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PULSE 6 SERVICE MANUAL

PAGE 6.1

2009

SUNRISE MEDICAL

Note: This procedure may be done with or without removing the motor from the power chair.
If the motor/gearbox is to be removed from the power chair, refer to the Motor and Gearbox
Removal section of this manual.

Consider replacing any motor/gearbox assembly that does not pass the following test. Refer
to the Motor Gearbox Removal section of this manual.

1.

Inspect the output shafts for signs of grease

leakage (

fi

g. 6.1).

2.

Inspect the cotter pin connecting the

gearbox release arm to the motor/gearbox
assembly. Ensure that it is tight and not damaged
(

fi

g. 6.2)

3.

Manually operate each gearbox release

lever to ensure that they operate easily and fully
engage and disengage

Note: When removing the brush assemblies,
remove one brush assembly at a time. Note its
orientation so that it can be inserted into the
brush holder the same way it was removed.

Caution: Use care not to damage the brush
cap with excessive force in the next step.

4.

Remove the brush by using a common

screwdriver to unscrew the cap (

fi

g. 6.1).

Motor/Gearbox Inspection

Section 6

fig. 6.1

fig. 6.2

fig. 6.3

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Summary of Contents for Quickie Pulse 6 BC

Page 1: ...Quickie Pulse 6 Service Manual 2009 Sunrise Medical Inc 111425 Rev A ...

Page 2: ...ars Left Motor Disconnected 3 1 Three Bars Left Motor Wiring Trip 3 2 Four Bars Right Motor Disconnected 3 3 Five Bars Right Motor Wiring Trip 3 4 Six Bars Charger Connected 3 4 Seven Bars Possible Joystick Trip 3 4 Seven Bars Speed Profile Indicator Communi cation Error 3 4 Eight Bars Possible Control System Trip 3 5 Nine Bars Solenoid Brake Trip 3 5 Ten Bars High Battery Voltage 3 5 Section 4 R ...

Page 3: ...d 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 procedur...

Page 4: ...le from Joystick to the Bus Line b Control Module for the Pulse located at back of chair behind shroud c Are all necessary connections fastened or inserted Battery connectors to the batteries a Cable between Joystick and the Control b Both Motor Connectors to the Control Module c Is the Drive Gear engaged With the power off the chair should not move if pushed from behind a If the chair moves when ...

Page 5: ...egative and as the name suggests it s the common element to all of the testing circuits Think of it as the ground rail Voltage Resistance and Continuity port 2 This is commonly used option Connect the red positive probe to this port when using any voltage readings resistance readings or when checking wire continu ity explained in more detail later in the tutorial Current up to 300mA 3 This port is...

Page 6: ...ould be I but since current is measured in Amps and the readout value is in amps the symbol makes sense This measures the current that is flowing through the part of the circuit between the two probes the meter itself Typically you need to plug the positive terminal into a port marked A or Current You need to put the meter In Series in the circuit to use this feature correctly Resistance This symb...

Page 7: ...teries away from all sources of ignition Do not place objects on the battery tops Always try to keep someone within earshot of your work area so that they may come to your assistance if needed Always wear personal protection when handling batteries including eye face protection and gloves Make sure there is easy access to soap and water in case of acid spills Avoid touching eyes or unprotected par...

Page 8: ...isibly damaged return the unit to the dealer supplier for inspection EMI means electromagnetic EM interference I EMI comes from radio wave sources such as radio transmitters and transceivers A transceiver is a device that both sends and receives radio wave signals There are a number of sources of intense EMI in our daily environment Some of these are obvious and easy to avoid Others are not and we...

Page 9: ...e intense as you get closer to the source For this reason EMI from handheld devices is of special concern A person using one of these devices can bring high levels of EM energy very close to a power chair without the user s knowledge Immunity level The level of EM is measured in volts per metre V m Every power wheelchair can resist EMI up to a certain level This is called its immunity level The hi...

Page 10: ... an ESD jack or an unpainted metal component on the system such as a captive installation screw Handle Printed Circuit Boards by the edges only avoid touch ing the Printed Circuit Board and connector pins Place any removed Printed Circuit Board on an antistatic sur face or in a static shielding bag Avoid contact between the Printed Circuit Boards and clothing The wrist strap only protects the card...

Page 11: ...e occurs but not common in gel sealed batteries KEEP SPARKS AND FLAMES AWAY FROM BATTERIES Burns dropping a wrench or screwdriver across battery terminals results in sparks and intense heat Improper assembly of battery boxes or battery box wiring may short the battery through the wiring and produce a possible electrical fire Electronic damage batteries that are improperly wired can short out elect...

