Otto Bock B500 advanced Operating instructions

Q U A L I T Y F O R L I F E
Service Instructions
Electric wheelchair B500

Page1
ServiceInstructionsB500
Table of contents
4.1Foreword................................................................................................. 2
4.2Safety ...................................................................................................... 2
4.3Maintenancescheduleand tools needed ............................................... 3
4.4Settings/substitution/replacement ......................................................... 6
4.4.1 B500 .......................................................................................................... 6
4.4.1.1 Control unit ......................................................................................................... 6
4.4.1.2 Battery ................................................................................................................ 7
4.4.1.3 Frame................................................................................................................. 9
4.4.1.4 Motors............................................................................................................... 12
4.4.1.5 Lighting ............................................................................................................. 13
4.4.1.6 Front wheels..................................................................................................... 16
4.4.1.7 Rear wheels ..................................................................................................... 18
4.4.1.8 Standard seat ................................................................................................... 19
4.4.1.9 Recaro seat...................................................................................................... 23
4.4.1.10 Seat systems options....................................................................................... 25
4.4.1.11 Lateral elements............................................................................................... 29
4.4.1.12 Foot notch ........................................................................................................ 31
4.4.1.13 Control unit accessories................................................................................... 33
4.4.1.14 Accessories...................................................................................................... 34
Tableofcontents

Page2 ServiceInstructionsB500
4.1 Foreword
Periodic servicing is important as it increases safety and extends the product’s service
life.
Every rehabilitation product needs to be inspected and serviced on a yearly basis.
We recommend to inspect, adjust, and, if necessary, service a product every six
months if the product’s users change frequently (children and young people growing
up), or when the user’s clinical picture is subject to changes.
Use only original spare parts for all service and maintenance work.
Service and maintenance work must only be performed by appropriate expert
personnel!
The service instructions refer to the spare-parts catalogue, and to the operating
instructions. All the documents should be used together.
4.2 General safety instructions
Please observe the following principles during all servicing and repair work:
- Read the service and maintenance instructions carefully before you start any work.
- Familiarize yourself with the product’s functions. If you do not know the product, you
should study the operating instructions carefully before you begin with the
inspection.
The operating instructions can be obtained from the manufacturer (see the list
of Otto Bock’s branch offices in „Otto Bock Worldwide“).
- You can also download the documents from our home page:
www.ottobock.de or www.ottobock.com.
- Use only suitable tools.
- Wear appropriate clothing, and put on gloves and goggles whenever required.
- The product must be secured so as to prevent it from overturning or falling down,
e.g., from the work bench.
- Clean and disinfect the product before starting inspection. Observe the instructions
for care in addition to any product-specific inspection instructions included in the
operating instructions.
- Screws and nuts with thread locks are used in very many screwed connections.
The corresponding nut or screw must be replaced by a new nut or screw with
a thread lock whenever a screwed connection with a thread lock needs to
beopened.
If screws or nuts with a thread lock should be unavailable, be sure to use a liquid
thread locking compound with medium strength (e.g., Euro LockA24.20).
- Some parts are very heavy as, e.g., batteries, frame, seat, or motors!
Be sure to use a correct ergonomic approach when lifting these heavy parts.
Foreword/Safety

Page3
ServiceInstructionsB500
Maintenanceschedule
4.3 Maintenance schedule and tools needed
The following list contains appropriate tools and auxiliary devices.
Reversibleratchetand
socket wrench inserts,
sizes 8 - 19
Wrench
sizes 8 - 24
Hexagonal
screwdriver
sizes 2.5 - 8
Screwdriver
bladewidth
2.5; 3.5 and 5.5 mm
Crosstipscrewdriver
size 2
Plastic hammer Hammer approx. 300g
Waterpumppliers
DIN8976
grip width up to 32 mm
Diagonalcutter
Pinpunch
Ø 3 mm

Page4 ServiceInstructionsB500
Maintenancescheduleandtoolsneeded
Drillingmachine
Twist drill
Ø 4 mm
Ø 5 mm
Ø 6 mm
Carpetcutter
withacrescent-shaped
blade
Liquid
“mediumstrength“thread
lockcompound
Brushand
standardgrease

