Otto Bock B400 User manual

B400 Power Wheelchair
Service Manual

Edition 7.08/1
Editorial date: 23.07.2008
© Otto Bock HealthCare
The dissemination and duplication of the service manual and all accompanying documents as well as the utilization and com-
munication of its content is prohibited unless explicitly authorized in writing by Otto Bock HealthCare GmbH. Failure to comply
results in liability for compensation.
We reserve the right to file for patents, utility models, and designs.

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Service Manual for the B400 Power Wheelchair
Contents Page
1 General Information ..........................................................................................................6
1.1 Preface ....................................................................................................................6
1.2 Intended Use...........................................................................................................6
2 Safety Instructions ............................................................................................................7
2.1 Explanation of Symbols...........................................................................................7
2.2 Standards and Directives........................................................................................7
2.3 General Safety Instructions ....................................................................................7
2.4 Safety Instructions Regarding the Use of Tools and Auxiliary Means....................8
2.5 Safety Instructions for Maintenance Works............................................................9
2.6 Safety Instructions for Maintenance Works on Electrical Components ...............10
2.7 Safety Instructions for Disposal............................................................................ 11
3 Transportation and Storage ............................................................................................11
3.1 Transportation ....................................................................................................... 11
3.2 Storage .................................................................................................................12
4 Required Tools and Auxiliary Means ...............................................................................13
5 Information Display ........................................................................................................14
6 Service Works..................................................................................................................15
6.1 Inspecting the General Condition .........................................................................15
6.2 Replacing the Fuse ...............................................................................................15
6.3 Batteries................................................................................................................16
6.3.1 Checking the Liquid Level and Filling Up (only with lead-acid batteries) ............... 16
6.3.2 Charging the Batteries ............................................................................................18
6.3.3 Replacing the Batteries........................................................................................... 19
6.3.4 Removing the Battery Case ....................................................................................20
6.3.5 Laying New Battery Cables .....................................................................................20
6.4 Replacing the Controller .......................................................................................21
6.5 Side Panels ...........................................................................................................22
6.5.1 Adapting/Replacing the Side Panels.......................................................................22
6.5.2 Replacing the Clothing Protectors ..........................................................................24
6.6 Footrests ...............................................................................................................25
6.6.1 Adapting/Replacing the Footrests...........................................................................25
6.6.2 Replacing the Footplates.........................................................................................28

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6.7 Wheels...................................................................................................................29
6.7.1 Inspecting the General Condition ............................................................................29
6.7.2 Replacing the Casing or Inner Tube of Pneumatic Tyres ........................................29
6.7.3 Replacing the Drive Wheel.......................................................................................30
6.7.4 Replacing the Wheel Flange ....................................................................................31
6.7.5 Mounting Splash Guards for Drive Wheels (option) ................................................32
6.7.6 Replacing the Caster ...............................................................................................32
6.7.7 Replacing the Caster Fork .......................................................................................33
6.7.8 Mounting Splash Guards for Caster Forks (option) ................................................34
6.8 Control Panel / Light Module................................................................................35
6.8.1 Replacing the VR2/VR2-L Control Panel .................................................................35
6.8.2 Replacing the Control Panel Holder........................................................................36
6.8.3 Mounting the Light Module...................................................................................... 37
6.9 Lights.....................................................................................................................39
6.9.1 Retrotting Lights.....................................................................................................39
6.9.2 Replacing Defective Lamps.....................................................................................40
6.10 Seats ...................................................................................................................42
6.10.1 Replacing the Bearing Plate ..................................................................................42
6.10.2 Standard Seat: Replacing/Adjusting the Back Upholstery ...................................43
6.10.3 Standard Seat: Replacing the Seat Frame............................................................43
6.10.4 Standard Seat: Replacing the Seat Plate..............................................................44
6.10.5 Standard Seat: Changing the Seat Height............................................................45
6.10.6 Standard Seat: Setting the Seat Inclination..........................................................45
6.10.7 Standard Seat: Replacing/Setting the Side Panel Attachment Devices ..............46
6.11 Replacing the Drive Unit Sustainer .....................................................................47
6.12 Replacing the Drive Motor ...................................................................................48
6.13 Brakes and Brake Release..................................................................................48
6.14 Accessories .........................................................................................................49
6.14.1 Retrotting Mechanical Seat Tilt Mechanism ........................................................49
6.14.2 Attaching the Bowden Cable (for seat tilt) ...........................................................50
6.14.3 Retrotting a Curb Climbing Assist ....................................................................... 51
6.14.4 Retrotting a Rearview Mirror ................................................................................ 51
6.14.5 Installing a Swivel Lock (option) ............................................................................52
6.14.6 Assembling the Holding Device for Headrest Attachment (option) ......................52
6.14.7 Retrotting a Lap Belt (option)...............................................................................53
6.14.8 Mounting a Luggage Carrier (option).....................................................................53
7 Error Diagnosis ...............................................................................................................54
7.1 Diagnostic Steps ...................................................................................................55
7.2 Diagnosis with LED Display "Battery Capacity”....................................................55
7.3 Diagnosis Using the Hand Programming Device (see also Section 8.3) .............57
7.4 Other Errors (not displayed) .................................................................................60

