Levo AG Combi User manual

LEVO combi /combi JR
SERVICE MANUAL
This manual is for use by LEVO AG agents or their authorised dealers.
Read these instructions before servicing the wheelchair.
This service manual must be read in conjunction with the user manual.
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.

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Contents
SERVICE MANUAL ................................................................................... 1
2. Health & safety ................................................................................... 3
3. Adjustments ....................................................................................... 3
3.1. Seat depth...............................................................................................3
3.2. Low shearing at the back...............................................................................3
3.3. Adjustment of the backrest.............................................................................3
3.4. Electronic control system ..............................................................................4
4. Repairs: general instructions.................................................................... 4
5. Tools & torque settings .......................................................................... 4
6. Important points .................................................................................. 5
7. Recommended safety checks .................................................................... 5
8. Cleaning ........................................................................................... 7
9. Repairs ............................................................................................. 7
9.1. Replacing the drive wheels.............................................................................7
9.2. Replacing the tire of a drive wheel ....................................................................7
9.3. Replacing the front wheels .............................................................................8
9.4. Replacing the back wheel ..............................................................................8
9.5. Replacing the gas spring of the back wheel...............................................................9
9.6. Replacing the wheel fork (front and back) .......................................................... 10
9.7. Replacing the connector of the back low shearing system.......................................... 10
9.8. Replacing the motor disengaging cable (free wheel device)........................................ 11
9.9. Replacing the driving motor ......................................................................... 12
9.10. Replacing the batteries ............................................................................... 13
9.11. Replacing the joystick module R-net ................................................................... 13
9.12. Replacing the power module R-net..................................................................... 14
9.13. Replacing the gas spring ............................................................................. 15
9.14. Replacing the actuator “standing” ................................................................... 16
9.15. Replacing the actuator “lift” ......................................................................... 16
9.16. Replacing the actuator “lying” ....................................................................... 17
9.17. Replacing the safety cut-out ......................................................................... 17
9.18. Replacing bulbs....................................................................................... 18
9.19. Replacing the light (front, white) .................................................................... 19
9.20. Replacing the indicator............................................................................... 19
10. Testing the wheelchair ......................................................................... 20
11. Cleaning ......................................................................................... 20
12. Technical information.......................................................................... 20
12.1. Measurements (metric)............................................................................... 20
12.2. Measurements (imperial)............................................................................. 21
12.3. General technical information ....................................................................... 22
12.4. Electromagnetic Interference (EMI) ................................................................. 23
13. Crash Test protocol............................................................................. 24

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Introduction
Apart from regular charging of the batteries and keeping the wheelchair clean the
LEVO combi is maintenance-free and no attention is required by the user.
Because of the complexity of the wheelchair the LEVO agent or authorised dealer
should carry out a safety check at least once per year.
This service manual is to be used by the LEVO agent or authorised dealer. The
manual gives information on how to perform a safety check and carry out repairs to
the LEVO combi. This manual provides a good service to the persons in charge of the
maintenance of the LEVO combi. And of course, the user appreciates the safety and
the reliability of a well maintained wheelchair.
This manual must always be read and used with the user manual.
2. Health & safety
Accidents do occur. When working on or testing the wheelchair be aware of the
dangers and take care to ensure your own and other peoples health and safety.
3. Adjustments
The majority of the adjustments can be carried out by the user or his family and are
covered in the instruction manual. However, the LEVO agent should always, on
delivery, adjust the wheelchair to suit the user.
3.1. Seat depth
The adjustment of the seat depth should only be done by the LEVO agent or
authorised dealer. For information consult the user instruction manual at section 7.1.
3.2. Low shearing at the back
The adjustment of the low shearing at the back should only be done by the LEVO
agent or authorised dealer. For information consult the user instruction manual at
section 7.5.
3.3. Adjustment of the backrest
The adjustment of the backrest should only be done by the LEVO agent or authorised
dealer. For information consult the user instruction manual at section 7.6. and 7.7.