Page5
ServiceInstructionsB500
Maintenancescheduleandtoolsneeded
Maintenanceschedule
foryearlyinspection B500
Component
o ElectronicsControlunit o Fluid level
o Batterybox
o Cabling
o Suspension
o Drive support
o Motor
o Rockers
o Brake release
o Tilting protection
o Cabling
1
6
7
5
4
3
2
8
9
10
11
12
13
Lateralelements
Controlunitaccessories
Accessories
Footnotch
Seat system options
Recaro seat system
Standardseat
Drivewheels
Frontwheels
Lighting
Frame
Battery
Item
o Light holders
o Lamp housing
o Lamps
o Cabling
o Handlebar fork
o Suspension
o Handlebar lock
o Edge mounting aid
o Tires
Function Damage/
Deformation Screw
connections
o Covering
o Seat & back frame
o Seat section
o Lateral element retainer
o Seat lugs
o Tires
o Seat lock
o Subframe
o Seat modules
o Seat lugs
o Seat shell retainer
o Abduction wedge
o Head rests
o Foot notch socket
o Foot board
o Foot notch support
o Control unit holder
o Joystick
o Treatment table
o Arm rests
o Arm supports
Check (Check the box when the item is OK)
x
x
xx
x
x
xx
xx
xx
xx
xx
xx
xx
xx
xx
Servicingperformedby: dated:

Page6 ServiceInstructionsB500
Settings/substitution/replacement
Programming and Fault Finding
When making any control settings, please refer to
the operating instructions of Penny & Giles.
Theseinstructionsincludeanextensive description
of all steps and notices regarding the control
system.
Refitting or replacing the control for lighting
and/or escort control
Thefollowingisrequiredtorefitthewheelchairfor
lighting or escort control:
- Operatorpanelforlighting
- Lightingmodule
- Lighting
- Y cable if for lighting and
escortcontrol
Replacing the control system:
Removal:
- Loosenthecontrol cable
- Undobothscrewconnectionsbelow
the control unit
- Removethecontrolunit
Installation:
- Fasten the control unit using both
screwconnections
- Plug in the control cable
Fastening the escort control
Usetheparts provided for this purpose to fasten
the escort control to the rear of the seat or to the
head rest on Recaro seats:
- Pull off the head rest
- Insertboth head rest tubes through the
bushings of the escort control
(seefigureto the left)
- Fasten the head rest to the seat.
4.4 Settings/substitution/replacement
4.4.1 B500
4.4.1.1 Control unit
Escort control
Operator panel for lighting

Page7
ServiceInstructionsB500
Settings/substitution/replacement
Read the cautions supplied by the battery manufacturer before starting any work on the batteries!
4.4.1.2 Battery
Battery
TheB500standardversionisequippedwithtwo
12 V lead-acid batteries with a capacity of 60Ah.
A conversion of the water-acid mix to gas will
occur for a short time during the charging process.
Check the liquid level on a weekly basis, and refill
if necessary. To do so, first remove the seat
cushion together with the seat section:
- Openthe Velcro fasteningofseatcushion
back and seat section, fold the seating
surfaceforward
- Open the catch lock at the rear end of the
batterycase,andremovethecover(for
Recaro seats: open the seat lock under the
seat,andremovethecover)
Fortheversionwithspring-mountedrearwheels,
pull the lock at the rear wheelchair bottom, and
pull out the drawer with the batteries (see figure to
theleft).
Charging the battery
- Connect the charger to the charge socket
attheoperatorpanel
- Connect the charger to 230 V
Thecharging process will startautomaticallywhile
the LED’s are displaying the current charge status.
An incrementing LED display indicates the charg-
ingprocess at the operator panel:
- yellow LED lights up = battery charging
- green LED lights up = battery charged
- yellowLED flashes = fault, battery defective,
Connectioninsufficient...
- NoLED indication = Nomainsvoltage,
Batterychargerdefective
Thechargerhasaprogrammedrechargephase.
You can leavethedeviceconnectedwithoutany
problemsevenwhenafullchargelevelisreached
althoughyouhavebeenchargingacompletely
dischargedbatteryfor8 hours, approximately.
When charging is complete, first pull out the mains
plug, then pull out the charging plug. The B500 is
readytooperate after switching the control offand
onagain.
Notes
o Charge batteries promptly whenever the
red LED’s are flashing!
o Do not charge in the green area!
o We do not assume any warranty for
damage caused by total discharge!
o Do not use any charger other than the
charger specified by Otto Bock!
o The B500 needs to be charged every month
when it is not used for a long period.

Page8 ServiceInstructionsB500
Settings/substitution/replacement
Caution!
o Pull out the main fuse first before starting
any work on the batteries!
o Smoking is prohibited near the charger,
and when work is performed on the
batteries!
o Avoid fire or sparking!
o Explosive gasses may be generated when
batteries are being charged, so make
certain that the gasses are properly vented!
o Be sure that the venting slots are not
covered!
Removing and installing batteries
Forbattery removal or installation,takeofftheseat
as described in section 4.4.1.8, or pull out the
batterycasefromthespring-mountedversion.
Removal:
- Open the strap catch lock, and remove the
cover
- Removethefuse
- Disconnectthebatteries,and remove them
from the battery case
Installation:
- Place the batteries into the battery case,
andconnect the batteries
- Insertthefuse
- Install the cover, and close the strap catch
lock
Replacing or removing the battery case
Toreplace or remove the battery case:
- Dismounttheseat;for the spring-mounted
version,you only need to pull outthedrawer
- Openthestrapasdescribedabove
- Removethebatteries,anddismountthe
battery case.

