Otto Bock C2000 Operating instructions
Rear-wheel driveFront-wheel drive
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Contents Page
1.1 Preface ....................................................................................................................6
1.2 Support ...................................................................................................................6
2.1 Symbol Legend .......................................................................................................6
2.2 General Safety Instructions ...................................................................................6
2.3 Safety Requirements for the Use of Tools and Aids ..............................................7
2.4 Safety Requirements for Service and Maintenance Tasks ....................................8
2.5 Safety Requirements for Maintenance Tasks on Electrical Components ...........10
2.6 Safety functions ...................................................................................................12
2.7 Safety Instructions for Controller Conguration ..................................................12
2.8 Safety Requirements for Disposal .......................................................................12
3.1 Transportation ...................................................................................................... 13
3.1.1 Folding for Transportation ........................................................................................ 14
3.1.2 Folding the back rest ............................................................................................... 14
3.1.3 Folding the back rest with electric back angle adjustment .................................... 15
3.2 Storage .................................................................................................................16
6.1 Inspecting the General Condition ........................................................................20
6.2 Fuse Replacement ...............................................................................................20
6.3 Batteries ...............................................................................................................21
6.3.1 Charging the Batteries ............................................................................................. 21
6.3.2 Battery Replacement ...............................................................................................24
6.4 Reinstalling the Battery Cable .............................................................................25
6.5 Replacing the Charging Receptacle ....................................................................26
6.6 Replacing the Controller ......................................................................................27
6.7 Replacing the Seat Module ..................................................................................28
6.8 Wheels ..................................................................................................................29
6.8.1 Inspecting the General Condition ............................................................................29
6.8.2 Removing the Drive Wheel .......................................................................................30
6.8.3 Removing the Steering Caster ................................................................................ 31
6.8.4 Replacing the Casing and / or Inner Tube ..............................................................32
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6.8.5 Removing the Drive Wheel Splash Guard ...............................................................33
6.8.6 Removing the Steering Caster Splash Guard .........................................................33
6.8.7 Caster Fork ..............................................................................................................34
6.9 Removing Springs, Changing the Spring Tension ...............................................34
6.9.1 Removing the Drive Axle Spring ..............................................................................34
6.9.2 Removing the Steering Axle Spring .........................................................................35
6.10 Steering ..............................................................................................................36
6.10.1 Adjusting the Chain Tension...................................................................................36
6.10.2 Steering motor .......................................................................................................38
6.10.3 Steering Potentiometer ..........................................................................................38
6.11 Wheel Lock and Wheel Lock Release .................................................................39
6.11.1 Replacing the Wheel Lock Release and Bowden Cables .......................................39
6.11.2 Setting / Adjusting the Wheel Lock Release..........................................................40
6.11.3 Performing a Brake Setting Function Check .........................................................42
6.12 Lighting ...............................................................................................................43
6.12.1 Front lights ..............................................................................................................43
6.12.2 Rear lights ..............................................................................................................45
6.13 Seat ....................................................................................................................47
6.13.1 Standard Seat: Removing the Seat Cushion and Back Pad .................................48
6.13.2 Standard Seat: Replacing / Adjusting the Back Upholstery .................................48
6.13.3 Replacing the Bearing Plate (Standard and Contour Seat) ..................................49
6.13.4 Standard and Contour Seat: Replacing the Seat Plate .........................................49
6.13.5 Standard and Contour Seat: Replacing the Seat Frame ......................................50
6.13.6 Standard seat and contour seat: Adjusting the seat depth .................................. 51
6.13.7 Standard seat and contour seat: Adjusting the seat height .................................52
6.13.8 Standard seat and contour seat: Adjusting the seat angle ..................................52
6.13.9 Seat Brackets.........................................................................................................54
6.13.10 Removing the Side Panel .....................................................................................59
6.13.11 Adjusting / Replacing the Arm Rest .....................................................................59
6.13.12 Adjusting / Replacing the Clothing Protector ......................................................60