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3.4. Electronic control system
The preset settings are chosen to ensure safe operation. The settings are in
compliance with all relevant legal requirements regarding the entire operating range
of the joystick and the speed control. In case the preset settings don’t meet the needs
of the user, the control system can be programmed individually; the maximum speed
might be decreased for example.
Warning: Programming should only be conducted by healthcare professionals
with in-depth knowledge of Penny&Giles electronic control systems.
Incorrect programming could result in an unsafe set-up of a wheelchair for
the user. LEVO AG accepts no liability for losses of any kind if the drive or
stability characteristics of the wheelchair are altered without prior
notification and discussion with LEVO AG.
It is in the responsibility of the person programming the control system to make sure
that the stopping distance requirement specified for the country in which the
wheelchair will be used is satisfied. If the braking rate is low, the forward and reverse
maximum speed settings may need to be re-programmed. It is in the responsibility of
the person programming the control system to make sure that the settings are safe
and to note any programming changes made.
4. Repairs: general instructions
Only a LEVO agent or their authorized dealers should carry out servicing and repairs
to the LEVO combi.
!Repairs: For advice in all repairs in Switzerland contact LEVO AG, Switzerland. For
all other countries contact your local LEVO agent. Addresses are given at the front
of this service manual.
!Major repairs: For all major repairs, e.g. bent or damaged frame, always replace
complete components. Never try to repair damaged steel work or components.
!Replacement parts: Factory replacement components should be used in all repairs,
these are available from LEVO AG. To order parts see the parts list drawings and
the correlative list, both available at LEVO AG.
5. Tools & torque settings
The following tools are required to service the wheelchair:
!Spanners and sockets: 8 mm through to 24 mm.
!Hexagon key: 2 mm through to 8 mm.
!Screwdrivers: 1 Nm through to 50 Nm.
!Phillips head screwdriver and slotted screwdriver
!Soft headed hammer
!Snap through tool

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Torque settings:
Bolt size Torque Nm
M4 3
M5 6
M6 10
M8 25
M10 50
6. Important points
!Do not reuse nuts. Always replace with a new nut.
!Always use thread locking compound.
!Always use recommended components and parts available from LEVO AG.
!Do not modify or repair the frame.
!LEVO AG is responsible for any repairs on gas springs, motors and electronic
parts.
7. Recommended safety checks
The following safety checks should be carried out at least once per year. This should
be done by a LEVO agent or authorized dealer. If a fault is found do not allow the
wheelchair to be used until it has been corrected.
!Make sure that the backrest, options and additional material is fixed safely. Using a
V-Trak backrest system check the lever of the backrest. All levers have to be
completely pushed down. Repair any fault found immediately.
!
!Examine the wheelchair frame for any damage. Replace any damaged or faulty
components.
!Examine the condition of the seat cushion and the backrest cover (standard
version), respectively the therapod back shell cover (V-Trak backrest system) and
replace if necessary.
!Examine condition of all harnesses, straps and buckles and replace if necessary.
!Examine and operate the footrest mechanism. Replace any damaged or faulty
components.
!Examine nuts, bolts, pivots and frame plugs for tightness and general condition.
Replace any faulty components.
!Examine the rear wheel, the front wheels and their castors for free rotation and
security. Optimize the rotation and repair any fault found.

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!The tires are maintenance-free besides occasional cleaning. Use a damp cloth for
cleaning. Tires must get replaced when the tire’s profile is worn down. (For more
information please consult sector 8.1. to 8.4.).
!Check the free wheel device and the motor disengaging lever for correct operation.
Repair any fault found.
!Check the mechanical function of the motor disengaging lever. Pull the motor
disengaging lever out and turn it simultaneously to the OFF position. At this stage
it should be possible to push the wheelchair. Pull the motor disengaging lever out
and turn it simultaneously to the ON position to activate the motor brakes. The
power wheel should be blocked now. In case the power wheels are not completely
blocked, it is absolutely necessary to replace the motor.
!Check the powered function of the motor disengaging lever. Switch on the joystick
module and start driving forwards. Let of the joystick. As a reaction the wheelchair
should stop and the solenoid brakes of the motor should snap in evidence. Repeat
this check driving backwards and to each side. In case the motor brakes don’t
function correctly check the battery indicator on the joystick module for any failure
indication. Consult the controller self help guide (user manual sector 23) for details
about failure indications.
!Make sure all the connectors are properly inserted, that the brake solenoids are
energized and that the solenoid coil is not open or short-circuited by testing the
two bigger pins on the motor lead plug. If necessary, replace the motor.
!Check all electrical cables and wires for chafing and clamp spots. Replace if
necessary.
!Check all electrical connectors for corrosion and security. Replace if necessary.
!Clean the batteries and terminals. Test the battery capacity and advise the
customer of their condition. Charge the batteries before returning the wheelchair
to the customer.
!Check all MODE functions as standing-up and sitting as well as the optionally
added functions (lift, backrest reclining, seat tilt, lying to standing directly). Repair
any fault found.
!Check all lights and indications. Replace components with failures.
!Use all functions and drive the wheelchair as a final check. In case you notice any
kind of problems arrange the fixing.

