06 Maintenance 2.1.0 en

Chapter 6: Maintenance
6 Maintenance
Contents
Page
6 Maintenance............................................................................................... 6-1
6.1 Intervals....................................................................................................... 6-5
6.2 Annual maintenance.................................................................................... 6-6
6.2.1 Required tools......................................................................................... 6-6
6.2.2 Internal modules (annual maintenance) .................................................. 6-7
6.2.3 Opening the rear panel ........................................................................... 6-9
6.2.3.1 Vaporizer holder ............................................................................... 6-10
6.2.3.2 O-Ringe water trap holder ................................................................ 6-11
6.2.3.3 Replacement internal O2 measurement cell (fresh gas) .................... 6-12
6.2.3.4 Bacteria filter pressure sample line ................................................... 6-13
6.2.3.5 Closing the rear panel ...................................................................... 6-14
6.2.4 Anesthetic vaporizer.............................................................................. 6-15
6.2.5 Swiveling connector (docking)............................................................... 6-16
6.3 10,000 hr. Maintenance (every 3 years)..................................................... 6-19
6.3.1 Required tools....................................................................................... 6-19
6.3.2 Replacing the batteries ......................................................................... 6-21
6.3.3 Replacing device fuses ......................................................................... 6-22
6.3.4 Vaporizer holder.................................................................................... 6-23
6.4 20,000 hr. Maintenance (every 6 years)..................................................... 6-24
6.4.1 Required tools....................................................................................... 6-24
6.4.2 High pressure connections (pressure reducer)...................................... 6-25
6.4.2.1 Removing the gas box...................................................................... 6-27
6.4.2.2 Replacing the high pressure connections ......................................... 6-28
6.4.3 Replacing pressure regulators connector block..................................... 6-30
6.4.4 Replacing pressure regulators nitrous switch block ............................... 6-31
6.5 Maintenance cartridge (closed loop system).............................................. 6-32
6.5.1 Annual maintenance cartridge (closed loop system) ............................. 6-32
6.5.1.1 Required tools .................................................................................. 6-32
6.5.1.2 Preparation of the cartridge .............................................................. 6-34
6.5.1.3 Bellow holder.................................................................................... 6-35
6.5.1.4 Absorber........................................................................................... 6-36
6.5.1.4.1 Absorber Version I ....................................................................... 6-36
6.5.1.4.2 Absorber Version II ...................................................................... 6-36
6.5.1.5 Flow Sensors.................................................................................... 6-37
6.5.1.6 Slide valve (Cartridge bottom) .......................................................... 6-38
6.5.1.7 Absorber rotary valve ....................................................................... 6-39
6.5.1.8 PEEP Valve...................................................................................... 6-40
6.5.1.9 Emergency air valve ......................................................................... 6-41
6.5.1.10 Insp. / Exp. check valve .................................................................... 6-42
6.5.1.11 Slide valve (Cartridge top) ................................................................ 6-43
6.5.1.12 APL valve ......................................................................................... 6-44
6.5.1.13 O-rings sight glasses ........................................................................ 6-45
6.5.2 3-year maintenance cartridge (closed loop system) .............................. 6-46
6.5.2.1 Required tools .................................................................................. 6-46
6.5.2.2 Opening the cartridge ....................................................................... 6-48
6.5.2.3 Bellow holder.................................................................................... 6-51
6.5.2.4 Absorber........................................................................................... 6-52
Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-1

6.5.2.4.1 Absorber Version I ....................................................................... 6-52

6.5.2.4.2 Absorber Version II ...................................................................... 6-52
6.5.2.5 Flow Sensors.................................................................................... 6-53
6.5.2.6 Slide valve (Cartridge bottom) .......................................................... 6-54
6.5.2.7 Absorber rotary valve ....................................................................... 6-55
6.5.2.8 PEEP Valve...................................................................................... 6-56
6.5.2.9 Emergency air valve ......................................................................... 6-57
6.5.2.10 Cartridge top/bottom connector ........................................................ 6-58
6.5.2.11 Intermediate plate check valves........................................................ 6-59
6.5.2.12 Heating connector (intermediate plate) ............................................. 6-61
6.5.2.13 Slide valve (Cartridge top) ................................................................ 6-62
6.5.2.14 Surplus diaphragm (Cartridge top).................................................... 6-63
6.5.2.15 APL valve ......................................................................................... 6-64
6.5.2.16 Assembling the cartridge .................................................................. 6-65
Figures
Page
Figure 1: Opening the rear panel...................................................................................... 6-9
Figure 2: Internal modules................................................................................................ 6-9
Figure 3: Vaporizer holder.............................................................................................. 6-10
Figure 4: Selectatec gaskets .......................................................................................... 6-10
Figure 5: Position water trap holder................................................................................ 6-11
Figure 6: O-rings water trap holder................................................................................. 6-11
Figure 7: O2 cell drive gas generator .............................................................................. 6-12
Figure 8: Bacteria filter pressure sample line.................................................................. 6-13
Figure 9: Close the rear panel ........................................................................................ 6-14
Figure 10: Close the rear panel ...................................................................................... 6-14
Figure 11: Swiveling connector cushioning rings............................................................ 6-17
Figure 12: Swiveling connector sealing rings.................................................................. 6-18
Figure 13: Plateau valve sealing ring ............................................................................. 6-18
Figure 14: Rear panel of battery compartment ............................................................... 6-21
Figure 15: Disconnecting the batteries ........................................................................... 6-21
Figure 16: Connecting the batteries ............................................................................... 6-22
Figure 17: Replace fuses ............................................................................................... 6-22
Figure 18: Vaporizer holder............................................................................................ 6-23
Figure 19: Check valve .................................................................................................. 6-23
Figure 20: Removing the gas box................................................................................... 6-27
Figure 21: Detach high pressure connections ................................................................ 6-28
Figure 22: Removing the high pressure connections...................................................... 6-28
Figure 23: Replacing the high pressure connection........................................................ 6-29
Figure 24: Pressure regulators connector block ............................................................. 6-30
Figure 25: Pressure regulators nitrous switch block ....................................................... 6-31
Figure 26: Removing APL, domes.................................................................................. 6-34
Figure 27: Removing the absorber ................................................................................. 6-34
Figure 28: Removing the cartridge ................................................................................. 6-34
Figure 29: Removing the bellows ................................................................................... 6-35
Figure 30: Disassembling the absorber receptacle......................................................... 6-35
Figure 31: Bellows holder............................................................................................... 6-35
Figure 32: Absorber Version I ........................................................................................ 6-36
Figure 33: Absorber Version II ....................................................................................... 6-36
Figure 34: Flow Sensors ................................................................................................ 6-37
Figure 35: Slide valve Cartridge bottom ......................................................................... 6-38
Figure 36: Absorber ball valve........................................................................................ 6-39
Figure 37: PEEP Valve .................................................................................................. 6-40
6-2 Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0