6.13.13 Standard and Contour Seat: Replacing /
Adjusting the Side Panel Attachment Device ...................................................... 61
6.13.14 Retrotting the Four-Way Chest Strap (Option for Recaro® Seat Only) ...............62
6.13.15 Lap Belt .................................................................................................................63
6.13.16 Retrotting the arm strap .....................................................................................64
6.13.17 Installing the Contour Seat (Optional) .................................................................65
6.13.18 Installing the Recaro® Seat (Optional) .................................................................65
6.13.19 Adapting / Replacing the Footrests .....................................................................68
6.13.20 Removing the Footrest Connecting Tube ............................................................68
6.13.21 Removing the Footrest Including Adapter ...........................................................69
6.14 Electric Seat Functions .......................................................................................70
6.14.1 Retrotting the Electric Seat Tilt (Optional) ........................................................... 70
6.14.2 Retrotting the Electric Back Angle Adjustment (Optional) ..................................72
6.14.3 Retrotting the Seat Height Adjustment Function (Optional) ...............................73
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6.14.4 Retrotting the Seat Module .................................................................................. 74
6.14.5 Removing the Seat Tilt Actuator ............................................................................ 75
6.14.6 Removing the Back Angle Adjustment Actuator ...................................................76
6.14.7 Removing the Seat Height Adjustment Actuator ...................................................77
6.15 Replacing the Side Tube .....................................................................................78
6.16 Removing the Drive Motor ..................................................................................78
6.17 Removing the Drive Axle .....................................................................................80
6.18 Replacing the Steering Axle / Drive Axle Rubber Oscillating Crank Mount .......81
6.19 Replacing / Retrotting Control Elements .........................................................83
6.19.1 Mounting an LCD Monitor .......................................................................................83
6.19.2 Replacing the Control Panel ..................................................................................85
6.19.3 Replacing the Control Panel Holder ......................................................................85
6.19.4 Retrotting the Detachable and Swing-Away Control Panel .................................86
6.19.5 Retrotting the Height-Adjustable Control Panel Holder ......................................87
6.19.6 Retrotting Attendant Controls ..............................................................................88
6.19.7 Installing joystick accessories ...............................................................................89
6.20 Push Button Module ...........................................................................................90
6.20.1 Installing the Push Button Module ........................................................................90
6.20.2 Preparing the Push Button Module (Attaching Icons) ..........................................90
6.20.3 Turning Switches On / Off ..................................................................................... 91
6.20.4 Installing the Push Button Module ........................................................................93
6.20.5 Connecting External Switches ..............................................................................94
6.21 Accessories ........................................................................................................95
6.21.1 Retrotting the Headrest Adapter and Installation Kit ..........................................95
6.21.2 Retrotting the Signal Panel Installation Kit ..........................................................96
6.21.3 Retrotting the Rear View Mirror ...........................................................................96
6.21.4 Other Optional Add-On Components ....................................................................97
7.1 Troubleshooting Steps ..........................................................................................98
8.1 Overview .............................................................................................................100
8.2 Controller ........................................................................................................... 101
8.2.1 Wiring the Controller .............................................................................................. 102
8.2.2 Technical Data, Connections.................................................................................103
8.2.3 Actuator Outputs ................................................................................................... 103
8.3 Seat module .......................................................................................................104
8.3.1 Wiring the Seat Module ..........................................................................................105
8.3.2 Electrical Specications ........................................................................................106
8.4 Programming Devices ........................................................................................ 107
8.4.1 Handheld Programming Device ............................................................................. 107
8.4.2 PC Programming Station (PCPS) ..........................................................................109
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8.5 Programmable Parameters ................................................................................109
8.5.1 Main Parameters .................................................................................................... 110
8.5.2 "Driving" Parameter Settings ................................................................................ 114
8.5.3 “Joystick” Parameter Settings ............................................................................... 119
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1.1 Preface
These service instructions describe all regular maintenance tasks as well as repair and re-
placement tasks for the C2000 power wheelchair from Otto Bock. They include all information
required by authorised personnel to correct functional and mechanical defects on components
of the power wheelchair.
