Otto Bock C1000 User manual

C 1000
Service Manual

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Table of Contents
1 Safety .......................................................................................................................................3
2 Preface ...................................................................................................................................... 4
3 Required Tools and Maintenance Plan ....................................................................................4
4 Settings / Retrot / Replacement ............................................................................................7
4.1 Control Panel ........................................................................................................7
4.2 Battery / Fuse .....................................................................................................15
4.3 Side Panels .........................................................................................................16
4.4 Lighting ...............................................................................................................18
4.5 Standard Seat ....................................................................................................20
4.6 Contoured Seat ...................................................................................................21
4.7 Recaro Seating Systems ..................................................................................... 23
4.8 Seating System Options ......................................................................................25
4.9 Covering Parts ....................................................................................................26
4.10 Footrests .............................................................................................................27
4.11 Front Wheels ......................................................................................................29
4.12 Caster / Caster Fork ...........................................................................................30
4.13 Frame / Drive Unit Sustainer / Motors .................................................................33
4.14 Control Unit .........................................................................................................38
4.15 Electric Options ................................................................................................... 39
4.16 Accessories ........................................................................................................42

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Standard seat backrest
Armrests with clothing protectors
Standard seat with seat cushion
Control panel
Footrests
Module
Battery case
Front lights
Rear lights
Lateral motor cover
C1000 Power Wheelchair
Frame

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1 Safety
Observe the following guidelines for maintenance or repair work:
Use appropriate tools.
Wear appropriate clothing, including gloves and safety glasses, if necessary.
Secure the product to prevent it from tipping over or falling off the workbench.
Read the service and maintenance instructions before starting.
Familiarize yourself with the functions of the product. If you are not familiar with the product, read
the instructions for use manual before inspecting the product.
If you do not have an instructions for use manual, you can order one from the manufacturer (see the
overview of all Otto Bock Branches "Otto Bock Worldwide."). Alternatively, you can download the
document from our home page at www.ottobock.de or www.ottobock.com).
Clean or disinfect the product before starting inspection. See the instructions for use manual for
care instructions or specific product inspection information.
Many of the screw fastenings use thread lock or nylock nuts. If you have to undo such screw
fastenings, replace the nut or screw with a new thread lock and/or nut. If new screws or nuts with
thread lock are not available, use a medium-strength liquid thread lock substance (such as Euro
Lock A24.20).

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3 Required Tools and Maintenance Plan
The following list ensures that you use the right implement for every procedure.
Reversible ratchet handle wrench
and sockets, sizes 8 mm - 20 mm
Allen wrenches,
sizes 2.5 mm - 8 mm
Wrenches, sizes 8 mm - 24 mm
Water pump pliers DIN 8976,
gripping width up to 32 mm
Screwdrivers,
blade widths 2.5/3.5/5.5 mm
Phillips head screwdriver, size 2 mm
Plastic hammer Hammer approx. 300 g Pin punch ø 3 mm
2 Preface
Regular maintenance is important. It increases safety and prolongs the service life of the product.
All rehab products should be inspected and serviced once a year.
If the product is used frequently, or if it is used by growing children or patients with changing clinical conditions,
we recommend readjusting and servicing the product every 6 months.
Use only original spare parts for all service and maintenance.
The service and maintenance described in this manual should be performed by skilled specialists only and not
by the user.
This service and maintenance manual refers to the spare parts catalogs and instructions for use manuals for
the products described here. For this reason, it is important to use these documents together.
Use the maintenance plans (check list) as a template for making copies. Retain completed maintenance plans
and provide the customer with a copy.

