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Levo AG C3 Service Manual

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3
LEVO C

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 Ltd.; otherwise no warranty or
product liability will be accepted.
Version 1.9
1

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Summary of Contents for Levo AG C3

  • Page 1: Service Manual

    LEVO C 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 Ltd.;...

  • Page 2: Table Of Contents

    Content Introduction ................4 Health & safety ................4 Adjustments ................4 3.1. Seat depth .................. 4 3.2. Armrest height ................4 3.3. Adjustment of the knee support ............. 5 3.4. Electronic control system .............. 5 3.5. Standard programming PGDT VR2 and R-net ........6 General instructions ..............
  • Page 3 8.20. Assembling of the stand-up actuator unit ........27 8.21. Assembling of the tilt actuator unit ..........31 8.22. Exchanging of the fuse ............... 32 8.23. Exchanging the lights ..............33 8.24. How to get battery access without power ........34 Function control .................

  • Page 4: Introduction

    1. Introduction Apart from regular charging of the batteries and keeping the wheelchair clean the LEVO C is maintenance-free and no attention is required by the user. Because of the complexity of the wheelchair the LEVO agent or authorized dealer shall carry out a safety check at least once a year.

  • Page 5: Adjustment Of The Knee Support

    PG Drives 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.

  • Page 6: Standard Programming Pgdt Vr2 And R-Net

    To perform a smoother start and stop of the C3 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.

  • Page 7: General Instructions

    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.

  • Page 8: Tools & Torque Settings

    Do not reuse locknuts. Always replace with a new locknut. Always use thread locking compound. Always use recommended components and parts available from LEVO AG. Do not modify or repair the frame. LEVO is responsible for repairs on gas springs, motors and electronic parts.

  • Page 9: Recommended Safety Checks

    7. Recommended safety checks The following safety checks shall be carried out at least once a 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. Examine the backrest and possible accessories if they are fixed safely.

  • Page 10: Brake Test

    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.

  • Page 11: Gradient Test

    7.3. Gradient Test Before carrying out this test ensure another person is present to prevent the wheelchair from tipping backwards. Drive the wheelchair forwards up its maximum rated gradient. While on the gradient release the joystick and ensure the wheelchair comes to rest and the brakes are applied.

  • Page 12: Exchanging Components

    8. Exchanging components 8.1. Exchanging/Removing the covers The covers are attached with screws, clips and velcro. remove collateral covers, unscrew (A,B) at the front on the inside and at the rear first, and then take the cover upwards to remove it. To remove the rear cover, lift the cover at rear bottom and take it off the Velcro, now you can lift the cover...

  • Page 13: Adjusting The Front Wheel Clearance / Suspension

    8.2. Adjusting the front wheel clearance / suspension Adjusting the length of the shock absorber (A) will allow a fine tuning of the front wheel to the floor clearance as well as the suspension of the chair. Make sure the chair is in seating position.

  • Page 14: Exchanging The Middle Wheel

    8.3. Exchanging the middle wheel Bring the chair into the standing position to lift the middle wheels off the ground. Remove the cover cap in the middle of the wheel; lift the cap with a small screwdriver. Afterwards unscrew the screw and take off the wheel.

  • Page 15: Exchanging The Rear Caster

    8.6. Exchanging the rear caster Remove the cover cap by pushing upwards. Unscrew the nut until it could be taken out. Make sure you fasten the swiveling fork with a screw locking device. 8.7. Exchange the front wheel lowering cable Bring the seat in a seating position and in tilt backward position.
  • Page 16 The routing is beneath the design tubes The routing is above the light and indicator support . The deviation starts from this point. The cable will be routed through the chassis above the cross.
  • Page 17 The left cable will be overcrossed to the right cable and fitted to the actuator unit respectively attached at the levers of the Rosta element. Important Cable Tension The cable tension has to be adjusted Due the nut underneath the support in sitting position and only must be light or soft, so that the cable is nearly straight.

  • Page 18: Gas Spring Exchange For Tilt In Space

    8.8. Gas spring exchange for tilt in space Make sure the wheelchair is in the highest position of the tilt in space function. Take a screw driver and put it between the plastic heading and the metal clasp, push the clasp a couple of millimeters away from the heading but be careful that the clasp does not come off.

  • Page 19: Exchanging The Drive Motor

    8.11. Exchanging the drive motor Place something under the wheelchair so the drive wheels are of the ground. Remove middle wheel (see chapter 8.3.) and the front wheel (see chapter 8.4.) Unscrew the 7 screws (A) and now you can remove the driving motors and mount new ones.

  • Page 20: Exchanging The Batteries

    8.14. Exchanging the batteries Raise the wheelchair into the standing position and remove the middle cover in the back (see chapter 8.1.). Push the pole cover back and unscrew the screws on the battery poles. Now you can lift out the batteries. Put the new batteries in and fasten the cable to the right battery poles.

  • Page 21: Exchanging The Standing Actuator Unit - General Preliminaries

    8.17. Exchanging the standing actuator unit – general preliminaries CAUTION – seating system is tension loaded for standing configuration and is held back by the standing actuator. Before loosening standing actuator, assure the seat is secured by a tightening system. If the chair is more in standing position, secure it over the seat front side.

  • Page 22: Exchanging The Standing Actuator In Standing Position

    CAUTION – Before working on the standing actuator, the chair has to be brought into a full standing and tilted position to release the system. If this is impossible by power, follow the instruction «Exchanging the standing actuator in seating position» Option: If you have an external power unit, you can plug it in directly by the stand up actuator behind the leg rest unit.
  • Page 23 Unscrew the two allen screws of the base plate inside the leg rest assembly. Unscrew the two allen screws and disassemble the cable guidance. Release the countersunk screw in the front and then at least the support screw from below the leg rest assembly.

