Xperience and Xplore
Technical Service Manual
Introduction:
Please read the instructions in this service manual before
attempting to troubleshoot or repair this product for the first
time. If there is anything that is not clear or if you require
additional technical assistance, contact Sunrise Tech
Service at 1-888-703-9021. At the prompt, you will be
asked to either dial an extension or hit “0” for the operator
– dial either extension 8183736 or 8182107 – for
immediate assistance please dial “0” for paging and
operator.
Safely troubleshooting and/or repair of this product
depends on your diligence to 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 an/or common sense.
This Service Manual has been compiled as a troubleshooting
guide for the Quickie Xperience and Xplore.
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
servicing of this product should not carry out
troubleshooting procedures. This can result in future
servicing, and/or damage to the unit.
Note: Photographs, Parts and content may differ from the
actual products in some cases due to changes in
specifications and other factors.
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Tools Needed
The following list of tools should enable any task to be
dealt with. Some will only occasionally be needed, by it is
advisable to own or have access to them.
1. Metric Socket Set
2. SAE Socket Set
3. Hexagon Open End Wrenches (SAE & Metric)
4. 3.5 – 8 mm flat screwdriver
5. Number 0 – 2 Phillips or cross-head screwdriver
6. Vise Grips
7. Adjustable Pliers
8. Cir-clip Pliers
9. Hammer (Small & Large)
10. Soft Hammer (Rubber and/or Plastic)
11. Q-Tronix Programmer
12. R-Net In-line Programmer
13. Wire Strippers
14. Shraeder Valve
15. Ty-wraps short – medium - long
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Table of Contents
1. Batteries sizes and installation & troubleshooting
2. Charger and operation & troubleshooting
3. Motors - Operation – readings – and troubleshooting
4. Suspension – Base – Adjustments
5. Joysticks & Controls – Operation – options and parts –
VR2 – EL - RNET
6. Programming – Using Q-TRONX - In-line and Personal
Computer Software - DTT.
7. Seating – Installing – Operation – Tilt – Lift - Recline
Legrests – troubleshooting.
8. Specialty Controls and Setup
9. Diagnostics - section dedicated to every aspect of chair.
10. Acronym – Section
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Section 1
- Batteries
Description:
The batteries are used to power the chair and need to be
maintained to have full potential and use of product. Please
use specified batteries and follow all charging
recommendations. Please use charger provided by
manufacturer – neglect of this will void warranties.
Safety
If mishandled batteries can be dangerous and hazardous.
1. All mobility batteries whether Gel or Sealed type,
contain lead and sulfuric acid. Both of these materials
are toxic and in the case of sulfuric acid, highly
corrosive. Additionally, when batteries are
charged, they produce hydrogen gas which is “highly”
flammable and can cause a possible explosion.
This is why proper handling is mandatory at all times.
2. Battery explosion - this is the result of too low an
acid/electrolyte level in the battery, which allows high
concentrations of hydrogen to built up. This is possible
with all batteries if improper charging or battery failure
occurs. But not common in gel/sealed batteries.
3. Keep sparks and flames away from batteries
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4. Burns – dropping a wrench or screwdriver across battery
terminals results in sparks and arcing and intense heat.
Improper wiring and assembly may short the battery the
wiring and produce an electrical fire.
5. Pollution – Batteries should be disposed at a reliable battery
recycler. Improper disposal of batteries damage the
environment.
Battery Charger Cycle Illustration
Typical flooded battery
As battery discharges, the sulfate from the electrolyte
forms on the plates. As battery recharges, the sulfate is
driven back into the electrolyte.
22NF Battery GRP 24 Battery
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Wiring Diagram for Batteries
Note: The orange wires have recently been
changed to White and Black.
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Installation & Wiring
1. Make sure you installed the Red Wire to the Positive Post and
the Black wire to the negative post. The Back battery cover
has the 70 amp Circuit breaker included – strapped in by 2
ty-wraps and breaker with knurled nut as seen in photos below.
(Rear battery)
(Front battery)
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2. Check to insure the strap is fastened tightly around case
As shown in photos below:
Depressing Metal allows you to pull tighter on strapping
3. Check to make sure connector locks and plastic clips are
Engaged which ensures connector is locked see photos
Below:
Connector not locked fully
Fully Locked
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4. Batteries use a slide out battery tray and operation to open
is done by positive forward pressure on the back and pulling
of handle at same time shown below:
This allows release through
2 different tabs which secure it from releasing through heavy
vibration or terrain seen below:
This pulls enough for
Easy release of back and battery access Yellow Tabs for good
visual
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The battery slide out tray is shown in the picture below:
The battery holder itself has a rubber bumper and vent holes:
(Note: Rubbers to the back – prevents binding)
Photo below shows batteries on sliding tray
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5. Once batteries are installed and box is slid all the way
in the main power connector is connected for power to
the system show in picture below:
There is a finger holder on
plug to help match and make sure you don’t try to plug the
opposite way. Below shows connections:
Group 24
22 NF
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Troubleshooting Batteries
1. Check for good voltage at Module input charger
port. Should read between 23.5 and 25.8 volts for proper
operation. Less than 23.5 volts will give a low battery
Indicator (2 Bar flash).
