Sunrise Medical 931157 User Manual
Guardian Aspire Service Manual
©2003 Sunrise Medical Inc.
931157 Rev A
Guardian Aspire Troubleshooting Guide
INTRODUCTION ......................................................0.1
Specifications
VSI Controller ...........................................................0.2
Plugs/Connectors......................................................0.3
Main Wiring Diagram/Tool List ..................................0.4
Troubleshooting - No Power .......................Section 1
Step 1.0 Circuit Breaker Reset...................................1
Step 1.1 Test Joystick.................................................1
Step 1.2 Battery Test ..................................................1
Step 1.3 Recharging the Batteries..............................2
Step 1.4 Not Charging ................................................2
Step 1.5 Battery Connection Check ...........................2
Step 1.6 Battery Wire Harness ....................................3
Step 1.7 Battery Fuse.................................................3
Step 1.8 Circuit Breaker Test......................................3
Step 1.9 Main Harness ...............................................3
Understanding Controller Display ..............Section 2
2.1 Maximum Speed Indicator Ripples.......................4
2.2 Maximum Speed Indicator Flashes ......................4
2.3 Battery Gauge is Steady.......................................4
2.4 Battery Gauge Flashes Slowly .............................4
2.5 Battery Gauge Steps Up.......................................4
2.6 Battery Gauge Blinks Every 2.5 Seconds ............4
2.7 Battery Gauge Flashes Rapily..............................4
Understanding VSI Controller Diagnostics Codes
........................................................................Section 3
3.1 1 Bar (1 Red) Low Battery Voltage .....................5
3.2 2 Bars (2 Red) - Left Motor Disconnected ..........5
3.3 3 Bars (3 Red) - Left Motor Wiring Trip ...............6
3.4 4 Bars (3 Red,1 Yellow)
Right Motor Disconnected ...........................................7
3.5 5 Bars (3 Red, 2 Yellow)
Right Motor Wiring Trip................................................8
3.6 7 Bars (3 Red, 4 Yellow)
Possible Joystick Trip ..................................................9
3.7 8 Bars (3 Red, 4 Yellow, 1 Green)
Possible Control System Trip ......................................9
3.8 9 Bars (3 Red, 4 Yellow, 2 Green)
Solenoid Brake Trip .....................................................9
3.9 10 Bars (3 Red, 4 Yellow, 3 Green)
High Battery Voltage ..................................................10
Disassembly/Reassembly
and Adjustment.............................................Section 4
Step 1 (Controller and Seat) ......................................11
Step 2 (Cog Release) ................................................12
Step 3 (Seat Posts)....................................................12
Step 4 (Shroud)..........................................................13
Step 5 (Front Caster Cover) ......................................14
Step 6 (Charger) ........................................................15
Step 7 (Battery)..........................................................15
Step 8 (Motor/Wheel).................................................16
Step 9 (Motor Mounts)...............................................17
Step 10 (Front and Rear Caster Assembly)...............18
Step 11 (Wire Harnesses)..........................................19
ASPIRE SERVICE MANUAL
PAGE 0.1
2003SUNRISE MEDICAL
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.
This Service Manual has been compiled as a troubleshooting guide for the Guardian Aspire.
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.
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.
ASPIRE SERVICE MANUAL
PAGE 0.2
2003SUNRISE MEDICAL
VSI Controller
VSI Controller
SMASP0X01
SMASP0P01
VSI Controller Buttons
Battery Condition Meter- A
series of ten LED’s, which indicate charge level.
Speed/Profile indicator- A
series of five LED’s, whichdisplay
speed and profile settings
On/Off Key- Press to power on
or off the power chair or
Controller.
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.