The information in these service instructions is essential in order to work on the power wheelchair
correctly and safely. This is why this document, in particular the section “Safety Instructions”,
must be read carefully by all persons working on the power wheelchair. This will ensure that all
features of the power wheelchair can be utilised to their full advantage.
The service instructions were prepared based on the DIN EN 62079 standard “Preparation of
Instructions - Structuring, Content, and Presentation”. They are divided into 9 sections
The service instructions also contain cross references that make them easier to use, e.g. "see
Section 6.2".
1.2 Support
Your national Otto Bock team will be pleased to answer your technical questions. Contact ad-
dresses and telephone numbers are listed on the last two pages of this manual.
2.1 Symbol Legend
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 General Safety Instructions
Regular maintenance is important. It increases safety and prolongs the service life of the product.
Packaging materials must be kept out of reach of children.
All safety instructions contained in these service instructions and all other applicable documents must
be observed and complied with. The instructions must be available to personnel entrusted with serv-
ice work at all times.
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NOTICE
Service and maintenance tasks may only be completed
by properly trained authorised personnel. Use only original spare parts and the original options from
the manufacturer for all service and maintenance tasks.
NOTICE
Otto Bock recommends
having the power wheelchair inspected and maintained for functionality and operational safety by au-
thorised personnel at least 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.
NOTICE
Knowledge of the
service instructions and the instructions for use is essential for proper service.
The service and maintenance instructions must be read carefully before commencing work. The serv-
ice instructions apply in conjunction with the instructions for use and the spare parts catalogue. All
documents must be used together.
NOTICE
The power wheelchair 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 power wheelchair is 160
kg or 200 kg depending on the standard version. As an option, the power wheelchair can be retrot-
ted to a maximum load capacity of 260 kg.
Only use original options supplied by the manufacturer. The optional components may only be mounted
as described here. Failure to comply will void the warranty.
Familiarize yourself with the functions of the product. If you are not familiar with the product, read the
instructions for use prior to inspection. The instructions for use are available from the manufacturer
(see overview of all Otto Bock subsidiaries under “Otto Bock Worldwide”). Additional documentation
can be downloaded from the Otto Bock homepage at www.ottobock.de or www.ottobock.com.
2.3 Safety Requirements for the Use of Tools and Aids
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. In the use of tools and supplies, also consider the ergonomic
relationships between the place of work, tools and supplies, workplace organisation, workow and
tasks; this is particularly important in regards to posture during the use of tools and supplies.
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Ensure legally prescribed pro-
tective 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 power wheelchair is centred on the platform and no parts
project into the danger area.
Hazardous materials may only be kept at the place of work in the
quantities required for ongoing tasks. Regularly and safely remove waste and residue. Clean up spilled
substances immediately.
2.4 Safety Requirements for Service and Maintenance Tasks
When activating the xture to
adjust the seat height, back angle and seat tilt, there are pinch and shear points in the area between
the seat frame and wheelchair frame due to the construction. Inform all attendants about this. In order
to prevent injuries, ensure that body parts such as the hands and feet are always kept out of the dan-
ger zone, that no interfering objects such as clothing or obstacles are in the danger zone and that no
unauthorised persons are present there.
Screw and plug con-
nections must be loosened for all adjustment work and when folding the back rest for transportation.
This can cause uncontrolled movements of wheelchair components. Especially the backrest can fold
to the front or rear when removing the cotter pin (double spring cotter) from the backrest. To avoid in-
juries at pinch and shear points, carry out such tasks with the support of another person. Make sure
to always keep parts of the body (e. g. hands or head) out of the danger zone.
• The seat height adjustment function may only be used on a level surface.