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B
A
1
8. Cleaning
Before returning the wheelchair to the customer ensure the wheelchair is
clean and well presented:
!If there is any dirt it should be cleaned off using a damp cloth and then dried
thoroughly.
!For more stubborn stains wipe with a damp cloth using a mild solution of warm
water and soap.
!Never use furniture polish or any fluids containing alcohol to clean the
frame.
!In case of dirt on the seat cushion cover or the back rest cover, you can remove
both of it and wash it softly. Do not wash it warmer than 40 degree Celsius.
9. Repairs
9.1. Replacing the drive wheels
When removing a wheel, the wheelchair must be unoccupied. The wheelchair must be
supported (B) so that it neither falls over or moves when a wheel is removed.
!Pull off the protective end cap which covers the
countersunk screw.
!Remove the countersunk screw (A) using a 5 mm
hexagon key.
!Remove then the black washer (F, picture 2).
!Withdraw the wheel from the wheelchair.
!To mount the new wheels follow the instructions in the
reverse order.
9.2. Replacing the tire of a drive wheel
When replacing the tire, means removing a wheel, the wheelchair must be
unoccupied. The wheelchair must be supported so that it neither falls over or moves
when a wheel is removed.
!Remove the drive wheel as described in sector 8.1.
!Remove the four black countersunk screws (G) to take the flange © of the wheel
using a 5 mm hexagon key.
!Remove five screws (H) of the rim using a 6mm hexagon key.
!Withdraw the rims (B1 and B2) from the tire (A).
!Reassemble in reverse order.
!To fit the rims to the tire use gunk to make it easier.

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A
3
H
C B22
D E
B1 A
F G
Important: Take note of the circulation direction indicated on the tire
before fixing.
9.3. Replacing the front wheels
When removing a wheel, the wheelchair must be unoccupied. The wheelchair must
be supported so that it neither falls over nor moves when a wheel is removed.
!Pull off the protective end caps from the axle.
!Loosen the hexagon screw and washer using a 13
!mm hexagon key and remove the screw, the
!washer and the nut (A).
!Withdraw the wheel from the fork.
!Reassemble the new wheel in reverse order.
!Make sure all washers are placed correctly!
9.4. Replacing the back wheel
When removing the wheel, the wheelchair must be
unoccupied. The wheelchair must be supported so that
it neither falls over or moves when the wheel is
removed.
!Loosen the screw (A) using a 6 mm hexagon key
and remove the screw, the washer and the nut.
!Withdraw the back wheel from the fork.
!Reassemble the new wheel in reverse order.
!Make sure all washers are placed correctly!
A
4

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9.5. Replacing the gas spring of the back wheel
!Lift the back wheel up with a clamping set.
!Remove the supporting handle notice.
!Loose the clamping set, so that the gas springs are
relieved.
!Remove the securing clips at both gas springs above
and below with a screwdriver.
!Now you can take off the gas springs from the ball
pin and exchange them.
!Install everything again in reverse order.
4a
4b
4c
4d

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A
5
9.6. Replacing the wheel fork (front and back)
When removing a wheel and/or a wheel fork, the
wheelchair must be unoccupied. The wheelchair must be
supported so that it neither falls over nor moves when a
wheel is removed.
!Loosen the hexagon spike (A) at the wheel fork axle
as much as it needs to withdraw the fork from the
mount. (Use a 24 mm hexagon key.)
!Replace the wheel fork.
!Reassemble the used wheel in case it is still in a
good condition. Doing so please follow the instruction
in sector 8.3. respectively 8.4.
!Mount the new wheel fork in the reversed order.
(Picture 3 shows all parts in details.)
9.7. Replacing the connector of the back low shearing system
As a standard a connector of medium size is fixed. The shearing range regarding
the back movement is 9 cm / 3,5”. The replacement of this connecting piece using
a shorter or a longer piece causes a variation of 8 cm / 3” respectively 10 cm / 4”
of the shearing range.
!Raise the seat to its maximum upright standing
position.
!Switch off the joystick module.
!Loosen the fillister head screw at the backrest tube
as well as the double-head screw at the seat plate
using a 4 mm hexagon key.
!Remove the mentioned screws, the washers and the
connector.
First mount the upper end of the new connector at the
backrest tube. Make sure to put the two washers back in
place.
After that mount the lower end of the new connector at
the seat plate using the corresponding punched hole (A
on picture 6
and 7). Again make sure to put the two washers back in
place.
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