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8 VR 2 Wheelchair Control – Installation and Programming .............................................61
8.1 Overview................................................................................................................61
8.2 Installation and Wiring ..........................................................................................61
8.3 Programming Tools...............................................................................................62
8.3.1 Hand Programming Device......................................................................................62
8.3.2 PC Programming Device .........................................................................................62
8.4 Programmable Parameters ..................................................................................63
8.4.1 Speed Settings ........................................................................................................63
8.4.2 Setting of General Parameters ...............................................................................66
8.4.3 Programming of the Light Module...........................................................................67
8.4.4 Log Functions ..........................................................................................................67
9 Maintenance and Service Plan B400 ..............................................................................68

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1 General Information
1.1 Preface
This service manual describes all regularly required maintenance work as well as all repair and
replacement work on the B400 from Otto Bock HealthCare GmbH. It provides the authorized
dealer with all the knowledge required to eliminate malfunctions and mechanical defects on
components of the B400.
Correct and safe execution of the works on the B400 requires the knowledge contained in this
service manual. Therefore, the document, especially the section "Safety”, must be studied care-
fully by all persons entrusted with working on the B400. This ensures the functionality of the
B400 is fully utilized.
The service manual has been prepared on the basis of DIN EN 62079 "Preparation of instruc-
tions – Structuring, content and presentation.” It is divided into 9 chapters. The service manual
also contains cross references that make it easier to use, e.g. "See Chapter 6.2.”
1.2 Intended Use
The B400 power wheelchair is intended for individual self-transportation by persons with limited
mobility, indoors and outdoors. The B400 power wheelchair may only be used by persons who
have the required physical and mental capacities.
Any other use is considered improper use. The manufacturer is not liable for any personal injury
or damage to property resulting from improper use; in such cases, the user has sole liability.
The B400 power wheelchair may only be used by persons trained to use it. Training is one of the
prerequisites in order to protect against personal risks and in order to operate the B400 power
wheelchair safely and properly.

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2 Safety Instructions
2.1 Explanation of Symbols
WARNING Warnings regarding possible risks of severe accident or injury.
CAUTION Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
INFORMATION Information regarding operation. Information for service personnel.
2.2 Standards and Directives
All information on safety contained in this service manual 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 this service manual, 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 con-
tained in this service manual must be complied with at all times without restrictions.
The B400 power wheelchair has been constructed in accordance with the currently valid techni-
cal rules and is safe to operate. The safety of the B400 power wheelchair has been confirmed
by CE certification and the declaration of conformity.
2.3 General Safety Instructions
INFORMATION
Regular maintenance is important – it improves the safety and increases the lifespan of the product.
CAUTION
Risk of suffocation. Make sure to keep packaging material away from children.
NOTICE
Damage as a result of unauthorized service. Service and maintenance may be performed by skilled
specialists only. Only original spare parts may be used for all service and maintenance.
NOTICE
Damage as a result of non-compliance with maintenance intervals. Otto Bock HealthCare GmbH
recommends to have the B400 power wheelchair serviced and inspected by authorized personnel for
functional reliability and driving safety once a year. If case of frequent user changes (growing children or
adolescents) or in case of users with changing clinical conditions, the wheelchair should be inspected,
readjusted, and serviced every six months.

