Levo AG C3 User manual

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LEVO C3
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

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Content
1. Introduction ................................................................................ 4
2. Health & safety............................................................................ 4
3. 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
4. General instructions ..................................................................... 7
5. Tools & torque settings ................................................................. 8
6. Important points.......................................................................... 8
7. Recommended safety checks......................................................... 9
7.1. Brake Test ................................................................................ 10
7.2. Drive Test ................................................................................. 10
7.3. Gradient Test ............................................................................ 11
7.4. Lubrication ................................................................................ 11
8. Exchanging components ............................................................. 12
8.1. Exchanging/Removing the covers................................................. 12
8.2. Adjusting the front wheel clearance / suspension ........................... 13
8.3. Exchanging the middle wheel ...................................................... 14
8.4. Exchanging the front wheel ......................................................... 14
8.5. Exchanging the back rotatable wheel............................................ 14
8.6. Exchanging the rear caster.......................................................... 15
8.7. Exchange the front wheel lowering cable....................................... 15
8.8. Gas spring exchange for tilt in space ............................................ 18
8.9. Moving the seat to the front or back............................................. 18
8.10. Exchanging the brake release cable.............................................. 18
8.11. Exchanging the drive motor......................................................... 19
8.12. Tightening the drive chain........................................................... 19
8.13. Exchanging the foot plate ........................................................... 19
8.14. Exchanging the batteries............................................................. 20
8.15. Exchanging the joystick module ................................................... 20
8.16. Exchanging the power module ..................................................... 20
8.17. Exchanging the standing actuator unit –general preliminaries......... 21
8.18. Exchanging the standing actuator in standing position .................... 22
8.19. Exchanging the standing actuator in seating position...................... 24

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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
9. Function control......................................................................... 34
10. Cleaning ................................................................................... 34
11. Technical information ................................................................. 35
11.1. General information ................................................................... 35
11.2. Measurements (metric)............................................................... 36
11.3. Measurements (british)............................................................... 37
11.4. Electromagnetic Interference (EMI) .............................................. 38
12. Controller self help guide VR-2 .................................................... 39
13. Controller self help guide R-net.................................................... 40
14. Battery - Wiring ......................................................................... 40
15. Version-Management.................................................................. 41

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1. Introduction
Apart from regular charging of the batteries and keeping the wheelchair clean
the LEVO C3is 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.
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 C3.This manual provides a good service to the persons in charge of
the maintenance of the LEVO C3. 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 their family
and are covered in the instruction manual. However, the LEVO agent must
always adjust the wheelchair correctly when delivered so that it fits the user.
3.1. Seat depth
The adjustment of the seat depth can be done by the user or their family (see
user manual, chapter 9.1.).
3.2. Armrest height
The adjustment of the armrest height can be done by the user or their family
(see user manual, chapter 9.6.).

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3.3. Adjustment of the knee support
The adjustment of the knee support can be done by the user or their family (see
user manual, chapter 9.9.).
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 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.
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.

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3.5. Standard programming PGDT VR2 and R-net
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 C3drive programs are made to give the user more ease of use and even
better drive characteristics.
All C3will 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.
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 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.
Service Instructions:
The new programs can be downloaded from the secured Login section of the
LEVO website: www.levo.ch

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4. General instructions
Only a LEVO agent or their authorized dealers should carry out servicing and
repairs to the LEVO C3.
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.
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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
Torque key: 1 Nm through to 50 Nm
Phillips head screwdriver and slotted screwdriver
Soft headed hammer
Torque settings:
Bolt size
Torque Nm
M4
3
M5
6
M6
10
M8
25
M10
50
6. Important points
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.

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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.
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 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 8.3. to 8.5.).
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
quick release bolt out and press the motor disengaging lever downwards.
Now you should be able to push the wheelchair manually. Push the motor
disengaging lever upwards and be careful that the quick release bolt is
locked; the wheels should be locked now. If one wheel turns now, the
magnetic brake of the motor is damaged. The motor has to be changed.
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 chapter 16 using VR2 or chapter 17
using R-net) for details about failure indications.

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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.
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 lights and indications. Replace components with failures.
Check the front wheel lowering cable and mechanism regarding suitable
clearance to the floor while sitting and correct movement by changing into
stand-up configuration (the middle wheel must be lifted up in standing
configuration).
Use all functions and drive the wheelchair as a final check. In case you
notice any kind of problems arrange final repairs.
7.1. Brake Test
These tests should be carried out on a level floor with at least one meter clear
space around the wheelchair.
Switch on the control system.
Check the display remains on, or flashes slowly, after one second.
Push the joystick slowly forwards until you hear the parking brakes
operate. The wheelchair may start to move.
Immediately release the joystick. You must be able to hear each parking
brake operate within 2 seconds.
Repeat the test a further three times, pushing the joystick slowly
backwards, left and right.
7.2. Drive Test
With the maximum speed control in the minimum position, drive the wheelchair
in all directions, ensuring the drive is comfortable and easy to control for the
user.
Repeat the above but with the speed control set to maximum.

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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.
Deflect the joystick forwards and continue driving up the slope. Ensure the pick
up is smooth and positive.
Stop the wheelchair and reverse down the gradient. While on the gradient
release the joystick and ensure the wheelchair comes to rest and the brakes are
applied.
7.4. Lubrication
There is no need, to lubricate the moving parts and the joints on the chair.
There are 3 exceptions:
At the conversion support (if the chair is equipped with option tilt in
space), it is necessary to put on some grease, once a year.
At the back rest assembly, once a year use an oil spray to lubricate the
back rest tubes.
If there is some noise while stand-up or tilt in space activity, then you may
use an oil spray to lubricate the causing part/location.