Figure 38: Emergency air valve...................................................................................... 6-41

Figure 39: Inspiration/Expiration valve............................................................................ 6-42
Figure 40: Slide valve (Cartridge top) ............................................................................. 6-43
Figure 41: APL valve...................................................................................................... 6-44
Figure 42: Valve domes assembly ................................................................................. 6-45
Figure 43: Removing APL, domes.................................................................................. 6-48
Figure 44: Removing the absorber ................................................................................. 6-48
Figure 45: Removing the cartridge ................................................................................. 6-48
Figure 46: Removing the bellows ................................................................................... 6-49
Figure 47: Disassembling the absorber receptacle......................................................... 6-49
Figure 48: Disassembling the bellows holder ................................................................. 6-49
Figure 49: Dismantling cartridge lock ............................................................................. 6-49
Figure 50: Opening the cartridge.................................................................................... 6-50
Figure 51: Bellows holder............................................................................................... 6-51
Figure 52: Absorber Version I ........................................................................................ 6-52
Figure 53: Absorber Version II ....................................................................................... 6-52
Figure 54: Flow Sensors ................................................................................................ 6-53
Figure 55: Slide valve Cartridge bottom ......................................................................... 6-54
Figure 56: Absorber ball valve........................................................................................ 6-55
Figure 57: PEEP Valve .................................................................................................. 6-56
Figure 58: Emergency air valve...................................................................................... 6-57
Figure 59: Cartridge connector....................................................................................... 6-58
Figure 60: Check valves................................................................................................. 6-59
Figure 61: Inspiration/Expiration valve............................................................................ 6-60
Figure 62: Heating connector ......................................................................................... 6-61
Figure 63: Slide valve (Cartridge top) ............................................................................. 6-62
Figure 64: Surplus diaphragm ........................................................................................ 6-63
Figure 65: APL valve...................................................................................................... 6-64
Figure 66: Closing the cartridge ..................................................................................... 6-65
Figure 67: Lock assembly .............................................................................................. 6-65
Figure 68: Valve domes assembly ................................................................................. 6-66
Tables
Page
Table 1: Contents of annual maintenance kit for internal modules.................................... 6-7
Table 2: Internal module replacement parts ..................................................................... 6-8
Table 3: Contents of swiveling connector maintenance kit ............................................. 6-16
Table 4: Swiveling connector replacement parts ............................................................ 6-16
Table 5 : Contents of maintenance kit for 10,000 hr. maintenance (Item no. 0209066) .. 6-20
Table 6: 6 Year maintenance kit high pressure PIN-Index (0209070)............................. 6-25
Table 7: 6 Year maintenance kit high pressure DIN (0209075) ...................................... 6-25
Table 8: 6 Year maintenance kit high pressure PIN-Index without N2O (0209070-1) ...... 6-25
Table 9: 6 Year maintenance kit high pressure DIN without N2O (0209075-1) ............... 6-25
Table 10: Gas box replacement parts............................................................................. 6-26
Table 11: Contents of 12 months maintenance kit cartridge ........................................... 6-33
Table 12: Contents of 3 years maintenance kit cartridge................................................ 6-47

6.1 Intervals
Every 12 months (maintenance):
• Annual Maintenance (chapter 0)

• Annual maintenance cartridge (chapter 6.5.1)
• System calibration (see chapter System Calibration)
• Tests (see chapter Tests)
Every 3 years or 10,000 operating hours (general overhaul):

• 3-year (10,000 hr.) maintenance (chapter 0)
• 3-year (10,000 hr.) maintenance cartridge (chapter 6.5.2)
Every 6 years or 20.000 operating hours (general overhaul):

• 3-year (10,000 hr.) maintenance (chapter 0)
• 6-year (20,000 hr.) maintenance (chapter 6.4)
• 3-year (10,000 hr) maintenance cartridge (chapter 6.5.2)

6.2 Annual maintenance

All small components, subject to particular mechanical and/or chemical wear and tear (e.g.,
through constant movement and exposure to anesthetic gases) and that cannot be replaced
by the operating personnel, should be replaced during annual maintenance.
An annual maintenance cartridge (see chapter 6.5.1) is also needed.
CAUTION!
The external oxygen measurement cell (if there is one) does not
necessarily require replacement during annual maintenance. Its aging
process depends heavily on the operating conditions, which causes the
service life of measurement cells to vary.
The cells do not need to be replaced until calibration can no longer be

performed. Operating personnel or hospital technical personnel can
replace the cells.
6.2.1 Required tools
Tools required:
• Socket wrench (size: 5.5 mm)
• Allen key (sizes 2mm, 2.5 mm, 3 mm, 4 mm, 5 mm (short))
• Open end wrench (size: 10 mm, 25 mm, 32mm)
• Phillips screwdriver (size 1)
• Torx wrench (size TX20)
• Slotted screwdriver (size 0.4 x 2.5 mm)