2. If no voltage at port go to cable that inputs voltage to
Control found on battery box connector shown earlier.
Once again verify voltage and check for popped circuit
Breaker. Reset Circuit breaker.
3. If still no power go directly to individual batteries across
+ and – posts to see at least 12.2 to 13 volts (fully charged).
4. The 3 tests above will verify voltage in what is known as an
unloaded state. The next test is to insure batteries last under
load. This can be done a number of ways. 2 ways of
checking are listed below:
a) The load test across the + and – terminals of battery - make
sure battery is in full charged state. Hook up load tester
and draw 100 amp load across for 10 seconds.
b) The chair has a free wheel release where the motor and
gearbox can be run un-loaded – this still draws 3 -4 amps
across the load. Hold joystick or input device for 1 minute
If after release in a minutes time it drops more than a volt
Change batteries – if it drops between .6 and 1 volt it has a
Cell that is weak and batteries will no stay fully charged
It is recommended to change batteries. If the voltage after
a minutes time drop less that .1 volt but not greater than
0.5 volts the batteries are in good shape.
Code 2C00 – indicates Low Battery - 1 Bar Flashing
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Chargers
Introduction: The battery charger is another essential part of the
Power Chair for the batteries need to be fully charged daily for
heavy users. It is strongly recommended of any technician to
make sure they have a spare charger that is working well and/or
a good set of batteries.
1. Lester Off-Board 8 amp Charger - The Lester Off Board
charger part number BATC8LS – is a Transformer Driven 8
amp charger that has been working in this industry for over 17
years. It have an easy to operate switch that turns on the charger
and has 2 LED’s to indicate charge rate and faults.
The chargers operation is when AC and DC voltage are
available (Note: 18 volts minimum DC) the Green Light flashes
to indicate charge rate. A slow flash indicates the batteries need
a charge and it is output 8 amps as the charging continues when
the voltage approaches the bulk charge rate it starts flashing the
Green LED rapidly indicating 2 amp rate until is sees a change
of less than 500 mV and then turns Solid Green to indicate full
charge cycle.
The table below depicts operation of Green and Red LED
operation and fault modes.
Red Light Gr een Light Function
Off Off No AC power or no battery connected
Steady Steady Light test when AC connected
Off Slow Blink Charging (< 80% charged)
Off Fast Blink Charging (> 80% charged)
Off Steady Normal charge completed
Steady Off Undervoltage shut off, < 18.0 volts
Slow Blink Off Overvoltage shutoff, > 33.96 volts
Fast Blink Off Max timer shutoff, > 16 hours
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The 24 Volt Charger is depicted below:
The D.C. and A.C. wiring are shown below:
The 3 Connection Points are Shown Below from the DC
Connector:
Pin 1 + Pin 2 –
Pin 3 Inhibit
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2. Troubleshooting Chargers - When troubleshooting electronic
equipment there is equipment necessary for checking and
evaluation. The very first is a Multi-meter used for checking
Resistance (continuity) – AC voltage from the Wall Plug – D.C.
voltage from the batteries and Current the flow of the charger.
The second is a load tester needed to evaluate (normally at 100
amps for 10 seconds) the batteries capacity to hold a charge rate.
The other two items recommended but not a necessity is a
good set of batteries and/ or another known good charger.
Troubleshooting Tips
1. Check for battery voltage and polarity at chair’s charger
input.
The voltage needs to be at least 18 volts for the charger
to turn on.
2. Check for continuity between cable (DC output and inside)
this is performed with a Multimeter
on the setting of resistance and with each of the
connector points test the wiring from one end to the
other which is inside the charger plug and charger.
3. Check for A.C. voltage. The wall outlet in North America
should give a reading between 110 and 120 volts A.C.
4. Check for possible blown fuse. As a protection to the
charger and chair components this fuse will go if it
attains close to 15 amps of current - it will not operate
charging of chair until replaced.
Code 1E03 – Charging chair Scroll repeat on Display
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Motors
Intro: The motor is an essential part of any Power Chair and
needs to be looked at annually or when an error occurs which
point to one of 3 parts that make up Motor Assemblies. The
motor assembly consists of the motor – brake – and gearbox.
The Xperience and Xplore both use the same style motor
and there are 2 varieties of motors to choose from. The next
section shows parts of the Motor – Removal – and Diagnostics
for trouble-shooting the motor.