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8. Exchanging components
8.1. Exchanging/Removing the covers
The covers are attached with screws,
clips and velcro.
To remove the 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
upwards to remove it.
If your wheelchair is equipped with
light, you have to unplug the lights as
well to remove the cover.
A
B

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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.
Dismount the shock absorber (A)
from the motor ball connection (B).
Use a lever towards the absorber to
relax the absorber’s pressure.
Release the two allen key pins (B).
The top part of the shock absorber
has a threat (C), which allows
rotating the lower part.
Rotating “anti clock wise” the shock
absorber gets shorter less front
wheels to floor clearance.
Rotating “clock wise” will extend the
absorber more front wheels to floor
clearance.
If more clearance is requested than
you can reach, the cable tension
either on the front or the back end of
the cable must be loosened.
The cable ends in the support, which is
attached at the end tube.
The cable tension has to be adjusted
in sitting position and only must be
light or soft, so that the cable is
nearly straight.
If it’s to hard, the standing actuator
may stop.
After adjustments, assure the allen
key pins are tightened directly to the
flat surface (D) of the top part (C).
Reassemble the whole shock absorber
the opposite way you dismounted it.
A
B
A
B
D
C

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8.3. Exchanging the middle wheel
8.4. Exchanging the front wheel
8.5. Exchanging the back rotatable 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.
To fit the new wheel, mount the parts
in the reverse order, use thread
locker to mount the screw.
Make sure the wheelchair is in the
sitting position, that the front wheels
are lifted off the ground.
Remove the cover cap in the middle
of the wheel; lift the cap with a small
screwdriver. Then loosen the screw
and take off the wheel. To fit the new
wheel, mount the parts in the reverse
order, use thread locker to mount the
screw.
Remove the cover cap in the middle
of the 7” twin wheel by using a fine
screw driver to lift the cover cap off,
do that with both wheels. Unscrew
the screw going through both wheels
and now remove the worn wheel.
Now mount all pieces back together,
the other way round.
Remove the cover cap of the 8”
single wheel. Unscrew the screw
going through the fork and remove
the worn wheel. Now mount all pieces
back together, the other way round.

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8.6. Exchanging the rear caster
8.7. Exchange the front wheel lowering cable
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.
Bring the seat in a seating position and in tilt
backward position.
Dismount the shock absorber (A) from the
motor ball connection (B) as described in 8.2..
Unscrew the nut (C) at the cable end at the
rear.
Release the C-clips (D) which holds the cable
support. Take off the cable assembly (E).
Dismount the front cover (G) loosening the
screws (F).
Release the metal ear (M) which holds the head
of the front end cable (H) and take off the cable
head. Loosen the screw of the cable hose
tension adjustment (I) and bring it off the
holder (K) through the open gap (L).
The whole cable assembly can now be replaced.
Assure that you line up the cable hose the
same. Reassemble and adjust the cable, the
front cover and the shock absorber the
opposite way.
Once the cables are replaced, assure the front
wheel to the floor clearance is as described in
8.2.
The following pages would describe the cable
routing more detailed:
C
A
B
D
E
F
M
H
K
I
L

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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.

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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.
Further details on the spare part list

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8.8. Gas spring exchange for tilt in space
8.9. Moving the seat to the front or back
8.10. Exchanging the brake release cable
(only if one hand device / special)
A
A
A
B
C
D
E
Unscrew the two clasp screws (A), cut of the
end cap of the cable and take the cylinder
head (D) off. Now loosen the screw (B) that
is holding the brake release lever. Pull the
lever from the bolt and pull the cables off.
Now pull the cables from the other end (C)
through the magnetic brake levers on the
motor top end.
Enter the new cables the other way around
and mount the brake release lever again.
Now bring the cylinder head (D) to the
position closely to the brake release lever
where the cables are getting through and
fasten the clasp screw (A) of the cylinder
head (D) again.
If you now use the brake release lever, you
should hear a „click“ in the middle of the
braking distance. If this is not the case,
adjust the tension of the cable by adjusting
the cylinder head (D).
Unscrew the 4 screws (A), and then slide the
seat back or forth. When you reach the
required position, put the screws back in and
tighten them again.
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. After you have lifted the clasp a bit,
you should be able to remove the gas spring.
Afterwards do the same thing on the other
side.
The new gas spring can just be pushed on
the ball head.

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8.11. Exchanging the drive motor
8.12. Tightening the drive chain
8.13. Exchanging the foot plate
Place something under the wheelchair
so the drive wheels are of the ground.
Remove the 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.
To control the tension of the drive
chain, you can remove the rubber
cover cap between the front wheel
and the middle wheel.
To adjust the tension, loosen grub
screw (A). Take two metal bolts and
place them in the two holes (B), push
a screw driver between the two bolts
and turn the excentric around the
chain to tighten or loosen it.
When you reach the wished tension,
tighten the grub screw again.
Unscrew the screw (A) below the foot
plate, now you can remove the foot
plate from the tube. Mount the new
foot plate and put the screw back in
place and tighten it.
A
A
A
B
B

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8.14. Exchanging the batteries
8.15. Exchanging the joystick module
8.16. Exchanging the power module
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.
If the batteries are not working,
please follow up the instructions at
chapter 8.21.
Remove all cable cords from the
joystick cable all the way down to the
seat pan and unthread the cable.
Unscrew both screws (A) under the
joystick, now you can replace the
joystick module.
Fasten the module again with both
screws on the joystick-holder, thread
the joystick cable and plug it in and
fasten it with cable binder on to the
armrest, to the back and under the
seat.
Remove the back cover in the middle
first (see chapter 8.1.). Unscrew the
screws (A), and then you can tip the
power module back. Unplug all plugs
from the power module. Switch the
power module and plug in the plugs
again. Mount the new power module
on the wheelchair with the two
screws.
A
A
A
A