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NOTICE
Damage as a result of non-observance of the service documents. Knowledge of the service docu-
ments and of the instructions for use is a basic prerequisite for proper service.
Prior to the execution of any works, the service and maintenance instructions must be studied care-
fully. The service manual is applicable in combination with the instructions for use and the spare parts
catalogue. All documents must be used conjointly.
All safety instructions contained in this service manual and in all other applicable documents must
be observed and complied with. They must at any time be available to the service and maintenance
staff.
NOTICE
Damage due to exposure to extreme temperatures. The B400 may be used within a temperature
range of -25 °C to +50 °C. It must not be operated outside this temperature range.
NOTICE
Damage caused by overload. The maximum load for the B400 power wheelchair is 140 kg/309 lbs.
INFORMATION
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. The instructions for use can be requested from the
manufacturer (see the overview of all Otto Bock branches "Otto Bock Worldwide”). Other documents
can be downloaded from the homepage of Otto Bock HealthCare GmbH at www.ottobock.de or www.
ottobock.com.
2.4 Safety Instructions Regarding the Use of Tools and Auxiliary Means
CAUTION
Health risk as a result of using inappropriate tools. For carrying out the works, only use tools which
are suitable for the conditions prevailing at the workplace and which ensure safety and health protec-
tion, if used properly.
Test the proper function prior to using the tool. For use of the work equipment, also take the ergonomic
relations between the workplace, work equiment, work organization, work flow, and task into consid-
eration; this especially applies to the body posture assumed when using the work equipment.
CAUTION
Health risk as a result of using inappropriate work clothes. Make sure to wear the legally prescribed
protective clothes.
CAUTION
Risk of injury when lifting or jacking up components or work equipment. If any repair or maintenance
is done requiring components or work equipment to be lifted or jacked up, secure them using appropri-
ate equipment to prevent them from falling down. Work equipment used for lifting loads must prevent
the loads from shifting in a dangerous way or falling freely, or becoming unintentionally unhooked.
When using lifting platforms, be sure that the B400 power wheelchair stands centrally on the lifting
platform area and that none of the wheelchair’s components, such as the anti-tipper, protrude into the
danger area.

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CAUTION
Danger caused by dangerous substances. Dangerous substances at the workplace are allowed only
in quantities needed for the progress of the work. Regularly and safely remove waste and residues.
Immediately scavange any spilled substances.
2.5 Safety Instructions for Maintenance Works
CAUTION
Risk of injury caused by pinch points. There are pinch points caused by the construction in the area
between the seat and frame of the B400. Extra caution is required when working on the respective
components.
CAUTION
Danger when working on the brake system. Note that, when the brake is unlocked, there is not any
brake function available. The brake may only be unlocked in dangerous situations and for maintenance
or repair. The corresponding force required for acceleration and deceleration must come from the
person pushing.
Once the push mode is no longer needed, the brake unlocking lever must be locked immediately.
NOTICE
Damage as a result of improperly prepared maintenance.
• For all maintenance works, the B400 power wheelchair must be switched off and the fuse be removed.
This does not apply to functional tests of the electrical components.
• Secure the product to prevent it from tipping over or falling off the workbench.
• Some components of the power wheelchair are very heavy, such as the batteries, frame, seat, and
motors. If the use of hoisting devices is required, they must have a sufficient capacity.
• Clean or disinfect the product before you start the inspection. Consult the instructions for use regard-
ing product care or product specific inspection information.
NOTICE
Damage as a result of unsecured screw connections. Unsecured screw connections can become
loose while using the product. Secure screws and nuts. After you have finished assembly, the screw
connections must be tightened with sufficient strength. If tightening torque values are specified, they
must be observed.
The screws and nuts for many of the screw connections are equipped with thread lock. If you have
to undo such screw connections, the nuts or screws must be replaced with new ones equipped with
thread lock. If new screws or nuts with thread lock are not available, apply a medium-strength liquid
thread lock substance (such as Loctite® 241 or Euro Lock A24.20) to the existing screws.
NOTICE
Risk of damage to the paddings. When working on the seat, the padding must be sufficiently protected
against mechanical and chemical stresses. The backrest and seat are flame retardant but nevertheless
flammable. They must be kept away from flames and embers.

