Otto B500 User manual




3


Table of Contents Page
 
1.1 Foreword .................................................................................................................6
1.2 Intended Use ..........................................................................................................6
 
2.1 Explanation of Symbols ..........................................................................................7
2.2 Standards and Directives .......................................................................................7
2.3 General Safety Instructions ...................................................................................7
2.4 Safety Instructions for the Use of Tools and Accessories .....................................8
2.5 Safety Instructions for Maintenance Tasks ............................................................9
2.6 Safety Instructions for Maintenance Tasks on Electrical Components ...............10
2.7 Safety Instructions for Disposal ........................................................................... 11
2.8 Safety Instructions for Controller Conguration .................................................. 11
 
3.1 Transportation ...................................................................................................... 12
3.2 Storage .................................................................................................................13
 
 
5.1 Information Messages ..........................................................................................15
5.2 Error Messages .................................................................................................... 16
 
6.1 Verication of General Condition ......................................................................... 17
6.2 Fuse Replacement ............................................................................................... 17
6.3 Batteries ...............................................................................................................18
6.3.1 Checking and Topping Up the Fluid Level (Only for Lead-Acid Batteries) ............. 19
6.3.2 Charging Batteries .................................................................................................20
6.3.3 Replacing Batteries ................................................................................................22
6.3.4 Removing the Battery Case ....................................................................................22
6.3.5 Reinstalling the Battery Cable ................................................................................23
6.3.6 Installing New Battery Vent Hoses (Only for Lead-Acid Batteries) ........................23
6.4 Replacing the Controller ......................................................................................24
6.5 Side Panels ..........................................................................................................25
6.5.1 Adapting / Replacing Side Panels ..........................................................................25
6.5.2 Replacing Clothing Protectors ................................................................................27
6.5.3 Retrotting Arm Straps ...........................................................................................27
6.6 Footrests ..............................................................................................................28

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6.6.1 Adapting / Replacing Footrests ..............................................................................28
6.6.2 Replacing the Footplate.......................................................................................... 31
6.7 Wheels ..................................................................................................................32
6.7.1 Verication of General Condition ............................................................................32
6.7.2 Replacing the Casing or Tube for Pneumatic Tyres................................................32
6.7.3 Replacing the Drive Wheel ......................................................................................33
6.7.4 Replacing the Wheel Flange ...................................................................................34
6.7.5 Removing the Drive Wheel Spring or Changing the Coefcient .............................35
6.7.6 Installing the Drive Wheel Splash Guard (Option) ..................................................36
6.7.7 Replacing the Steering Caster ................................................................................36
6.7.8 Replacing the Caster Fork / Installing the Curb Climbing Assist or Caster Spring 37
6.7.9 Installing the Caster Swivel Lock (Option, B500 Only) ...........................................39
6.7.10 Installing the Splash Guard for the Caster Fork (Option) .....................................39
6.8 Wheel Lock and Wheel Lock Release ..................................................................40
6.8.1 Replacing the Wheel Lock Release ........................................................................40
6.8.2 Setting / Adjusting the Wheel Lock Release .......................................................... 41
6.8.3 Wheel Lock Settings ...............................................................................................42
6.8.4 Functional Test of Wheel Lock Settings .................................................................42
6.9 Lighting .................................................................................................................43
6.9.1 Retrotting the Lighting ...........................................................................................43
6.9.2 Replacing Defective Lamps ....................................................................................44
6.10 Seats ...................................................................................................................46
6.10.1 Replacing the Bearing Plate ..................................................................................46
6.10.2 Standard Seat: Replacing / Adjusting the Back Upholstery ................................ 47
6.10.3 Standard Seat: Replacing the Seat Frame ...........................................................48
6.10.4 Standard Seat: Replacing the Seat Plate .............................................................48
6.10.5 Standard Seat: Changing the Seat Height ...........................................................49
6.10.6 Standard Seat: Adjusting the Seat Angle .............................................................50
6.10.7 Standard Seat: Replacing / Adjusting the Side Panel Attachment Device ..........50
6.10.8 Installing the Contour Seat (Option) ..................................................................... 51
6.10.9 Recaro® Seat: Replacing the Mobility Base ..........................................................52
6.10.10 Recaro® Seat: Replacing the Seat Attachment Device ......................................52
6.10.11 Recaro® Seat: Retrotting Seat Modules (Option) ..............................................53
6.11 Seating System Options .....................................................................................53
6.11.1 Installing / Replacing the Abductor (Option) .........................................................53
6.11.2 Installing the Headrest Installation Kit (Option) ....................................................54
6.11.3 Installing / Retrotting the Four-way Chest Strap
(Option for Recaro® Seat Only) ............................................................................. 55
6.11.4 Retrotting the Lap Belt (Option) ..........................................................................56
6.12 Mechanical Seat Function ..................................................................................56
6.12.1 Retrotting the Mechanical Seat Tilt .....................................................................56
6.12.2 Attaching the Bowden Cable ................................................................................57
6.12.3 Retrotting the Mechanical Back Angle Adjustment ............................................ 57
6.13 Electric Seat Functions .......................................................................................58