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Side cutting pliers Liquid thread lock "medium
strength" Hand drill
Twist drills Ø 4 mm, Ø 5 mm Stanley knife with sickle hooked
blade
Brush and standard grease

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Maintenance Plan
for Annual Service
C1000 Customer:
Item Component (group) Inspection (check list)
1.)
Function / setting
2.)
Damages /
deformations
3.)
Screw connections
1 Control unit - Electronics
2 Battery - Liquid level
- Battery case
- Cables
3 Frame - Spring system
- Drive unit sustainer
- Motor
- Oscillating cranks
- Brake release
- Anti-tippers
- Cables
4 Lighting - Light holders
- Lamp housings
- Lamps
- Cables
5 Rear wheels - Caster fork
- Spring system
- Caster swivel lock
- Tires
6 Driving wheels - Tires
7 Standard seat - Upholstery
- Seat and back frame
- Seat plate
- Side panel attachment device
- Seat brackets
8 Recaro seating systems - Seat lock
- Underframe
- Seat modules
- Seat brackets
9 Seating system options - Seating shell interface
- Abductor
- Headrests
10 Footrest - Footrest receiver
- Footplate
- Footrest holder
11 Control accessories - Control panel holder
- Joystick
- Tray
- Attendant control
- Suck/blow control
- Chin control
- Environment control
12 Electric additional modules - Electric back angle adjustment
- Electric seat tilt
- Electric lift seat
13 Side panels - Arm pads
14 Accessories
Maintenance performed by: on:

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4 C1000 Settings / Retrot / Replacement
4.1 Control Panel
Like the B600, the C1000 has two different control
panels: the Delta control panel and the MCS control
panel. Both control panels are attached to the control
panel holder in the same way (see next photo).
Two screws are used to attach the control panel
holder to the underside of the control panel.
Note: The standard control panel cannot be used if the C1000 has more than three electric options.
All control panel holders for the C1000 are attached to the armrest beneath the armrest pad. To mount or
replace a control panel holder, first unscrew the control panel. Next, take the side panel out of its holding
device. After loosening the three set screws, you can either change the position of the control panel holder or
completely remove it.
Control Panel Holder

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Standard control panel holder for MCS and Delta control
panel
Holder for indicator module
Control panel holder, downwards adjustable, MCS and
standard
Holder for LCD standard, swing-away
Holder for LCD, swing-away, height and angle adjustable Holder for LCD with gooseneck
All control panel holders and LCD holders are attached to the C1000 in the same way.
All holders are clamped to the underside of the armrest pad with an iron rail.

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The protective bow is mounted beneath the control panel. Attach it to the underside of the control panel
holder and use the two screws and the toothed lock washers to fasten it into place.
Protective Bow
Control panel holder, swing-away in parallel, MCS and
standard

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On the C1000 standard seat, the attendant control is mounted to the cross tube of the backrest. The
attachment plate provided is screwed into the two bore holes located here. The holder for the attendant control
is screwed to this attachment plate and the attendant control is then screwed to the holder.
On a Recaro® seat, remove the headrest and put the metal bars of the headrest through the two holes on the
control panel holder.
Two set screws can be used to set the width of the holder.
4.2 Battery / Fuse
Note: Before doing any maintenance on batteries, please read the battery manufacturer's
warnings!
Battery
The standard version of the C1000 includes two 12 V lead acid batteries with a capacity of 60 Ah. During
the charging process, the water acid mixture is converted into gas for a short time. The liquid level should be
checked on a weekly basis and be topped up as needed.
Now you can pull out the entire battery case.
To access the batteries of the C1000, first remove
the footrests or swing them to the side. Then release
the battery case by slightly pulling up the lever on the
lower front part of the battery case.
Attaching the Attendant Control

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Open the battery strap and remove the cover.
Battery Charging
First connect the battery charger to the charging receptacle, which is located in the side covering.
Next, connect the battery charger to the mains. Charging starts automatically. LEDs indicate the charging
status on the charger. On the control panel, the charging status is indicated by an increasing number of
LEDs.
Battery charger indicators:
- Yellow LED is lit = Battery is charging
- Green LED is lit = Battery is fully charged
- Yellow LED is flashing = Error! Defective battery, connection insufficient ...
- No LED is lit = No power supply, defective battery charger
You can now service the batteries as needed.

