ParaGolfer. Service Instructions

Transcription

1 ParaGolfer Service Instructions

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3 Service Instructions for the ParaGolfer Sports Wheelchair Table of Contents Page 1 General Information Preface Intended Use Safety Explanation of Symbols Standards and Directives General Safety Instructions Safety Requirements for the Use of Tools and Aids Safety Requirements for Service and Maintenance Tasks Safety Requirements for Maintenance Tasks on Electrical Components Safety Requirements for Disposal Transportation and Storage Transportation Storage Required Tools and Aids Information Display Service and Maintenance Inspecting the General Condition Battery Disconnect Switch Fuse Replacement Cover Removal Cover Plates Fan Removal Controller Removal Batteries Wheels Motor Removal Brakes and Brake Release Seat Replacing the Baggage Protection Options Diagnostics Diagnostic Steps Error Display on the Control Panel enable50 Wheelchair Control Installation and Programming Overview Controller Programming Devices Programmable Parameters Maintenance and Service Plan...66 ParaGolfer Ottobock 3

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5 General Information Safety 1 General Information 1.1 Preface These service instructions describe all regular maintenance tasks as well as repair and replacement tasks for the ParaGolfer sports wheelchair from Ottobock. They include all information required by dealers in order to correct functional and mechanical defects in components of the ParaGolfer. The information in these service instructions is essential in order to work on the ParaGolfer correctly and safely. This is why this document, in particular the section Safety Instructions, must be read carefully by all persons working on the ParaGolfer. This ensures the functionality of the ParaGolfer is fully utilised. 1.2 Intended Use The ParaGolfer is designed solely for persons who are unable to work or have a walking impediment for doing indoor or outdoor sports that require an upright body position. The ParaGolfer was specially designed for users who are able to independently move in a power wheelchair. 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 ParaGolfer 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 ParaGolfer safely and properly. 2 Safety 2.1 Explanation of Symbols WARNING Warnings regarding possible risks of severe accident or injury. CAUTION Warnings regarding possible risks of accident or injury. NOTICE Warnings regarding possible technical damage. Information Information regarding operation. Information for service personnel. 2.2 Standards and Directives All safety information contained in these service instructions 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 these service instructions, the BGV (Employer s Liability Insurance Association regulations), UVV (accident prevention regulations) and environmental protection regulations must be observed and complied with. All information contained in these service instructions must be complied with at all times without restrictions. The electrically operated ParaGolfer sports wheelchair has been constructed in accordance with state-of-the-art technology and is safe to operate. The safety of the ParaGolfer has been confirmed by CE certification and the declaration of conformity. ParaGolfer Ottobock 5

6 Safety 2.3 General Safety Instructions Information Regular maintenance is important. It increases safety and prolongs the service life of the product. CAUTION Risk of suffocation. Packaging materials must be kept out of reach of children. NOTICE Risk of damage due to unauthorised service. Service and maintenance tasks may only be completed by properly trained authorised personnel. Only original spare parts may be used for all service and maintenance tasks. NOTICE Risk of damage caused by failure to comply with maintenance intervals. Ottobock recommends having the ParaGolfer inspected and maintained for functionality and operational safety by authorised personnel at least once a year. NOTICE Risk of damage caused by failure to comply with the service documentation. 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 service instructions apply in conjunction with the instructions for use and the spare parts catalogue. All documents must be used together. All safety instructions contained in these service instructions and all other applicable documents must be observed and complied with. They must be available to service and maintenance personnel at all times. NOTICE Risk of damage due to excessive heat or cold. The ParaGolfer may only be operated in the temperature range from -25 C to +40 C (-13 F to 104 F). It must not be operated at temperatures outside this range. NOTICE Risk of damage caused by overload. The maximum load for the ParaGolfer is 140 kg (309 lbs). Information Familiarise 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 Ottobock subsidiaries under Ottobock Worldwide ). Additional documentation can be downloaded from the Ottobock homepage at or 6 Ottobock ParaGolfer

7 Safety 2.4 Safety Requirements for the Use of Tools and Aids CAUTION Risk of health impairment due to the use of incorrect tools. 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, workflow and tasks; this is particularly important in regards to posture during the use of tools and supplies. CAUTION Risk of health impairment due to the use of improper work clothing. Ensure legally prescribed protective work clothing is worn. CAUTION Risk of injury during tasks that involve lifting. When repair and maintenance tasks must be completed under raised parts or equipment, ensure suitable precautions are taken to secure the applicable components 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 ParaGolfer is centred on the platform and no parts project into the danger area. CAUTION Risk due to hazardous materials. 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. 2.5 Safety Requirements for Service and Maintenance Tasks WARNING Risk of pinching or crushing in the stand-up device range. When operating the stand-up device, there are pinch and shear points in the area between the seat frame and wheelchair frame caused by the construction. To avoid injuries, always make sure that no parts of the body, e. g. hands or feet, get into the danger zone, and that no interfering objects, e. g. clothing, or obstacles are within the danger zone. Special caution is required during all work on the corresponding components. CAUTION Hazards while working on the brake system. Note that there is no braking functionality when the brake is unlocked. The brake 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 brake release lever must be locked immediately. NOTICE Risk of damage caused by overload. The maximum load for the ParaGolfer is 140 kg (309 lbs). ParaGolfer Ottobock 7