(Alternative: balancing instruments for trimming potentiometers)
• Pliers for inner retaining rings
Materials required:
• Internal module maintenance kit (Item no. 0209060)
• Swiveling connector maintenance kit (Item no. 0209055)
• Oxygen grease (Item no. 0150042)

6.2.2 Internal modules (annual maintenance)
Internal module annual maintenance kit (Item no. 0209060):
Module Quan. Item no. Description
Rear panel 1 0209608 Filter for fan leon / leonplus
Vaporizer holder 4 0020005-1 O-ring ckeck valve vaporizer
Generator module 1 0208766 Oxygen cell leon / leonplus
Gas measurement 2 0020166 O-rings for dryline receptacle

1 369-0343-00 Bacteria filter for pressure sample line
Table 1: Contents of annual maintenance kit for internal modules

Internal module replacement parts:
Module Quan. Item no. Description
Vaporizer holder 4 0200499 Check valve, complete
Rear panel 1 0209005 Rear panel (fully assembled)

1 0208705 Adapter board (Rev. 0.3)
1 0208708 Protocol interface (board)
1 0208710 Main board (Rev. 4.3)
1 0208915 Flow Adapter Board
1 0208935 Mains Connection Board
1 0209605 AC/DC converter (power supply module)
1 0209607 Fan screen (complete with filter)
1 0209608 Filter for fan screen
1 0217751 Fan
Generator module 1 0208740 Generator module (complete)

1 0208750 Drive gas generator (complete)
1 0208750-1 Drive gas generator (w/o board)
1 0208750-2 Drive gas generator board (board only)
1 0208751 Fresh gas generator (complete)
1 0208751-1 Fresh gas generator (w/o board)
1 0208751-2 Fresh gas generator board (board only)
Front module 1 0208707 Controller board (complete)

0208800 Rotameter-block
Plateau valve 1 0208770 Plateau valve (block, complete)
Cabling 1 0208931 Fresh gas-O2 cell cable

1 0208701 Battery connector cable
1 0208734 Controller board/adapter board connector
cable
1 0208932 Flow sensor cables (4 pin)
(ACB -> Swiveling connector)
1 0208961 Heat, absorber, PEEP cable
(ACB -> Swiveling connector)
1 0208963 Plateau valve/switch cable
1 0209971 Protocol interface cable
1 0209972 Sensor interface cable
Options panel 1 0208623 Water trap holder (for devices with Oxima
oxygen analyzer)
1 0208635 Water trap holder (for devices with
Servomex oxygen analyzer)
Table 2: Internal module replacement parts

6.2.3 Opening the rear panel
Turn off the system!
Pull out the mains plug (A)! A
Remove screws (B) and open the rear

panel (C).
Also replace the filter on the housing B

fan (D) during this work step.
D C
Figure 1: Opening the rear panel
Figure 2: Internal modules
Important note!
Check whether there are other necessary work steps in addition to annual
maintenance that require opening the rear panel (e.g., replacement of the
high pressure connections for 20,000 hr maintenance).
Danger of electrical shock!

Some tasks require that the open device be running. Unplug the
leonplus / leon from the mains power when performing assembly
work, including opening and closing the device.

6.2.3.1 Vaporizer holder
The outer O-rings of the vaporizer holder (A) need

to be replaced annually.
Selectatec®- and Dräger® - compatible holders

have the same check valves. Maintenance is
therefore the same.
Figure 3: Vaporizer holder
The O-rings (1) and the 4 check valves must be

replaced 1
The following components must be replaced:

No. Quan. Item no. Description
O-ring check valve
1 4 0020005-1
vaporizer
Figure 4: Selectatec gaskets
Important note!
Check whether there are other necessary work steps in addition to annual
maintenance (for 10,000 hr or 20,000 hr maintenance refer to step 0 and
6.4 on page 6-19 respectively 6-24).

6.2.3.2 O-Ringe water trap holder
If the unit comes with a water trap holder (A), the

outer O-rings needs to be replaced annually.
Figure 5: Position water trap holder
1
1
Figure 6: O-rings water trap holder

1 2 0020166 O-ring for water trap holder

6.2.3.3 Replacement internal O2 measurement cell (fresh gas)
Replace the O2 measurement cell (1).

The cell is located above the fresh gas
blender inside the device. 1
Figure 7: O2 cell drive gas generator

1 1 0208766 Oxygen measurement cell
Important note!
The new O2 measurement cell is automatically calibrated during the system test the next time
the device is powered on. The sensor can also be calibrated from the Service menu (see
chapter Calibration Procedure).
CAUTION!
After calibration, run a 100% test to make sure the measurement cell
is functioning properly.
(Chapter 7 Calibration Procedure)

6.2.3.4 Bacteria filter pressure sample line
Replace the bacteria filter (1) in the

pressure sample line of the device.
Figure 8: Bacteria filter pressure sample line

1 1 369-0343-00 Bacteria filter pressure sample line

6.2.3.5 Closing the rear panel
Close the rear panel when all maintenance and calibration tasks are completed. If other
tasks need to be performed, finish those before closing up the device.
Pull out the mains plug!
When you close the rear panel, make

sure the tubes and lines are not
crimped or bent.
Figure 9: Close the rear panel
Screw the rear panel (B) back on the

attachment points (A).
Figure 10: Close the rear panel

6.2.4 Anesthetic vaporizer
The leonplus / leon has Selectatec® - or Dräger® - compatible vaporizer connections for 2
interlock compatible vaporizers. Corresponding products can be obtained from various
manufacturers.
All the anesthetic vaporizers used on the leonplus / leon must be checked and maintained
according to the manufacturer's instructions. The type, scope and intervals of the
maintenance work can vary.
CAUTION!
Conduct all necessary maintenance and service work on the
anesthetic vaporizers as specified in the manufacturer's service
documents.