Page 12: ... testing deep cycle batteries should follow these guidelines Never replace just one battery at a time This will create an imbalance when charging and ultimately damage both batteries Check batteries for a voltage difference A voltage difference of more than 4 volts D C is a true indicator of a bad battery Voltage test A dead battery cannot be effectively tested yet many people mistakenly try to do...

Page 13: ...a regular basis Starting or automotive type batteries use a rapid burst of power to start an engine and are quickly recharged by an alternator or generator They are rated by cold cranking amps a measure that has no relevance to wheelchair application Marine and RV batteries frequently are not deep cycle as they are often used for starting engines Only use Deep Cycle sealed type batteries in a whee...

Page 14: ... 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 ...

Page 15: ...mer 1 Black 2 White 3 Yellow 4 Red 2 1 3 charger port Motor Plug Port Charger port Outside View 4pin 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 On Board Charger not used 1 24 Vdc 2 0 Vdc 3 INHIBIT 1 PROGRAMMER VR2 Controller ...

Page 16: ...R NET Remote Controller On Off Key Press to power on or off the power chair or Controller Speed Profile Decrease Used to decrease the Speed Profile setting Speed Profile Increase Used to Increase the Speed Profile setting Horn Key Activates a warning horn ...

Page 17: ...R NET Remote Controller On Off Key Press to power on or off the power chair or Controller Speed Profile Decrease Used to decrease the Speed Profile setting Speed Profile Increase Used to Increase the Speed Profile setting Horn Key Activates a warning horn ...

Page 18: ...MOTOR JSM JOYSTICK MODULE INH 2 INHIBIT 2 A1 ACTUATOR 1 A2 ACTUATOR 2 OBC ON BOARD CHARGER BATTERY 1 24 Vdc 2 0 Vdc 3 Inhibit 1 Programmer 1 Black 2 White 3 Yellow 4 Red 2 1 3 charger port Motor Plug Port Charger port Outside View On Board Charger not used 1 24 Vdc 2 0 Vdc 3 INHIBIT 1 PROGRAMMER Rnet Controller ...

Page 19: ...ech Motor 4 Way Intech Motor 2 Way VR2 Intech Battery 3 Way P G D C harger 2 Way P G D Inhibit 4 Way Tyco Bus 2 Way PGD Actuator Inhibit2 Inhibit3 VR2 BUS SPLITTER VR2 DRIVE THRU SINGLE ACTUATOR Drive Right Drive Left Red Black 2 way SB50 Red Battery 2 way SB50 Black Red Black Battery 4 Way Amp Mate N Loc 6 Way Mini Fit J r B AS E S E AT ACTUATOR ADAPTOR HARNESS POWER HARNESS ACTUATOR HARNESS DR I...

Page 20: ...dule EL 4 Way Intech Motor 4 Way Intech Motor 2 Way VR2 Intech Battery 3 Way P G D C harger 2 Way P G D Inhibit 4 Way PGD Bus 2 Way PGD Actuator Inhibit2 Inhibit3 R NET DRIVE THRU SINGLE ACTUATOR Drive Right Drive Left Red Black 2 way SB50 Red Battery 2 way SB50 Black Red Black Battery 4 Way Amp Mate N Loc 6 Way Mini Fit J r Connector Block 4 X CAN 4 Way PGD Bus 4 Way PGD Bus 4 Way PGD Bus 4 Way P...

Page 21: ... Some will only occa sionally 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 Basic Tool List ...

Page 22: ... A1 5 2 2 If the voltage meter reads full voltage then replace the joystick module If the voltage meter reads zero voltage measure the corresponding 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 measure the Battery Connector as shown in fig 1 5 3 If the voltage meter reads full voltage ...

Page 23: ... If the polarity is reversed correct battery wiring A1 6 1 Check that the battery fuse is in good condition With the batteries disconnected set the meter to ohms and measure the resistance across the fuse see figure A1 7 1 If the meter reads more than one ohm change the wiring harness or else proceed to the next step Battery Fuse A1 7 1 Circuit Breaker Test To check the circuit breaker set the met...

Page 24: ...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 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 The control system has gone to sleep because ...

Page 25: ...n figure A3 2 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 left motor Two Bars Left Motor Disconnected 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 A...

Page 26: ...ed thick wire on the 4 pin left motor connector to each of the top contacts of the connector 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 Three ...