8 Safety NOTICE Risk of damage due to improper preparation of maintenance tasks. The ParaGolfer 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, e.g. off the workbench. Some components of the ParaGolfer, e.g. the batteries, frame, seat and motors, are very heavy. Hoisting devices of sufficient capacity must be used where applicable. Clean / disinfect the product before you start the inspection. Consult the instructions for use regarding product care or product-specific inspection information. NOTICE Risk of damage due to unsecured screw connections. 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. Defined torque specifications must be followed. The screws and nuts for many of the screw connections are equipped with thread lock. If you have to undo such screw connections, the nuts or screws must be replaced with new ones equipped with thread lock. If new screws or nuts with thread lock are not available, apply a medium-strength liquid thread lock substance (such as Loctite 241 or Euro Lock A24.20) to the existing screws. NOTICE Risk of damage to the padding. During any work on the seat, the padding must be adequately protected against mechanical and chemical damage. The back rest and seat bottom are flame retardant but nevertheless flammable. They must not come into contact with open flame or embers. NOTICE Risk of damage due to improper cleaning after the completion of maintenance tasks. The Para- Golfer 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 ParaGolfer after cleaning. Information The tyres of the ParaGolfer contain chemical substances that can react with other chemical substances (such as cleaning agents, acids, etc.). NOTICE Risk of damage due to oil leaks. If gas compression springs are installed, watch for oil leaks on the piston rods. Leakages reduce the functional capabilities of the gas compression springs and result in their failure. Defective gas compression springs (e. g. scratches or damage to the piston rod caused by impact; deformation of the cylinder tube) must be replaced immediately. Information Piston rods do not require lubrication. They are maintenance-free. 8 Ottobock ParaGolfer

9 Safety 2.6 Safety Requirements for Maintenance Tasks on Electrical Components NOTICE Risk of damage due to improper preparation of maintenance tasks. 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. CAUTION Risk of injury while working on the battery Only use a battery charger supplied by Ottobock which has been tested and approved for the respective batteries by Ottobock (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 flame 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 sufficient 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. Therefore, always disconnect the batteries when working on the motor control or wiring. NOTICE Risk of battery damage. 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 Risk of damage to the battery charger. Prevent overheating of the charger during the charging process. Ensure that the cooling ribs on the back of the device are not covered. Information The ParaGolfer has been tested according to EMC regulations. The following particularities must be observed when using the wheelchair: The driving characteristics of the ParaGolfer can be affected by electromagnetic fields (mobile phones or other radiating devices). Therefore all mobile devices must be turned off when driving. The ParaGolfer can generate electromagnetic fields that can cause interference with other devices. Therefore, turn off the control unit whenever you do not need it. Information During extended periods of disuse or shipment of the ParaGolfer, remove the fuse from the battery case in order to prevent deep discharge of the batteries due to standby consumption. ParaGolfer Ottobock 9

10 Transportation and Storage 2.7 Safety Requirements for Disposal Information 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. 3 Transportation and Storage The following environmental conditions apply to transportation and storage: Ambient temperature -40 C to +65 C (-40 F to +149 F) 3.1 Transportation CAUTION Risk of injury due to insufficient restraints. Secure the power wheelchair during transportation in another vehicle by tightening the tensioning straps properly. NOTICE Risk of damage due to falling. The empty weight of the ParaGolfer is 180 kg (397 lbs). For transportation, only the designated carry handles may be used. Hoisting devices and transportation vehicles must have sufficient capacity. Before transporting the power wheelchair, switch off the control unit and engage the brake. 10 Ottobock ParaGolfer

11 Transportation and Storage Reducing the Transportation Size Steps: 1. Turn the control unit off. 2. Lock the brake. 3. Move the seat bottom into the lowest position. 4. Swivel the caster wheel under the cover. 5. Remove the lateral pads (see Section ). 6. Remove the seat cushion (see Section ). 7. Remove the armrests (see Section ). 8. Remove the back rest (see Section ). Fig. 1 Transportation size Applying the Tension Belts Steps: 1. Front section: Place two tension straps around the drive unit sustainer, one along the right motor and one along the left motor. 2. Rear section: Place one tension strap in each of the retainer bushes for the golf bag holder. 3. Connect the tension straps with defined mounting points in the transportation vehicle. 3.2 Storage Information 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. Ottobock therefore recommends parking the wheelchair on a suitable surface during extended periods of disuse. ParaGolfer Ottobock 11

12 Required Tools and Aids 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 sufficient air circulation. There must not be any buildup of humidity. The ParaGolfer must not be subjected to any damaging exterior influences, e.g. rain, snow, or strong solar radiation during storage. Ottobock recommends storing the ParaGolfer 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 flat spots. 4 Required Tools and Aids Suitable tools and aids for the completion of service tasks are listed below: Phillips screwdriver Ring or open-end wrenches, sizes 6, 8, 10, 19 Ratchet wrench with different bits Allen wrenches, sizes 2, 3, 4, 5, 6, 8 Tyre levers Side cutting pliers Circlip pliers Liquid thread lock medium strength Fig. 2 Tools 12 Ottobock ParaGolfer

13 Information Display Fig. 3 Handheld programming device 5 Information Display Information Please see Section 7 for information on the display of error messages using the control panel display. Messages are shown on the control panel display: Display symbol(s) Information Driving menu with speed level and battery capacity Low battery capacity Charging process with drive lock Stand-up device Drive-away lock Creep speed Table 1 Information displays ParaGolfer Ottobock 13

