Levo AG Combi Troubleshooting guide

LEVO combi & combi JR
INSTRUCTION- and
SERVICE MANUAL
Please read the Instruction Manual carefully
before attempting to use your wheelchair
The Service Manual is provided for the use of
Agents and Authorized Repairers
Alterations in constructional and technical manner
or to the electronic require the written authorisation
of LEVO AG, otherwise no warranty or product
liability will be accepted.
In case of difficulty contact:
Manufacturer: Agent:
LEVO AG
Anglikerstrasse 20
CH-5610 Wohlen
Tel:[phone]
Fax:[phone]
Internet: http://www.levo.ch

Contents
INSTRUCTION MANUAL...............................................................................................................5
Possible positions ................................................................................................................................6
Declaration of Conformity.................................................................................................................9
Seating and Standing Assessment...................................................................................................10
1. Introduction .............................................................................................................................12
2. Warranty..................................................................................................................................13
3. Delivery ....................................................................................................................................13
3.1. Despatch and transportation ................................................................................................13
3.2. Delivery...............................................................................................................................13
3.3. Storage.................................................................................................................................14
4. Accessories ...............................................................................................................................14
5. Warning....................................................................................................................................14
6. Preparing the wheelchair for use and operation ..................................................................15
6.1. LEVO combi standard backrest ..........................................................................................15
6.2. V-Trak backrest system (optional)......................................................................................16
6.3. Further preparations ............................................................................................................16
7. First adjustments.....................................................................................................................16
7.1. Seat depth ............................................................................................................................16
7.2. Seat cushion.........................................................................................................................18
7.3. Footplate..............................................................................................................................18
7.4. Armrest................................................................................................................................19
7.5. Low shearing at the back.....................................................................................................20
7.6. Backrest assembly of the LEVO combi standard backrest .................................................21
7.7. V-Trak backrest system (option).........................................................................................21
8. Safety harness ..........................................................................................................................23
8.1. Knee support .......................................................................................................................23
8.2. Chest strap ...........................................................................................................................23
9. Using the LEVO combi ...........................................................................................................24
9.1. Getting into the wheelchair .................................................................................................24
9.2. Getting out of the wheelchair ..............................................................................................24
9.3. Sideways transfer ................................................................................................................25
9.4. Skirt guards .........................................................................................................................25
10. The safety cut-out ....................................................................................................................26
11. Joystick module .......................................................................................................................27
11.1. Security key.........................................................................................................................28
11.2. On / Off switch....................................................................................................................28
11.3. Battery indicator..................................................................................................................28
11.4. Joystick................................................................................................................................28
11.5. Speed selection....................................................................................................................28
11.6. Mode functions....................................................................................................................29
11.7. Lighting installation ............................................................................................................32
11.8. Horn.....................................................................................................................................33
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12. Electromagnetic interference (EMI)......................................................................................33
13.Driving the wheelchair............................................................................................................34
14.Motor solenoid brakes ............................................................................................................36
15.Free wheel device / Motor disengaging lever ........................................................................37
16.Batteries....................................................................................................................................37
16.1. Charging the batteries..........................................................................................................37
17. Attendant instructions ............................................................................................................38
17.1. Motor brakes .......................................................................................................................38
17.2. Lifting & general safety ......................................................................................................38
17.3. General safety......................................................................................................................39
18.Cleaning....................................................................................................................................39
19.Maintenance.............................................................................................................................39
19.1. Motor brakes .......................................................................................................................39
19.2. Spare parts ...........................................................................................................................39
20.Transporting your wheelchair ...............................................................................................39
21.Disposal ....................................................................................................................................40
22.Trouble shooting......................................................................................................................40
23.Controller self help guide .......................................................................................................41
