Levo Combi, Combi JR Service Manual
LEVO combi /combi JR
SERVICE MANUAL
This manual is for use by LEVO AG agents or their authorized 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.
Version 1.2
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Inhalt
1 Introduction ................................................................................................ 3
2 Disinfect ..................................................................................................... 3
2.1 Areas which has to be disinfected .............................................................. 3
2.2 Procedere ............................................................................................... 3
3 Health & safety ............................................................................................ 4
4 Adjustments................................................................................................ 4
4.1 Seat depth ............................................................................................. 4
4.2 Low shearing at the back ......................................................................... 4
4.3 Adjustment of the backrest ...................................................................... 4
5 Electronic control system .............................................................................. 5
5.1 Programming R-Net and VR2 .................................................................... 5
6 General repair instruction ............................................................................. 7
7 Tools & torque settings ................................................................................. 7
8 Important information .................................................................................. 7
9 Recommended safety checks ......................................................................... 8
10 Cleaning ..................................................................................................... 9
11 Repairs ..................................................................................................... 10
11.1 Replacing the drive wheels ..................................................................... 10
11.2 Replacing the tire of a drive wheel ........................................................... 10
11.3 Replacing the front wheels ..................................................................... 11
11.4 Replacing the back wheel ....................................................................... 11
11.5 Replacing the gas spring of the rear wheel ............................................... 12
11.6 Replacing the wheel fork (front and rear) ................................................. 13
11.7 Replacing of the rear fork ....................................................................... 13
11.8 Replacing the connector of the back low shearing system ........................... 14
11.9 Replacing the driving motor .................................................................... 15
11.10 Replacing the batteries .......................................................................... 16
11.11 Battery Wiring ...................................................................................... 16
11.12 Replacing the Joystick module R-Net ....................................................... 17
11.13 Replacing the power module R-Net .......................................................... 17
11.14 Control box .......................................................................................... 18
11.15 ISM-Box ............................................................................................... 18
11.16 Replacing the gas spring ........................................................................ 19
11.17 Replacing the actuator “standing”............................................................ 20
11.18 Replacing the actuator „Lift“ ................................................................... 21
11.19 Replacing the actuator “lying” ................................................................. 22
11.20 Replacing the "legrest" actuator .............................................................. 22
11.21 Replacing of lights and indicators ............................................................ 23
11.22 Front Light ........................................................................................... 23
11.23 Back Light ............................................................................................ 23
11.24 Indicators ............................................................................................. 24
12 Main fuse .................................................................................................. 24
13 Testing the wheelchair................................................................................ 24
14 Version Management .................................................................................. 25
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1 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 authorized dealer
should carry out a safety check at least once per year.
This service manual is to be used by the LEVO agent or authorized 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 Disinfecting
Before carrying out any service work it is advisable to disinfect. Use for disinfecting
ready, alcohol spray, which are suitable for whole areas e.g. "Germex spray" the
company Pramol chemistry
2.1 Areas which has to be disinfected
Armrest and Joystick
Back upholstery
Seat
Legrest
Footrest
Knee support
2.2 Procedere
Cover the Chassis with plastic films or the like as to protect them from corrosion.
Clean them. Above components with a water hose or better with a water hose
and a mild soap solution
Enter and leave the agent at least one minutes affect the above components with
a disinfectant spray.
Do not dry completely the components.
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3 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.
Please note all regulations and rules about safety in electronics and mechanics.
4 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.
The body-related settings of your LEVO combi are to be adapted precisely to
the needs of the patient. Improper settings can cause serious physical injury
to the user!
4.1 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.
4.2 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.
4.3 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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5 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.
5.1 Programming R-Net and VR2
The programming is done by dubbing the control software of a laptop or PC to the
Controller of the wheelchair. Laptop / PC must be equipped with the appropriate PGDT
software.
• Start the software on your laptop / PC.
• Insert the read-in between the cable ends of the control panel cable and the
Controller; the interface is located below the armrest.
• Connect via the USB interface, the read-in on the laptop / PC.
• Transfer the program
The drive programs are made to give the user more ease of use and even better
drive characteristics.
All will be fitted with standard programs that provide the user with different
standard profiles programmed in the drive software.
The benefit for the user is that there is a more flexible way of speed and driving
settings in the chair, for both indoor and outdoor use.
Because multiple profiles per ordered speed setting are used, you do not need
to make the choice for the Standard, Classic and Fun at the order form
anymore.
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Motor setting improvements:
To optimize the current through the motors when they are pushed to their
limits, we have improved some parameters in the motor settings section of the
drive software.
Your benefits with these improvements are that the motors will be driven
towards their limits in a less intense way, which gives the motors a more
durable and longer life during extreme situations.
To perform a smoother start and stop of the on slopes, we have optimized the
motor compensation value. Now the user of the chair will experience nearly no
rollback when coming to a full stop or when starting to drive on a slope.
Service Instructions:
The new programs can be downloaded from the secured Login section of the
LEVO website: www.levo.ch
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6 General repair instruction
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 or on the homepage www.levo.ch
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.
• Locknuts must never be reused, but must be replaced by new ones.
• Secure each screw connection against inadvertent release. Use lock nuts or screw
securing adhesive, medium strength.
• Repairs to engines and electronic components must only be performed by the LEVO.
7 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
Torque settings:
Bolt size
Torque Nm
M4
3
M5
6
M6
10
M8
25
M10
50
8 Important information
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.
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9 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 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.
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.
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