6.2.5 Swiveling connector (docking)
Swiveling connector maintenance kit (Item no.: 0209055):
Quan
. Item no. Description
1 0020054 O-ring gas supply (fresh gas)

4 0020119 O-ring for gas supply
1 0020156 O-ring plateau valve - docking
6 0020168 O-ring for connection mandrel (small)
2 0020170 O-ring for connection mandrel (big)
Table 3: Contents of swivelling connector maintenance kit
Swiveling connector replacement parts:
Quan. Item no. Description
7 0020159 O-ring damping cartridge

1 0208785 Peep valve (voice-coil)
1 0208786 Peep valve cover
1 0208788 Peep valve cover
2 0209101 Flow sensor socket (incl. cable)
1 0209102 Heating socket (incl. cable)
1 0209128 Absorber switch
1 0209295 Tube holder
Table 4: Swivelling connector replacement parts

Important note!
The O-rings located directly in the recesses on the top of the swivelling
connector have no other function except mechanical cushioning! They do
not come in contact with anesthetic gas nor are they subject to mechanical
loads. Therefore they do not need to be replaced! The leonplus / leon is
even safe to run without these O-rings.
However, missing or damaged rings must be replaced with new O-

rings.
The following parts are to be replaced if necessary:

A 7 0020159 O-ring damping cartridge
A
A
Figure 11: Swiveling connector cushioning rings

It is not necessary to open or to dismount the swing

arm from the device during maintenance.
Only open the swing arm if you have to replace

defective parts on the inside.

1 4 0020119 O-ring for gas supply
Swiveling Connector
O-ring for connection
2 6 0020168
mandrel (small)
O-ring for connection
3 2 0020170
mandrel (big)
O-ring gas supply
4 1 0020054
(fresh gas)
O-ring plateau valve
5 1 0020156
docking station
1
3 1
Figure 12: Swiveling connector sealing rings
Figure 13: Plateau valve sealing ring

6.3 10,000 hr. Maintenance (every 3 years)

The leonplus / leon requires a general overhaul after every 10,000 hours of operation or
every three years, whichever comes first. The work steps for the 10,000 hr. maintenance are
performed in addition to the work steps for the annual maintenance.
A 3-year maintenance cartridge (see chapter 6.5.2) also need to be done!
CAUTION!
During the 10,000 hr. maintenance, all components and modules are
replaced that are not guaranteed to operate for more than 10,000 hours.
All work steps for the annual maintenance and the 3-year
maintenance cartridge are performed in addition!
ESD Hazard!
Make sure you take steps to reduce the ESD hazard to the leonplus /
leon components and modules prior to starting maintenance work. Work
steps that require special attention are marked accordingly with symbols.
Tools required:
• For tools required for 3-year maintenance, refer to page 6-6
• Slotted screwdriver (size 1.2 x 6.5 mm)
Materials required:
• Maintenance kit for 10,000 hr. maintenance (Item no. 0209066)

Maintenance kit for 10,000 hr. maintenance (Item no. 0209066):
Module Quant. Item no. Description
Batteries 2 0208700 Leon Plus / Leon batteries
Rear panel 20 0170024 Fuse 2AT (5 x 20 mm)

(quantity 11 required)
Vaporizer-Holder 1 0209040-1 O-ring Kit check valve

includes:
4 0020005-1 O-ring upper part outside
4 0020081 O-ring valve housing top
4 0020173 O-ring valve housing bottom
4 0020174 O-ring valve housing outside (middle)
4 0020207 O-ring valve housing inside
Table 5 : Contents of maintenance kit for 10,000 hr. maintenance (Item no. 0209066)

6.3.2 Replacing the batteries
Pull out the mains plug!
Remove both left screws (A) on the bottle

holder and the screws (B) to remove the back
panel.
Figure 14: Rear panel of battery compartment
Pull off the exhaust air tube (C) D
Loosen the screws (D) enough to

allow you to lift the battery holding
plate (E) and remove the batteries. E
D C
E
Figure 15: Disconnecting the batteries

1 2 0208700 Battery Leon / Leon plus

Remove the wires from the battery

connections (G)!
Replace both batteries!
Make sure you insert the new

batteries with the poles in the G G
correct direction (G) F
Figure 16: Connecting the batteries
CAUTION!
Switching the battery connections can cause severe damage to the
leonplus / leon!
To reassemble, follow the instructions for disassembly in reverse.
6.3.3 Replacing device fuses
Replace the device fuses (1) in the

rearpanel (B). Eleven fuses must be
replaced.
Figure 17: Replace fuses

1 11 0170024 Fuse 2AT (5 x 20mm)

6.3.4 Vaporizer holder
Uncase the 4 check valves (A). Therefore firstly

unscrew the 4 screws in the underside of the A
Vaporizer holder. The screws are accessible from
inside the device.
Unscrew the upper part out of the valve housing

and replace all O-rings of the valve.
Figure 18: Vaporizer holder
2
5 5
Figure 19: Check valve

1 4 0020005-1 O-Ring upper part outside
2 4 0020081 O-Ring valve housing top
3 4 0020173 O-Ring valve housing bottom
4 4 0020174 O-Ring valve housing outside (middle)
5 4 0020207 O-Ring valve housing inside

6.4 20,000 hr. Maintenance (every 6 years)

The leonplus / leon requires a general overhaul after every 20.000 hours of operation or
every six years, whichever comes first. The work steps for the 20,000 hr. maintenance are
performed in addition to the work steps for the 10,000 hour and the annual maintenance. A
3-year maintenance cartridge also needs to be done!
CAUTION!
During the 20,000 hr. maintenance, all components and modules are
replaced that are not guaranteed to operate for more than 20,000 hours.
Tools required:
• Allen key (sizes 2mm, 2.5 mm, 3 mm, 4 mm, 5 mm (short))
• Open end wrench (set, sizes 5.5 – 22)
Materials required:
• Maintenance kit 20,000h maintenance
0209070 or 0209075 depending on the device's version (DIN/PIN-Index)

6.4.2 High pressure connections (pressure reducer)
6 Year maintenance kit high pressure PIN-Index (Art.-Nr. 0209070):

(For devices with Pin-Index pressure reducers)
Module Quan.. Item-no. Description