•
When using the seat height adjustment function, no unauthorised persons may be present in the
danger zone.
• There must not be any interfering objects or obstacles in the adjustment range.
• All attendants must be informed that there are pinch points caused by the construction in the area
between the seat frame and wheelchair frame.
• Users and attendants must not reach into the danger area.
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All repairs and adjustments to the wheel lock may only
be made by personnel that has been authorised by Otto Bock. Incorrect settings can lead to a loss of
brake functionality, and therefore to serious bodily injuries and even death.
Note that there is no braking functionality when the wheel lock is unlocked. The wheel lock must only
be unlocked in hazardous situations and for maintenance or repairs. The corresponding force required
for acceleration and deceleration must come solely from the person pushing.
Once push mode is no longer needed, the wheel lock release lever must be locked immediately.
Ensure limbs are not in the dan-
ger area when ipping the footplates up or down.
When screw connections with thread locks
are loosened, they must be equipped with new thread locks or secured with a medium-strength liquid
thread lock compound (e.g. Loctite 241®).
After the power wheelchair has been set and adjusted, the attachment screws and/or nuts must be
rmly retightened. Observe the applicable torque specications.
NOTICE
• The power wheelchair must be turned off and the fuse must be removed for all maintenance tasks.
This does not apply to functional tests of the electrical components.
• Secure the product to prevent it from tipping over or falling.
•
Some components of the power wheelchair, e. g. the batteries, frame, seat and motors, are very heavy.
Ensure lifting is done in an ergonomically correct manner or use hoisting devices of sufcient capacity.
• Clean / disinfect the product before you start the inspection. Consult the instructions for use regard-
ing product care or product-specic inspection information.
NOTICE
The power wheelchair can
be equipped with a seat height adjustment xture, electric back angle adjustment and electric seat tilt
function. The following particularities must be observed during operation:
• The seat function actuators are not intended for continuous use, but only for short-term limited op-
eration (10 % use, 90 % idle time). At maximum load capacity, 10 seconds of operation should be
followed by 90 seconds of idle time. The electric seat functions are considered independently of the
driving function for this purpose.
• The maximum load capacity of the seat with seat height adjustment function is 130 or 200 kg.
• The seat height adjustment function may not be operated in case of errors or malfunctions.
• If creep speed is not automatically activated when the seat height adjustment function is operated,
an error has occurred. This problem must be corrected promptly by personnel authorised and trained
by Otto Bock. The power wheelchair may only be used with the seat height adjustment in its lowest
position until the fault is repaired.
NOTICE
When raising the power wheelchair, e.g. with a jack,
secure it against slipping and tipping sideways by using a suitable block under the drive unit sustainer.
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NOTICE
During any work on the seat, the padding must be adequately pro-
tected against mechanical and chemical damage. The seat and backrest cushions are ame retardant
but nevertheless ammable. They must not come into contact with open ame or embers.
NOTICE
The power
wheelchair 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 motors
under any circumstances. Check the operating performance of the power wheelchair after cleaning.
Prior to using the power wheelchair, all the necessary mechanical adaptations (e. g. mounting special
controls) and software settings (e. g. programming the control unit) must be made to comply with the
individual requirements and abilities of the user. Settings may only be made by personnel that has been
authorised and trained by Otto Bock.
The tyres of the power wheelchair contain chemical substances that can react with other chemical
substances (such as cleaning agents, acids, etc.).
Piston rods do not require lubrication. They are maintenance-free.
2.5 Safety Requirements for Maintenance Tasks on Electrical Components
Explosive gases can develop while the batteries are charging.
The following safety instructions must be followed under all circumstances:
• Ensure sufcient ventilation when charging the batteries in an enclosed room.
• Smoking and open ames are not permitted.
• Sparks must be avoided.
• The air vents in the trim must not be covered.
• Only use a battery charger supplied by Otto Bock which has been tested and approved for the re-
spective batteries used by Otto Bock (observe information on the charger). Failure to do so can result
in a battery explosion and possible impairment of health due to contact with battery acid.