Page9
ServiceInstructionsB500
Settings/substitution/replacement
Replacing or removing the frame
Important!
o Turn off the B500 before starting any work
on the frame!
o Observe the cables fastened to frame, seat
or drive bracket using cable binders!
o Use caution to cut the cable binders
without damaging any cable using a
diagonal cutter or a knife!
- Place the B500 on a flat surface, and secure
it against rolling away.
-Removethe black plastic protector cap
- Use a size 19 socket and a ratchet to
unscrewandremovethefront-wheelfork
- Usea suitable deviceto protect thewheel-
chairagainst overturning
- UseanAllen wrench toremove theseat:
Undoallscrew connections
(fourrearandtwofrontscrewconnections)
which are used to secure the seat lugs to
theframe
- Unscrewallother parts fastened to theframe
(e.g.,lampsand brake release)
- Removetheframe
4.4.1.3 Frame

Page10 ServiceInstructionsB500
Replacing or removing the drive bracket
- Turnoff the B500, andpull out allplug
connectionsbeforedismounting the drive
bracket
- Undo the eight screw connections located at
therearframe(four per side)
- Removeframe,seat,andlamps
- Removethebatterycase
- Undo the two hexagon socket screws at the
drivebrackettoremovethebumper(ifany)
- Unscrew two screws each to dismount the
tiltingprotections
- Removethetires(see section on „Replacing
thetires“)
- Pulloffthewheelflanges
- Undothebrakereleasewires
- Unscrewthe four screw connections usedto
fastenthemotors
Replacing or removing the rear-wheel springs
Therear-wheelspringsare suspended at two
points: One point is at the top of the drive bracket
and the other on the rocker.
Therearwheelsneedtobedismountedbeforeyou
canremovethesprings:
- SecuretheB500againstslippingoroverturn-
ing, and place the B500 on a support which
enablestherear wheels to rotate freely
- Dismountthewheels
- Undo the two screws used to suspend the
rear-wheelsprings, andremovetherear-wheel
springs
- Installnewrear-wheelsprings,orchangethe
springeffect(turning the top plate either
downor up)
Settings/substitution/replacement

Page11
ServiceInstructionsB500
Removing or installing the rockers
Therearwheelrockersarefastenedtothedrive
bracketandrotatefreely.The wheels,the rear-
wheelsprings,andthe motors need to be removed
beforetherockers can be dismounted.
- Use a size 20 socket to unscrew and replace
therockers
- Install the spring in one of the three rear
rockerboreholes
- Suspend the spring at the top in the last drive
bracketborehole
Installing or replacing the tilting protection
The B500 tilting protections can only be used in
pairs(oneleft, one right).
Use two carriage bolts to secure the tilting protec-
tionsto the drive bracket(see arrow).Use an
open-endorringspannertoeitherunscrewor
tighten the nuts.
Settings/substitution/replacement

Page12 ServiceInstructionsB500
4.4.1.4 Motors
Replacing or removing the motors
- TurnofftheB500beforestarting any work on
themotors
- Removeframe andseat
(refertothesectionson„Replacingorremov-
ingtheframe“, and „Replacing or removing
thedrive bracket“)
- Undothe brake releasewirebeforeremoving
the frame (to protect the mechanism against
damageormisadjusting)
- Undotheplug-and-socketconnectionsofthe
motors
- Undotheplug-and-socket connections to the
battery case, and remove the battery case
- Unscrewthefour screw connections used
to fasten the motors
Replacing or removing the brake release
- Before staring any work on the motors, turn
off the B500, secure it against rolling, and
undothebrakerelease
Removal:
- Useascrewdriver to remove the Bowden
cables which lead to the motors
- Unscrew the hexagon socket screw at the
frame cross strut
Installation:
- Tighten the hexagon socket screw at the
frame cross strut
- Tightenthe Bowden cables which leadto the
motorsusinga screwdriver
Settings/substitution/replacement