14 Service and Maintenance 6 Service and Maintenance 6.1 Inspecting the General Condition Check all safety-related components for corrosion, repair if required and reapply corrosion protection. Check weld seams. Check tightness of screw connections; replace thread-locking compound if required; observe any defined torque specifications; replace defective screws (e. g. in case of corrosion). Check cables for ruptures, signs of wear and proper attachment; replace defective cables. Check cable connections and plug connections. 6.2 Battery Disconnect Switch The ParaGolfer is equipped with a battery disconnect switch. This battery disconnect switch is located underneath the seat next to the fuse box. If you pull off the battery disconnect switch, the entire control of the ParaGolfer is blocked. To do so, turn the battery disconnect switch by 90 and then pull it off. 1 2 Fig. 4 Battery disconnect switch 1 Battery disconnect switch 2 Fuse box 6.3 Fuse Replacement The 120 A fuse is located in a small yellow housing with a hinged cover next to the battery disconnect switch. Steps: 1. Open the cover of the fuse housing. 2. Pull out the fuse and replace if required. 14 Ottobock ParaGolfer

15 Service and Maintenance 3. When inserting the fuse, make sure that it is pressed into the centre of the spring contacts and that it is not seated at an angle. 4. Close the cover. You should feel the cover lock in place. Properly reassemble all components upon completion of the work. 2 1 Fig. 5 Pulling the fuse out 1 Cover cap, opened A fuse 6.4 Cover Removal Tools: Allen wrench, size 6 Steps: 1. Move the seat with stand-up function up. 2. Loosen the six Allen head screws along the inner edge of the cover. 3. Remove the cover. Fig. 6 Disassembling the cover ParaGolfer Ottobock 15

16 Service and Maintenance Fig. 7 Removing the cover 6.5 Cover Plates Removing the Upper Cover Plate The upper cover plate protects the mechanical and electronic components that are installed in the chassis from outside influences such as dirt and water. It is attached to the chassis with the same screws as the cover. Preparation Remove the cover (see Section 6.4). Steps: 1. Remove the cover plate upwards. Fig. 8 Cover plate Removing the Lower Cover Plate The lower cover plate is located at the front between the wheels and protects the drive motors from outside influences such as dirt and water. Preparation: Remove the cover (see Section 6.4). 16 Ottobock ParaGolfer

17 Service and Maintenance Tools: Allen wrench, size 6 Steps: 1. Loosen the five Allen head screws at the lower edge of the cover plate. 2. Loosen the six Allen head screws at the upper edge of the cover plate (three screws each on the right and left side). 3. Remove the cover plate downwards. Fig. 9 Cover plate screw connections at the lower edge Fig. 10 Cover plate screw connections at the upper edge 6.6 Fan Removal The fan is located at the front, beneath the upper cover plate. Preparation: Remove the cover (see Section 6.4). Remove the upper cover plate (see Section 6.5.1). Tools: Ring or open-end wrench, size 8 Steps: 1. Loosen the two hexagon head screws (one each on the right and left side of the mounting sheet). 2. Remove the fan including mounting plate and replace if required. Properly reassemble all components upon completion of the work. ParaGolfer Ottobock 17

18 Service and Maintenance Fig. 11 Removing the fan 6.7 Controller Removal The controller is located at the front, beneath the cover plate and behind the fan. It is fastened to the chassis with the same attachment as the fan. Preparation: Pull out the fuse. Remove the cover (see Section 6.4). Remove the upper cover plate (see Section 6.5.1). Remove the fan (see Section 6.6). Steps: 1. Loosen all cable connections to the controller 2. Remove the controller and replace if required. Properly reassemble all components upon completion of the work. Fig. 12 Controller attachment 18 Ottobock ParaGolfer

19 Service and Maintenance Fig. 13 Connectors on the controller 1 J8 Actuator ½ and driver outputs 2 J9 Lighting connection 3 J1 Analogue input connector 4 J2 Analogue input connector 5 J3 Analogue input connector 6 J4 Bus connector 7 J5 BUS and charger inhibit connector 8 J6 Encoder connector 9 M1 Motor 1 connector 10 BATT Battery connector 11 M2 Motor 2 connector 12 J7 Encoder / switch connector 6.8 Batteries CAUTION Risk of injury while working on the battery. Smoking and open flame 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 sufficient 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. Therefore, always disconnect the batteries when working on the motor control or wiring. NOTICE Risk of battery damage. 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 and battery capacity meter. ParaGolfer Ottobock 19

20 Service and Maintenance The ParaGolfer is equipped with two rechargeable 12 V gel traction batteries with a capacity of 110 Ah (C20). The batteries are located underneath the seat, centred in the chassis. They are rechargeable and maintenance-free Battery Charging WARNING Risk of injury due to explosive gases. Explosive gases can develop while the batteries are charging. The following safety instructions must be followed under all circumstances: Ensure sufficient ventilation when charging the batteries in closed rooms. Smoking and fire are not permitted. Sparks must be avoided. Do not cover the air vents in the trim. WARNING Explosion hazard due to sparks. The battery charger must always be switched off and the mains plug be removed before disconnecting the battery. NOTICE Risk of battery damage. Ensure correct polarity is used when connecting the battery charger to the batteries. NOTICE Risk of damage due to incorrect battery handling. Please note the following when handling the batteries: Charge the batteries immediately if the bar at the bottom of the battery indicator is flashing. Do not charge in the green range. During extended periods of disuse, charge the batteries of the ParaGolfer weekly. Ottobock assumes no liability for damage caused by deep discharge. NOTICE Risk of damage to the battery charger / risk of damage caused by the battery charger. Please note the following when using the charger: Only use a battery charger supplied by Ottobock which has been tested and approved for the respective batteries by Ottobock (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. The information on the nameplate of the charger must match the country-specific voltage of the respective power supply network. Only use the battery charger within the specified ranges of temperature and humidity. Place the rubber feet of the battery charger on a level surface. When setting the charger up close to a window, protect it against direct sunlight. Keep the charger from overheating. The vent openings on the back of the charger must not be covered. Turn off the control unit during the charging process so that the entire charging current flows to the battery. Avoid dust and dirt. Only clean with a dry cloth. 20 Ottobock ParaGolfer