• Smoking and open ame are prohibited while working on the battery. Sparks must be avoided.
• Explosive gases can develop while the batteries are charging. Observe the safety instructions pro-
vided by the battery manufacturer. Wear protective goggles. Ensure sufcient ventilation when charg-
ing the batteries in an enclosed room.
• The air vents in the trim must not be covered.
•
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.
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The fuse must always be removed for any mainte-
nance work where the battery cover is open.
The weight of a battery is approximately . When
removing or installing the batteries, use hoisting devices of sufcient capacity or complete these tasks
with the support of a helper.
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.
• Water must not come into direct contact with the electronics or battery during maintenance tasks.
• When attaching plug connections on the controller, ensure the contacts are assigned correctly.
NOTICE
Hoisting devices used for transportation must have a sufcient
capacity. Secure the batteries against falling.
NOTICE
• Always remove the main fuse before doing any work on the batteries. In order to prevent short cir-
cuits, always use insulated tools.
• Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery
damage.
• Ensure correct polarity is used when connecting the batteries. The black cable must be connected
to the negative pole and the red cable to the positive pole.
NOTICE
Prevent overheating of the charger during the charging proc-
ess. Ensure that the cooling ribs on the back of the device are not covered.
For the purpose of shipping or when the C2000 power wheelchair is not being used for an extended
period of time, remove the fuse
from the battery case in order to prevent deep discharge of the batteries due to standby current.
The power wheelchair has been tested according to EMC regulations. The following particularities
must be observed when using the wheelchair:
• The driving characteristics of the power wheelchair can be affected by electromagnetic elds (mo-
bile phones or other radiating devices). Therefore all mobile devices must be turned off when driving.
• The power wheelchair can generate electromagnetic elds that can cause interference with other
devices. Therefore, turn off the control unit whenever you do not need it.
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2.6 Safety functions
In dangerous situations, the power wheelchair can be turned off at any time using the on/off button.
When the button is pressed, the power wheelchair brakes immediately and the electric functions will
be stopped.
Malfunctions such as an insufcient supply of power to the wheel lock are recognised by the software,
triggering the emergency stop brake or reducing the speed of the power wheelchair. At the same time,
a warning signal will be emitted.
2.7 Safety Instructions for Controller Conguration
Modied parameter settings in
the conguration can lead to changes in driving characteristics. In particular, changes to the speed,
acceleration, braking or joystick settings can lead to unexpected and therefore uncontrollable operat-
ing performance with a risk of accidents. Always test the driving characteristics of the power wheel-
chair after conguration / programming is complete. Programming must only be completed by author-
ised personnel. Neither Otto Bock nor the control unit manufacturer are liable for damages (especially
in combination with special controls) caused by programming that was not properly / professionally
adapted to the abilities of the wheelchair user.
2.8 Safety Requirements for Disposal
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.
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The following environmental conditions apply to transportation and storage:
Ambient temperature -40 °C to +65 °C
3.1 Transportation
Secure the power wheelchair during transportation in
another vehicle by tightening the tensioning straps properly. Only attach the tensioning straps to the
corresponding eyebolts and mounting points.
Ensure limbs are not in the dan-
ger area when ipping the footplates up or down.
NOTICE
The maximum net weight of the power wheelchair is . Hoisting
and transportation devices used for transportation must have a sufcient capacity.
The eyebolts on the drive and steering ends of the power wheelchair serve as mounting points
for tensioning straps. Attachment to the spokes on the rims is not permitted! Before transport-
ing the power wheelchair, switch off the control unit and engage the wheel lock.
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1. Flip up the footrests.
2. Remove the side panels (see Section 6.13.10).
3. Fold down the back rest (see Section 3.1.2).
1. Remove the side panels (see Section 6.13.10).
2. Pull the release strap to the rear.
3. Fold the back rest forward by hand and lay it down onto the seat bottom.
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1. Remove the side panels (see Section 6.13.10).
