Otto Bock B 500 Service Instructions Manual

Brand: Otto Bock

Model: B 500

Type: Service Instructions Manual

Q U A L I T Y F O R L I F E

Service Instructions

Electric wheelchair B500

Page 1

Service Instructions B500

Table of contents

4.1 Foreword................................................................................................. 2

4.2 Safety ...................................................................................................... 2

4.3 Maintenance schedule and tools needed ............................................... 3

4.4 Settings/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

Table of contents

Page 2 Service Instructions B500

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

be opened.

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 Lock A24.20).

- 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

Page 3

Service Instructions B500

Maintenance schedule

4.3 Maintenance schedule and tools needed

The following list contains appropriate tools and auxiliary devices.

Reversible ratchet and

socket wrench inserts,

sizes 8 - 19

Wrench

sizes 8 - 24

Hexagonal

screw driver

sizes 2.5 - 8

Screwdriver

blade width

2.5; 3.5 and 5.5 mm

Crosstip screwdriver

size 2

Plastic hammer Hammer approx. 300 g

Water pump pliers

DIN 8976

grip width up to 32 mm

Diagonal cutter

Pin punch

Ø 3 mm

Page 4 Service Instructions B500

Maintenance schedule and tools needed

Drilling machine

Twist drill

Ø 4 mm

Ø 5 mm

Ø 6 mm

Carpet cutter

with a crescent-shaped

blade

Liquid

“medium strength“ thread

lock compound

Brush and

standard grease

Page 5

Service Instructions B500

Maintenance schedule and tools needed

Maintenance schedule

for yearly inspection B500

Component

o ElectronicsControl unit o Fluid level

o Battery box

o Cabling

o Suspension

o Drive support

o Motor

o Rockers

o Brake release

o Tilting protection

o Cabling

Lateral elements

Control unit accessories

Accessories

Foot notch

Seat system options

Recaro seat system

Standard seat

Drive wheels

Front wheels

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)

Servicing performed by: dated:

Page 6 Service Instructions B500

Settings/substitution/replacement

Programming and Fault Finding

When making any control settings, please refer to

the operating instructions of Penny & Giles.

These instructions include an extensive description

of all steps and notices regarding the control

system.

Refitting or replacing the control for lighting

and/or escort control

The following is required to refit the wheelchair for

lighting or escort control:

- Operator panel for lighting

- Lighting module

- Lighting

- Y cable if for lighting and

escort control

Replacing the control system:

Removal:

- Loosen the control cable

- Undo both screw connections below

the control unit

- Remove the control unit

Installation:

- Fasten the control unit using both

screw connections

- Plug in the control cable

Fastening the escort control

Use the parts 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

- Insert both head rest tubes through the

bushings of the escort control

(see figure to 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

Page 7

Service Instructions B500

Settings/substitution/replacement

Read the cautions supplied by the battery manufacturer before starting any work on the batteries!

4.4.1.2 Battery

Battery

The B500 standard version is equipped with two

12 V lead-acid batteries with a capacity of 60 Ah.

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:

- Open the Velcro fastening of seat cushion

back and seat section, fold the seating

surface forward

- Open the catch lock at the rear end of the

battery case, and remove the cover (for

Recaro seats: open the seat lock under the

seat, and remove the cover)

For the version with spring-mounted rear wheels,

pull the lock at the rear wheelchair bottom, and

pull out the drawer with the batteries (see figure to

the left).

Charging the battery

- Connect the charger to the charge socket

at the operator panel

- Connect the charger to 230 V

The charging process will start automatically while

the LED’s are displaying the current charge status.

An incrementing LED display indicates the charg-

ing process at the operator panel:

- yellow LED lights up = battery charging

- green LED lights up = battery charged

- yellow LED flashes = fault, battery defective,

Connection insufficient...

- No LED indication = No mains voltage,

Battery charger defective

The charger has a programmed recharge phase.

You can leave the device connected without any

problems even when a full charge level is reached

although you have been charging a completely

discharged battery for 8 hours, approximately.

When charging is complete, first pull out the mains

plug, then pull out the charging plug. The B500 is

ready to operate after switching the control off and

on again.

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.

Page 8 Service Instructions B500

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

For battery removal or installation, take off the seat

as described in section 4.4.1.8, or pull out the

battery case from the spring-mounted version.

Removal:

- Open the strap catch lock, and remove the

cover

- Remove the fuse

- Disconnect the batteries, and remove them

from the battery case

Installation:

- Place the batteries into the battery case,

and connect the batteries

- Insert the fuse

- Install the cover, and close the strap catch

lock

Replacing or removing the battery case

To replace or remove the battery case:

- Dismount the seat; for the spring-mounted

version, you only need to pull out the drawer

- Open the strap as described above

- Remove the batteries, and dismount the

battery case.

Page 9

Service Instructions B500

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.

-Remove the black plastic protector cap

- Use a size 19 socket and a ratchet to

unscrew and remove the front-wheel fork

- Use a suitable device to protect the wheel-

chair against overturning

- Use an Allen wrench to remove the seat:

Undo all screw connections

(four rear and two front screw connections)

which are used to secure the seat lugs to

the frame

- Unscrew all other parts fastened to the frame

(e.g., lamps and brake release)

- Remove the frame

4.4.1.3 Frame

Page 10 Service Instructions B500

Replacing or removing the drive bracket

- Turn off the B500, and pull out all plug

connections before dismounting the drive

bracket

- Undo the eight screw connections located at

the rear frame (four per side)

- Remove frame, seat, and lamps

- Remove the battery case

- Undo the two hexagon socket screws at the

drive bracket to remove the bumper (if any)

- Unscrew two screws each to dismount the

tilting protections

- Remove the tires (see section on „Replacing

the tires“)

- Pull off the wheel flanges

- Undo the brake release wires

- Unscrew the four screw connections used to

fasten the motors

Replacing or removing the rear-wheel springs

The rear-wheel springs are suspended at two

points: One point is at the top of the drive bracket

and the other on the rocker.

