Ekso Bionics EVO Exoskeleton User manual

OPERATING MANUAL
EVO™Exoskeleton

Contact Information
HEADQUARTERS:
Ekso Bionics, Inc.
1414 Harbour Way South, Suite 1201
Richmond, CA 94804
Office: 1.510.984.1761
Fax: [phone]
www.eksobionics.com
EMEA OFFICE:
Ekso Bionics, GmbH
Friesenweg 4, House 13
22763 Hamburg
Germany
Office: +49.40.800.4049.0
[e-mail]
Ekso Bionics Customer Experience
Monday – Friday 6 a.m. to 6 p.m. PST
Phone: [phone]
[e-mail]
Copyright
© 2020 Ekso Bionics, Inc.
All Rights Reserved
No part of this publication may be reproduced,
transmitted, transcribed, stored in a retrieval system,
or translated into any language or any computer
language, in any form or by any third party, without the
prior written permission of Ekso Bionic, Inc.
Trademarks
Ekso®, EVO™, Ekso Bionics®, the Ekso Bionics Icon,
are trademarks of Ekso Bionics, Inc.
Patents/Patents Pending
For a list of patents and patents pending, refer to the
Ekso Bionics website.
Disclaimer
Potentially serious injury may occur in connection with
the use of Ekso EVO. Ekso Bionics, Inc. shall not be
liable for any injury or damage suffered by any person,
either directly or indirectly, as a result of the use or
repair of Ekso EVO in violation of your contract with
Ekso Bionics, Inc. Ekso Bionics, Inc. does not accept
any responsibility for any damage caused to its
products, either directly or indirectly, as a result of use
and/or repair by unauthorized personnel.
WARNING: Potentially severe injury may occur from misuse. DO NOT use the Ekso EVO unless you
are capable of protecting the safety of yourself and any other person in the vicinity. Ekso Bionics, Inc.
is not responsible for any loss or damage that occurs in connection with your use of the Ekso EVO.

Table of Contents
Contact Information .........................................................................................ii
Ekso Bionics Customer Experience ................................................................ii
Copyright .........................................................................................................ii
All Rights Reserved .........................................................................................ii
Trademarks......................................................................................................ii
Patents/Patents Pending .................................................................................ii
Disclaimer........................................................................................................ii
Table of Contents ...........................................................................................iii
CHAPTER 1: Introduction.................................................................................. 2
CHAPTER 2: What Is Included.......................................................................... 3
CHAPTER 3: EVO Sizing and Fit Adjustments ................................................. 4
MEASUREMENT AND FITTING INFORMATION.......................................... 4
Fit Guide Tables ............................................................................................. 5
CHAPTER 4: Donning and Doffing EVO ........................................................... 6
Donning EVO .................................................................................................. 6
Doffing the EVO .............................................................................................. 7
CHAPTER 5: Turning EVO On and Off ............................................................. 7
Turning EVO On ............................................................................................. 7
Turning EVO Off ............................................................................................. 7
CHAPTER 6: Installing and Changing Actuator Springs ................................... 8
EXO Actuator Spring Support Levels ............................................................. 8
Installing Actuator Springs.............................................................................. 8
CHAPTER 7: Adjusting the ACTIVATION Zone................................................ 9
CHAPTER 8: Fit Adjustments.......................................................................... 10
CHAPTER 9: Maintenance and Troubleshooting ............................................ 11
CHAPTER 10: Components and Accessories .............................................. 12

2Introduction
108842 A
CHAPTER 1: INTRODUCTION
EVO is an upper body exoskeleton that alleviates the burden of repetitive work on the shoulders, which is the most
common cause of lost workdays due to workplace injuries. Based on collaboration and insights from Ekso’s global
install base and experience with its ground-breaking EksoVest technology, EVO is designed to improve the user
experience and drive adoption.
Stacked link structure. EVO’s patented stacked-link structure seamlessly follows the user’s arm through the full
range of motion while providing proper joint alignment. Extreme positions like reaching directly overhead, across the
body, or even into a back pocket for a phone are unrestricted.
Independent load path. Completely decoupled left and right shoulder support structures allow full flexibility of the
user’s torso and waist, such that twisting and bending to the site feel completely natural. The user’s back is also
completely free of structure, allowing unrestricted airflow and leaving plenty of room for a fall harness.
Minimized body contact. EVO is designed to only contact the user’s body where it is absolutely essential, while still
staying firmly in place during use. The result is more comfortable and cooler to wear than even a backpack, especially
in hot environments.
Adjustable high force actuator. EVO’s actuators are proven to be extremely durable with millions of cycles of testing
and field data. The assistance level can be adjusted for the user and task by easily swapping out the set of compact
gas springs. Different levels can even be selected for each arm if appropriate for the task.
Light weight, no compromises. Light weight can be achieved without sacrificing functionality. EVO strikes the
optimal balance between device weight, functionality, assistance levels, and durability.
Compact storage. With the included durable, 26” tool bag-style carrying case, EVO stores, ships and transports to
and around the job site easily and conveniently. Interior storage bag pockets provide ample storage of accessories
and other tools.
Scan this code for videos on how to get started using your EVO