2. Push up the lever and release the cross bolt at the lower end of the drive unit.
3. Remove the cross bolt from the holder.
4. Fold the back rest forward and lay it down onto the seat bottom.
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3.2 Storage
If the power wheelchair is not moved for several days, permanent colour changes may occur where
the wheelchair comes into contact with the surface it is standing on. A suitable mat should be used
when parking the wheelchair for extended periods of time.
Tyres contain chemical substances that can react to other chemical substances (such as cleaning
agents, acids, etc.).
Black tyres contain soot particles. They can leave black traces on the ground. For this reason, Otto
Bock recommends choosing grey tyres when using the power wheelchair mainly indoors.
Direct sunlight/UV light causes the tyres to age prematurely. As a result, the tread surface hardens
and corner pieces break out of the tread.
Avoid parking the wheelchair outdoors whenever possible. Regardless of wear and tear, replace the
tyres every .
Remove the fuse for shipping or when the power wheelchair is not being used for an extended period
of time.
The power wheelchair must be stored in an enclosed area. Remove the main fuse; otherwise,
there is a risk of deep discharge.
The storage location must be dry and have sufcient air circulation. There must not be any build-
up of humidity. The power wheelchair must not be subjected to any damaging exterior inuences,
e.g. rain, snow, or strong solar radiation during storage.
Otto Bock recommends storing the 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 frost. Regularly rotating the wheels helps to prevent at spots.
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Suitable tools and aids for the completion of service tasks are listed below:
❒Flat screwdrivers, blade widths: 2.5/3.5/5.5 mm
❒Phillips head screwdriver, size 2 mm
❒Reversible ratchet handle wrench and sockets, sizes 8 – 20 mm
❒Ring or open-end wrenches, size 8 – 24 mm
❒Allen wrenches, sizes 2 – 8 mm
❒Torque wrench
❒Socket, size 19 mm
❒Puller
❒Pin punch, Ø 3 mm
❒Plastic hammer
❒Hand drill
❒4 mm drill bit
❒Tyre lever
❒Plastic tyre mounting lever
❒Inner tube repair kit
❒Side cutting pliers
❒Circlip pliers
❒Water pump pliers, gripping width up to 32 mm
❒Liquid thread lock “medium strength”
❒Handheld Programming Device
❒Battery charger
❒Hoisting devices of sufcient capacity
❒Jack
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For information on the display of errors with the help of the control panel display / LCD monitor or with
the help of the handheld programming device / PC software, please see Section 7 and 8.
Messages are shown on the control panel display or LCD monitor:
Driving menu with speed level and battery capacity
Low battery capacity
Charging process with drive stop
Electric back adjustment
Electric seat tilt
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–Coupled electric seat adjustment
(back rest and seat tilt)
–Special functions, e.g. coupled electric seat ‘
adjustment (back adjustment and seat tilt)
Seat height adjustment
Electric footrests, coupled
Electric footrest, left
Electric footrest, right
Drive-away lock
Creep speed
Attendant control
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6.1 Inspecting the General Condition
❒Check all safety-related components for corrosion, repair if required and reapply corro-
sion protection.
❒Check weld seams.
❒Check tightness of screw connections; replace thread-locking compound if required; ob-
serve any dened torque specications; replace defective screws (e. g. in case of corro-
sion).
❒Check cables for ruptures, signs of wear and proper attachment; replace defective com-
ponents.
❒Check cable connections and plug connections.
6.2 Fuse Replacement
The 100 A fuse is located in a fuse housing on the side of the drive unit sustainer next to the
charging receptacle.
❒Turn the control unit off.
1. Open the hinged cover of the fuse housing.
2. Pull out the fuse and replace if required.
Properly reassemble all components upon completion of the work.
2
1
1 Fuse housing with open cover
2 Fuse
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4
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