Otto Bock B400 User manual

B400
Service Manual

B400 Family Ottobock | 3
Tabel of contents

1.1 Foreword ..................................................................................................................6
1.2 Intended use ...........................................................................................................6

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
2.5 Safety instructions for maintenance work ..............................................................9
2.6 Safety instructions for maintenance work on electrical components ..................10
2.7 Safety instructions for disposal ............................................................................ 11

3.1 Transport ............................................................................................................... 11
3.2 Storage ................................................................................................................. 12



6.1 Checking the general condition ............................................................................ 14
6.2 Replacing the fuse ................................................................................................ 14
6.3 Batteries ................................................................................................................15
6.3.1 Charging the batteries .............................................................................................. 15
6.3.2 Replacing the batteries ............................................................................................ 17
6.3.3 Reinstalling the battery cable .................................................................................. 18
6.4 Replacing the controller ........................................................................................ 19
6.5 Side panels ...........................................................................................................20
6.5.1 Adapting/replacing the side panels .........................................................................20
6.5.2 Replacing the clothing protector ..............................................................................22
6.6 Footrests ...............................................................................................................23
6.6.1 Adapting/replacing the footrests ..............................................................................23
6.6.2 Replacing the footplate ............................................................................................26
6.7 Wheels ...................................................................................................................27
6.7.1 Checking the general condition ................................................................................ 27
6.7.2 Replacing the casing or inner tube for pneumatic tyres .......................................... 27
6.7.3 Replacing the drive wheel .........................................................................................28
6.7.4 Replacing/retrotting with the drive wheel splash guards.......................................29
6.7.5 Replacing the castor wheels ....................................................................................30

 Page

Tabel of contents
B400 Family4 | Ottobock
6.7.6 Replacing the castor fork..........................................................................................30
6.7.7 Installing the splash guard for the castor fork (option) ............................................ 31
6.8 Control panel/lighting module ..............................................................................32
6.8.1 Replacing the control panel ......................................................................................32
6.8.2 Replacing the control panel holder ..........................................................................33
6.8.3 Mounting the lighting module ..................................................................................34
6.9 Lighting ..................................................................................................................36
6.9.1 Retrotting with lighting ............................................................................................36
6.9.2 Replacing defective lamps ....................................................................................... 37
6.10 Seats ...................................................................................................................39
6.10.1 Replacing the bearing plate ....................................................................................39
6.10.2 Standard seat: Replacing/adjusting the back upholstery ......................................40
6.10.3 Standard seat: Replacing the seat frame ..............................................................40
6.10.4 Standard seat: Replacing the seat plate ................................................................ 41
6.10.5 Standard seat: Changing the seat height ..............................................................42
6.10.6 Standard seat: Adjusting the seat inclination ........................................................42
6.10.7 Standard seat: Replacing/adjusting the side panel bracket ..................................43
6.10.8 Standard seat: Replacing the backrest ..................................................................44
6.10.9 Installing the Contour seat (option) ........................................................................44
6.11 Replacing the drive unit bracket ..........................................................................45
6.12 Replacing the drive motor ...................................................................................46
6.13 Suspension/oating discs/rocker arm ................................................................47
6.13.1 Replacing the spring element .................................................................................47
6.13.2 Adjusting the spring element ..................................................................................47
6.13.3 Replacing the oating discs on the rocker arm .....................................................48
6.13.4 Replacing the rocker arm .......................................................................................49
6.14 Brakes and brake release ...................................................................................50
6.15 Accessories .........................................................................................................50
6.15.1 Retrotting with mechanical seat tilt ......................................................................50
6.15.2 Attaching the Bowden cable for seat tilt ................................................................ 51
6.15.3 Retrotting with mechanical back angle adjustment.............................................52
6.15.4 Retrotting with kerb climber .................................................................................53
6.15.5 Retrotting with rearview mirror .............................................................................53
6.15.6 Installing castor swivel lock (option) ......................................................................54
6.15.7 Installing the bracket for headrest mounting (option) ............................................55
6.15.8 Retrotting with a lap belt (option) .........................................................................55
6.15.9 Installing a luggage carrier (option) .......................................................................56
6.15.10 Retrotting with a crutch holder ...........................................................................56
6.15.11 Retrotting with a bag ...........................................................................................57