Cap & Brushes Armature
Commutator Permanent Magnet(s)
Resistance Value
15 – 16 ohms
0 – 2 ohms
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Motor Resistance & Meter Check for Xperience & Xplore
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Motor Assembly - Removal
Xperience
1. Take the 4 - 5/8” bolts from the Wheel Assembly shown in
photo below:
2. Remove connector from motor control - access through front
of chair box shown below:
Note: no tools necessary for step above
Shows access and removal of connector for ease of removal –
disconnect yellow communication connector as well
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3. Remove shroud and release assembly - 10 mm and Phillips
screwdriver required as well as pliers and 7/16” wrench
Remove shroud bracket assembly
using a 7/16” open end and ratchet.
4. Remove cotter pin using long nose pliers to firmly remove
5. Disassemble the release mechanism further using a Phillips
screwdriver to remove 3 screws holding attaching plate
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Note: Pictures below show parts after removal and removal
of Plastic restraining clip. This step is necessary for both
motor and motor assembly removal.
6. Next step in removing complete assembly is to remove with
a ratchet or open wrench the quantity 5 - 10mm head bolts.
Note: remove rubber stopper prior to removing back bolt
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If the plate is not removed you will need an open end wrench
to remove the corner bolt near plate holder.
7. Finally to remove complete Gearbox and Motor the
Chair needs to be moved on its side as shown.
This allows to move frame downward to remove assembly
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Xplore Motor Assembly - removal
1. Follow details found on page 17 - removal of Drive Wheel
and removal of motor connector from control.
2. This gives access to the motor and shroud assembly
Remove the 2 Phillips Screw with No. 2 Phillips Screwdriver
3. You now have access to the Motor Gearbox 5 - 10 millimeter
head bolts – remove cotter pin first prior to the bolts with a
pair of Long Nose pliers as mentioned on page 18 of manual
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Place where Cotter pin should be removed
Removal of 5 bolts using ratchet with 10 mm socket
Unlike the Xperience the Xplorer Motor assembly can be
removed if the bolts and cotter pin are removed no need to lay
chair on its side.
Motor only on both chairs:
To remove only the motor a 3/16" allen key socket is needed
and then remove the cotter pin from the holder on the frame as
well as removing connector from control.
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Troubleshooting Motors
1. Testing the motors you will have various means to do this
by. The first way is if the motor has shut down and this is
verifying what Diagnostic Code you have there are 2 main
codes for left and right motor and 2 main codes for the
brake and solenoid. They are as follows:
3B00 – for the M1 connection open – control does not see
proper connection or resistance to Motor 1. Left Code for
rear wheel drive units and right code(3C00) for Mid- wheel
drive. (This is in reference to the Motor mounted on the left)
3C00 – for the M2 connection open – control does not see
proper connection or resistance to Motor 2. Right Code for
rear wheel drive units and left code(3B00) for Mid- wheel
drive. (This is in reference to the Motor mounted on the right)
1505- for the Right Brake open – control does not see good
Brake resistance – two cases: normally open – close to
0 ohms or shorted - ultra high resistance.
1506 - for the Left Brake open – control does not see good
Brake resistance – two cases: normally open – close to
0 ohms or shorted - ultra high resistance.
2. The check is very simple as shown on page 16 - check the
the small connector brake and large connector for motor.
15 – 16 ohms
0 – 2 ohms
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3. The Motor may have a high resistance reading and this could
be due to one or two or more brushes that are damaged.
To extract, use a Large Straight edge screwdriver that
matches to the brush holder. This eliminates stripping and
basically ruining the entry of the brush housing.
Once extracted check the brush for spring wear and length of
Carbon material – it should be no shorter than 1//2 inch in
length and brushes should be wearing smoothly on
Commutator.
Brush & Cap Set - 4 Brushes & Caps – Part # 014819
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Suspension
3
• Innovative Drive system
– Front swing arm (1)
– Rear floating arm (2)
– Shock absorber (3)
– 4 pivot points connecting all
components together
3
2
• Ground compensation
• Gravity compensation
• Gravity control
1
4
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Gravity Compensation
GC3 Technology
Sunrise’s MWD design solution: “interactive suspension”
• The connected front and rear arms create a wide footprint that joins
front and rear casters to the drive wheels
• Always redistributes the load over drive wheels and casters
CG
Interactive suspension:
• Adjustment free
• The performance of the system is based on the
geometry of the pivot points and the links
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Ground Compensation
Movement of the front swing relative to the base frame
• Reduces posterior projection
• Reduces anterior projection
• The seat remains closer to it’s neutral position going
over an obstacle.
Note: Same on Xperience
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Gravity control
Load distribution over casters and drive wheels depends on:
• User’s body type
– Ectomorph
– Mesomorph
– Endomorph
• Seating system
– Thickness of the back
• Static position
– Static tilt
– Back angle
• Dynamic positioning
– Usage of a power tilt and/or recline system
• Options
– Vent tray
– Back pack
Common impacts
– Limits the chair capability:
• Limited outdoor performance (traction)
• Can’t climb obstacle from the front
• Can’t climb obstacle from the back
– Affects the resistance on the castors
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