Page 1
Quickie Prelude Service Manual
©2007 Sunrise Medical Inc.
103748 Rev A
Page 2
Quickie Prelude Service Manual Contents
Introduction .................................................... 0.1
VR2 Controller ............................................... 0.2
Plugs/Connectors .......................................... 0.3
Basic Tool List & Main Wiring Diagram ........ 0.4
Section 1
Troubleshooting: No Power ................................ 1
1.1 Circuit Breaker Reset ....................................1
1.2 Test Joystick ..................................................1
1.3 Battery Test ....................................................1
1.4 Battery Connection Test ...............................2
1.5 Circuit Breaker Test ......................................3
1.6 Check Battery Wire Harness ....................... 3
1.6 Main Harness ...............................................4
Section 2
Chair is not Charging ...........................................5
2.1 Not Charging ...............................................5
Section 3
Understanding VR2 Controller Display ................6
3.1 The Speed/Profile Indicator Ripples Up and
Down ...................................................................6
3.2 The Speed Indicator Flashes .......................6
3.3 Battery Gauge is Steady...............................6
3.4 Battery Indicator Ripples up and off. ...........6
3.5 Battery Gauge Blinks Once Every 2.5 Sec-
onds .....................................................................6
3.6 Battery Gauge Flashes Rapidly ...................6
Section 4
Understanding VR2 Controller Diagnostics
Codes ............................................................... 7
4.1 One Bar - Low Battery Voltage ) .................7
4.2 Two Bars – Right motor Disconnect / Low
battery voltage ...................................................7
4.3 Three bars – Right Motor Wiring Trip / Low
battery voltage. ..................................................8
4.4 Four Bars- Left Motor Disconnected..........9
4.5 Five Bars - Left Motor Wiring Trip ............10
4.6 Six Bars - Inhibit Active ...........................10
4.7 Seven Bars - A Joystick Trip is Indicated 10
4.8 Eight Bars - Possible Control System Trip
.........................................................................10
4.9 Nine Bars - Solenoid Brake Trip ................ 11
4.10 Ten Bars - High Battery Voltage .............11
Section 5
Disassembly/Reassembly, and Adjustment ....12
Step 1 - Seat removal ......................................12
Step 2 - Footrest adjustment and removal .....13
Step 3 - Shroud removal..................................14
Step 4 - Battery removal ..................................15
Step 5 - Controller removal..............................15
Step 6 - Motor removal ....................................16
Step 7 - Caster Fork removal ..........................17
Step 8 - Changing Drive Tire ...........................17
Page 3
Introduction
Please read and follow instructions in this service manual before attempting to troubleshoot
or repair this product for the first time.If there is anything in this Service Manual that is not
clear, or if you require additional Technical assistance, contact Sunrise Medical at: (800)
333-4000 option 2, then option 1.
Safely troubleshooting and/or repair of this product depends on your diligence in following
the instructions within this manual. Sunrise Medical is not responsible for injuries or
damage resulting from a person’s failure to exercise good judgement and/or common
sense.
There are warning symbols used in this document to focus attention on any hazard that could effect the safety of the individual troubleshooting the chairs covered in this Service Manual.
This Service Manual is intended as a troubleshooting guide for the Quickie Prelude. Photographs 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 this product should not carry out troubleshooting procedures. This can result in problems with future servicing, and/or damage
to the unit.
Parts and configuration or specifications of Products included in this Service Manual
are subject to change without prior notice.
PRELUDE SERVICE MANUAL
2006SUNRISE MEDICAL
PAGE 0.1
Page 4
VR2 Controller
Battery Gauge
A series of ten LED’s, which
indicate charge level.
Horn Key- Activates a warning
horn.
Speed/ Profile Decrease. Used
to decrease the Speed/ Profile
setting.
VR2 Controller Buttons
On/Off Key- Press to power on
or off the power chair or Controller.
Speed/Profile indicator- A series of five LED’s, which display
speed and profile settings
Speed/ Profile Increase. Used
to Increase the Speed/ Profile
setting.