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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. When the
battery has finished charging, disconnect the battery
charger from the mains and then from the wheelchair.
Before the C1000 can be used, the wheelchair
control must be switched off and on.
To charge the battery, plug the 4-pole plug into the
charging receptacle of the C1000. The charging
receptacle is located in the side covering of the
C1000 and is protected by a rubber cover.
Important:
- If possible, do not charge the battery if the green LEDs of the battery indicator are lit. Charge the battery as
soon as the red LEDs begin to flash.
- The warranty becomes void in the case of damages resulting from a completely discharged battery!
- If the C1000 is not used over extended periods of time, it must be charged once a month.
- Only use the battery charger provided by Otto Bock.
Explosive gases can develop while the batteries are charging. For this reason, make sure that the gases can
escape easily. Do not smoke near the battery charger or while handling the batteries. Avoid fire and sparks!
Do not cover the vent slots.
Installing and Removing Batteries
To install or remove the batteries, pull out the battery case.
Proceed as described at the beginning of this section.

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First remove the fuse, then the battery. The fuse is
located in a small box on the front wall of the battery
case (see page 14). Disconnect the battery and
remove the battery from the battery case. To install a
battery, follow the steps described above in reverse
order.
To remove or replace the battery case, first pull out
the drawer. You can now remove the batteries and
then replace the battery case. Before doing this, make
sure that all connections between battery, motor and
module have been disconnected. A 13 mm ring wrench
or open-end wrench is required for connecting or
disconnecting the batteries.
Note: Before you perform any maintenance work on the batteries, the main fuse must be disconnected!
Always use insulated tools when working on the batteries!
When positioning new battery cables, lead them
through the hole at the rear side of the battery case
and connect the batteries.
You require a 13 mm ring wrench or open-end wrench
for connecting the batteries.
Be sure to connect the battery poles (positive and
negative) correctly.
Attention! Danger of electric shock. Use only
insulated tools.
Once you have connected the two batteries, lead the
two ventilating hoses to the front and put them through
the two small holes in the battery case. To remove the
batteries, follow these steps in reverse order.
Next, reinstall the fuse and put the cover on the battery
case. Finally, secure the cover with the battery strap
and push the battery drawer under the seat. Make
sure that the battery drawer snaps into place.
Removing / Replacing the Battery Case

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To install or replace the fuse, pull out the battery case
and remove the cover as described in the previous
sections. The fuse is located in a small box at the front
of the battery case. Once you have opened the box,
the fuse can be easily pulled out or inserted.
Replacing / Installing the Fuse

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4.3 Side Panels
Changing the Position of the Side Panels
A side panel attachment device is located on the left
and right sides of the seat frame.
By loosening the two set screws you can change the
position of the side panels. Once you have found the
correct position, simply retighten the two set screws
using a 3 mm Allen wrench.
To replace the whole side panel, simply loosen the
thumb screw located on the bottom side of the panel
attachment device. Above this screw, there is a set
screw for setting the armrest height. Loosen this screw
using a 3 mm Allen wrench, adjust the armrest to the
desired height and retighten the screw.
The clothing protector is attached to the side panel with
two screws. Loosen these two screws to replace the
clothing protector or to change its position.
The arm pad of the side panel is attached to the rod
assembly of the side panel with two set screws.
Loosen these two screws to move the arm pad into
a more comfortable position for the user. The third
set screw, which can be seen at the right in the
photograph above, is used for clamping the control
panel holder.
This control panel holder is usually long, and the
additional clamping point prevents it from slipping or
wobbling.
Proceed in a similar manner when replacing the arm
pads for Recaro® seats.
The arm strap must be anchored in the armrest rail.
Insert the metal plate into the rail and move it to the
desired position. Then put the two ends with the
eyelets onto the set screw and secure the connection
with a nut.
Replacing and Setting the Side Panels
Replacing the Arm Pads Replacing / Retrotting the Arm Straps