Tabel of contents
B400 Family Ottobock | 5
6.16 Power seat functions ...........................................................................................58
6.16.1 Retrotting with power back angle adjustment (optional) .....................................58
6.16.2 Retrotting with power seat tilt (optional) ..............................................................59
6.16.4 Retrotting with seat height adjustment (optional) ................................................63
6.16.5 Installing the changeover box .................................................................................64
6.16.6 Attaching the Y-splitter ...........................................................................................65
6.17 Retrotting with attendant control .......................................................................65
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7.1 Troubleshooting steps ...........................................................................................67
7.2 Troubleshooting via "battery capacity" LED display .............................................67
7.3 Troubleshooting via hand-held programming device (also see section 8.3) ........69
7.4 Additional errors (not displayed) ...........................................................................72

8.1 Overview ................................................................................................................73
8.2 Installation and wiring ...........................................................................................73
8.3 Programming tools ...............................................................................................73
8.3.1 Hand-held programming device ............................................................................... 74
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


General information
B400 Family6 | Ottobock


Date of last update: 2013-06-14
• Please read this document carefully.
• Follow the safety instructions.
1.1 Foreword
This service manual describes all regular maintenance tasks as well as repair and replacement
tasks for the B400 from year of manufacture 2013. It includes all information required by dealers
in order to correct functional and mechanical defects in components of the 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. This ensures that the functionality of the B400 is
fully utilised.
1.2 Intended use
The B400 power wheelchair is intended as a means of conveyance in indoor and outdoor areas
for individuals with limited mobility. The B400 power wheelchair may only be used by persons
who have the required physical and mental capabilities.
Any other use is considered improper use. The manufacturer is not liable for any personal injury
or damage to property resulting from improper use; the user has sole liability in such cases.
The B400 power wheelchair may only be used by appropriately trained persons. Training is one
of the prerequisites in order to protect against personal risks and to operate the B400 power
wheelchair safely and properly.

Safety instructions
B400 Family Ottobock | 7

2.1 Explanation of symbols
 Warnings regarding possible risks of severe accident or injury.
 Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
 Information regarding operation. Information for service personnel.
2.2 Standards and directives
All safety information contained in these service instructions refers to the currently valid national
laws and regulations of the European Union. In other countries, compliance with the applicable
laws and national regulations is required.
In addition to the safety instructions contained in these service instructions, the user is required
to observe and comply with the BGV (Employer's Liability Insurance Association regulations),
UVV (accident prevention regulations) and environmental protection regulations. All information
contained in these service instructions must be complied with at all times without restrictions.
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 conrmed by
CE certication and the declaration of conformity.
2.3 General safety instructions

Regular maintenance is important – it improves safety and increases the lifespan of the product.

Packaging materials must be kept out of reach of children.
NOTICE
Service and maintenance work may only be completed
by qualied personnel. Only original spare parts may be used for all service and maintenance tasks.
NOTICE
 The manufacturer recommends
having the B400 power wheelchair inspected and maintained for functionality and operational safety
by authorised qualied personnel once a year. In case of frequent user changes (growing children or
youths) or users with changing clinical pictures, the wheelchair should be inspected, adjusted and
maintained twice a year.

Safety instructions
B400 Family8 | Ottobock
NOTICE
 Knowledge of the
service instructions and the instructions for use is a prerequisite for proper service.
The service and maintenance instructions must be read carefully before commencing work. The service
manual applies in conjunction with the instructions for use and the spare parts catalogue. All docu-
ments must be used together.
All safety instructions contained in this service manual and all other applicable documents must be
observed and complied with. They must be available to service and maintenance personnel at all times.
NOTICE
 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.
NOTICE
 The maximum load capacity for the B400 power wheelchair is
140 kg.

Familiarise yourself with the functions of the product. If you are not familiar with the product, read the
instructions for use before testing it. The instructions for use are available from the manufacturer (see
overview of all Ottobock subsidiaries under "Ottobock Worldwide"). Additional documentation can be
downloaded from the manufacturer's website at www.ottobock.de or www.ottobock.com.
2.4 Safety instructions for the use of tools and accessories

When completing the tasks, only use
tools that are suitable for the conditions at the place of work and for which safety and the protection
of health are assured with proper use.
Verify proper functionality before use. For use of the work equipment, the ergonomic relations between
the workplace, work equipment, work organisation, workow and task must be taken into consideration;
this especially applies to the body posture assumed when using the work equipment.

