Sunrise Medical Melody, Service Manual

Page 1: ...Quickie Melody Service Manual 2006 Sunrise Medical Inc 101975 Rev A ...

Page 2: ... 2 5 Seconds 5 2 7 Battery Gauge Flashes Rapidly 5 Section 3 Understanding Controller Diagnostics Codes 6 3 1 One Bar Low Battery Voltage 6 3 2 Two Bars Left Motor Disconnected 6 3 3 Three Bars Left Motor Wiring Trip 7 3 4 Four Bars Right Motor Disconnected 8 3 5 Five Bars Right Motor Wiring Trip 9 3 6 Six Bars Charger Connected 9 3 7 Seven Bars Possible Joystick Trip 9 3 8 Eight Bars Possible Con...

Page 3: ...roubleshooting guide for the Quickie Melody Photo graphs and content may differ from the actual products in some cases due to changes in specifications and other factors This Service Manual is intended for use by persons with a basic working knowledge and the skills required in servicing and maintaining Power Wheelchairs Persons without a General Working knowledge and expertise in the servicing of...

Page 4: ...ate charge level Speed Profile indicator A se ries of five LED s which display speed and profile settings On Off Key Press to power on or off the power chair or Control ler Horn Key Activates a warning horn Speed Profile Decrease Used to decrease the Speed Profile setting Speed Profile Increase Used to Increase the Speed Profile setting ...

Page 5: ... Vdc 2 0 Vdc 3 Inhibit 1 Programmer 1 Black 2 White 3 Yellow 4 Red 2 1 3 charger port Motor Plug Charger port Outside View 4 pin M1 RIGHT SIDE MOTOR M2 LEFT SIDE MOTOR JSM JOYSTICK MODULE INH 2 INHIBIT 2 A1 ACTUATOR 1 A2 ACTUATOR 2 OBC ON BOARD CHARGER BATTERY VR2 Controller ...

Page 6: ...er Package Basic Tool List The following list of tools should enable any task to be dealt with Some will only occasionally be needed but it is advisable to own or have access to them 17mm Deep Socket wrench 10mm combination wrench 13mm combination wrench Cutter for zip tie Needle nose pliers 4mm Allen wrench 5mm Allen wrench 3 8 combination wrench Phillips screwdriver 2 18mm combination wrench Fla...

Page 7: ... to step 1 6 1 2 Test Joystick 1 1 Circuit Breaker Reset A1 2 1 If On off button is pressed and no light or bar is shown check for tripped circuit breaker see figure A1 1 1 and make sure all connections are clean and tight including the batteries If the problem persists then perform the following diagnostics A1 1 1 2 1 3 1 3 Battery Test Check that the batteries are fully charged and in good condi...

Page 8: ...lts proceed to the next step 1 4 Not Charging A1 4 1 If the charging port is OK check that the battery fuse is in good condition With the batteries disconnected remove the fuse cap inspect the fuse to see if the fuse is blown To make sure the fuse is not blown set the meter to ohms and measure the resistance across the fuse See figure A1 4 2 If the meter reads more than one ohm change the fuse or ...

Page 9: ...f the voltage meter reads full voltage then replace the controller If the voltage meter reads full voltage then replace the joy stick module If the voltage meter reads zero voltage measure the cor responding pins on the VR2 controller as shown in figure 1 5 2 If the voltage meter reads full voltage then replace the jumper cable If the voltage meter reads zero then mea sure the Battery Connector as...

Page 10: ...er to ohms and measure the resistance across the fuse Measure the negative terminal of the battery box and the positive termi nal of the battery harness Measure the positive terminal of the battery box and the negative terminal of the battery harness figure A1 7 1 If the meter reads more than one ohm change the harness or else proceed to the next step 1 7 Battery Fuse A1 7 1 If the meter reads mor...

Page 11: ... V the red light starts to blink Each bar represents a 5V value The controller requires 18V to start and a minimum of 16V to work once started Indicates the wheelchair batteries are being charged with the off board charger You will not be able to drive the wheel chair until the charger is disconnected and you have reset the control system by switching off the power and then power ing up again The ...