24.Technical information.............................................................................................................42
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SERVICE MANUAL .......................................................................................................................43
1. Introduction .............................................................................................................................44
2. Health & safety ........................................................................................................................44
3. Adjustments .............................................................................................................................44
3.1. Seat depth ............................................................................................................................44
3.2. Low shearing at the back.....................................................................................................44
3.3. Adjustment of the backrest..................................................................................................44
3.4. Electronic control system ....................................................................................................44
4. Repairs: general instructions .................................................................................................45
5. Tools & torque settings ...........................................................................................................45
6. Important points......................................................................................................................46
7. Recommended safety checks ..................................................................................................46
8. Repairs......................................................................................................................................48
8.1. Replacing the drive wheels .................................................................................................48
8.2. Replacing the tire of a drive wheel......................................................................................48
8.3. Replacing the front wheels..................................................................................................49
8.4. Replacing the back wheel....................................................................................................49
8.5. Replacing the wheel fork (at front and back)......................................................................50
8.6. Replacing the connector of the back low shearing system..................................................50
8.7. Replacing the motor disengaging cable (free wheel device)...............................................51
8.8. Replacing the driving motor................................................................................................52
8.9. Replacing the batteries ........................................................................................................52
8.10. Replacing the joystick module ............................................................................................53
8.11. Replacing the power module...............................................................................................53
8.12. Replacing the ALM (Actuator-Lights-Module)..................................................................54
8.13. Replacing the gas spring .....................................................................................................54
8.14. Replacing the actuator "standing" .......................................................................................55
8.15. Replacing the actuator "lift" ................................................................................................55
8.16. Replacing the actuator "lying" ............................................................................................56
8.17. Replacing the safety cut-out................................................................................................56
8.18. Replacing bulbs ...................................................................................................................57
8.19. Replacing the light (front, white) ........................................................................................58
8.20. Replacing the indicator........................................................................................................58
9. Testing the wheelchair ............................................................................................................59
10. Cleaning....................................................................................................................................59
11. Technical information.............................................................................................................60
11.1. Measurements (metric)........................................................................................................60
11.2. Measurements (imperial).....................................................................................................61
11.3. General technical information.............................................................................................62
11.4. Electromagnetic Interference (EMI) ...................................................................................63
4

LEVO combi & combi JR
INSTRUCTIONMANUAL
Please read these instructions carefully
before attempting to use your wheelchair
5

Possible positions
LEVO combi
Seating position (standard)
LEVO combi
Seating position
plus lift (option)
6

LEVO combi
Lying position (option) and
armrest mechanism for reclined
position (option)
LEVO combi
Standing position (standard)
7

LEVO combi
Relax position (option)
LEVO combi
Sitting position shown with
powered reclining backrest
and legrest (options).
8

LEVO
Declaration of Conformity
As manufacturer of the LEVO Stand-up wheelchair, the company
LEVO AG
Anglikerstrasse 20
CH-5610 Wohlen
Switzerland
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Internet: http://www.levo.ch
declares in all responsibility that the product hereby mentioned (see following list)
corresponds with the valid direction of the EC instructions for medical products determined
14th June, 1993 (93/42/EWG).
Moreover we declare valid the correspondence of this products with following norms /
nominal documents:
EN 12 184 Electrically powered wheelchairs, scooters and their chargers
UNI 14971 Medical Equipment – Risk Management
EN 60601-1-2 Medical electrical equipment: General requirements for safety,
electromagnetic compatibility
EN 61000-4-2 Electromagnetic compatibility (EMC): Electrostatic discharge
immunity test
EN 61000-4-3 Electromagnetic compatibility (EMC): Radiated, radio-frequency,
electromagnetic field immunity test
EN 61000-4-4 Electromagnetic compatibility (EMC): Electrical fast transient/burst
immunity test
EN 61000-4-5 Electromagnetic compatibility (EMC): Surge immunity test
Type of stand-up wheelchairs:
LEVO Combi S-M / L-XL
Wohlen, July 1. 2004 Dr. Kurt H. Fischer Thomas Räber
Declaration of Conformity
9

Seating and Standing Assessment
Seat depth: too long Seat depth: too short
Seat depth: correct
Knee support attachment
screw even with center of knee
Knee support attachment
screw beyond center of knee
Knee support attachment
screw short of center of knee
Knee joint hyper extended Incomplete knee extension
Ankle/Knee/Hip joint straight
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Correct position
Back too deep/thick
Backrest cushion or solid
back for more comfort or
stability
Seat cushion too high
Cushion for pressure relief
in seated position
Backrest
cushion
Seat
cushion
Pelvis tilt !
incomplete hip
extension
Hyper extended
spine
Backrest
cushion
High
pressure
Hyper
Lordosis
Spine
physiological
Seat
cushion
Legs straight
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1. Introduction
Thank you to choose the LEVO combi.
The LEVO combi has been designed as a powered stand-up wheelchair for indoor and
outdoor use. As such it belongs to the wheelchair category B.
The LEVO combi makes it possible to stand-up and to drive in a standing as well as in a
sitting position; all these functions are powered. (As an option there are more functions beside
sitting and standing available.) The mentioned functions provide to the users great
independence.
The LEVO combi is made for everyone whose muscles do not support them to propel a
wheelchair manually. The LEVO combi is a unique aid for those facing difficulties in
standing and walking.
The LEVO combi has been designed for older children and adults who will benefit from
motorised mobility and the ability to stand up at will.