  • Page 24: Exchanging The Standing Actuator In Seating Position

    The stand up actuator unit can be taken off from underneath the leg rest assembly. Assure that the front wheel cables are behind the unit. 8.19. Exchanging the standing actuator in seating position CAUTION: During movements assure nobody has their fingers or hands inside the seating system or main frame.
  • Page 25 Unscrew the two allen screws of the base plate inside the leg rest assembly. Unscrew the two allen screws and disassemble the cable guidance. Release the countersunk screw in the front and then at least the support screw from below the leg rest assembly.
  • Page 26 The cables of the joystick and the lights have to be unplugged. Feed out the cables out of the actuator unit towards the front respectively out of moving parts. Loose the coupling bolt at the base underneath the seat so that it could be unscrewed later by hand.

  • Page 27: Assembling Of The Stand-Up Actuator Unit

    8.20. Assembling of the stand-up actuator unit Plug in the Actuator unit at the control and move it in as short as possible The chair has to be fully tilted to get space to feed in / up the stand-up unit from below.
  • Page 28 Move your position to the left or right side of the chair to hold the actuator in one hand and set the coupling into the coupling base underneath the seat. Set the coupling bolt, which has to be medium locked into the base and the coupling.

  • Page 29: Cable Routing

    Cable routing To protect the cables, the routing is through the gas-spring and actuator section. The cable has to be routed from behind between the lowering cables and gas-spring and actuator towards the front (at least to the rear) respectively the actuator plug. Now the cables will be feed from the front to the rear between the gas-cylinder and the actuator.
  • Page 30 The cables have to be plugged in. The cables are now protected installed and would not be squeezed anymore. Final check Now, the chair has to be driven at min. 2 times in standing and seating Position. After that, tighten the crews at the actuator unit again Now the stand-up function could be tested and checked.

  • Page 31: Assembling Of The Tilt Actuator Unit

    8.21. Assembling of the tilt actuator unit Set the wheelchair in the highest position possible of tilt in space, so that the gas springs are relieved. Then unplug the actuator. Remove the spring lock (A) on the top bolt and remove the bolt. Now you can equip the actuator and replace it with a new one.

  • Page 32: Exchanging Of The Fuse

    8.22. Exchanging of the fuse Cut out version until March 2011 Put the wheelchair in the standing position and remove the back cover (see chapter 8.1.). Turn circuit breaker respectively the cut out and unscrew the nut (A) to remove the circuit breaker.

  • Page 33: Exchanging The Lights

    8.23. Exchanging the lights Head lights: The head lights are LED lights and can only be replaced complete. Disconnect the cabling from the main chassis and unscrew the nut (A) holding the head light in place. Mount and connect the new head light the same way as you dismounted the old one.

  • Page 34: How To Get Battery Access Without Power

    8.24. How to get battery access without power The chair has to be almost in standing position. Take off the rear cover and get access to the battery box. If this is impossible by power, follow the instruction «Exchanging the standing actuator» Chapter 8.17 –...

  • Page 35: Technical Information

    11. Technical information 11.1. General information Driving wheels dimensions 3.00-8" Tires only airless tires Front wheels dimensions 2.80/2.50-4“ airless tires Tires Rear wheels dimensions 7x1 3/4" airless tires Tires 0 - 10 km/h precision control (In certain countries there are regulations, considering Speed speed limits for wheelchairs) Drive motors...

  • Page 36: Measurements (Metric)

    11.2. Measurements (metric) Model S – XL Seat width 32 / 36 / 40 / 44 / 48 / 52 cm Seat depth adjustable (incl. leg protector) 38 - 66 cm Seat height 48 cm Armrest height (from top of cushion) 15 - 36 cm Footrest height (from top of cushion) 30 - 50 cm...

  • Page 37: Measurements (British)

    11.3. Measurements (british) Model S – XL Seat width 12.6 / 14.2 / 15.8 / 17.4 / 18.9 / 20.5" Seat depth adjustable (incl. leg protector) 15 - 26" 19“ Seat height 5.9 – 14.2" Armrest height (from top of cushion) 11.8 –...

  • Page 38: Electromagnetic Interference (Emi)

    Finally, be aware that adding accessories and components, or modifying the powered wheelchair, may make it more susceptible to EMI. LEVO AG will not take any responsibility for the effects of EMI, if your wheelchair has been altered...

  • Page 39: Controller Self Help Guide Vr-2

    If the fault is not rectified after following the recommended instructions, please contact your local dealer for advice. Please provide your dealer with the serial number, which is noted on the warranty card. This number is important in case of any questions of the manufacturing company LEVO AG.

  • Page 40: Controller Self Help Guide R-Net

    13. Controller self help guide R-net The joystick module has its own error-management-system. If an error occurs, a message is indicated on the display, for example this could look like that: If you can’t solve the problem, just with the showed message, you can enter the trip code on the PG Drives homepage (http://www.pgdt.com/diagmob/diagnostic.asp), there you’ll get some more information about the error and how you can solve it.

  • Page 41: Version-Management

    15. Version-Management Version- Date Description Author 2008.07.10 First released version T. Meier 2008.12.09 Additions for Handicap Institute T. Meier 2009.02.05 Miscellaneous changes in chapters T. Meier 2010.01.01 Miscellaneous changes in chapters T. Räber 1.31 2010.05.27 Additional information Standing Actuator H. Bögli 2010.07.12 New Stand-up Actuator Unit H.

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