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6.13.1 Retrotting the Electric Seat Tilt (Option) .............................................................58
6.13.2 Retrotting the Electric Back Angle Adjustment (Option) ....................................60
6.13.3 Retrotting the Lift Seat (Option, B500-S Only) ................................................... 61
6.13.4 Retrotting Electric Footrests (Option) .................................................................62
6.14 Replacing the Frame...........................................................................................63
6.15 Replacing the Drive Unit Sustainer ....................................................................64
6.16 Replacing the Drive Motor ..................................................................................66
6.17 Installing the Anti-tipper .....................................................................................67
6.18 Replacing the Oscillating Crank .........................................................................67
6.19 Accessories ........................................................................................................68
6.19.1 Installing Joystick Accessories ..............................................................................68
6.19.2 Retrotting Rear View Mirrors ...............................................................................69
6.19.3 Retrotting Attendant Controls .............................................................................69
6.19.4 Replacing the Control Panel .................................................................................70
6.19.5 Replacing the Control Panel Holder .....................................................................70
6.19.6 Installing the Bumper Bar (B500 Only) ................................................................. 71
 
7.1 Overview ...............................................................................................................72
7.2 Installation and Wiring ..........................................................................................72
7.3 Programmable Parameters ..................................................................................73
7.3.1 “Conguration” Parameter ...................................................................................... 74
7.3.2 “MyChair” Parameter .............................................................................................. 75
7.3.3 Drive Menu .............................................................................................................. 76
7.3.4 Steer Menu .............................................................................................................. 77
7.3.5 Hand Controls Menu ...............................................................................................78
7.3.6 Speed Mode ............................................................................................................ 79
7.3.7 Joystick Menu ..........................................................................................................80
7.3.8 Sound and Display Menu ........................................................................................80
7.3.9 Charger Inhibit Menu .............................................................................................. 81
7.3.10 Seat Menu ............................................................................................................. 81
7.3.11 Lights Menu ...........................................................................................................82
7.3.12 Current Limits Menu ..............................................................................................82
7.3.13 Multi-Function Input 1 Menu ..................................................................................83
7.3.14 Multi-Function Input 2 Menu ..................................................................................83
7.3.15 Multi-Function Input 3 Menu ..................................................................................84
7.3.16 Compensation Menu .............................................................................................85
7.3.17 Motor and Brakes Menu ........................................................................................86
7.3.18 Custom Battery .....................................................................................................86
7.3.19 Monitor Menu .........................................................................................................87
7.4 Hand Programming Device ..................................................................................88
7.4.1 Operating the Hand Programming Device ..............................................................89
7.4.2 Hand Programming Device Menu ...........................................................................90
 

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 
1.1 Foreword
This service manual describes all regular maintenance tasks as well as repair and replacement
tasks for the B500/B500-S power wheelchair from Otto Bock. They include all information required
by dealers to correct functional and mechanical defects on components of the B500/B500-S.
The knowledge in this service manual is essential in order to work on the B500/B500-S cor-
rectly and safely. This is why this document, in particular the section “Safety Instructions”, must
be read carefully by all persons working on the B500/B500-S. This ensures the functionality of
the B500/B500-S is fully utilised.
1.2 Intended Use
The B500/B500-S power wheelchair is intended for indoor and outdoor individual self-transpor-
tation by persons with limited mobility. The B500/B500-S 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 B500/B500-S power wheelchair may only be used by properly trained persons. Training
is one of the prerequisites in order to protect against personal risks and in order to operate the
B500/B500-S power wheelchair safely and properly.

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 
2.1 Explanation of Symbols
 Warnings regarding possible risks of severe accident or injury.
 Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
 Additional information on the tting/use.
2.2 Standards and Directives
All safety information 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 B500/B500-S power wheelchair has been constructed in accordance with state-of-the-art
technology and is safe to operate. The safety of the B500/B500-S power wheelchair is conrmed
by the CE symbol and the declaration of conformity.
2.3 General Safety Instructions

Regular maintenance is important – it improves the safety and increases the lifespan of the product.

Packaging materials must be kept out of reach of children.
NOTICE
 Service and maintenance tasks may only be completed by pro-
perly trained authorised personnel. Use only original spare parts for all service and maintenance tasks.
NOTICE
 Otto Bock recommends having
the B500/B500-S power wheelchair inspected and maintained for functionality and operational safety
by authorised 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.