All functions are powered and it is easy to change position by using a joystick. The standard
model of the LEVO combi allows comfortable sitting and standing on every stage between the
sitting and the complete standing position. Driving is possible in all stages.
As an option the LEVO combi model includes a powered seat lift and/or a reclining back. The
seat tilt function comes with the seat lift in a wide range of angles and correlating to the seat
height, respectively the space between the battery cover and the seat plate in a limited range.
Seat tilt in combination with the backrest reclining function allows the user to be in a most
comfortable position called “relax”, which means the seat plate is tilted at its end, the backrest
is reclined and the feet rest is raised.
As further option “lying to standing directly” can be chosen.
The wheelchair has two drive wheels in the middle, two castors at the front and one security
back wheel. This construction allows easy steering. The LEVO combi is constructed with a
mid wheel drive for the smallest turning circle. The turning radius is 57,5 cm or 22,6 inches.
For easier transportation it is possible to detach the back. The armrests lift up for easy
sideways transfer.
The seat and backrest are fully adjustable to meet the needs of a wide range of users.
The maximum load weight is 120 kilograms or 265 pounds; this includes all personal
belongings carried along too.
The LEVO combi is certificated with a
-sign. This product corresponds to the regulations
notified as 93/42 EWG.
Several technical features of the LEVO combi are protected by patents. LEVO AG possesses
the US-Patent No. 5’964’473 and patents pending in other countries.
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2. Warranty
Your LEVO product is guaranteed from the date of purchase for:
!Two years covering all material and manufacturing defects of mechanical parts.
!One year covering all electronic components including the motors.
!Batteries are excluded from the warranty.
LEVO AG will not repair or replace free of charge any part or parts found to be defective due
to abuse, misuse or lack of maintenance.
Warranty claims should be directed to:
!In Switzerland LEVO AG
!Other Countries To your local agent
Addresses and telephone numbers are given on the front page.
3. Delivery
3.1. Despatch and transportation
For delivery all LEVO wheelchairs are packed in a big cardboard box. The back is detached
for careful packing. Especially sensitive parts have extra protection to avoid any damages
caused by transportation. All wheelchairs are carried by lorry or air freight.
3.2. Delivery
Because of the complex nature of this wheelchair it will be delivered and demonstrated to you
by your local agent.
The wheelchair comprises the following components:
Item Component Number
Wheelchair base 1
Seat unit 1
Backrest unit 1
Knee support 1
Chest strap 1
Footrest 1
Set of batteries 1
Joystick unit 1
Battery charger 1
Accessories as on delivery note Corresponding to order form
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3.3. Storage
The ideal condition to store the LEVO combi is a temperature between – 40° and + 60°
Celsius (between -30° and +140° Fahrenheit). The humidity should not be above 90%. Please
take care to guarantee these mentioned conditions to provide a long life time for the LEVO
combi.
4. Accessories
There are many kinds of suitable accessories to the LEVO combi. A list of accessories is
available from your local agent.
5. Warning
For your own safety you should read and carefully follow all instructions in the manual.
!Before using the LEVO combi, have your LEVO dealer explain the instructions to you. It
also helps if you have a friend to listen as well. Study the instruction manual yourself or if
you cannot understand it, get a friend to help you doing so. Don't hesitate to ask for any
explanation.
!The LEVO combi is designed for outdoor and indoor use. In principle it is not
recommended to drive on uneven, soft or steeply sloping ground. Using the LEVO combi
outdoors switch on the lights at dawn and dusk and in the dark of course.
!Avoid driving through puddles. The wheelchair and especially electrical components are
very sensitive to too much water even some splashes of water don't harm. (There is a
danger of false function regarding some electrical parts getting too wet.)
!It is not recommended to drive long distances in the standing position in outdoor areas.
This function is meant for moving around standing indoors, as in the kitchen or in the
office for examples.
!The LEVO combi is a complicated piece of machinery. Do not attempt to maintain it
yourself. For all maintenance work, please contact an authorized dealer. It is
recommended that your authorized dealer is in charge to services the wheelchair once
every year.
!Standing up stresses your body in ways you may not be used to. Therefore we recommend
you to consult your doctor or physical therapist before using the LEVO combi.
!The LEVO combi is only allowed to bring you into the stand-up position when the free
wheel device is "ON", this guarantees the motor brakes function correctly.
!We recommend to stand-up only when in company in case of sudden spasticity,
convulsions and similar problems.