The rear wheels need to be dismounted before you

can remove the springs:

- Secure the B500 against slipping or overturn-

ing, and place the B500 on a support which

enables the rear wheels to rotate freely

- Dismount the wheels

- Undo the two screws used to suspend the

rear-wheel springs, and remove the rear-wheel

springs

- Install new rear-wheel springs, or change the

spring effect (turning the top plate either

down or up)

Settings/substitution/replacement

Page 11

Service Instructions B500

Removing or installing the rockers

The rear wheel rockers are fastened to the drive

bracket and rotate freely. The wheels, the rear-

wheel springs, and the motors need to be removed

before the rockers can be dismounted.

- Use a size 20 socket to unscrew and replace

the rockers

- Install the spring in one of the three rear

rocker boreholes

- Suspend the spring at the top in the last drive

bracket borehole

Installing or replacing the tilting protection

The B500 tilting protections can only be used in

pairs (one left, one right).

Use two carriage bolts to secure the tilting protec-

tions to the drive bracket (see arrow). Use an

open-end or ring spanner to either unscrew or

tighten the nuts.

Settings/substitution/replacement

Page 12 Service Instructions B500

4.4.1.4 Motors

Replacing or removing the motors

- Turn off the B500 before starting any work on

the motors

- Remove frame and seat

(refer to the sections on „Replacing or remov-

ing the frame“, and „Replacing or removing

the drive bracket“)

- Undo the brake release wire before removing

the frame (to protect the mechanism against

damage or misadjusting)

- Undo the plug-and-socket connections of the

motors

- Undo the plug-and-socket connections to the

battery case, and remove the battery case

- Unscrew the four 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

undo the brake release

Removal:

- Use a screwdriver 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

- Tighten the Bowden cables which lead to the

motors using a screwdriver

Settings/substitution/replacement

Page 13

Service Instructions B500

Replacing or removing defective incandescent

lamps

Head lamp:

- Unscrew the lower screw at the head lamp

(see arrow)

- Pull off the front section, and replace the

defective lamp

Flashing light:

- Insert the screwdriver into the opening from

below, and loosen the screw with a quarter

turn

- Replace the incandescent lamp

Rear light:

- Undo the two screws to remove the cover

see arrows)

- Apply slight pressure to the right to pull

forward the incandescent lamp on the

left-hand side

- Replace the incandescent lamp

Mounting the complete light system

A new operator panel is needed to convert the

B500 for lighting. This operator panel has additional

buttons, display functions, and connecting ports.

A light module to be screwed under the seat is

supplied together with the complete light system.

- Insert the additional plug of the light operator

panel into the centre port of the light module

- Insert the light plugs into the left port or,

correspondingly, into the right port

- 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

plugs to the front of the frame crossbar

- 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

Cross bar

Settings/substitution/replacement

Page 14 Service Instructions B500

Installing and removing the light module

The light module is fastened by two screws to the

cross strut located under the seat (see arrows).

Turn off the B500, and undo all plug-and-socket

connections before starting any work on the light

module.

Settings/substitution/replacement

Page 15

Service Instructions B500

Settings/substitution/replacement

4.4.1.6 Front wheels

Replacing and removing the handlebar fork

Removal:

- Remove the black plastic dust protection cap

at the top of the handlebar fork retainer using

a screwdriver

- 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

- Unscrew and remove both hexagon socket

screws (M10x25)

- Establish the connection between spring fork

and edge mounting aid: Install the thrust plate

between spring fork and edge mounting aid,

hen screw in the threaded bolts

- Fasten the spring mounting with the leg

spring: Make certain that the inside leg of the

spring is located between fork and threaded

bush

- Secure the screw connection using „Loctite“,

and tighten the screws

Replacing or removing the springs

To replace the front-wheel fork springs, undo the

screw located in the spring. The spring effect is

modified by strongly tightening the screw.

Page 16 Service Instructions B500

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

spring will fall out below)

Installation:

- Slip the spring on the thin bolt end, and insert

spring and bolt from below 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

secure the front frame part against overturning

or slipping.

The wheel must rotate freely.

- Use two size 5 Allen wrenches to remove

or install the handlebar

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:

- Deflate the tire

- Unscrew all screws using an Allen key

The B600 has a divisible rim.

- Loosen the screws, separate the rim, and

replace either the inner tube or the outer

cover

- Replace the tube, or repair it using a com-

mercially available bicycle tire repair set

Page 17

Service Instructions B500

Settings/substitution/replacement

Installation:

- Insert the inner tube into the outer cover

- Fit the rim together, and all screws using

an Allen key

- Inflate the tire

Page 18 Service Instructions B500

Settings/substitution/replacement

4.4.1.7 Rear wheels

Replacing or removing the rear wheels

- Use suitable objects, e.g., wood blocks to

secure the rear frame part against overturning

or slipping.

The wheel must rotate freely.

Removal:

- Use a crosstip screwdriver to unscrew the

protection cap screwed to the rim

- Use a size 5 Allen wrench to unscrew all four

screws which hold the wheel, and remove

the wheel

Installation:

- Mount the wheel and tighten all four screws

using a size 5 Allen wrench

- Screw the protection cap to the rim using

a crosstip screwdriver

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“.

Page 19

Service Instructions B500

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

- Remove the back covering completely, 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): one narrow, one wide, two narrow, and

one wide Velcro strips

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Otto Bock B 500 Service Instructions Manual

Otto Bock B 500 Service Instructions Manual

Otto Bock B 500 Service Instructions Manual

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