1 0209553 Pressure regulator connector block bottom
1 0209554 Pressure regulator connector block top
2 0209556 Pressure regulator nitrous switch block
1 0341006 O2 pressure reducer (generally Pin Index)
1 0341016 N2O pressure reducer (generally Pin Index)
Table 6: 6 Year maintenance kit high pressure PIN-Index (0209070)
6 Year maintenance kit high pressure DIN (Art.-Nr. 0209075):

(For devices with DIN pressure reducers)
Module Quan. Item-no. Description

1 0341001 O2 pressure reducer (generally DIN)
1 0341011 N2O pressure reducer (generally DIN)
Table 7: 6 Year maintenance kit high pressure DIN (0209075)
6 Year maintenance kit high pressure PIN-Index without N2O (Art.-Nr. 0209070-1):
(For devices with Pin-Index pressure reducer, without N2O)

1 0341006 O2 pressure reducer (generally Pin Index)
Table 8: 6 Year maintenance kit high pressure PIN-Index without N2O (0209070-1)
6 Year maintenance kit high pressure DIN (Art.-Nr. 0209075-1):

(For devices with DIN pressure reducer, without N2O)

1 0341001 O2 pressure reducer (generally DIN)
Table 9: 6 Year maintenance kit high pressure DIN without N2O (0209075-1)

Gas box replacement parts:

Module Quant. Item no. Description
*1 0341005 O2 pressure reducer (Pin Index, new)
*1 0341015 N2O pressure reducer (Pin Index, new)
*1 0341000 O2 pressure reducer (DIN, new)
*1 0341010 N2O pressure reducer (DIN, new)
Table 10: Gas box replacement parts

6.4.2.1 Removing the gas box
CAUTION!
Make sure that the system is completely disconnected from the gas
supply before starting the work steps.
You must remove all the bottles that are connected to the system.
There are usually different high pressure connections (country-specific) depending on the
configuration of the device on delivery. However, the replacement procedure is the same for
all variants!
Unscrew the vacuum

adjusting knob to be able to
remove the gas box
Disconnect the screws (A) on the back panel of the

gas box module. Pull the module out of the housing
without disconnecting any tubes or cables.
Figure 20: Removing the gas box

6.4.2.2 Replacing the high pressure connections
Remove the mounting screws (B) on the B

high pressure connections.
Figure 21: Detach high pressure connections
Loosen the tube screw connections (C). Pull the pressure tubes from the PIF connectors (D).
Then, remove the high pressure connectors (E) carefully from the rear panel.
Figure 22: Removing the high pressure connections

Loosen the compression fitting (F) and

detach the high pressure line (G) from
the pressure reducer (H).
Attach the high pressure line to the new

pressure reducer.
To reinstall the new high pressure

connections, follow the instructions for H
deinstallation in reverse order.
Figure 23: Replacing the high pressure connection
CAUTION!
During reassembly, make sure that the ends of the high pressure line
(G) are seated firmly against the limit stop of the connections before
you tighten the compression fittings.

6.4.3 Replacing pressure regulators connector block
Replace both pressure regulators in the connector

block. Therefore lose the screws (A).
gas box 1
A A

1 1 0209554 Pressure regulator connector block bottom
2 1 0209553 Pressure regulator connector block top
Figure 24: Pressure regulators connector block
CAUTION!
After replacing the pressure regulators in the connector block
perform a calibration of the pilot pressure (see chapter system
calibration), before you insert the cartridge in the device.
If the pilot pressure is too high, the surplus diaphragm can get
destroyed.

6.4.4 Replacing pressure regulators nitrous switch block
Replace both pressure regulators (1) in the switch

block. Therefore lose the screws (A).
In case of different revisions of the switch block you

will find the pressure regulators in different positions
A
gas box
A switch block Rev. 01/02
CAUTION!
After the replacement of

the pressure regulators in
the switch block perform a
calibration of the fresh
gas blender inlet
pressures (see chapter A
system calibration).
1
switch block Rev. 03

1 2 0209556 Pressure regulator switch block
Figure 25: Pressure regulators nitrous switch block

6.5 Maintenance cartridge (closed loop system)
CAUTION!
If you perform an annual maintenance cartridge you ONLY perform
the chapter annual maintenance cartridge.
If you do a 3-year maintenance cartridge you ONLY perform the
chapter 3-year maintenance cartridge
6.5.1 Annual maintenance cartridge (closed loop system)
6.5.1.1 Required tools
Tools required:
• see required tools annual maintenance page 6-6
Materials required:
• cartridge annual maintenance kit (Item no. 0209050)

Cartridge maintenance kit 12 months (Item no. 0209050):
Cartridge bottom Quan. Item no. Description

1 0020000 O-ring rotary valve outside (big)
1 0020096 O-ring emergency air valve
2 0020148 O-ring flow sensor
4 0020156 O-ring rotary valve outside (small)
1 0020158 O-ring PTFE rotary valve outside
1 0020202 O-ring seal rotary valve
1 0020203 O-ring bayonet fitting / PEEP
1 0020500 Flat gasket bellow holder
1 0205041 Diaphragm emergency air valve
1 0209109 PEEP valve diaphragm
Cartridge bottom/top Quan. Item no. Description

9 0020138 O-ring for piston (big)
3 0020140 O-ring for piston (small)
3 0020141 O-ring for cover / piston
Cartridge top Quan. Item no. Description

1 0020046 O-ring APL-bayonet fitting
2 0020162 O-ring for sight glass
2 0020167 O-ring for valve seat for insp. / exp.
2 0020206 O-ring for APL valve
2 0209106 Flap valve
Absorber Quan. Item no. Description

1 0020153 O-ring absorber outside
1 0020163 Flat gasket inside for absorber
1 0020180 Gasket for absorber, version II
Table 11: Contents of 12 months maintenance kit cartridge