!To eliminate a potential risk of tipping while driving in the standing position, the LEVO
combi features a tilt switch. The tilt switch system prevents to drive in the complete or
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almost complete standing position on ground showing a wide downtilt. Increases the
downtilt to 3 degrees (only at downhill rides), it will be impossible to continue to drive in
the complete or almost complete standing position. To drive on lower the seat,
respectively reduce the standing angle.
!Before standing up it is absolutely vital that the knee support and chest strap are fitted
correctly (see section 8) and the two backrest locking pins are properly located. Always
check these pins so they are fully in place each time you use the wheelchair.
!Important: Check if the quick release axles are fitted correctly into the leg rest tubes and
so the footplate is fixed securely at the leg rest pieces.
!The following symbols are to be found on the wheelchair:
Warning, risk of pinching! Make sure no parts of the body, clothing or other
items get jammed.
Warning, read user’s manual!
Caution: Federal law restricts this device to sale by or on the order of a medical professional
licensed by the law of the State in which he /she practices.
You should under no circumstances attempt to stand up without following all safety
precautions.
6. Preparing the wheelchair for use and operation
A specialist should be responsible for first adjustments and he should get the chair ready for
operation.
!Please make sure that all components listed are delivered with the chair. Check the list
shown in sector 3.2.
6.1. LEVO combi standard backrest
Information about the assembly of the LEVO combi standard backrest is printed under the
sector 7.6. The standard backrest is not developed for quick fitting and removing.
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6.2. V-Trak backrest system (optional)
Fitting and removing the V-Trak backrest
!Lift both backrest levers (A) at the back shell the
way that they can turn freely.
Fitting:
1
A
B
!For fitting the back stick the clamp bolt of both
backrest levers in the tubes of the connecting
piece (B) of both backrest tubes. The back shell
should be in front of the backrest tubes for
fitting. For fixing both backrest lever (A) push
them down. (See picture 1).
Removing:
!For removing the back fold the backrest lever
(A) up on both sides. Now lift the backrest up
and remove it.
6.3. Further preparations
!Fold down the footrest.
!Put the seat upholstery on the seat. Fix the upholstery on the seat metal plate using the
velcro fastener.
!Screw the joystick module to the intended holder at the armrest.
!Plug in the control cable behind the joystick module.
!Check that the free wheel device is clicked shut and the motor brakes function. (For more
information about that subject consult sector 14)
!Ensure that the main fuse below the battery cover is put on.
7. First adjustments
7.1. Seat depth
The seat depth has to be adjusted to the length of the upper legs. Precise adjustment is very
important considering a perfect sitting and standing position. Let a specialist adjust your seat
depth according to the measurements indicated on the order form.
For an individual adjustment of the seat depth it is necessary to change four components:
1. Seat support plate
2. Both seat supports
3. Adjusting lever on the right hand side
4. Adjusting lever on the left hand side
Is the LEVO combi equipped with the option reclining backrest, it is also necessary to adapt
the adjustable plates of the actuator for backrest reclining.
(See picture 4, B)
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The seat cushion is fixed on the adjustable plate of the seat support made of metal.
!Detach the seat cushion first.
!Move the seat in a more upright position using the joystick module for easier access.
!Switch off the joystick module as well as the fuse automatic.
!Remove the four adjusting screws on the seat support plate using a 4 mm hexagon key, to
adjust the depth of the seat support plate. (See picture 2).
3
A
2
Extending plate
Seat support plate
Velcro fastener for seat
cushion
Ad
j
ustable screws
!Remove two screws (A) at each seat support using a 4 mm hexagon key. (See picture 3).
Pull or push the seat support in the requested position and tighten the screws.
(all positions must be adjusted to the same number, see positions-marks in picture 3a and
3b)
!Push the extending plate to the corresponding position and also tighten the screws.
(See picture 2).
Marks
3a 3b
4
B A
For any changes of position regarding the adjusting lever
and the adjustable plates of the actuator for backrest
reclining, please follow the instructions:
!Remove both screws (A) from the adjusting lever using
a 4 mm hexagon key. (See picture 4).
!Remove all together four screws (B) from the adjusting
plates of the actuator for backrest reclining using an 6
mm hexagon key. (See picture 4).
!Push or pull the adjusting lever and the adjusting plate
to the correspondent position and tighten all screws.
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Important: When changing the seat depth please take care that all four components (seat
support, extending plate, adjustable lever and adjustable plate) are adjusted at the same time!
All four components must be fixed at exactly the same position (see picture 3 and 4).
7.2. Seat cushion
The seat cushion is shaped in such a way at the front edge to provide you the most comfort
and the ideal distribution of pressure. The cushion will be fixed with a Velcro fastener so it
doesn't move around. For fixation just put it on the seat and push it down.