21 Service and Maintenance The remaining battery capacity determines the range of the power wheelchair. The following factors affect the battery capacity: Ambient temperature Age of the batteries Amount of use Charging process Driving for an extended period of time in the lower range of the battery indicator will result in deep discharge and therefore battery damage. In addition, there is the risk that the ParaGolfer may stop due to zero battery capacity and put the user in a dangerous situation. The charging receptacle of the ParaGolfer is located at the front of the battery case (Fig. 14). Tools: Battery charger intended for use by Ottobock. Steps: 1. Turn off the control of the ParaGolfer. 2. Pull back the metal slide on the battery charger s plug, connect the plug to the charging receptacle on the ParaGolfer and turn the plug clockwise until it engages. 3. Connect the charger to the power supply network. Charging starts automatically 1. Disconnect the power supply plug after the charging process is complete. 2. Pull back the metal slide to release the lock. 3. Turn the charging plug counter-clockwise until it hits the stop, then pull the plug from the charging receptacle. 4. Turn the control unit of the ParaGolfer on. The ParaGolfer is ready for operation. Fig. 14 Charging receptacle on the ParaGolfer ParaGolfer Ottobock 21

22 Service and Maintenance 1 Fig. 15 Connecting the battery charger to the charging receptacle 1 Metal slide 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. The battery charger indicates the following states: Display symbol(s) Orange LED is lit Green LED is lit Red LED flashes Red LED is lit Green LED flashes Information Battery is charging (main charging phase). Battery is fully charged. Trickle charge is active. There is a malfunction. There is a battery fault. Self-test is performed (only when switching on). Table 2 Battery capacity indicator on the battery charger If none of the LEDs are lit, there is no power supply Battery Replacement CAUTION Risk of injury due to electric current. Always remove the main fuse before doing any work on the batteries. NOTICE Risk of battery damage. Ensure correct polarity is used when connecting the batteries Preparation: Pull out the fuse. Remove the cover (see Section 6.4). Remove the upper cover plate (see Section 6.5.1). 22 Ottobock ParaGolfer

23 Service and Maintenance Tools: Ring or open-end wrench, size 13 Steps: 1. Open the black and red cover caps. 2. Disconnect all connection cables from the battery. 3. Lift out the batteries and replace if required. Properly reassemble all components upon completion of the work. Fig. 16 Batteries 6.9 Wheels CAUTION Risk of accidents due to worn or defective tyres! Replace the casing of pneumatic tyres if it is bald or shows signs of cracking or other damage. The ParaGolfer is propelled by the two 16 front wheels. The rear wheel has a size of Inspecting the General Condition Information 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. Information Avoid parking the wheelchair outdoors whenever possible. Regardless of wear and tear, the tyres should be replaced every 2 years. If the wheelchair is parked for an extended period of time or the tyres overheat (e.g. in the vicinity of radiators or in case of exposure to strong sunlight behind glass), the tyres may become permanently deformed. Therefore, sufficient clearance should always be maintained from sources of heat, and the power wheelchair should be moved frequently or placed on blocks for storage. ParaGolfer Ottobock 23

24 Service and Maintenance Steps: Verify the tyre condition in regards to tread, porosity and cracking Drive Wheel Removal NOTICE Risk of damage due to improper preparation of maintenance tasks. Use suitable objects such as wooden blocks to secure the ParaGolfer against sliding or tipping. The drive wheels must rotate freely. Preparation: Turn off the control unit. Tools: Jack Allen wrench, size 5 Ring or open-end wrench, size 6 Torque wrench Steps: 1. Jack the ParaGolfer up until the corresponding drive wheel rotates freely. 2. Loosen the six outer cap nuts. 3. Remove the wheel and replace if required. Properly reassemble all components upon completion of the work. Information When installing the drive wheel, tighten all six cap nuts to a torque of 10 Nm (7.4 ft.lbf/88 in.lbf). 1 Fig. 17 Removing the drive wheel 1 Cap nut 24 Ottobock ParaGolfer

25 Service and Maintenance Changing Tyres The drive wheels are equipped with tubeless tyres. Preparation: Remove the drive wheel (see Section 6.9.2). Tools: Tyre lever Steps: 1. Let all the air out of the tyre. 2. Using the tyre lever, remove the casing from the wheel rim and replace if required. Properly reassemble all components upon completion of the work Caster Wheel Removal NOTICE Risk of damage due to improper preparation of maintenance tasks. Use suitable objects such as wooden blocks to secure the ParaGolfer against sliding or tipping. The caster wheel must be able to rotate freely. Preparation: Turn off the control unit. Remove the cover (see Section 6.4). Tools: Jack Allen wrench, size 6 Steps: 1. Jack the ParaGolfer up until the caster wheel rotates freely. 2. Loosen the Allen head screw in the middle of the caster wheel. 3. Remove the cover. 4. Remove the caster wheel and replace if required. 5. Pull of the wheel bearing and clean of replace it if required. 6. Properly reassemble all components upon completion of the work. Properly reassemble all components upon completion of the work. NOTICE Risk of damage due to improper installation. Observe the torque of 25 Nm (22.1 ft.lbf/265 in.lbf) when tightening the Allen head screw upon installation of the caster wheel. ParaGolfer Ottobock 25