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2006SUNRISE MEDICAL
PAGE 0.2
Page 5
4pin
4 = Red (+)
Plugs/Connectors
charger port
3 = Yellow
2 = White
1 = Black (-)
Motor Plug
VR2 Controller
2
1
3
Charger port
Outside View
1 = 24 Vdc
2 = 0 Vdc
3 = Inhibit 1/ Programmer
M1 = RIGHT SIDE MOTOR
M2 = LEFT SIDE MOTOR
JSM = JOYSTICK MODULE
INH-2 = INHIBIT 2
A1 = ACTUATOR 1
A2 =ACTUATOR 2
+ - =BATTERY
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Page 6
Basic Tool List & Main Wiring Diagram
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
• 13mm combination wrench
• Cutter for zip-tie
• Needle nose pliers
• 5mm Allen wrench
• 3/8 combination wrench
• Phillips screwdriver #2
• 18mm combination wrench
• Flat blade screwdriver
• 19mm socket wrench
• 5mm socket wrench
24v BRAKE
SOLENOID
LEFT MOTOR
FUSE
Wiring Diagram for VR2 Controller Package
A/C INPUT
CHARGER
24v BRAKE
SOLENOID
RIGHT MOTOR
FUSE
RIGHT
BATTERY
CIRCUIT
BREAKER
PRELUDE SERVICE MANUAL
LEFT
BATTERY
2006SUNRISE MEDICAL
PAGE 0.4
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Section 1
Troubleshooting: No Power
1.1 Circuit Breaker Reset
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.
1.2 Test Joystick
Check that voltage is going to the controller. Set the meter
to DC volts and take a voltage reading using the red lead
in pin 1 and the black lead in pin 2 of the charger port on
the VR2 joystick. (See figure A1.2.1) If the voltage meter
reads approximately 24 volts, try replacing the joystick. If
the meter reads 12 volts or less, proceed to the next step.
A1.1.1
Note: Make sure the polarity is correct. If polarity is
reversed proceed to step 1.5
1.3 Battery Test
Check that the batteries are fully charged and in good
working condition. Remove the seat and battery cover. Use a
volt meter to check the voltage across the battery terminals.
(See figure a1.3.1) The batteries should measure within 2
or 3 tenths of a volt of each other. If the batteries are not
within 2-3 tenths of a volt, load test the batteries and replace
if necessary.
If the batteries measure below 10 volts, replace the
batteries or remove the batteries and charge with a 12
volt charger. Batteries must be connected in parallel to
charge with a 12 volt charger. Connect the positive terminal
of the first battery to the positive terminal of the second
battery as well as connecting the negative terminal of the
first battery to the negative terminal of the second battery.
Charge batteries until the voltage in each battery measures
approximately 12 volts. Connect batteries back into chair
and complete charge with standard on-board or off board
charger.
If the voltage meter reads below 12 volts, charge the batteries.
A1.2.1
2
1
3
A1.3.1
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Section 1
Troubleshooting: No Power (cont.)Troubleshooting: No Power (cont.)
1.4 Battery Connection Test
Check that the female VR2 control cable has voltage. Unplug joystick from control cable. Set the volt meter to DC
volts and measure the voltage using the red lead in port 1
and the black lead in port 4 as shown in (figure 1.5.1.)
If the voltage meter reads approximately 24 volts, then
replace the joystick. If the voltage reads 12 volts or less,
measure the corresponding pins on the VR2 controller as
shown in (figure 1.5.3.) If the voltage meter reads full voltage, then replace the jumper cable.
If the voltage meter reads approximately 24 volts, replace
the control cable. If the voltage reads 12 volts or less then
proceed to measure the voltage from the battery harness
plugging into the controller. If the voltage measures approximately 24 volts, replace the controller. If it reads 12 volts or
less proceed to the next step.
A1.5.1
A1.5.2
If all of the measurements read full voltage, then replace the controller.
A1.5.3
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Troubleshooting: No Power (cont.)
If the meter reads more than one ohm, change the Battery harness.
1.5 Circuit Breaker Test
To check the circuit breaker, remove the left rear shroud
by unscrewing the two Phillips head screws (figure A1.8.1).
Set the meter to ohms and measure the resistance or
check for a “tone” (continuity). If you are not getting a
“tone” or the resistance measures more then 1 ohm, replace the circuit breaker. If meter gives a “tone” or resistance measures less then 1 ohm, proceed to next step.
A1.8.1
If the meter reads more than 1 ohm, then change the circuit breaker.