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NOTICE
Damage caused by incorrect cleaning after completion of maintenance. Never use a water jet or
high-pressure cleaning apparatus for cleaning the B400. Use a cleaning rag or sponge for cleaning.
Direct contact of water with the motor must absolutely be avoided.
After cleaning of the B400 power wheelchair, check its operating performance.
INFORMATION
The tyres of the B400 power wheelchair contain chemical substances that can react with other chemi-
cal substances (such as cleaning agents, acids, etc.).
2.6 Safety Instructions for Maintenance Works on Electrical Components
NOTICE
Damage as a result of improperly prepared maintenance.
• To prevent uncontrolled driving through accidental joystick manipulation, turn off the wheelchair control
or jack up the drive wheels when the driving function is not required.
• During maintenance, it is essential to avoid direct contact of water with the electronics and battery.
• When establishing the plug connections of the controller, observe the correct assignment of the
contacts.
CAUTION
Risk of injury when working on the battery. Only use battery chargers from Otto Bock that have been
tested and approved by Otto Bock HealthCare GmbH for the batteries used (see information on the
battery charger). Non-observance can result in battery explosion and health risk due to contact with
acid.
When working on the batteries, smoking and open flames are not permitted. Sparks must be
avoided.
Explosive gases can develop while the batteries are charging. Observe the safety instructions of the
manufacturer of the battery. Wear protective goggles. Provide for sufficient ventilation when charging
the batteries in closed rooms.
Drive batteries can supply very high energies, and arcs can occur when they are short-circuited. There-
fore, always disconnect the batteries when working on the motor control or wiring.
NOTICE
Risk of battery damage. Always use insulated tools when working on the batteries in order to prevent
short circuits.
Avoid deep discharge of the batteries in order to prevent function failure and permanent damage to
the batteries.
When connecting the batteries, ensure correct pole assignment.
NOTICE
Risk of damage to the battery charger. Avoid overheating of the battery charger during the charging
process. Make sure that the cooling ribs on the back side of the battery charger are not covered.

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INFORMATION
The B400 has been tested according to EMC regulations. The following particularities must be com-
municated to the user and must be observed when using the B400:
• The driving characteristics of the B400 can be affected by electromagnetic fields (mobile phones or
other radiating devices). Therefore all mobile devices must be turned off when driving.
• The B400 can generate electromagnetic fields that can cause interference with other devices. There-
fore, turn off the control whenever you do not need it.
INFORMATION
When the B400 is not used over an extended period of time or for dispatching the B400, remove the
fuse from the battery case to avoid deep discharge of the batteries by standby current.
2.7 Safety Instructions for Disposal
INFORMATION
If the power wheelchair is no longer in use, it must be disposed of properly in accordance with national
regulations.
If a wheelchair is to be disposed of, all components and materials of the power wheelchair must be
recycled or disposed of properly.
CAUTION
There is a risk of polluting the environment with battery acid. The batteries of the power wheelchair
contain a toxic acid. They must not be disposed of with regular domestic waste and the battery acid
must not enter the sewage water system or ground. You must observe the battery manufacturer’s
instructions printed on the batteries.
3 Transportation and Storage
For transportation and storage, the following ambient temperature range must be ob-
served:
Ambient temperature range from -40 °C to +65 °C
3.1 Transportation
CAUTION
Insufficient fastening may result in accidents. Adequately fasten the B400 power wheelchair to the
means of transportation, e.g. with tensioning straps.
NOTICE
Risk of damage if the B400 falls down. The maximum empty weight of the B400 power wheelchair is
95 kg / 209 lbs. The means of transportation and hoisting devices used for transportation must have
a sufficient capacity.

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Secure the B400 power wheelchair to the means of transportation, e.g. with tensioning straps.
Use the fixing eyelets at the front and back of the power wheelchair as well as the defined anchor
points in the transportation vehicle.
Before transporting the power wheelchair, switch off the control and lock the brake.
You can reduce the size of the power wheelchair for transportation by folding down the backrest
and removing the side panels and footrests.
1
2
Fig. 1 Fixing eyelets
1 Rear fixing eyelets
2 Front fixing eyelets
3.2 Storage
INFORMATION
If the B400 power wheelchair is not moved for several days, permanent colour changes might result on
the ground where the wheelchair comes into contact with it. Otto Bock HealthCare GmbH therefore
recommends using a suitable mat when parking the wheelchair for extended periods of time.
The B400 power wheelchair must be stored in an enclosed area. Remove the main fuse to pre-
vent the risk of deep discharge.
The storage location must be dry, and sufficient air circulation must be provided. There must not
be any build-up of humidity. The B400 power wheelchair must not be subjected to any damaging
exterior influences, e.g. rain, snow, or strong solar radiation during storage.
Otto Bock HealthCare GmbH recommends to store the B400 power wheelchair with slightly
elevated tyre pressure and to use assembly stands or wooden blocks in order to raise the tyres
(completely) off the ground in order to protect them from frost. Regularly rotating the wheels
helps to prevent flat spots.