26 Service and Maintenance Fig. 18 Removing the caster wheel, pulling off the bearing 1 Allen head screw 2 Cover 3 Wheel bearing Splash Guard Removal NOTICE Risk of damage due to improper preparation of maintenance tasks. Use suitable objects such as wooden blocks to secure the ParaGolfer against sliding or tipping. Preparation: Turn off the control unit. Remove the caster wheel (see Section 6.9.4). Tools: Ring or open-end wrench, size 10 Allen wrench, size 4 Steps: 1. Loosen the two cap nuts. 2. Remove the splash guard and replace if required. Properly reassemble all components upon completion of the work. 26 Ottobock ParaGolfer

27 Service and Maintenance Fig. 19 Removing the splash guard 6.10 Motor Removal CAUTION Risk of injury due to electric current. Turn off the control unit of the ParaGolfer and disconnect all plug connections to the controller before performing any work on the drive motors. Preparation: Turn off the control unit. Remove the cover (see Section 6.4). Remove the upper cover plate (see Section 6.5.1). Remove the lower cover plate (see Section 6.5.2). Remove the drive wheel (see Section 6.9.2). Tools: Allen wrench, size 6 Steps: 1. Loosen the four screws (two on each motor) that affix the brake release linkage to the motor. 2. Loosen the six Allen head screws (tree at the top, three at the bottom). 3. Remove the motor downwards and replace if required. Properly reassemble all components upon completion of the work. ParaGolfer Ottobock 27

28 Service and Maintenance Fig. 20 Upper motor screw connections fig. 21 Lower motor screw connections (only 2 screws are visible) 6.11 Brakes and Brake Release WARNING Risk of accidents and injury due to improper maintenance, repairs or adjustments. All repairs and settings on the brake system may only be made by staff authorised by Ottobock. Incorrect settings can lead to brake failure, and therefore to serious bodily injuries and even death. WARNING Risk of accidents and injury due to improper maintenance, repairs or adjustments. In the event of defects on the parking brake, the motor is replaced entirely. Repairs on the parking brake are not permitted. WARNING Risk of accidents and injury due to a lack of brake functionality when the brake is disengaged. When working on the brake system, note that there is no braking functionality when the brake is unlocked. The corresponding force required for acceleration and deceleration must come from the person pushing. NOTICE Before working on the brake release, turn off the ParaGolfer and secure it so it cannot roll away. Both drive motors are electrically braked simultaneously by the control unit. When standing still, the mechanical parking brakes in the motor are active. In case of control system failure or insufficient battery capacity, the ParaGolfer can be pushed. To do so, the brake is unlocked with the mechanical brake release. The brake release is located at the front between the drive motors above the footplate (see 647G555 Instructions for Use). 28 Ottobock ParaGolfer

29 Service and Maintenance Preparation: Remove the motor (see Section 6.10). Tools: Allen wrench, size 4 Steps: 1. Unscrew the brake release lever. 2. Loosen the two Allen head screws. 3. Remove the brake linkage and replace if required. Properly reassemble all components upon completion of the work. NOTICE Secure all screw connections on the brake linkage with a thread-locking compound, e. g. Loctite Fig. 22 Removing the brake release linkage 1 Brake release lever 2 2 x Allen head screw 3 Brake linkage 4 Motor (here: right drive motor) 6.12 Seat CAUTION Risk of burns in the proximity of fire. The back upholstery and seat cushion of the ParaGolfer are flame retardant but nevertheless flammable. Therefore utmost caution is required near any sources of open flame or sparks, especially lit cigarettes. NOTICE Risk of damage to seat padding. During any work on the seat, the padding must be adequately protected against mechanical and chemical damage. ParaGolfer Ottobock 29

30 Service and Maintenance Fig. 23 Seat elements 1 Armrest 2 Lateral pad 3 Clothing protector 4 Seat cushion Lateral Pads Removal The lateral pads are attached to the clothing protectors on the right and left side with a hookand-loop closure and can simply be pulled away Seat Cushion Removal The seat cushion is attached to the seat plate with two hook-and-loop closures and can simply be pulled away. It has the shape of a wedge and is place on the seat plate with the small side facing the back rest Seat Plate Removal The seat plate is hooked into the seat frame at the front and otherwise only laid onto the frame. Steps: 1. Pull up the rear end of the seat plate. 2. Slightly press the seat plate to the front and unhook it from the seat frame. Properly reassemble all components upon completion of the work. Fig. 24 Seat plate 30 Ottobock ParaGolfer

31 Service and Maintenance Side Panel Removal The side panel features a clothing protector. Steps: 1. Press the release pin on the armrest holder. 2. Pull the side panel including armrest out and replace if required. Properly reassemble all components upon completion of the work. Fig. 25 Unlocking the side panel Removal of the Side Panel Attachment Device Preparation: Move the seat into the upright position. Tools: Allen wrench, size 5 Steps: 1. Loosen the two Allen head screws. 2. Remove the side panel attachment device and replace if required. Properly reassemble all components upon completion of the work. Fig. 26 Removing the side panel attachment device ParaGolfer Ottobock 31