1.6 Check Battery Wire Harness
Check that the battery wire harness has the polarity correct. Set the meter to DC volts and measure the voltage
with the red lead in the white connector and the black lead
in the black connector as shown in (figure 1.6.1.) If both
wiring harnesses have approximately 12 volts and polarity
is correct, replace the main battery harness plugging into
the controller. If voltage is less then 10 volts proceed to
section 1.3.
If polarity is reversed correct battery wiring.
A1.8.2
A1.6.1
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Section 1
Troubleshooting: No Power (cont.)
1.7 Main Harness
If the previous steps did not correct the problem, check the
main harness. Disconnect the main harness from the front
and rear battery harness. Check the continuity between the
white rear connector (figure 1.9.1) and the black front connector.
Next check the continuity between the black rear connector
(figure 1.9.2) and the left contact on the controller plug.
A1.9.1
Next check the continuity between the white rear connector
(figure 1.9.3) and the right contact on the controller plug.
If the meter reads more than 1 ohm in any of the above
tests replace the main harness.
A1.9.2
A1.9.3
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2006SUNRISE MEDICAL
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Section 2
Chair is not Charging
2.1 Not Charging
If the chair is not charging through the charging port, Insure
that the three pin charger socket is properly connected and
in good condition. Then test the voltage coming out of the
joystick (refer to section 1.2) If voltage at joystick charger
socket on the VR2 joystick is less then 18 volts (refer to
section 1.3.) If the voltage is greater then 18 volts refer to
you charger troubleshooting manual.
If all of the measurements read full voltage, then replace the controller.
A2.1.1
2
1
3
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Section 3
Understanding VR2 Controller Display
3.1 The Speed/Profile Indicator Ripples Up and Down
Indicates that the wheelchair is locked. To unlock the wheelchair,
deflect the joystick forwards until the control system chirps. Then deflect the joystick in reverse until
the control system chirps. Release the joystick, there will be a long beep. The wheelchair is now unlocked.
To lock the wheelchair, while the control system is switched on, depress and hold the on/off button.
After 1 second, the control system will chirp. Now release the on/off button, deflect the joystick forwards
until the control system chirps, and deflect the joystick in reverse until the control system chirps. Release
the joystick, there will be a long beep. The wheelchair is now locked.
3.2 The Speed Indicator Flashes
This indicates that the chair is charging via on-board charger. The chair will be ready to drive as soon as
the charger is unplugged.
3.3 Battery Gauge is Steady
This indicates the battery level and that all is well and chair is ready to drive.
3.4 Battery Indicator Ripples up and off.
Indicates the wheelchair batteries are being charged with the offboard charger. You will not be able to drive the
wheelchair until the charger is disconnected and you have reset the control system by switching off the
power and then powering up again.
3.5 Battery Gauge Blinks Once Every 2.5 Seconds
The control system has "gone to sleep" because the wheelchair has not been driven for a period of time.
The time period depends on the programming of the system. To re-start, reset the system by switching
off the power and then powering up again.
3.6 Battery Gauge Flashes Rapidly
Make sure the Joystick is completely released. The control system safety circuits have been activated and the control
system has been prevented from moving the wheelchair. This indicates a system trip, i.e. the VR2 has detected a problem
somewhere in the wheelchair's electrical system. Please refer to Section 3 (VR2 Controller Diagnostics).
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Section 4
Understanding VR2 Controller Diagnostics Codes
4.1 One Bar - Low Battery Voltage )
This code could indicate discharged batteries, failed batteries, or poor battery connections. Begin by recharging the batteries and then refer to Section 1 to check batteries and connections.
4.2 Two Bars – Right motor Disconnect / Low battery voltage
Programmer will indicate left motor fault. Motor faults are reversed on this unit.
If the chair runs while two bars are flashing, chair indicates
low battery voltage. Refer to section 4.1.
If the chair does not run while flashing two bars check the
connections from the right motor to the controller, look for a
loose or damaged connector.
Use a volt meter to check the resistance across the two
bottom contacts with connector for plug on upside of plug
as shown in (figure a4.2.2). If the meter reads between
0-1.5 then proceed by swapping the motor leads into the
controller. Turn unit off and back on and if two bar flash is
still present, replace the controller.
A4.2.1
If the meter does not read between 0 – 1.5 proceed by
swapping the motor leads into the controller. Turn unit off
and back on, if two bar flash becomes a four bar flash,
replace the right motor.
If none of the above corrects the problem, replace the left motor.