6.5.1.2 Preparation of the cartridge
Open the swing arm with the cartridge. Unscrew the

APL valve (A) and both domes (B) from the top of the B
cartridge.
B
Figure 26: Removing APL, domes
Remove the absorber (C)!
C
Figure 27: Removing the absorber
Release the lock (D) and take the cartridge out of

the swing arm
D
Figure 28: Removing the cartridge

Next, remove the chamber and the bellows (E)
E
Figure 29: Removing the bellows
Turn the cartridge over and place it top down on a

flat surface. F
Remove the three screws (F) and remove the

holder (G) and ball valve (H). Removing the ball
valve (rotary valve) requires a bit of force. Turn the
holder a little when pulling it out. H
G
Figure 30: Disassembling the absorber receptacle
6.5.1.3 Bellow holder
Replace the flat gasket (1).
Cartridge bottom

1 1 0020500 Flat gasket bellow holder
Figure 31: Bellows holder

6.5.1.4 Absorber
6.5.1.4.1 Absorber Version I
Replace the O-ring (1) and the flat gasket (2) in the
1
absorber lid.
2

1 1 0020153 O-ring absorber outside
Flat gasket inside for
Absorber Version I 2 1 0020163
absorber, version I
Figure 32: Absorber Version I
6.5.1.4.2 Absorber Version II
1 Replace the O-ring (1) and the

gasket (2) in the absorber lid.
Folgende Teile sind zu ersetzen:

Nr. Anz. Art.-Nr. Bezeichnung
1 1 0020153 O-Ring absorber outside
Absorber Version II 2 1 0020180 Gasket, absorber version II
Figure 33: Absorber Version II

6.5.1.5 Flow Sensors
Unscrew the lock nuts (A) and pull out the

flow sensors at the tube connections (B).
Replace the O-rings (1) at the sensors' end.
Cartridge bottom
Figure 34: Flow Sensors

1 2 0020148 O-Ring flow sensor

6.5.1.6 Slide valve (Cartridge bottom)
Remove the retaining ring (A), in order to remove the

slide valve from the lower part of the cartridge.
Remove lid (B), piston (C) and spring (D), one after
the other. The spring guide (E) does not have to be
removed.
A
Cartridge bottom
E D C B

1 1 0020141 O-ring for cover / piston
2 1 0020140 O-ring for piston (small)
3 3 0020138 O-ring for piston (big)
3 1
CAUTION!
The O-rings should be

treated with a special
oxygen grease to reduce
friction and increase
tightness.
Figure 35: Slide valve Cartridge bottom

6.5.1.7 Absorber rotary valve
Replace all existing O-rings on the under 0

dismantled ball valve (A).
B
A
Cartridge bottom
A B

O-ring seal rotary
1 1 0020202
valve
O-ring rotary valve
2 4 0020156
outside (small)
O-ring rotary valve
3 1 0020000
outside (big)
O-ring PTFE rotary
4 1 0020158
valve outside
1
CAUTION!

treated with a special oxygen
grease to reduce friction and 4
increase tightness.
3
2 (4x)
Figure 36: Absorber ball valve

6.5.1.8 PEEP Valve
Remove the bayonet connector (A), remove the

membrane (B) afterwards.
A B
Cartridge bottom

PEEP valve
1 1 0209109
diaphragm
O-ring bayonet fitting
2 1 0020203
PEEP
CAUTION!
Make sure to assemble the

diaphragm the right way.
The inlaying metal disk and 2
the label TOP should be
seen through the hole in the
bayonet connector.
Figure 37: PEEP Valve

6.5.1.9 Emergency air valve
Remove the retaining ring (A) and pull the valve seat
(B) out. Remove the valve (C).
It is not mandatory to remove the cage (D) from the
lower cartridge part.
Cartridge bottom C B
A
B C
D
A

Diaphragm
1 1 0205041
emergency air valve
O-ring emergency air
2 1 0020096
valve
Figure 38: Emergency air valve

6.5.1.10 Insp. / Exp. check valve
Pull the valve seat (B) from the port (C), using the
pins (A).
B
C
Intermediate plate

1 2 0209106 Flap valve
O-ring for valve seat
2 2 0020167
insp. / exp.
Cutoff the two fixing pins (D) of the flap valve directly
below the cone.
D 2
2x
Figure 39: Inspiration/Expiration valve

6.5.1.11 Slide valve (Cartridge top)

slide valves from the lower part of the cartridge.
Remove lid (B), piston (C), and spring (D) one after
removed.
Cartridge top B
E D C
C
D

CAUTION! 1

tightness.
3
2
Figure 40: Slide valve (Cartridge top)

6.5.1.12 APL valve
Open the bayonet connection (A) and remove the

APL valve (B).
Replace all visible O-rings!
B
Cartridge top A
1

O-ring for APL-bayonet
1 1 0020046
fitting
2 2 0020206 O-ring for APL valve
Figure 41: APL valve

6.5.1.13 O-rings sight glasses
Remove both sight glasses (1) above Replace both O-rings (2), located in the
the inspiration and expiration valves. sight glasses.