3What Is Included
108842 A
CHAPTER 2: WHAT IS INCLUDED
The mechanical and hardware components of each EVO are identified in the following drawing and table.
Component
Identifier
Component Name
A
Arm Cuff Plate
B
Actuator Spring
C
ON/OFF Switch and Tether
D
Actuator Activation Zone Indicator
E
Actuator
F
Link Assembly
G
Torso Pad Support
H
Torso Tube
I
Waist Plate
J
Belt Extensions
A
B
C
D
E
F
G
H
I
J

4EVO Sizing and Fit Adjustments
108842 A
CHAPTER 3: EVO SIZING AND FIT ADJUSTMENTS
EVO is designed to be custom fit for each operator (see MEASUREMENT AND FITTING INFORMATION below).
Record the operator’s measurements to find the ideal size configuration for a secure and comfortable fit.
MEASUREMENT AND FITTING INFORMATION
To find the initial size configuration for your EVO, take the measurements listed below using a flexible
measuring tape. Use these measurements to look up the operator’s correct size configuration according to the fitting
guide tables. These values serve as a starting point, and additional adjustments may be required.
Belt size
Measure the distance around your back
between your 2 hip/pelvic bones (the iliac
crest). Be sure to make the measurement
over your typical work clothes.
Measurement
___________inch
(cm)
Figure 1: Hip-to-Hip Measurement
Arm Cuff size
Measure the circumference of your bicep at
the widest point in a relaxed position. Be
sure to make the measurement over your
typical work clothes.
Measurement
___________inch
(cm)
Figure 2: Bicep Measurement
Torso Tube size
Place your hands on your hips with your
index finger resting on your hip bone. Extend
your thumbs toward each other around the
center of your back. Have an assistant
measure the distance from the imaginary line
between your thumbs to the bony protrusion
at the base of your neck.
Measurement
___________inch
(cm)
Figure 3: Torso Measurement

5EVO Sizing and Fit Adjustments
108842 A
Figure 4: Hip Belt Slot Positions
Figure 5: Upper
Torso Tube
Positions
Fit Guide Tables
Table 1: Belt Size
Table 2: Arm Cuff Size
Arm Cuff Measurement
Arm Cuff Size
in
cm
S
9 - 11.5
22.9 - 29.2
M
11.5 - 14
29.2 - 35.6
L
14 - 17
35.6 - 43.2
XL
17 - 20
43.2 - 50.8
Table 3: Torso Length
Belt Size Measurement
Hip-to-Hip Distance
Hip Belt Slot
Setting
in
cm
S/M WING
1
19 - 22.5
48.3 - 57.2
2
22.5 - 24
57.2 - 61
3
24 - 25.5
61 - 64.8
4
25.5 - 27
64.8 - 68.6
5
27 - 28.5
68.6 - 72.4
L/XL WING
1
28.5 - 30
72.4 - 76.2
2
30 - 31.5
76.2 - 80
3
31.5 - 33
80 - 83.8
4
33 - 34.5
83.8 - 87.6
5
34.5 - 36
87.6 - 91.4
Torso Length
Lower Torso Tube
Size
Upper Torso Tube
Position
in
cm
SMALL TUBE
1
14 - 14.6
35.5 - 37
2
14.6 - 15.2
37 - 38.5
3
15.2 - 15.7
38.5 - 40
4
15.7 - 16.3
40 - 41.5
5
16.3 - 16.9
41.5 - 43
6
16.9 - 17.5
43 - 44.5
LARGE TUBE
1
16.9 - 17.5
43 - 44.5
2
17.5 - 18.1
44.5 - 46
3
18.1 - 18.7
46 - 47.5
4
18.7 - 19.3
47.5 - 49
5
19.3 - 19.9
49 - 50.5
6
19.9 - 20.5
50.5 - 52

6Donning and Doffing EVO
108842 A
CHAPTER 4: DONNING AND DOFFING EVO
Now that the EVO has been custom fit to the operator, it is time to put it on.
Donning EVO
1. Before putting on EVO, make sure to
unbuckle the hip belt, loosen the hip belt
webbing, and loosen the arm cuff straps.
2. Start by draping the EVO over your shoulders.
3. Secure the hip belt using the buckle. Position
the hip pads so they are covering your hip
bones, then tighten the belt by pulling on the
webbing loops inward. The belt should be tight
enough to avoid shifting, but not
uncomfortable.
4. Slip each arm through the arm cuff. Use the
pull handle strap to fully open the cuff to allow
for easier insertion.
5. Tighten the three straps on each arm from
bottom to top for a snug but comfortable fit.
Figure 6: Donning EVO Steps