Page13
ServiceInstructionsB500
Replacing or removing defective incandescent
lamps
Headlamp:
- Unscrewthe lower screwat the headlamp
(seearrow)
- Pull off the front section, and replace the
defectivelamp
Flashinglight:
- Insertthescrewdriverintotheopening from
below, and loosen thescrew with a quarter
turn
- Replacetheincandescentlamp
Rearlight:
- Undothetwoscrewsto remove the cover
seearrows)
- Apply slight pressure to the right to pull
forwardtheincandescentlamponthe
left-handside
- Replacetheincandescentlamp
Mounting the complete light system
Anewoperatorpanelisneeded to convert the
B500forlighting.Thisoperatorpanelhasadditional
buttons, display functions, and connecting ports.
A light module to be screwed under the seat is
supplied together with the complete light system.
- Inserttheadditional plug of the light operator
panel into the centre port of the light module
- Insert the light plugs into the left port or,
correspondingly,intotherightport
- Secure the rear light to the last frame
borehole
- Secure the front light to the front of the seat
frame
- Use Velcro strips to fasten the bus system
plugsto the frontof the framecrossbar
- Use cable binders to fasten the lighting
cables at both the frame and the seat frame
Replacing the fuse
The fuse of the B500 is located in a black case
inside the battery case.
- Open the case and replace the fuse
4.4.1.5 Lighting
Seat section
Crossbar
Settings/substitution/replacement

Page14 ServiceInstructionsB500
Installing and removing the light module
The light module is fastened by two screws to the
cross strut located under the seat (see arrows).
TurnofftheB500,andundoallplug-and-socket
connections before starting any work on the light
module.
Settings/substitution/replacement

Page15
ServiceInstructionsB500
Settings/substitution/replacement
4.4.1.6 Front wheels
Replacing and removing the handlebar fork
Removal:
- Remove the black plastic dust protection cap
atthetop of the handlebar fork retainerusing
ascrewdriver
- Use a size 20 socket to unscrew the nut, and
slide out the fork toward the bottom
Installation:
- Insert the fork, and tighten the nut using a
size 20 socket
- Put on the black plastic dust protection cap
Installing or replacing the edge mounting aid
- Unscrewandremovebothhexagonsocket
screws(M10x25)
- Establishtheconnection between spring fork
and edge mounting aid: Install the thrust plate
betweenspringforkandedgemountingaid,
hen screw in the threaded bolts
- Fasten the spring mounting with the leg
spring: Make certain that the inside leg of the
springislocatedbetweenforkand threaded
bush
- Secure the screw connection using „Loctite“,
and tighten the screws
Replacing or removing the springs
Toreplacethefront-wheelforksprings,undothe
screw located in the spring. The spring effect is
modifiedby strongly tightening the screw.

Page16 ServiceInstructionsB500
Settings/substitution/replacement
Replacing or removing the handlebar lock
Removal:
- Use a pin punch to remove the cotter pin at
the top of the locking device (locking bolt and
springwillfall out below)
Installation:
- Slip the spring on the thin bolt end, and insert
springandboltfrombelow into the borehole
- Set the bolt on the catch lever, and secure it
with the cotter pin
Replacing or removing the handlebar
- Use suitable objects, e.g., wood blocks to
securethefrontframe part against overturning
orslipping.
Thewheelmustrotatefreely.
- Use two size 5Allen wrenches to remove
orinstallthehandlebar
Replace the outer cover or the inner tube of
pneumatic tires
Caution!
Replace the outer cover whenever the tread
pattern is worn out, cracked or damaged.
Removal:
- Deflatethetire
- Unscrew all screws using anAllen key
TheB600has a divisible rim.
- Loosen the screws, separate the rim, and
replaceeither the inner tube or theouter
cover
- Replace the tube, or repair it using a com-
merciallyavailable bicycle tire repair set

Page17
ServiceInstructionsB500
Settings/substitution/replacement
Installation:
- Inserttheinner tube into the outer cover
- Fit the rim together, and all screws using
anAllen key
- Inflatethetire

Page18 ServiceInstructionsB500
Settings/substitution/replacement
4.4.1.7 Rear wheels
Replacing or removing the rear wheels
- Use suitable objects, e.g., wood blocks to
securetherear frame part against overturning
orslipping.
Thewheelmustrotatefreely.
Removal:
- Usea crosstip screwdriver to unscrew the
protection cap screwed to the rim
- Use a size 5Allen wrench to unscrew all four
screwswhichholdthewheel,andremove
thewheel
Installation:
- Mountthe wheel and tightenall four screws
using a size 5Allen wrench
- Screw the protection cap to the rim using
acrosstipscrewdriver
Repair instructions on how to replace the outer covers or the inner tubes of pneumatic tires.
Refer to the sections 4.4.1.6 on „Front wheels“.

Page19
ServiceInstructionsB500
Settings/substitution/replacement
4.4.1.8 Standard seat
Replacing the end cover
Unscrew the three screws as indicated by the
arrows.
The screw located at the centre of the end cover is
used as a stop for back angle adjustment.
Replacing and adjusting the back covering
- Removethebackcoveringcompletely, and
re-adjust the Velcro strips (as required by the
user)
- Proceed as follows to attach the Velcro strips
to the back frame (starting at the top back
tube):onenarrow, one wide, two narrow,and
one wide Velcro strips