12 2 0020162 O-ring for sight glass
Figure 42: Valve domes assembly

6.5.2 3-year maintenance cartridge (closed loop system)
6.5.2.1 Required tools
Tools required:
• see tools required annual maintenance, page 6-6
Materials required:
• maintenance kit cartridge 3 years (item no. 0209050-1)

Maintenance kit cartridge 3 years (Item no. 0209050-1):
Cartridge bottom Quan. Item no. Description

1 0020000 O-ring rotary valve outside (big)
4 0020021 O-ring bellow holder (small)
1 0020030 O-ring cartridge underside
1 0020096 O-ring emergency air valve
1 0020140 O-ring for piston (small)
1 0020143 O-ring bellow holder (big)
2 0020148 O-ring flow sensor
4 0020156 O-ring rotary valve outside (small)
1 0020158 O-ring PTFE rotary valve outside
1 0020202 O-ring seal rotary valve
1 0020203 O-ring bayonet fitting / PEEP
1 0020210 Flat gasket, damping spring guidance
1 0020500 Flat gasket bellow holder
1 0205041 Diaphragm emergency air valve
1 0209107 Sealing cord lower part
1 0209109 PEEP valve diaphragm
Intermediate Plate Quan. Item no. Description

2 0020110 O-ring for valve seat
6 0020149 O-ring connectors cartridge
2 0020167 O-ring for valve seat for insp. / exp.
1 0020022 O-ring for heating connector
Cartridge top Quan. Item no. Description

1 151 233 E Surplus diaphragm
1 0020046 O-ring APL-bayonet fitting
1 0020056 O-ring cartridge lock
2 0020140 O-ring for pistons (small)
1 0020146 O-ring for pressure piece diaphr. seat
2 0020162 O-ring for sight glass
2 0020205 O-ring seal diaphragm seat
2 0020206 O-ring for APL valve
2 0020210 Flat gasket, damping spring guidance
1 0209108 Sealing cord upper part
Absorber Quan. Item no. Description

1 0020153 O-ring absorber outside
1 0020163 Flat gasket inside absorber, version
1 0020180 Gasket for absorber, version II
Table 12: Contents of 3 years maintenance kit cartridge

6.5.2.2 Opening the cartridge
Open the swing arm with the cartridge. Unscrew

the APL valve (A) and both domes (1) from the B
top of the cartridge.
B
Figure 43: Removing APL, domes
Remove the absorber (C)!
C
Figure 44: Removing the absorber
Release the lock (D) and take the cartridge out of

the swing arm
D
Figure 45: Removing the cartridge

Next, remove the chamber and the bellows (E)
E
Figure 46: Removing the bellows
Turn the cartridge over and place it top down on a

flat surface. F
Remove the three screws (F) and remove the

holder (G) and ball valve (H). Removing the ball
valve (rotary valve) requires a bit of force. Turn the
holder a little when pulling it out. H
G
Figure 47: Disassembling the absorber receptacle
Remove the four screws (I) on the underside of the

bellows holder (J) and remove the holder.
I
Figure 48: Disassembling the bellows holder
Loosen the threaded pins (K) of the lock (L) and

carefully press the bolts (M) out.
K
L
Figure 49: Dismantling cartridge lock

Remove the screws (O) on the underside of the cartridge to separate the top, bottom, and
intermediate plate from one another. Note that the screws have different lengths. This is
important later when you are reassembling the cartridge.
Cartridge
(view from below)
O O
Figure 50: Opening the cartridge

6.5.2.3 Bellow holder
Replace the O-ring (1) and the O-rings (2) on the top
of the bellows holder (A).
2
Cartridge bottom
Replace the O-ring (3) in the bottom part of the

cartridge (B). Replace the flat gasket (4)
accordingly.
3
4

1 1 0020143 O-ring bellow holder (big)
2 4 0020021 O-ring bellow holder (small)
3 1 0020030 O-ring cartridge underside
4 1 0020500 Flat gasket bellow holder
Figure 51: Bellows holder

6.5.2.4 Absorber
6.5.2.4.1 Absorber Version I
Replace the O-ring (1) and the flat gasket (2) in the
1
absorber lid.

Flat gasket inside for
Absorber Version I 2 1 0020163
absorber, version I
Figure 52: Absorber Version I
6.5.2.4.2 Absorber Version II
1 Replace the O-ring (1) and the

gasket (2) in the absorber lid.

Absorber Version II 2 1 0020180 Gasket, absorber version II
Figure 53: Absorber Version II

6.5.2.5 Flow Sensors
Unscrew the lock nuts (A) and pull out the

flow sensors at the tube connections (B).
Replace the O-rings (1) at the sensors' end.
Cartridge bottom
Figure 54: Flow Sensors

1 2 0020148 O-Ring flow sensor

6.5.2.6 Slide valve (Cartridge bottom)

removed.
A
Cartridge bottom
E D C B

2 1 0020140 O-Ring for piston (small)
3 3 0020138 O-Ring for piston (big)
Flat gasket, damping
4 1 0020210
spring guidance
3 1
CAUTION!

tightness.
2
4
Figure 55: Slide valve Cartridge bottom

6.5.2.7 Absorber rotary valve
Replace all existing O-rings on the under 6.5.2.2

dismantled ball valve (A).
B
A
Cartridge bottom
A B

O-ring seal rotary
1 1 0020202
valve
O-ring rotary valve
2 4 0020156
outside (small)
O-ring rotary valve
3 1 0020000
outside (big)
O-ring PTFE rotary
4 1 0020158
valve outside
1
CAUTION!

oxygen grease to reduce 4
tightness. 3
2 (4x)
Figure 56: Absorber ball valve

6.5.2.8 PEEP Valve
Remove the bayonet connector (A), remove the

membrane (B) afterwards.
A B
Cartridge bottom

PEEP valve
1 1 0209109
diaphragm
O-ring bayonet fitting
2 1 0020203
PEEP
CAUTION!
Make sure to assemble the

diaphragm the right way. The
inlaying metal disk and the 2
label TOP should be seen
through the hole in the
bayonet connector.
Figure 57: PEEP Valve

6.5.2.9 Emergency air valve
Remove the retaining ring (A) and pull the valve seat
(B) out. Remove the valve (C).
It is not mandatory to remove the cage (D) from the
lower cartridge part.
Cartridge bottom C B
A
B C
D
A

Diaphragm
1 1 0205041
emergency air valve
O-ring emergency air
2 1 0020096
valve
Figure 58: Emergency air valve

6.5.2.10 Cartridge top/bottom connector
Replace the O-rings (1) of the cartridge connector (A).

Please note during the cartridge's assembly that the
connectors have different lengths.
Exchange also the sealing cord (2).
Cartridge bottom
A
2x
Connector 11 mm
A
1x
Connector 18 mm