32 Service and Maintenance Adjusting / Removing the Armrest CAUTION Risk of injury due to tipping out of the ParaGolfer. To change the armrest setting you first have to move the seat from the sitting position into the standing position. If you make the adjustment while the user is sitting in the wheelchair, all belts must be fastened first. Preparation: Move the seat into the upright position. Werkzeug: Allen wrench, size 3 Steps: 1. Loosen the two set screws. 2. Adjust or remove the armrest. Properly reassemble all components upon completion of the work. Fig. 27 Adjusting or removing the armrest Adjusting the Seat Depth Information Move the back rest forwards or backwards along the seat rail evenly with both hands so that it does not twist. To adjust the seat depth, the position of the back rest can be changed in increments of 2.5 cm. Preparation: Move the seat into the standing position until the screws are freely accessible. Tools: Allen wrench, size 8 32 Ottobock ParaGolfer

33 Service and Maintenance Steps: 1. Loosen the four Allen head screws (two on each side). 2. Pull out the locking pins and turn them by 90 into the unlocked position. 3. Move the back rest in the seat rail forwards or backwards. 4. Insert the locking pins into the corresponding holes of the desired position. Properly reassemble all components upon completion of the work. Fig. 28 Adjusting the seat depth Fig. 2 Pulling the locking pin Adjusting the Lower Leg Length The distance between the seat and footplate can be adjusted as needed to the lower leg length. For this purpose, there is spindle at the front of the seat frame that can be turned to lower or raise the seat bottom. Tools: Allen wrench, size 8 ParaGolfer Ottobock 33

34 Service and Maintenance Steps: 1. Apply the Allen wrench to the spindle head. 2. Turn clockwise to lower the seat bottom. Turn counter-clockwise to raise the seat bottom. Fig. 30 Turning the spindle Adjusting / Removing the Footplate Werkzeug: Ring or open-end wrench, size 19 Steps: 1. Loosen the two hexagon head screws (on the right and left of the footplate). 2. Move the footplate up or down as required, or remove and replace it if required. Properly reassemble all components upon completion of the work. Fig. 31 Adjusting the footplate 34 Ottobock ParaGolfer

35 Service and Maintenance Seat Removal NOTICE Secure all screw connections on the brake linkage with a thread-locking compound, e. g. Loctite. Preparation: Move the seat into the standing position until the Allen head screws are freely accessible. Loosen all cables connected to the seat frame by cable ties. Tools: Allen wrench, size 6 Allen wrench, size 8 Steps: 1. Loosen the two Allen head screws at the rear. 2. Loosen the two Allen head screws at the front. 3. Remove the seat including frame and the stand-up device. Properly reassemble all components upon completion of the work. Fig. 32 Allen head screws at the rear/front Removing the Stand-up Device Actuator NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process. Preparation: Remove the seat cushion. Remove the seat plate (see Section ). ParaGolfer Ottobock 35

36 Service and Maintenance Tools: Circlip pliers Steps: 1. Loosen the circlip on both ends of the actuator. 2. Remove the bolt. 3. Remove the actuator. Properly reassemble all components upon completion of the work. Fig. 33 Front actuator attachment fig. 34 Rear actuator attachment Adjusting / Removing the End Switch NOTICE Risk of cable damage. Take note of the cables attached to the seat frame with cable ties. Carefully cut the cable ties with side-cutting pliers or a knife. Ensure that you do not damage the cables during this process. As soon as the end switch is reached when operating the stand-up function, the control switches to creep speed. Achievement of the creep speed can be adjusted in the slot holes. Preparation: Remove the seat cushion (see Section ). Remove the seat plate (see Section ). Tools: Phillips screwdriver Steps: 1. Loosen the two Phillips head screws. 2. Move the two Phillips head screws forwards or backwards in the slot holes. 36 Ottobock ParaGolfer

37 Service and Maintenance Fig. 35 End switch Adjusting / Removing the Back Rest CAUTION Risk of injury due to improper attachment of the back rest. To ensure sufficient stability of the back rest, observe a minimum clamping range, identified by a red mark on the back rest tubes, when adjusting the backrest. The clamps must be attached below this range. CAUTION Risk of pinching or crushing the fingers. Make sure to not reach into the danger zone between the clamp and the seat when adjusting the back rest. Information Move the back rest up or down evenly with both hands so that it does not twist. Steps: 1. Manipulate the clamping levers on the right and left tubes of the back rest frame and loosen the clamps. 2. Move the back rest in the tube up or down, or remove and replace it if required. Properly reassemble all components upon completion of the work. ParaGolfer Ottobock 37

38 Service and Maintenance Fig. 36 Loosening the clamps and adapting the back height Replacing the Back Upholstery The back upholstery is attached to the back rest frame with three hook-and-loop straps. It can simply be pulled away to the front and replaced if required. Fig. 37 Hook-and-loop straps of the back upholstery Removing the Lap Belt Preparation: Move the seat into the standing position until the Allen head screws are freely accessible. Tools: Allen wrench, size 5 Steps: 1. Loosen the two Allen head screws (on the right and left rear side of the seat frame). 2. Remove the strap and replace if required. Properly reassemble all components upon completion of the work. 38 Ottobock ParaGolfer