Page 12: ...n 0 to 1 5 ohms then replace the controller If none of the above corrects the problem replace the left motor 3 2 Two Bars Left Motor Disconnected 3 1 One Bar Low Battery Voltage This code could indicate discharged batteries failed batteries or poor battery connections Begin by recharging the bat teries and then refer to Section 1 to check batteries and connections A3 2 1 A3 2 2 If the meter reads ...

Page 13: ...acts of the connector see figure A3 3 1 Measure the resistance from the bottom contact of the black thick wire on the 4 pin left motor connector to each of the top contacts of the connector see below right If all of the readings are open then replace the controller If any of the readings are short then replace the left motor 3 3 Three Bars Left Motor Wiring Trip A3 3 1 Test 1 Test 2 Test 3 Test 4 ...

Page 14: ...tom contacts of the thicker wires on the 4 pin motor connector as shown in figure A3 4 2 If the meter reads between 0 to 1 5 ohms then replace the controller If none of the above corrects the problem replace the right motor Otherwise check the brushes on the right motor Ensure that they are not excessively worn replace as required as shown in Figure A3 4 1 3 4 Four Bars Right Motor Disconnected A3...

Page 15: ...joystick is in the center position before switching on the control system Check that the batteries are fully charged and in good condition examine the joystick for damage This fault can be caused by a joystick that fails to center itself due to being dirty bent or broken If this is the case replace the joystick mod ule 3 7 Seven Bars Possible Joystick Trip The Onboard Batteries are being charged w...

Page 16: ...reads more than 30 volts replace the charger If the Batteries connections and voltage level are correct replace the controller The parking brakes have a bad connection Check the parking break and motor connections Make sure the con trol system connections are secure Measure the two small contacts on the four pin motor connector fig 3 8 1 If both motor connectors read approximately 60 ohms then re ...

Page 17: ...nt Disassembly Unplug joystick connector figure s1 1 Push seat lever forward and lift off seat figure s1 2 Lift and remove battery case figure s1 3 Lift T handle and separate front frame assembly from rear frame assembly figure s1 4 1 2 3 4 Step 1 Seat removal Frame Separation s1 1 s1 2 s1 3 s1 5 ...

Page 18: ...he two screws fig s2 1 holding rear shroud 1 Front shroud Remove the ten screws mounting the front shroud fig s2 3 Remove the front shroud 1 2 Step 2 Shroud removal Disassembly Reassembly and Adjustment cont s2 1 s2 2 s2 3 Remove the rear shroud fig s2 2 to access motor controller 2 ...

Page 19: ...ase to the bottom battery case fig s4 1 Remove 4 spade connectors from batteries fig s4 2 1 2 Step 4 Battery removal s4 1 s4 2 Remove the rubber mat from the footplate fig s3 1 Remove the three screws mounting the footplate to the shroud fig s3 2 Remove the bolt mounting the footplate to the frame fig s3 3 1 2 3 Step 3 Footrest removal s3 1 s3 2 s3 2 ...

Page 20: ...f the shaft Remove the two screws mounting the freewheel handle to the motors fig s5 4 Unplug motor from the controller fig s5 5 Use a four mm hex key and an eight mm wrench to remove the four bolts and nuts mounting the motor to the frame figs5 6 1 2 3 4 s5 2 Step 5 Motor removal s5 1 s5 3 s5 4 Disassembly Reassembly and Adjustment cont ...

Page 21: ...y Reassembly and Adjustment cont Step 6 Caster removal s6 1 s6 2 Remove caster cap fig s7 1 Use a 19mm socket wrench to remove the caster nut fig s7 2 1 2 Step 7 Anti tip removal s7 1 Use two 10 mm wrenches to remove the bolt and nut retaining the anti tip wheel fig s7 1 1 ...

Page 22: ...embly Reassembly and Adjustment cont s8 1 Step 8 Main wiring harness removal Remove the two screws mounting battery plug to the frame fig s8 1 1 s5 5 Step 9 Rear bumper removal Use an 11mm wrench to remove the two bolts secur ing the rear bumper to the frame fig s5 2 1 ...