8
NOTICE
 Familiarity with the service
manual and instructions for use are essential for proper service.
The service and maintenance manual must be read carefully before commencing work. The service
manual applies in conjunction with the instructions for use and the spare parts catalogue. All docu-
ments must be used together.
All safety instructions contained in this service manual and in all further applicable documents are to be
observed and complied with. They must be available to service and maintenance personnel at all times.
NOTICE
 The B500/B500-S 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 B500/B500-S power wheelchair
is 140 kg. The maximum load capacity for the lift seat (only B500-S) is 130 kg in the standard version.

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 are available from
the manufacturer (see overview of all Otto Bock subsidiaries under “Otto Bock Worldwide”). Addi-
tional documentation can be downloaded from the Otto Bock homepage under www.ottobock.de or
www.ottobock.com.
2.4 Safety Instructions for the Use of Tools and Accessories

When completing the tasks, only use
tools that are suitable for the conditions at the place of work and for which safety and the protection
of health are assured with proper use.
Verify proper functionality before use. In the use of tools and supplies, also consider the ergonomic
relationships between the place of work, tools and supplies, workplace organisation, workow and
tasks; this is particularly important in regards to posture during the use of tools and supplies.

 Ensure legally prescribed
protective work clothing is worn.

When repair and maintenance tasks must be completed
under raised parts or equipment, ensure suitable precautions are taken to secure the applicable com-
ponents against falling. Equipment used to raise loads must prevent the load from accidentally shifting
in a dangerous manner, dropping in free fall or being accidentally released.
When using lifting platforms, ensure that the B500/B500-S power wheelchair is centred on the platform
and no parts such as the anti-tipper project into the danger area.

9

 Hazardous materials may only be kept at the place of work in
quantities required for ongoing tasks. Regularly and safely remove waste and residue. Clean up spilled
substances immediately.
2.5 Safety Instructions for Maintenance Tasks

 For design reasons, there are pinch points between the seat and
frame of the B500/B500-S. Special caution is required during all work on the corresponding components.

 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 from the person pushing.
Once push mode is no longer needed, the wheel lock release lever must be locked immediately.
NOTICE

• The B500/B500-S power wheelchair must be turned off and the fuse must be removed for all main-
tenance tasks. This does not apply to the functional tests of the electrical components.
• Secure the product to prevent it from tipping over or falling, e.g. off the workbench.
• Some components of the power wheelchair, e.g. the batteries, frame, seat and motors, are very
heavy. Hoisting devices of sufcient capacity must be used where applicable.
• Clean / disinfect the product before you start the inspection. See the instructions for use for care
instructions or specic product inspection information.
NOTICE
Unsecured screw connections can become loose
while using the product. Secure screws and nuts. The screw connections must be tightened properly
after all installation tasks. Dened torque specications must be followed.
The screws and nuts for many of the screw connections are equipped with thread lock. If such screw
connections are opened, the respective nuts / screws must be replaced with components with a new
thread lock. If new screws or nuts with thread lock are not available, use a medium-strength liquid
thread lock substance (such as Loctite 241 or Euro Lock A24.20).
NOTICE
 During any work on the seat, the upholstery must be adequately protected
against mechanical and chemical damage. The back rest and seat are ame retardant but nevertheless
ammable. They must not come into contact with open ame or embers.

10
NOTICE
 The B500/B500-S
may not be cleaned with a jet of water or a pressure washer under any circumstances. A cloth or sponge
may be used for cleaning. Water must not come into direct contact with the motor.
Check the operating performance of the B500/B500-S power wheelchair after cleaning.

The tyres of the B500/B500-S power wheelchair contain chemical substances that may react with
other chemical substances (e.g. cleaning agents, acids etc.).
2.6 Safety Instructions for Maintenance Tasks on Electrical Components
NOTICE

• If the driving function is not required, turn off the control unit or jack up the drive wheels in order to
prevent uncontrolled operation through accidental joystick activation.
• 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.

 Only use a battery charger supplied by Otto Bock which
has been tested and approved for the respective batteries 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 information provided
by the battery manufacturer. Wear protective goggles. Ensure sufcient ventilation when charging the
batteries in an enclosed room.
Drive batteries can supply very large amounts of energy and may arc if they are short-circuited. This is
why the battery must be disconnected prior to any work on the motor controls or wiring.
NOTICE
 In order to prevent short circuits, always use insulated tools when working
on the batteries.
Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery
damage.
Ensure correct polarity is used when connecting the batteries.
NOTICE
 Prevent overheating of the charger during the charging process.
Ensure that the cooling ribs on the back of the device are not covered.