7Turning EVO On and Off
108842 A
Doffing the EVO
1. Undo and loosen the arm cuff straps. Use the
pull handle strap to slide each arm out of the
arm cuff.
2. Drape the EVO arms over your shoulders.
3. Loosen the hip belt webbing, then release the
hip belt buckle.
4. Lift EVO off your shoulders.
5. Disassemble arms from the hip belt by
pressing the silver buttons on the bottom of the
torso tubes. Place all components back into
the Ekso carrying bag.
CHAPTER 5: TURNING EVO ON AND OFF
Each EVO arm has an ON / OFF switch (with tether) located on the actuator housing. Moving the switch to the ON
position activates the spring support of the actuator. Take care if activating the switch while the EVO is not being worn,
as the arm can raise up in an uncontrolled manner.
Turning EVO On
To turn EVO on, the operator must keep their arm fully down by their
side. The switch on the actuator can then be flipped to the ON position.
Do this for both arms before starting to use EVO.
Turning EVO Off
To turn EVO off, the operator must lower their arm fully to their side.
The switch on the actuator can then be flipped to the OFF position. Do
this for both arms before doffing EVO.
Figure 7: Doffing Evo Steps
Figure 8: Turning EVO On

8Installing and Changing Actuator Springs
108842 A
CHAPTER 6: INSTALLING AND CHANGING ACTUATOR SPRINGS
EXO Actuator Spring Support Levels
The force assistance level provided by EVO can be adjusted by changing the actuator springs in each arm. There are
three (3) sets of actuator spring levels to choose from. Each spring level corresponds to an approximate amount of lift
assist support.
The support level of each spring is shown on the spring’s end cap. Level 1 provides the least amount of arm support,
while Level 3 provides the most. The following table shows the different spring labels and the approximate lift support
offered by each of the four different actuator springs.
Table 4: Spring Labels and Approximate Spring Support
Support Level 1
Support Level 2
Support Level 3
5 – 7 lb.
7 – 9 lb.
9 – 12 lb.
(2.2 – 3.1 kg)
(3.1 – 4.0 kg)
(4.0 – 5.4 kg)
When sizing EVO, Ekso Bionics recommends beginning with a lower force spring and changing to a higher force level
as needed.
Installing Actuator Springs
Installing/changing the actuator springs should be performed when the
EVO is not being worn. To change the actuator springs, follow the steps
below:
1. Secure one arm of EVO in the lowered (down) position. Flip the
actuator switch to the ON position.
2. Carefully guide the EVO arm upwards to the fully raised (up)
position.
3. Undo the snap fastener and strap near the spring.
4. Unscrew and remove the spring from actuator cylinder chamber.
5. Select the desired spring and insert into actuator cylinder
chamber. Screw in the spring until hand-tight.
6. Carefully guide the EVO arm downwards into the fully lowered
(down) position. Flip the actuator switch to the OFF position.
7. Repeat steps 1 through 5 on opposite side as needed.
Figure 9: Installing Actuator Springs

9Adjusting the ACTIVATION Zone
108842 A
CHAPTER 7: ADJUSTING THE ACTIVATION ZONE
EVO features an adjustable “activation zone”. The activation zone is the area in
which EVO provides support to the operator’s arms while performing in-front and
overhead work.
EVO offers three different activation zone settings:
•H (high) setting (usually for overhead work)
•“Standard” setting (marked by the middle line)
•L (low) setting (usually for in-front work).
The Figure shows how each setting changes the activation zone starting points
and max support areas.
The table below lists the approximate angle (from 0° fully lowered position) for
each activation zone starting point and max support point.
Table 5: Activation and Support Angles
As described in the following procedure, adjusting the activation zone must be done when the EVO is not being worn.
Personal comfort and preference should always guide which activation zone setting to use for each arm.
To adjust the activation zone:
1. Secure one arm of the EVO in the down (lowered) position. Enable that actuator
by flipping the switch to the ON position.
2. Carefully guide the EVO arm upwards to the fully raised (up) position.
3. Use T25 driver to loosen the top socket head cap screw on the end link. Loosen
the screw approximately one-quarter turn.
4. Using the end link graphic as a guide, adjust the dial to H (high) or L (low) setting
as desired; default adjustment will be set at the “standard” setting (middle line).
Activation Setting
Degree (from 0°) for Starting
Support Point (approximate)
Degree (from 0°) for Max
Support Point (approximate)
Low Setting
15°
105°
Standard Setting
25°
115°
High Setting
35°
125°
Figure 10: Activation Zone Settings
Figure 12: High, Standard, and Low Activation Zone Settings
Figure 11: Loosening
End Link Screw