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To change the halogen lamp of the front light, lightly
push the black engaging lever at the lower end of the
lamp. Now the pane and lamp can be folded forward
and removed.
Hold the lamp by the lock ring, pull it back and
replace it with a new one.
When installing the lamp, make sure that the notch on
the lamp socket is positioned correctly.
For replacing the front direction indicators, it is
best to use a small flathead screwdriver. Insert
the screwdriver into the notch at the bottom of the
housing and turn it a quarter turn to the left or right.
This will make the pane come loose from the housing
so you can replace the lamp.
To reattach the pane, place it on the housing the right
way around and press it down firmly.
4.4 Lighting
To replace defective rear lamps, first remove the
upper part of the rear covering, which is secured with
a thumb screw and a hook and loop strap.
Once you have undone this connection, you can
easily lift the covering and disconnect the lamps.
Once you have removed the rear covering and
disconnected the lamps, you can disassemble the
lighting units. Each of these units is attached to the
covering with an Y-shaped holder. Once you have
disassembled the lighting units, you can also remove
the lamp housing and replace the defective lamp. You
need an 8 mm wrench to loosen the screws on the
lighting unit.
Note: When reinserting the panes, make sure they are seated correctly on the housing and ensure that the
screws are firmly tightened. Do not expose the lamps to moisture!
Replacing Defective Lamps

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The front lights of the C1000 are attached to the
frame by a metal sheet.
There are two pre-drilled holes on the underside of
the front part of the frame for attaching the metal
sheet. Apply the two screws and tighten them using a
Phillips head screwdriver.
Screw the lighting unit to the metal sheet using a
6 mm Allen wrench and a 13 mm open-end wrench.
Attaching the Front Lights

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4.5 Standard Seat
To replace the bearing plate, loosen the three screws
next to the arrows in the photograph above. The
screw in the middle of the plate serves as stop for the
back angle adjustment.
You require a 6 mm Allen wrench and a 13 mm open-
end wrench.
To replace or readjust the back upholstery, pull the
back upholstery completely off and readjust the hook
and loop straps.
To replace the upholstery completely, you must first
attach the hook and loop straps to the back frame.
The seat frame of the C1000 can be replaced by
completely disassembling the seat.
To change the seat frame, you have to remove the
back part first. To do this, loosen the two screws on
each side and remove the back. A 6 mm Allen wrench
and a 13 mm open-end wrench are required. You can
now easily remove the seat plate and the side panel
attachment devices. Also untie all cables connected
to the seat frame by cable ties.
Next, loosen the screws of the front seat brackets and
remove the seat frame.
Note: Be careful not to damage any cables
attached to the seat frame!
To reassemble the seat, follow the above steps in
reverse order.
See also the sections on the seat plate, side panel
attachment device and back.
Replacing the Bearing Plate Back Upholstery
Replacing the Seat

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Replacing the Seat Plate
To change the height of the C1000 standard seat,
you have to replace the seat brackets.
There are two brackets at the rear, one on the left
and one on the right, and both are attached with two
hexagon socket head screws.
There are also two brackets at the front, one on the
left and one on the right, both of which are attached
to the frame with clamping brackets.
You can now remove the seat frame, separate the
seat brackets from the seat frame and replace them.
To reassemble the seat frame with the new brackets,
follow the above steps in reverse order.
Note: When removing the seat, take care not to
damage the cables attached to the seat frame!
The two front seat brackets are used for setting the
seat inclination. These brackets have several bore
holes on their lower end. You can change the seat
inclination by using a different bore hole as follows:
Upper bore hole 0°, middle bore hole 3°, or lower bore
hole 6°. To do this, loosen the screw connections that
connect the seat brackets to the adjustment brackets.
Push the seat unit up or down to the desired seat
inclination. Once you have found the desired position,
screw the two brackets together.
Changing the Seat Height (standard seat)
Setting the Seat Inclination
(For standard seats without electric seat tilt)
Only standard seats have a seat plate.
To replace the seat plate, simply remove the seat
cushion and then pull out the seat plate with a tug.
To remount the plate on the seat frame, hook the rear
end behind the two spacers located at the end of the
seat frame and push the seat plate firmly into place.