O-ring connectors
1 6 0020149
cartridge
Sealing Cord lower
2 1 0209107
part
2
Figure 59: Cartridge connector

6.5.2.11 Intermediate plate check valves
Remove screws (A) and remove the valve seat (B).
Intermediate plate
A
1
2
B

2 2 0020110 O-ring for valve seat
CAUTION! 1
The side of the valve seat

that faces the diaphragm
has a sealing edge. Make
sure that you insert the
valve seat facing in the 2
right direction.
Figure 60: Check valves

Pull the valve seat (B) from the port (C), using the
pins (A).
B
C
Intermediate plate

O-ring for valve seat
2 2 0020167
insp. / exp.
Cut off the two fixing pins (D) of the flap valve directly
below the cone.
D 2
2x
Figure 61: Inspiration/Expiration valve

6.5.2.12 Heating connector (intermediate plate)
Replace the O-ring (1) of the

heating connector (A) on the
intermediate plate.

No. Quan. Item no. description
O-ring heating
1 1 0020022
connector
Figure 62: Heating connector

6.5.2.13 Slide valve (Cartridge top)

removed.
Cartridge top B
E D C
C
D

Flat gasket, damping
4 2 0020210
spring guidance
CAUTION! 1
4
tightness.
3
2
Figure 63: Slide valve (Cartridge top)

6.5.2.14 Surplus diaphragm (Cartridge top)
Loosen the screws of the membrane plate (a).

Remove the membrane disk (A), membrane (B) and
the pressure piece (C) from the upper part of the
cartridge.
Devices without the pressure piece do not contain the
respective O-ring (No. 2, see below).
Cartridge top C
A
C
B
A

O-ring for pressure
1 1 0020205
piece diaphr. seat
O-ring seal diaphragm
2* 1 0020146
seat
3 1 151 233 E Surplus diaphragm
Sealing cord upper
4 4 1 0209108
part
(*only for devices with pressure piece (C))
3 2
CAUTION!

oxygen grease to
increase tightness.
1
Figure 64: Surplus diaphragm

6.5.2.15 APL valve
Open the bayonet connection (A) and remove the

APL valve (B).
Replace all visible O-rings!
B
Cartridge top A
1

O-ring for APL-bayonet
1 1 0020046
fitting
2 2 0020206 O-ring for APL valve
Figure 65: APL valve

6.5.2.16 Assembling the cartridge
Reassemble the cartridge by following the disassembly instructions in reverse (chapter

6.5.2.2, page 6-48). Please note that the screws for closing the cartridge are of varying
lengths.
Cartridge
(view from below)
B
(4x35mm)
A A
(4*40mm)
Figure 66: Closing the cartridge
Replace the O-ring (1) of the lock (C) before putting

it back in the cartridge.
1
C
1 1 0020056 O-ring cartridge lock
Figure 67: Lock assembly

O-rings sight glasses
Remove both sight glasses (1) above Replace both O-rings (2), located in the
the inspiration and expiration valves. sight glasses.

12 2 0020162 O-ring for sight glass
Figure 68: Valve domes assembly

06 Maintenance 2.1.0 en

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Chapter 6: Maintenance

Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-1

6.5.2.4.1 Absorber Version I ....................................................................... 6-52

6-2 Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0

Figure 38: Emergency air valve...................................................................................... 6-41

Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-3

Every 12 months (maintenance):

• Annual Maintenance (chapter 0)

Every 3 years or 10,000 operating hours (general overhaul):

• Annual Maintenance (chapter 0)

Every 6 years or 20.000 operating hours (general overhaul):

• Annual Maintenance (chapter 0)

Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-5

6.2 Annual maintenance

The cells do not need to be replaced until calibration can no longer be

6.2.1 Required tools

• Socket wrench (size: 5.5 mm)

• Allen key (sizes 2mm, 2.5 mm, 3 mm, 4 mm, 5 mm (short))

• Open end wrench (size: 10 mm, 25 mm, 32mm)

• Phillips screwdriver (size 1)

• Torx wrench (size TX20)

• Slotted screwdriver (size 0.4 x 2.5 mm)

• Pliers for inner retaining rings

• Internal module maintenance kit (Item no. 0209060)

• Swiveling connector maintenance kit (Item no. 0209055)

• Oxygen grease (Item no. 0150042)

6-6 Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0

6.2.2 Internal modules (annual maintenance)

Internal module annual maintenance kit (Item no. 0209060):

Module Quan. Item no. Description

Rear panel 1 0209608 Filter for fan leon / leonplus

Vaporizer holder 4 0020005-1 O-ring ckeck valve vaporizer

Generator module 1 0208766 Oxygen cell leon / leonplus

Gas measurement 2 0020166 O-rings for dryline receptacle

Table 1: Contents of annual maintenance kit for internal modules

Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-7

Internal module replacement parts:

Module Quan. Item no. Description

Vaporizer holder 4 0200499 Check valve, complete

Rear panel 1 0209005 Rear panel (fully assembled)

Generator module 1 0208740 Generator module (complete)

Front module 1 0208707 Controller board (complete)

Plateau valve 1 0208770 Plateau valve (block, complete)

Cabling 1 0208931 Fresh gas-O2 cell cable

Table 2: Internal module replacement parts

6-8 Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0

6.2.3 Opening the rear panel

Turn off the system!

Pull out the mains plug (A)! A

Remove screws (B) and open the rear

Also replace the filter on the housing B

Figure 1: Opening the rear panel

Figure 2: Internal modules

Danger of electrical shock!

Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0 6-9

6.2.3.1 Vaporizer holder

The outer O-rings of the vaporizer holder (A) need

Selectatec®- and Dräger® - compatible holders

Figure 3: Vaporizer holder

The O-rings (1) and the 4 check valves must be

The following components must be replaced:

Figure 4: Selectatec gaskets

6-10 Heinen + Löwenstein®, Service Manual leonplus / leon Rev. 2.1.0