 Ensure that legally prescribed protective
work clothing is worn.

When repair and maintenance tasks must be completed
under raised parts or equipment, ensure suitable precautions are taken to secure the applicable com-
ponents against falling. Equipment used to raise loads must prevent the load from accidentally shifting
in a dangerous manner, dropping in free fall or being accidentally released.
When using lifting platforms, ensure that the B400 power wheelchair is centred on the platform and
that the anti-tipper and other parts are not protruding into the danger zone.

Safety instructions
B400 Family Ottobock | 9

 Hazardous materials may only be kept at the place of
work in quantities required for ongoing tasks. Regularly and safely remove waste and residue. Clean
up spilled substances immediately.
2.5 Safety instructions for maintenance work

 For design reasons, there are pinch points between the seat and
frame of the B400. Special caution is required during all work on the corresponding components.

 Note that there is no braking function-
ality when the wheel lock is unlocked. The brake must only be unlocked in hazardous situations and
for maintenance or repairs. The corresponding force required for acceleration and deceleration must
come from the person pushing.
Once push mode is no longer needed, the brake unlocking lever must be locked immediately.
NOTICE

• 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.
• Secure the product to prevent it from tipping over or falling, e.g. off the workbench.
• Some parts of the power wheelchair such as the batteries, frame, seat and motors are very heavy.
Hoisting devices of sufcient capacity must be used where applicable.
• Clean/disinfect the product before you start testing it. Consult the instructions for use regarding
product care and product-specic testing instructions.
NOTICE
Unsecured screw connections can become
loose when the product is being used. Secure screws and nuts. The screw connections must be tight-
ened properly after all installation tasks. Dened torque specications must be followed.
Many screw connections utilise screws and nuts equipped with a thread lock. If such screw connec-
tions need to be loosened, the nuts or screws must be replaced with nuts/screws supplied with a new
thread lock. If new screws or nuts with a thread lock are not available, apply a medium-strength liquid
thread locking compound (such as Loctite® 241 or Euro Lock A24.20) to the existing screws.
NOTICE
 The upholstery must be adequately protected against mechanical
and chemical damage during all work on the seat. The backrest and seat bottom are ame retardant
but nevertheless ammable. They must not come into contact with open ames or embers.
NOTICE
 The B400
may not be cleaned with a jet of water or a pressure washer under any circumstances. A cloth or
sponge may be used for cleaning. Water must not come into direct contact with the motor under any
circumstances.
Check the driving behaviour of the B400 power wheelchair after cleaning it.

Safety instructions
B400 Family10 | Ottobock

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

• If the driving function is not required, turn off the control unit or jack up the drive wheels in order to
prevent uncontrolled operation through accidental joystick activation.
• When carrying out maintenance work make sure water does not come into direct contact with the
electronics or the battery.
• When attaching plug connectors on the controller make sure the contacts are assigned correctly.

 Only use Ottobock battery chargers which
have been tested and approved for use with the given batteries by the manufacturer (observe informa-
tion on battery charger). Failure to do so can result in a battery explosion and endangerment to health
due to contact with battery acid.
Smoking and open ames are prohibited while working on the batteries. Sparks must be avoided.
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.
NOTICE
 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 when connecting the batteries.
NOTICE
 Prevent overheating of the charger during the charging proc-
ess. Ensure that the cooling ns on the back of the device are not covered.

The B400 has been tested according to EMC regulations. The following particularities must be observed
during operation and communicated to the user:
• The driving characteristics of the B400 can be affected by electromagnetic elds (mobile phones or
other radiating devices). Therefore all mobile devices must be turned off when driving.
• The B400 can generate electromagnetic elds which can lead to interference with other devices.
Therefore, the control unit must be switched off whenever it is not needed.

During extended periods of disuse or shipment of the B400 power wheelchair, remove the fuse from
the fuse holder to prevent deep discharge of the batteries due to standby consumption.

Transport and storage
B400 Family Ottobock | 11
2.7 Safety instructions for disposal

If the power wheelchair is no longer in use, it must be disposed of properly in accordance with national
regulations.
All components and materials of the power wheelchair must be recycled or disposed of properly.

