................17
5.6 Options.....................................................................................................................17
5.7 Frame / Adapter Plates.............................................................................................18
5.8 Assembly of the z50 to Manual Wheelchairs ............................................................. 18
6 Maintenance Plan....................................................................................................................19

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1 General View
Desk side panel
Control unit
Battery pack
Footrest
Release lever
z50 wheel with hub motor
Swinging anti-tipper

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2 Safety
Observe the following guidelines for maintenance or repair work:
Danger!
Use caution near flammables or especially when holding lit cigarettes. The back upholstery and
seat cushion may catch fire.
Danger!
When getting into or out of the wheelchair with power add-on drive, the electronic control must
be switched off.
Danger!
When using lifting platforms, be sure that the wheelchair is standing centrically on the lifting
platform area and that none of the wheelchair‘s components, such as the anti-tipper, are
protruding into the danger area.
Danger!
Explosive gases can develop while the batteries are charging. For this reason, provide for
sufficient ventilation when using the battery charger in closed rooms. Do not smoke when near
the battery charger or handling the batteries. Avoid fire and sparks!
Danger!
When mounting the z50 wheel or manual wheelchair wheel, make sure before driving that the
locking mechanism has engaged (see sections ‘Assembly of the z50 Wheel’ and ‘Assembly of
the Manual Wheelchair Wheel’ in the Instructions for Use).
Attention!
After cleaning the z50 power add-on drive check its operating performance.
Attention!
Driving over a longer period of time with only 2 LEDs of the battery indicator lit will result in
battery discharge. To avoid function failure and permanent damage, charge the battery of the
z50 power add-on drive immediately.
Attention!
To avoid overheating the battery charger, make sure that the cooling ribs or vent slots are
uncovered.
Attention!
To prevent uncontrolled driving through accidental joystick manipulation, switch off the
wheelchair when nobody is using it or the driving function is not required.
Attention!
Do not use the footplates when getting into or out of the wheelchair.
Attention!
Never use a water hose or high-pressure cleaning apparatus for cleaning the wheelchair.

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Note!
Use appropriate tools.
Note!
Always use insulated tools when working on the batteries.
Note!
Wear appropriate clothing, including gloves and safety glasses, if necessary.
Note!
Secure the product to prevent it from tipping over or falling off the workbench.
Note!
Read the service and maintenance instructions before starting.
Note!
Familiarize yourself with the functions of the product. If you are not familiar with the product,
read the Instructions for Use before inspecting the product.
Note!
If no Instructions for Use are available, please order one from the manufacturer. (Refer to the
overview of all Otto Bock Branches ‘Otto Bock Worldwide’.)
Note!
You can also download the document from our homepage under www.ottobock.de or
www.ottobock.com.
Note!
Clean or disinfect the product before starting inspection. See the Instructions for Use for care
instructions or specific product inspection information.
Note!
Many of the screw fastenings use thread lock or nylock nuts. If you have to undo such screw
fastenings, replace the nut or screw with a new thread lock and/or nut. If new screws or nuts
with thread lock are not available, use a medium-strength liquid thread lock substance (such as
Euro Lock A24.20).
Note!
To allow for complete charging current to be fed into the battery, the control is to be switched off
during the charging process.
Note!
When the z50 power add-on drive is not used over extended periods of time or for dispatching
the add-on drive, the main plug should be removed to avoid standby current of the control.

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4 Required Tools
The following list ensures that you use the right implement for every procedure. You will find the maintenance
plan at the end of the service instructions manual.
Reversible ratchet handle wrench
and sockets, sizes 8 – 21
Allen wrenches,
sizes 2.5 – 8
Wrenches,
sizes 8 – 24
Water pump pliers DIN 8976,
gripping width up to 32 mm
Screwdrivers, blade
widths 2.5/3.5/5.5 mm
Phillips head screwdriver, size 2 mm
Plastic hammer Hammer approx. 300 g Side cutting pliers
3 Preface
Regular maintenance is important. It increases safety and prolongs the service life of the product.
All rehab products should be inspected and serviced once a year. If the product is used frequently, or if it is used by
growing children or patients with changing clinical conditions, we recommend readjusting and servicing the product
every 6 months. Use only original spare parts for all service and maintenance. The service and maintenance described
in this manual should be performed by trained specialists only and not by the user. This service and maintenance
manual refers to the spare parts catalog and Instructions for Use. For this reason, it is important to use these
documents together.
Liquid thread lock ‘medium strength’

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Both variants of the control panel holder for the z50 are attached to the armrest beneath the armrest pad. To
remove the control panel, first pull out the central plug which is attached to the frame, and then remove the
control panel.
5 Adjusting and Replacing z50
5.1 Control Unit
There is only one control panel variant available for the z50 power add-on drive. The control panel is
attached to the plug-on holder with two screws. Therefore, the control panel is disconnectable and can be
easily mounted and removed.
Note:
For adaption of the z50 power add-on drive, the desk side panel is always recommended!
Control panel holder
Standard control panel holder
The two control panel holders are attached in the same way to the side panel of the manual wheelchair. Both
are clamped with an iron rail to the underside of the armrest pad of the desk side panel.
Control panel holder, swing-away in parallel

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The central plug is attached to the crossbrace where
both braces run closely along each other.
First attach the two plastic clips to the crossbrace.
Screw the metal sheet for central plug attachment
onto these clips. For this purpose you require the
Allen wrench size 3.
Make sure when laying the cables leading to the
central plug that the cables are not clamped while
folding the wheelchair. Always secure cables to
braces with cable ties at random intervals.
Central Plug

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5.2 Battery Pack / Fuse
Battery
The z50 standard equipment includes a 12 Ah gel battery pack. A 16 Ah gel battery pack is available as an
option.
Except for battery charging, these battery packs do not require servicing.
For installation of the battery case, first connect the battery cable plug into the battery case's receptacle and
lock and engage the plug by rotating it to the right. Put the battery case into the carrying bag and secure with
hook and loop flap.
To disconnect the battery cable, slide the silver locking pin slightly to the rear and rotate the plug to the left
until it reaches the stop. Remove the plug from the battery case to separate the battery from the wheelchair.
Battery Charging
The remaining battery capacity determines the distance range of the z50 power add-on drive. Many factors
have an influence on the battery's capacity. Besides the ambient temperature, the age of the batteries and
the time and extent of driving, the way you charge the batteries has considerable effects on the capacity and
thus on the distance range.
Driving over a longer period of time with only the red LEDs of the battery indicator lit will result in battery
discharge and thus battery damage. In addition, there is the risk that the z50 may stop due to zero battery
capacity and put the user in a dangerous situation.
If the z50 is not used for a longer period of time, a charging cycle should be carried out once a week to
maintain the battery's capacity.
Note:
The warranty is void in case of damages that result from a totally discharged battery. When the
z50 is not used over extended periods of time it must be charged once a week. Only use the
battery charger provided by Otto Bock.
The indications on the type plate of the battery charger must be identical to the voltage of the mains supply
of your country. Charging will start automatically. The current charging state is indicated by the LEDs of the
battery charger.