CNTRLLR BTNS
ASPIRE SERVICE MANUAL
PAGE 0.3
2003SUNRISE MEDICAL
Plugs/Connectors
8
6
4
2
7
5
3
1
0 Vdc
9
0 Vdc
24 Vdc
24 Vdc
LH Motor -
LH Motor +
1 = 24 Vdc
2 = 0 Vdc
3 = Inhibit 1/ Programmer
1 = Brake Solenoid
2 = Brake Solenoid
3 = Motor
4 = Motor
1 = 0 Vdc
2 = Inhibit 3
3 = 24 Vdc
RH Motor -
RH Motor +
+24 Vdc Solenoid Brake Input
2
1
3
2
1
3
4
2
1
3
9-pin Connect Harness Socket Face
3-pin connect
Outside View
3pin
9pin
charger port
Motor Plug
4-pin connect
Charger port
Outside View
Controller and Harness
BLACK
FUSE
FUSE
BLACK
BLACK
ORANGE
ORANGE
RED
RED
RED
Main Wiring Diagram/Tool List
ASPIRE SERVICE MANUAL
PAGE 0.4
2003SUNRISE MEDICAL
For correct maintenence, adjustment, and for
disassembly/reassembly of the power chair you
will need the following tools:
1. 3mm Allen wrench
2. 5mm Allen wrench
3. 13mm Open-end wrench
4. 13mm Socket wrench
5. 16mm Open-end wrench
6. 17mm Deep Socket wrench
7. 19mm Open-end wrench
8. Phillips screwdriver #2
9. Flat blade screwdriver
10. Cutter for the zip-tie
Wiring Diagram
Basic Tool List
WIRE_DGM1
ASPIRE SERVICE MANUAL
PAGE 1
2003SUNRISE MEDICAL
Section 1
Troubleshooting: No Power
Check that the voltage is going to the controller, set the
meter to dc volts and take a voltage reading from pin 1
(using the red lead) and pin 2 (using the black lead) to the
charger port of the VSI controller (see figure A1.1.1) If the
voltage meter reads approximately 24 volts, replace the controller, if the meter reads less than 12 volts, proceed to the
next step.
Note: Make sure the polarity is correct. If the reading is intermittent, there is a connection or Controller problem.If polarity is reversed proceed to step 1.6
1.1 Test Joystick
1.0 Circuit Breaker Reset
A1.1.1
If On/off button is pressed and no light or bar is shown, check
for tripped circuit breaker (see figure A1.0.1) and make sure
all connections are clean and tight (including the batteries). If
the problem persists, then perform the following diagnostics.
1.2 Battery Test
If the total Battery Voltage reads approx. 24 V, and the Polarity is correct, replace the controller.
Check that the batteries are fully charged and in good condition. Remove the seat, and the battery cover, with controller connected and turned on, use the meter to check the
voltage across the battery terminals (see figure A1.2.1). If
the voltage meter reads between 12 -13.5 volts, then proceed to next step. If the voltage meter reads below
12volts,charge the batteries.
Note: To find a bad battery, use a battery load tester.
A1.2.1
If the voltage meter reads below 12 volts, charge the batteries.
A1.0.1
2
1
3
ASPIRE SERVICE MANUAL
PAGE 2
2003SUNRISE MEDICAL
1.5 Battery Connection Check
Check that the female Beau plug on the chair has voltage.
Set the meter to dc volts and measure pins 5 (using the red
lead of the meter) and 7 (using the black lead of the meter)
as shown in (figure A1.5.1).
If the voltage meter reads full voltage, then measure pins 6
(using the red lead of the meter) and 8 (using the black
lead of the meter) as shown in (figure A1.5.2). If both the
measurements read full voltage, then replace the controller,
or else proceed to the next step.
A1.5.1
A1.5.2
If both of the measurements read full voltage, then replace the controller.
If the total Battery voltage is less than 8 Volts, charge each Battery separately with a 12 Volt Trickle Charger for a few
hours. This should bring the voltage back up to the level that the On-Board Charger will activate.
1.3 Re-Charging the Batteries
Check the charger indicator light in the front shroud. If it is not lighted, check the connection from the light to the charger.
Check the Circuit Breaker Box and make sure it is not tripped. Make sure the 3 pin Charger plug is connected properly
and is in good condition. Check all batteries and harness connections following steps 1.2 and 1.5 - 1.9 Check the
connection from the A/C charging outlet to the charger. If none of these actions have corrected the problem, then replace
the charger.
Note: On Board Charger Indicator Light shows Amber color when charging, and Green when fully charged.
1.4 Not Charging
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