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4 Required Tools and Auxiliary Means
The following list includes appropriate tools and auxiliary means for the execution of the service
works:
Flathead screwdriver und Phillips screwdriver
Ring wrench or open-end wrench; sizes: 8 to 24 mm
Allen wrench; sizes: 2, 3, 4, 5, 6, 7 mm
Torque wrench
Wrench socket; size: 19 mm
Pull-off tool
Pin punch, Ø 3 mm
Plastic hammer
Drill bit; size 4/6 mm + hand drill
Plastic tyre mounting levers
Inner tube repair kit
Side cutting pliers
Water pump pliers, gripping width up to 32 mm
Liquid thread lock "medium strength”
Fig. 2 Tools
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Fig. 3 Hand programming device
5 Information Display
INFORMATION
For error indication information with the LED display "Battery capacity” or with the aid of the hand
programming device (Fig. 3)/PC software, please refer to section 7 "Error Diagnosis”.
The wheelchair functions are displayed on the LED display fields of the control panel:
LED display Function
"Battery capacity"
The LEDs show the battery capacity (see instructions for use 647G485).
"Speed levels"
The LEDs show the currently selected speed level (from 1 to 5).
Table 1 LED display fields on the control panel

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6 Service Works
6.1 Inspecting the General Condition
Check safety-relevant components for corrosion, repair if necessary, and restore corrosion
protection.
Check weld seams.
Check screw connections for strength; reapply thread-locking compound, if necessary; observe
defined tightening torque values; in case of defects (e.g. corrosion), replace the screws.
Check cables for breaks, wear and tear, and proper attachment; in case of defects, replace
the cables in accordance with the cable plan.
Check the cable connections/ plug connections.
6.2 Replacing the Fuse
The fuse is located in a small yellow box with folding cover in front of the battery case.
Steps:
Open the cover of the fuse box.
Pull out the fuse and replace, if necessary.
Properly reassemble all components upon termination of the work.
1
2
Fig. 4 Replacing the fuse
1 Fuse box with opened cover
2 Fuse, pulled out
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1.
2.

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6.3 Batteries
CAUTION
Risk of injury when working on the battery. When working on the batteries, smoking and open flames
are not permitted. Sparks must be avoided.
Explosive gases can develop while the batteries are charging. Observe the safety instructions of the
manufacturer of the battery. Wear protective goggles. Provide for sufficient ventilation when charging
the batteries in closed rooms.
Drive batteries can supply very high energies, and arcs can occur when they are short-circuited. There-
fore, always disconnect the batteries when working on the motor control or wiring.
CAUTION
There is a risk of polluting the environment with battery acid. The batteries of the power wheelchair
contain a toxic acid. They must not be disposed of with regular domestic waste and the battery acid
must not enter the sewage water system or ground. You must observe the battery manufacturer’s
instructions printed on the batteries.
NOTICE
Risk of battery damage. Always use insulated tools when working on the batteries in order to prevent
short circuits.
Avoid deep discharge of the batteries in order to prevent function failure and permanent damage to
the batteries.
When connecting the batteries and the device for measuring the battery‘s capacity, ensure correct
pole assignment.
The standard version of the B400 power wheelchair includes two 12 V lead acid batteries with
a capacity of 50 Ah. During the charging process, the water acid mixture is converted into gas
for a short time. It is optionally possible to equip the B400 power wheelchair with two gel bat-
teries with a capacity of 40 Ah.
6.3.1 Checking the Liquid Level and Filling Up (only with lead-acid batteries)
INFORMATION
Check the battery‘s liquid level and fill up, if required.
Tools:
Flathead screwdriver, wide
Steps:
Open the battery cover and remove the cover.
Pull out the fuse (see Section 6.2).
Disconnect all connection cables.
Lift out the batteries and place them on a level surface.
Compare the liquid level, which is visible from outside, with the "min” and "max” marks at the
front and rear of the batteries.
If the liquid level is too low, open the cover of the respective cell.
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1.
2.
3.
4.
5.
6.

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Top up with distilled water until the liquid level is between the "min” and "max” marks.
Properly reassemble all components upon termination of the work.
1
2
Fig. 5 Opening the battery case, disconnecting the connections
1 Opening the battery case
2 Disconneting the battery cables
1
2
Fig. 6 Liquid level marks, battery cell
1 Min/max marks for the liquid level
2 Closures of an individual battery cell
7.