5
The edge in front of the cushion is shaped to cover
optimally the seat. (See picture 5).
There is the possibility to use seat cushions from other
manufacturers. We recommend a leg protector to avoid any
risk of pressure ulcers at the front edge of the seat.
The leg protector is available as an option. (See picture 5a).
For more information please contact your local specialist.
5 a
7.3. Footplate
The adjustment of the footplate is possible in between a
range of 13 cm/5” (8 different positions of holes (D) with
a distance of 18 mm/0.07” from one to the next).Adjust the
height of the footplate removing both hexagon screws (A)
by using a 6 mm and a 10 mm hexagon key (see picture 6).
Lift the footplate to the requested height and tighten the
screws.
6
C
D
A
B
!In case the footplate is meant to be fixed at the most
upper position, so replace the quick release axle by a
hexagon screw (A).
For transportation the footplate and the leg rest tubes can
be detached.
Use the lift function or put the chair in the lying position.
!Push the button in the center of the quick release (B)
and pull these pieces out of both leg rest. (See picture
6).
!Remove the leg rest including the footplate.
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7A
The angle of the footplate can be changed in a range from
minus 5° to plus 15° to the horizontal level. To put the angle
of the footplate in the requested position adjust the two
threaded pins (A) below the footplate using a 6 mm hexagon
key. Turn the pins in or out just the way needed to get the
requested angle of the footplate.
Caution: Both pins must touch the leg rests when the
footrests are in a flip-down position.
7.4. Armrest
The armrest can be put in a flip-up position for an easy transfer sideways. This also allows a
better access to the chair. (See picture 8).
A
810
9B
The height of the armrests is fully adjustable in between a range of 14 cm/5.5” to 33 cm/13”;
the height of the armrest is measured from the upper edge of the seat cushion to the upper part
of the armrest.
!Loosen the cylindrical screw on either side of the armrest joints using a 5 mm hexagon
key. (See picture 9).
!Now push the connecting rod and the armrest joints along the backrest tube for the ideal
position.
!Tighten the cylindrical screw on the right and left side.
The angle of the armrest is also adjustable.
!For lifting the armrest in front turn the threaded pin in (B) using a 2,5 mm hexagon key.
Turn the pin clock wise further in the armrest joints. (See picture 10).
!For lowering the armrest in front turn the threaded pin out (B) using a 2,5 mm hexagon
key. Turn the pin counter clock wise further out of the armrest joints. (See picture 10).
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The support of the joystick module can be swung away to the side and further pushed back.
This allows the wheelchair user to get closer to the table.
!Push the release catch (A) to the side and backwards
simultaneously (see picture 11). Now move the joystick
module first to the side and then backwards.
11
A
As a further option the LEVO combi features a tilted armrest mechanism. (See picture 24 on
page 22). Armrests tilting while changing position from sitting to lying, provide most comfort
to the user, because his arms are horizontally well-positioned and they feel continuously
stable. This function is set on the program and, therefore, there is no action necessary. The
tilted armrest mechanism also function reversed, that means that the armrests raise, when the
chair is moved back from the lying or relaxing position to the sitting position or as well when
activating the function (optional) “lying to standing directly”. During both actions the
armrests move in such a way that the user’s arms are lying stable and comfortably on it.
Caution: Do not use the joystick as a support. Please use the armrests to support you when
transferring to another chair or to the bed or back to the LEVO combi.
Caution: To prevent the risk of snapping off the joystick module, please be careful and avoid
hitting the joystick against any object.
7.5. Low shearing at the back
The LEVO combi is equipped with a new low shearing
mechanism (see picture 12) which eliminates the shearing
movements for most comfort as a user benefit in a sitting
as well as standing position. This shearing mechanism
counteracts to the shifting of the wheelchair's back
towards the upper body of the user. This shifting
movements were often considered as uncomfortable.
Thanks to the low shearing mechanism the LEVO combi
feels like tailor made in each position. The most
comfortable stand-up motion is also realized by the fact
that the distance between the armrest and shoulders stays
constantly the same.
12
A
9 cm
The new unique low shearing mechanism is adjustable to the individual body measurements
using correlatively one of the three different positions to mount the connecting piece (A).
As a standard the connecting piece is fixed to middle drill hole; this means the medium
adjustment and the compensation of 9 cm / 3.5". Fixing the connecting piece on one of the
other holes the compensation will be of 8 cm / 3", respectively 10 cm / 4". Please read the
service instructions for more information about this subject. (Service instruction section 8.6.)
20