If the meter reads between 0 to 1.5 ohms, then replace the controller.
A4.2.2
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Section 4
Understanding VR2 Controller Diagnostics Codes (cont.)
4.3 Three bars – Right Motor Wiring Trip / Low battery voltage.
Programmer will indicate left motor fault. Motor faults are reversed on this unit.
Check that the batteries are fully charged and in good
condition; and check all cables and connections. Check the
connections to the left motor, look for a loose or damaged
connector.
Measure the resistance from the bottom contact of the red
thick wire on the 4-pin left motor connector to each of the
top contacts of the connector see (figure A4.3.1). 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.
Test 1
A4.3.1
Test 2
If all of the readings are open, then replace the controller.
If any of the readings are short, then replace the left motor.
Test 3
Test 4
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2006SUNRISE MEDICAL
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Page 15
Section 4
Understanding VR2 Controller Diagnostics Codes (cont.)
4.4 Four Bars- Left Motor Disconnected
Programmer will indicate right motor fault. Motor faults are reversed on this unit.
Check the connections from the left motor to the controller,
look for a loose or damaged connector. Use a volt meter to
check the resistance across the two bottom contacts with
connector for plug on upside of plug as shown in (figure
a4.4.2). If the meter reads between 0-1.5 then proceed by
swapping the motor leads into the controller. Turn unit off
and back on and if four bar flash is still present, replace the
controller.
A4.4.1
If the meter does not read between 0 – 1.5 proceed by
swapping the motor leads into the controller. Turn unit off
and back on, if four bar flash becomes a two bar flash, replace the left motor.
A4.4.2
If the meter reads between 0 and 1.5 ohms, then replace the controller. If this does not correct the problem,
then replace the right motor.
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2006SUNRISE MEDICAL
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Page 16
Section 4
Understanding VR2 Controller Diagnostics Codes (cont.)
4.5 Five Bars - Left Motor Wiring Trip
Programmer will indicate right motor fault. Motor faults are reversed on this unit.
Check that the batteries are fully charged and in good
condition; and check all cables and connections. Check the
connections to the right motor, look for a loose or damaged
connector.
Measure the resistance from the bottom contact of the red
thick wire on the 4-pin right motor connector to each of the
top contacts of the connectors see (figure A4.5.1). Measure
the resistance from the bottom contact of the black thick
wire on the 4-pin right motor connector to each the top contacts of the connector (below right). If all of the readings
are open, then replace the controller. If any of the readings
are short, then replace the right motor.
Test 1
A4.5.1
Test 2
Test 3
Test 4
If all of the readings are open, then replace the controller.
If any of the readings are short, then replace the right motor.
4.6 Six Bars - Inhibit Active
The wheelchair is being prevented form driving by an external signal. One possibility is the battery charger is connected,
or possibly an actuator inhibit.
4.7 Seven Bars - A Joystick Trip is Indicated
Seven bar flash with speed indicator flashing. Inspect wiring between joystick module and main controller. Replace the
control cable first and then try a joystick module. If the problem persists replace the controller. Make sure that the joystick
is in the center position before switching on the control system. 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
If the joystick fails to center because it is bent or broken, replace the joystick module.
4.8 Eight Bars - Possible Control System Trip
Controller Fault - A control system trip is indicated. Make sure that all connections are secure. Check that the batteries
are fully charged and in good condition, and check all joystick connections and cables. If this does not correct the problem, then replace the controller.
PRELUDE SERVICE MANUAL
2006SUNRISE MEDICAL
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Page 17
Section 4
Understanding VR2 Controller Diagnostics Codes (cont.)
4.9 Nine Bars - Solenoid Brake Trip
The parking brakes have a bad connection. Check the
parking break and motor connections. Make sure the control system connections are secure. Measure the two small
contacts on the four-pin motor connector (fig 4.9.1). If both
motor connectors read approximately 60 ohms, then replace the controller. Otherwise replace the motor that does
not read approximately 60 ohms.
If both motor connectors read approximately 60 ohms, then replace the controller. Otherwise, replace the
motor that does not read approximately 60 ohms.
4.10 Ten Bars - High Battery Voltage
An excessive voltage has been applied to the control
system. This is usually caused by a poor battery connection. Check the battery connections.