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6.3.2 Charging the Batteries
WARNING
Risk of injury as a result of incorrectly set characteristic curve. When changing from wet cell batteries
to gel batteries, the characteristic curve must be changed (see information on the battery charger).
NOTICE
Risk of damage as a result of improper battery handling. For battery handling, observe the follow-
ing:
• Immediately charge the battery, if only one LED is flashing in the LED display "Battery capacity”.
• Do not charge, if green LEDs are lit.
• When the B400 power wheelchair is not used over extended periods of time, charge the wheelchair
once a week.
• The guarantee of Otto Bock HealthCare GmbH does not cover damages resulting from deep dis-
charge.
NOTICE
Risk of damage to the battery charger/ Risk of damage caused by the battery charger. For use of
the battery charger, observe the following:
• Only use battery chargers from Otto Bock that have been tested and approved by Otto Bock Health-
Care GmbH for the batteries used (see information on the battery charger). Non-observance can
result in battery explosion and health risk due to contact with acid.
• The indications on the type plate of the battery charger must be identical to the voltage of the mains
supply of your country.
• Only use the battery charger within the indicated ranges of temperature and humidity.
• Place the rubber feet of the battery charger on a level surface.
• When the battery charger is in use, protect it from direct sunlight.
• Avoid overheating the battery charger. The cooling ribs on the back side of the battery charger must
not be covered.
• During charging, switch off the wheelchair control to allow the charging current to be fed completely
into the battery.
• Avoid dust and dirt. Clean wit a dry cloth only.
The remaining battery capacity determines the distance range of the B400 power wheelchair.
The following factors have an influence on the battery capacity:
Ambient temperature
Age of the batteries
Amount of use
Charging method
Driving over a longer period of time in the lower range of the battery indicator will discharge
the batteries completely and damage the batteries. In addition, there is the risk that the B400
power wheelchair may stop due to zero battery capacity and bring the user into a dangerous
situation.
Tools:
Battery charger provided by Otto Bock HealthCare GmbH
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Steps:
Turn off the control of the power wheelchair.
Connect the plug of the battery charger to the charging receptacle on the underside of the
control panel.
Connect the battery charger to a wall socket. The batteries will start charging automatically,
and the current charge status is indicated by the LEDs of the battery charger (see Table 2).
Upon termination of the charging process, disconnect the battery charger from the mains
supply, then from the control panel.
Turn on the control, and the power wheelchair is ready for driving.
The following statuses are indicated by the battery charger:
Display Function
All LEDs light up
for a moment
Once the connection to the mains supply has been established
Yellow LED is lit Battery is charging
Yellow LED flashes Battery is charged to 90 %
Green LED is lit Battery is fully charged; battery charger has changed to trickle charge
Red LED is lit Incorrect pole assignment (immediately unplug the battery charger from the
wall outlet and reconnect the cables with correct pole assignment)
Red LED flashes Error in the course of the characteristic curve; charging time has been
exceeded
Table 2 LED display on the battery charger
The battery charger features 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.
6.3.3 Replacing the Batteries
CAUTION
Risk of injury due to electric current. Disconnect the main fuse before you perform any maintenance
work on the batteries.
NOTICE
Risk of battery damage. When connecting the batteries, ensure correct pole assignment.
Preparation:
Remove the battery cover (see Section 6.3.1).
Pull out the fuse (see Section 6.2).
Tools:
Ring wrench or open-end wrench, size 11 mm
1.
2.
3.
4.
5.
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Steps:
Disconnect all connection cables from the batteries.
Remove the batteries and replace them, if necessary.
Properly reassemble all components upon termination of the work.
6.3.4 Removing the Battery Case
NOTICE
Risk of battery damage. When connecting the batteries, ensure correct pole assignment.
Preparation:
Remove the battery cover (see Section 6.3.1).
Pull out the fuse (see Section 6.2).
Remove the batteries (see Section 6.3.3).
Steps:
Once the preparatory works have been completed, the battery case can simply be taken out
and replaced, if necessary.
Properly reassemble all components upon termination of the work.
6.3.5 Laying New Battery Cables
NOTICE
Risk of battery damage. When connecting the batteries, ensure correct pole assignment.
Preparation:
Remove the battery cover (see Section 6.3.1).
Pull out the fuse (see Section 6.2).
Disconnect and remove the batteries (see Section 6.3.3).
Remove the battery case.
Tools:
Allen wrench, size 3 mm
Ring wrench or open-end wrench, size 11 mm
Steps:
Unplug the old battery main cable from the controller (for connections on the controller see
Fig. 7).
Unscrew the yellow fuse holder of the old fuse cable from the frame.
Connect the new battery main cable to the controller.
Screw the yellow fuse holder of the new fuse cable to the frame.
Reposition the battery case and reinsert/connect the batteries.
1.
2.
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1.
2.
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5.