10 Fit Adjustments
108842 A
5. When the indicator is at the desired setting, retighten the screw. The split
clamp should be evenly spaced.
6. Carefully guide the EVO arm downwards into the fully lowered (down)
position. Flip the actuator switch to the OFF position.
7. Repeat steps 1 through 6 on the opposite side, as needed.
CHAPTER 8: FIT ADJUSTMENTS
Before the operator starts using the EVO, some fit adjustments may be required for maximum comfort. If the operator
is feeling any discomfort, try the adjustments described below.
Table 6: Fit Adjustment Troubleshooting
Issue
Solution
You feel pressure near the elbow when you raise your
arm.
Torso length likely too long. Try decreasing torso tube
length by 1 notch
You feel tugging around your bicep / upper arm when
you raise your arm.
Torso length likely too short. Try increasing torso tube
length by 1 notch
Your arm is not aligned with the EVO actuator arm.
Make sure that hip belt is properly positioned and
tightened. Adjust torso length if needed.
The arm cuff slides up and down on your arm.
The arm cuff straps are likely too loose. Readjust and
tighten arm cuff straps as needed.
The webbing straps are digging into your waist.
Check the position of the hip pads, and adjust to ensure
they are centered over your hip bones
The arm cuff is too tight no matter how it is adjusted.
If wearing extra layers, the padding in the arm cuff can
be removed for a more accommodating fit. Otherwise,
try swapping to a large arm cuff size.
You feel restricted when moving your arm across your
body.
For operators with larger shoulders, try moving the arms
of EVO from the inner lug position on the hip belt to the
outer lug position.
You feel discomfort when moving your arm across your
body.
If the arms of EVO are in the outer lug position on the
hip belt, try moving them to the inner lug position.
Note: For the best fit and comfort, be sure that the tops of the actuators are
slightly higher than the tops of the user’s shoulders. Adjust the torso lengths if
necessary to achieve proper alignment.
Figure 13: Evenly Spaced Split
Clamp

11 Maintenance and Troubleshooting
108842 A
CHAPTER 9: MAINTENANCE AND TROUBLESHOOTING
Table 7: Maintenance and Additional Troubleshooting
Issue Solution/Maintenance Frequency of Maintenance
Soft goods are dirty and/or sweaty.
Wash soft goods in washing
machine using laundry detergent
and cold water; use a low-heat
dryer cycle. Ensure that all Velcro
straps are secured before washing.
Ekso Bionics recommends washing
and drying items in a mesh bag.
As needed from wear
Actuator springs are loose.
Hand tighten both actuator springs
such that they are securely seated
in the actuator base. DO NOT USE
TOOLS TO TIGHTEN OR LOOSEN
ACTUATOR SPRINGS.
Daily
Soft goods are damaged.
Examine all soft goods (arm cuffs,
torso pads, hip pads, and lumbar
pad) for wear or damage. Examine
both sides of each soft good and all
stitching for visible damage,
discoloration, or deterioration;
manually inspect the material with
fingers to feel for wear, such as
tearing, fraying, unevenness, or
loose threads. Examine snaps,
straps, and buckles for proper
operation. If any damage or
deterioration is discovered,
discontinue use and contact Ekso
Bionics for replacements
Weekly
Actuator spring does not thread in
smoothly.
Inspect actuator spring threads. If
dirty or dusty, clean with cloth
and/or compressed air before
inserting spring into actuator
assembly.
As needed

12 Components and Accessories
108842 A
CHAPTER 10: COMPONENTS AND ACCESSORIES
The items below are included with every EVO.
Item
Qty
Details
EVO Kit
Notes
EVO Arm Assembly 2
108830 (Right)
108831 (Left) Included
Large Torso Tube
2
108549
Included
Hip Belt
1
108832
Included
Large Belt
Extensions 4 108701 (Large) Included
Arm Cuffs 8
108659 (Left S)
108658 (Right S)
108661 (Left M)
108660 (Right M)
108663 (Left L)
108662 (Right L)
108769 (Left XL)
108768 (Right XL)
One Pair Included
LEFT RIGHT
Actuator Springs 3
Level 1: 107199
Level 2: 107200
Level 3: 107201
One Set (2 Springs)
Included
(shipped in storage
bag pockets)
EVO Quick Start
Guide 1 108848 Included
Storage Bag
1
108779 Included