. 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 system or penetrate into the ground. The instructions of the battery manufacturer
printed on the batteries must be observed.

:
Ambient temperature -40 °C to +65 °C
3.1 Transport

Risk of accidents due to insufcient fastening. Properly fasten the B400 power wheelchair to the trans-
port vehicle, e.g. with tensioning straps, to secure it against shifting.
NOTICE
 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 sufcient capacity
for transport.
Secure the B400 power wheelchair to the means of transport, e.g. with tensioning straps. Use
the eyebolts at the front and back of the power wheelchair and the dened anchor points in the
transport vehicle.
Before transporting the power wheelchair, switch off the control unit and engage the brake.
You can reduce the size of the power wheelchair for transport by folding down the back rest and
removing the side panels and footrests.

Transport and storage
B400 Family12 | Ottobock

1 Eyebolts, front
2 Eyebolts, rear
3.2 Storage

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.
The B400 power wheelchair must be stored in an enclosed room. Remove the main fuse as
otherwise there is a risk of deep discharge.
The storage location must be dry and have sufcient air circulation. Humidity must not build up.
The B400 power wheelchair must not be subjected to any damaging exterior inuences, e.g.
rain, snow or strong solar radiation, during storage.
The manufacturer recommends storing the B400 power wheelchair with slightly elevated tyre
pressure and using assembly stands or wooden blocks in order to raise the tyres (completely)
off the ground in order to protect them from ground frost. Regularly rotating the wheels helps
prevent at spots.

Required tools and accessories
B400 Family Ottobock | 13

Suitable tools and aids for the completion of service tasks are listed below.
❒Straight and Phillips screwdrivers
❒Ring or open-end spanners, sizes: 8 – 24
❒Allen wrenches, sizes: 2, 3, 4, 5, 6, 7
❒Torque spanner
❒Socket, size: 19
❒Pin punch, Ø 3 mm
❒Plastic hammer
❒Drill bit, size 4/6 mm + hand drill
❒Plastic tyre lever
❒Inner tube repair kit
❒Side cutting pliers
❒Water pump pliers, gripping width up to 32 mm
❒Liquid thread lock "medium strength"



Information display
B400 Family14 | Ottobock


For error indication information with the LED display "Battery capacity" or with the aid of the hand-held
programming device/PC software, please refer to section 7 "Diagnostics".
The wheelchair functions are displayed on the LED display elds of the control panel:
 
"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).
 

6.1 Checking the general condition
❒ Check all safety-related components for corrosion, repair if required and reapply corrosion
protection.
❒Check weld seams.
❒
Check tightness of screw connections; replace thread-locking compound if required; observe
any dened tightening torques; replace defective screws (e.g. in case of corrosion).
❒Check cables for ruptures, signs of wear and proper attachment; replace defective compo-
nents according to the cable layout plan.
❒Check cable connections and plug connections.
6.2 Replacing the fuse
The fuse is in a fuse enclosure with hinged cover in front of the battery cover beside the control
unit.

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.

Service work
B400 Family Ottobock | 15

1 Fuse holder
2 Fuse enclosure cover
3 Fuse
6.3 Batteries

 Smoking and open ames are prohibited
while working on the batteries. Sparks must be avoided.
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.
NOTICE
 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 when connecting the batteries and state of charge meter.
The standard version of the B400 power wheelchair is equipped with two maintenance-free
AGM batteries with a capacity of 50 Ah (C5) or optionally with gel batteries with a capacity of
63 Ah (C5).


 When switching from AGM to gel bat-
teries, changing the charging prole on the charger is mandatory (see instructions on the charger).
NOTICE
 Please note the following when handling the bat-
teries:
• Charge the batteries as soon as possible if only one LED is ashing 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.

Service work
B400 Family16 | Ottobock
NOTICE
 Please note the following when using the charger:
• Only use Ottobock battery chargers which have been tested and approved for use with the given
batteries by the manufacturer (observe information on battery charger).
• The information on the name plate of the charger must match the mains voltage in the respective
country.
• Only use the battery charger within the specied temperature and humidity limits.
• Place the battery charger on a level surface.
• If you position the battery charger near a window, protect it from direct sunlight.
• Keep the charger from overheating. The vent openings on the back of the charger must not be cov-
ered.
• Turn off the control unit during the charging process so that the entire charging current ows to the
battery.
• Avoid dust and dirt. Only clean with a dry cloth.
The remaining battery capacity determines the range of the B400 power wheelchair. The follow-
ing factors inuence battery capacity:
❒Ambient temperature
❒Age of the batteries
❒Driving load
❒Charging method
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.