39 Service and Maintenance Fig. 38 Removing the lap belt 6.13 Replacing the Baggage Protection Preparation: Remove the cover (see Section 6.4). Tools: Phillips screwdriver Steps: 1. Loosen the four Phillips head screws. 2. Remove the baggage protection and replace if required. Properly reassemble all components upon completion of the work. Fig. 39 Baggage protection ParaGolfer Ottobock 39

40 Service and Maintenance 6.14 Options Information Only use original manufacturer s options. The optional components may be mounted only as described here. Failure to comply will void the warranty Mounting the Golf Bag Holder CAUTION Risk of injury if the ParaGolfer tips over. Attaching a golf bag will change the centre of gravity of the ParaGolfer. Keep in mind that the driving and braking characteristics of the ParaGolfer will change accordingly, in order to avoid falls and dangerous situations. In addition, the ParaGolfer will have larger dimensions. CAUTION Risk of accidents due to overloading the ParaGolfer. Attaching a golf bag will change the loading proportion of the ParaGolfer. The weight of the user together with the weight of the golf bag must not exceed the permissible total weight of 140 kg (309 lbs). Information The golf bag holder can be mounted and the right and left side of the ParaGolfer. The respective matching mounting bracket set is required for this purpose. The golf bag holder is mounted laterally to the ParaGolfer into the designated retainer bushes on the drive unit sustainer. Steps: 1. Insert the two mounting brackets into the retainer bushes. 2. Insert the golf bag holder into the mounting brackets. When inserting the golf bag holder into the mounting brackets, make sure that the locking pins firmly engage. 3. Place the golf bag on the two supports and fix with the straps. 4. Loosen the clamping levers of the front support and adjust to the length of the golf bag. Fig. 40 Mounting kit: mounting brackets with locking pins; mounting brackets inserted 40 Ottobock ParaGolfer

41 Service and Maintenance Fig. 41 Golf bag holder attached Replacing the Control Panel Holder with Spring Plate The ParaGolfer can be equipped with a detachable control panel. For this purpose, the control panel features a spring plate as holding device, which must be inserted into the square tube beneath the armrest. Tools: Allen wrench, size 4 Steps: 1. Loosen the Allen head screw on the underside of the armrest. 2. Pull out the control panel towards the front. 3. Pull the holder out of the receiving square tube. 4. Loosen and remove the two Allen head screws on the underside of the holder. 5. Remove the control panel and mount to another control panel holder, if desired. Properly reassemble all components upon completion of the work. If necessary (e. g. for transportation), the control panel can be pulled off to the front. ParaGolfer Ottobock 41

42 Service and Maintenance Decorative Wheel Covers The drive wheels of the ParaGolfer can be equipped with decorative wheel covers. Tools: Allen wrench, size 5 Steps: 1. Hold the decorative wheel cover onto the wheel. 2. Tighten the Allen head screw in the middle of the wheel. Fig. 43 Decorative wheel cover 42 Ottobock ParaGolfer

43 Diagnostics 7 Diagnostics NOTICE Risk of damage due to unauthorised service. Improper or poorly executed repairs may result in the unsafe operation of the power wheelchair. The error diagnosis may therefore only be carried out by authorised dealers who have established knowledge of electronic controllers from Ottobock. Ottobock will not assume any liability for damages that are due to improperly or poorly executed repairs. Information Experience has shown that problems with the wheelchair electrical system are frequently caused by errors and defects in the plug connections and cabling. They should be inspected first for this reason. Information Should you encounter problems while troubleshooting or if you do not manage to completely eliminate a problem by following the measures described here, please contact Ottobock. Errors are either shown on the control panel display (see Section 7.2) or displayed using the handheld programming device. The handheld programming device (see Section 8.3) can capture errors more precisely using error codes. The separate enable50 instructions for use contain a table with error codes, causes and possible steps for resolution. 7.1 Diagnostic Steps For an efficient and successful error diagnosis, proceed as follows: Verify whether the error was generated for a concrete reason or if the error was displayed sporadically. Check the possible causes in the error display table (see Section 7.2) or the error codes (enable50 instructions for use). Perform the recommended checks and corrective actions. 7.2 Error Display on the Control Panel For troubleshooting purposes, the control system of the ParaGolfer identifies the following categories depending on the effect of the malfunction on the system: Error Warning Defect A warning indicates a status or malfunction of one or several individual components of the Para- Golfer. All problems that have ever occurred are saved in a list and can be retrieved, e. g. in case of a general overhaul of the ParaGolfer. The saved data can be used to determine future service and maintenance intervals, for example. The following table shows the different error messages on the control panel display or separate LCD monitor: On the LCD monitor, the error message also includes the identification number of the error that has occurred (for more detailed information see the enable50 instructions for use (647G490=D/GB)): ParaGolfer Ottobock 43

44 Diagnostics Error / warning / defect Controller temperature warning Motor temperature warning Motor temperature warning Joystick warning Hand control device fault Controller fault Cause Overheating due to excessive load Overheating due to excessive load Control unit has switched to creep speed due to overheating Joystick not in zero position when switching on Defective joystick Defective controller Measure Cool down phase Cool down phase Cool down phase Bring joystick to zero position before switching on Communication error (alternating flashing signal) Battery under voltage Faulty connection between the hand control device and controller. Defective cabling, software or hardware Battery deep discharge Check cabling / plug connections Charge as soon as possible Battery over voltage Drive motor fault Stand-up device motor fault Voltage too high (after full charge and driving downhill) Faulty cabling or plug connection, defective actuator Faulty cabling or plug connection, defective actuator Brake fault Open brake release / defective brake Emergency stop Severe fault caused by controller, hand control device, and/or drive motor malfunction Continue driving slowly Check cabling / plug connections Check cabling / plug connections Close brake release; check brake (e. g. the Bowden cable) Table 3 Error display 44 Ottobock ParaGolfer