A4.9.1
Battery Fault
Check that the batteries are fully charged, the correct voltage and in good condition. Take a voltage reading from
pin 1 and pin 2 of the charger port of the VR2 controller,
see (figure A4.10.1) If the meter reads more than 30 volts,
then check the charger. Otherwise, replace your controller.
2
If the meter reads more than 30 volts replace the charger,
If the Batteries, connections, and voltage level are correct replace the controller.
A4.10.1
1
3
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2006SUNRISE MEDICAL
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Page 18
Disassembly/Reassembly, and Adjustment
Step 1 - Seat removal
Disassembly
Unplug joystick at the base of the chair. (figure s1.1).
1.
Note: Remember to lay cables on the seat otherwise
they may become tangled when taking off the seat.
Unlatch the seat and rotate slightly (figure s1.2).
2.
Lift the seat verticaly to remove (figure s1.3).
3.
Section 5
s1.1
s1.2
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2006SUNRISE MEDICAL
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Page 19
Section 5
Disassembly/Reassembly, and Adjustment
Step 2 - Footrest adjustment and removal
To adjust footplate position
Remove the two attachment bolt ( fi g s2.1)
1.
Slide footrest assembly up or down to desired position
2.
and reinsert attachment bolts.
s2.1
To adjust footplate angle
turn screw in or out ( fi g s2.3) 1.
s2.3
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2006SUNRISE MEDICAL
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Page 20
Disassembly/Reassembly, and Adjustment (cont)
Step 3 - Shroud removal
Main shroud:
Remove seat post pin and lift out the seat post (fi g
1.
s3.1).
Lift the shroud from the velcro and remove (fi g.s3.2)..
2.
Section 5
s3.1
Fender shroud
Loosen and remove the two philips screws holding the
1.
fender shroud in place.(fi g. s3.3).
Remove fender shroud .
2.
Rear shroud
Loosen and remove the two philips screws holding the
1.
rear shroud in place.(fi g. s3.4).
Remove rear shroud .
2.
s3.2
s3.3
PRELUDE SERVICE MANUAL
s3.4
2006SUNRISE MEDICAL
PAGE 14
Page 21
Disassembly/Reassembly, and Adjustment (cont)
Step 4 - Battery removal
Remove seat (step 3).
1.
Remove main shroud (step 3).
2.
Disconnect battery harnesses (fi g s4.1)
3.
Carefully lift batteries and remove (fi g s4.2).4.
Section 5
s4.1
Step 5 - Controller removal
1.
Remove main shroud (step 3).
2.
Disconect battery harnesses (fi g s4.1) .
3.
Remove front battery.
4.
Gently remove controller from velcro inside battery
tray( fi g s5.1).
5.
Unplug all connectors from the controller.
6.
Remove controller from battery tray.
s4.2
s5.1
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2006SUNRISE MEDICAL
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Page 22
Step 6 - Motor removal
Complete steps 1,3-5, removal of seat, shrouds batter-
1.
ies and controller.
Unplug the motor connector from the controller and
2.
remove any zip ties holding the cable harness to the
frame.
Remove battery tray from velcro.(fig. s6.1)
3.
Use a 17mm socket wrench to remove the drive wheel
4.
(fig s6.2).
Using two 13mm wrenches, remove the four bolts and
5.
nuts ( s6.3) holding motor plate to the frame.
Remove the cotter pin (A) (fig s6.4) holding the cog
6.
release handle (B) to the cog release lever arm (C).
Section 5
s6.1
Warning-If motor plate is removed form the gear
box the gear box plate may come off.
s6.3
s6.2
B
C
A
s6.4
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2006SUNRISE MEDICAL
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Page 23
Disassembly/Reassembly, and Adjustment (cont)
Step 7 - Caster Fork removal
Remove caster cap (fig s7.1)
1.
Use a 19mm socket wrench to remove the caster nut
2.
(fig s7.2)
Section 5
s7.1
Step 8 - Changing Drive Tire
Support the wheel chair base.
1.
Use a 17mm socket wrench to remove the nylock nut,
2.
washer and drive wheel (fig s8.1)
Use two 13mm socket wrenches to remove the three
3.
wheel hub fasteners (fig s8.2)
Separate the wheel hubs and remove the tire.
4.
Reassembly:
Ensure the Motor Shaft Key is properly inserted and reverse above instructions
s7.2
s8.1
PRELUDE SERVICE MANUAL
s8.2
2006SUNRISE MEDICAL
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