❒Battery charger provided by Ottobock

1. Turn the control unit on the power wheelchair off.
2.
Insert the plug of the battery charger into the charging receptacle on the underside of the
control panel.
3. Connect the battery charger to a wall outlet. The batteries will start charging automatically,
and the current charge status is indicated on the LEDs of the battery charger (see Table 2).
4. When the charging process is nished disconnect the mains plug and the battery charger
plug on the control panel.
5. Turn on the control unit; the power wheelchair is now ready to use.

Service work
B400 Family Ottobock | 17
The battery charger indicates the following states:
 
All LEDs light up for a mo-
ment
Once the connection to the mains supply has been established
Yellow LED is lit Battery is charging
Yellow LED is ashing Battery is 90% charged
Green LED is lit Battery is fully charged; battery charger has changed to trickle charge
Red LED is lit Incorrect polarity (immediately unplug the mains plug and reconnect
the cables with correct polarity)
Red LED is ashing Error in charging prole progression; charging time exceeded
 
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.
If the power wheelchair will not be used for an extended period of time the manufacturer recom-
mends disconnecting the battery charger and removing the main fuse.
6.3.2 Replacing the batteries

. Always remove the main fuse before doing any work on the
batteries.
NOTICE
 Ensure correct polarity when connecting the batteries.

❒Remove the fuse (see section 6.2).

❒Ring or open-end spanner, size 11

1. Remove the fuse (see section 6.2).
2. Open the battery cover and remove the cover (see g. 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.

Service work
B400 Family18 | Ottobock


6.3.3 Reinstalling the battery cable
NOTICE
 Ensure correct polarity when connecting the batteries.

❒Remove the battery cover (see section 6.3.2).
❒Remove the fuse (see section 6.2).
❒Remove the batteries (see section 6.3.2).

❒Allen wrench, size 3
❒Ring or open-end spanner, size 11

1. Disconnect the old main battery cable from the controller (for connections on the controller,
see g. 7).
2. Unscrew the fuse holder of the old fuse cable from the frame.

Service work
B400 Family Ottobock | 19
3. Connect the new battery main cable to the controller.
4. Screw the fuse holder of the new fuse cable to the frame.
5. Reinsert/reconnect the batteries.
6. Connect the battery cable at the proper location on the battery.
Properly reassemble all components upon completion of the work.
2
1

1 Main battery cable connector
2 Motor plugs
6.4 Replacing the controller
Replacing the controller is necessary both during replacement and during installation of power
seat options or lighting in conjunction with the extended control panel – version A (see section
6.8.1):
❒Controller standard: 493U65=SK001
❒
Controller, additional power functions: 493U65=SK006 (for controlling actuators for the power
seat options)

When connecting the cables, ensure correct assignment.

For information about the assembly of the lighting module refer to section 6.8.3.

❒Remove the battery cover (see section 6.3.2).
❒Remove the batteries (see section 6.3.3).
❒Remove the fuse (see section 6.2).

❒Allen wrench, size 3

Service work
B400 Family20 | Ottobock

1. Disassemble the protective cover (see g. 8).
2. Disconnect all connections from the controller.
3. Loosen the two Allen head screws, remove the controller and replace it if required.
Properly reassemble all components upon completion of the work.
4 2 5 31
6

1Control unit connector
2Connection for motor 1
3Connection for motor 2
4Connection for lights
5Battery connector
6Connection, actuator left/right
6.5 Side panels
6.5.1 Adapting/replacing the side panels
Side panel mounting brackets are located on the left and right sides of the seat frame. The side
panels with armrests are inserted into these brackets. The heights and positions of the side
panels can be individually adapted to the arm length of the wheelchair user.

❒Allen wrench, size 2



1. Loosen the two Allen head screws (g. 9, item 1).
2. Change the positions of the armrests by moving them forward or backward, or remove and
replace them if required.