45 enable50 Wheelchair Control Installation and Programming Information The enable50 instructions for use 647G490=D/GB contain information on troubleshooting. 8 enable50 Wheelchair Control Installation and Programming Information The enable50 instructions for use 647G490=D/GB contain more detailed information about the control unit and the connection of input devices. 8.1 Overview The enable50 control unit is extremely versatile, featuring smooth operation, good responsiveness and concise colour displays. Various input devices can be used alternately in order to meet the needs of users. Special Input Device ED (LCD) Actuator Light Light Input Device PB (Controller) AAM (Seat module) Batt. Fig. 44 Control unit elements With the enable50 control unit, the power wheelchair can indicate the causes of error messages on the display. Error sources in the drive section and in the electric options are indicated by flashing of the corresponding sections in the display s pictogram or a visual display on the separate LCD monitor (see Section 7.2). The handheld programming device can be used to make parameter changes (available separately). ParaGolfer Ottobock 45

46 enable50 Wheelchair Control Installation and Programming Fig. 45 Components of the enable50 wheelchair control 1 Attendant control 2 Hand control device 3 Controller 4 Separate LCD monitor 8.2 Controller The controller is attached to the wheelchair with two screws (see Section 6.4) Fig. 46 Controller 1 J8 Actuator ½ and driver outputs 2 J9 Lighting connection 3 J1 Analogue input connector 4 J2 Analogue input connector 5 J3 Analogue input connector 6 J4 Bus connector 7 J5 BUS and charger inhibit connector 8 J6 Encoder connector 9 M1 Motor 1 connector 10 BATT Battery connector 11 M2 Motor 2 connector 12 J7 Encoder / switch connector 46 Ottobock ParaGolfer

47 enable50 Wheelchair Control Installation and Programming The housing heats up during high-current operation. Therefore, installing the controller on a metal surface with sufficient clearance for air circulation around the housing is recommended. This transfers heat away from the device, improving performance and increasing the lifespan of the controller Wiring the Controller The illustration below shows the wiring of the enable50 controller for a system that has drive motors equipped with encoders. Fig. 47 Controller connection schematic Technical Data, Connections Wire gauge Mating force M1, M2: Motors mm² 40 Nm M1, M2: Brakes mm² 18 Nm Battery mm² 40 Nm J4 (bus), J9 (12-pin) mm² 1.5 kg ParaGolfer Ottobock 47

48 enable50 Wheelchair Control Installation and Programming Actuator Outputs The controller has two independent actuator outputs. Technical data for the first actuator output: Voltage Current for 20 seconds Steady current % V Batt 20 A 10 A Technical data for the second actuator output: Voltage Current for 20 seconds Steady current % V Batt 15 A 7 A The actuator outputs are short-circuit protected. However, short-circuiting the actuator output against the negative pole of the battery while the actuator is in operation may damage the output. The actuators have high impedance when they are not in operation. 8.3 Programming Devices The enable50 control unit is programmable, this means that the settings for the various programmable parameters can be set using a programming device. Two programming devices are available: a handheld programming device and a PC programming station (PCPS). The PCPS has additional functions not offered by the handheld programming device. On the other hand, the handheld programming device is more portable. The PCPS is usually used to establish the initial parameter settings, while the handheld programming device is used for changes after deployment Handheld Programming Device The handheld programming device (493U36=SK180) is designed for programming, inspection and debugging of the wheelchair control. Fig. 48 Handheld programming device 48 Ottobock ParaGolfer

49 enable50 Wheelchair Control Installation and Programming Control and display elements: 1. LCD: graphic display ( pixels) to display functions and parameters. 2. Four-directional button: A control element to navigate the cursor in the menu tree. Press the up / down arrow to move the cursor vertically in the menu tree. Press the right hand arrow at the branch points to open the corresponding sub-functions and press the left hand arrow to close these sub-functions again. 3. Rocker button: This control element is used to increase or decrease the selected parameter values. 4. Programmable bookmarks: 3 user-defined bookmarks. This function enables you to jump quickly among various points in the menu tree. To set a bookmark, select an item and press the button for a longer time (at least 3 seconds). Then the cursor will jump to the predefined position by pressing the button quickly. Initial operation: 1. Turn on the wheelchair control. 2. Ensure the cable is securely connected to the handheld programming device. 3. Connect the bus plug of the handheld programming device to a free bus receptacle (e.g. on the bottom of the display module). Operation: a) Display The interface is displayed using a so-called menu tree. The displayed menu tree range may consist of up to 7 lines. The selected function is indicated by a blinking box. The menu tree branches into several levels, with the lowest level containing individual parameters with numerical values displayed on the far right. Fig. 49 Menu tree For easier navigation of the selected branch in the menu tree, the display includes nodes (rectangles). They are connected with lines to indicate the relationship between items on the same level in the vertical direction and the depth of branching in the horizontal direction. The selected branch is indicated with a solid node, while the currently selected function is indicated by a blinking node. ParaGolfer Ottobock 49