Page 27: ...maged connector Use the meter to check the resistance across the two bottom 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 Figure A3 4 1 Ensure that they are not excessively worn R...

Page 28: ... 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 module Note If replacing the joystick does not resolve the issue replace the cable connecting the joystick to th...

Page 29: ...A3 9 1 2 1 3 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 3 8 1 If both motor connectors read approximately 60 ohms then replace the controller Otherwise replace the motor that does not read approximately 60 ohms A3 8 3 Controller Fault A ...

Page 30: ...s present replace the following components in this order a Cables b Hand control c Control module Refer to Control Module Replacement section of this manual d Retest as necessary 3 Verify that the buss cables are correctly mated between the hand control and the control module fig 4 2 Note This connector is mated incorrectly The connectors are designed to visually indicate when they are not mated c...

Page 31: ...test as necessary Note The power connector is the larger 2 pin connector between the left and right motor cable 6 Manually tilt the seat back and remove the shroud from the base Refer to Battery Removal section of this manual 7 Verify that the circuit breaker located at the front of the power chair is not tripped fig 4 4 Reset if it is tripped and retest 8 Disconnect the batteries fig 4 5 Rnet Tro...

Page 32: ...ormal resistance is less than 1 ohm If open replace the defective battery harness Retest as necessary Caution To prevent damage to the Multimeter ensure that the batteries are disconnected 11 Check for continuity across the circuit breaker fig 4 8 Normal resistance is less than 1 ohm If open replace the circuit breaker Retest as necessary Note Access to the circuit breaker terminals is easier if t...

Page 33: ... off the excess charge Check the condition of the battery charger M1 Brake Error Verify that the left motor is connected to the control module Complete the Motor and Gearbox Inspection section of this manual M2 Brake Error Verify that the right motor is connected to the control module Complete the Motor and Gearbox Inspection section of this manual M1 Motor Error Verify that the left motor is conn...

Page 34: ...correctly mated If a module has been replaced recently suspect that module may be defective Contact Sunrise Technical Service for assistance Bad Cable Inspect and replace the defective cable s Bad Settings Verify that the programming agrees with the installed equipment If all settings are correct the control module may be defective Contact Sunrise Technical Service for assistance Module Error Recy...

Page 35: ...ection Contact Sunrise Medical Technical Service for assistance The wheelchair is being prevented from driving by an external signal Verify that the battery charger is not connected Contact Sunrise Medical Technical Service for assistance Ensure that the joystick is centered upon power up If it is centered replace the hand control and or cable A control system fault is indicated Make sure that all...

Page 36: ...r and Gearbox Inspection section of this manual and retest Power Chair Will Not Drive Full Speed An external micro switch is mounted next to the actuator in the rear of the tilt system This micro switch is open when the tilt is lowered The opening of this micro switch blocks a signal from being sent to the control module through the 6 pin connector located on the back of the tilt The absence of th...

Page 37: ... not change proceed to step 5 5 Lower the tilt system 6 Locate the 6 pin connector at the rear of the tilt fig 5 4 7 Disconnect the connector leading to the control module 8 Test the micro switch wiring by performing the following test a Ensure that the seat is in the full down position b Use Multimeter and measure continuity between the indicated pins below on the 6 pin connector mounted on the t...

Page 38: ...r Omni 1 Tilt the seat all the way back and observe the hand control or Omni to see if the turtle symbol is displayed 2 If the turtle is displayed fig 5 6 contact Sunrise Technical Service for assistance The programming for the power chair is incorrectly set 3 Use the hand control and tilt the seating system beyond 20 degrees 4 Locate the 6 pin connector on the rear of the tilt fig 5 7 5 Disconnec...

Page 39: ... appears to be running but the tilt is not moving replace the tilt actuator Refer to Tilt Actuator and Micro Switch Removal section of this manual Retest as necessary 3 Locate the 6 pin connector on the rear of the tilt fig 5 10 4 Disconnect the 6 pin cable leading to the control module The tilt actuator used in the tilt system receives power through a 6 pin connector located at the rear of the ti...

Page 40: ... 12 Note The polarity of the voltage is not important since it is reverses when the opposite direction is selected 7 If voltage is not present replace the cable leading to the control module If this does not solve the problem replace the control module Refer to Control Module Removal section of this manual Retest as necessary Voltage to the actuator 8 At the 6 pin connector fig 5 13 on the rear of...

Page 41: ...ng as there is continuity in one direction only This value may even be high The value recorded in the other direction is across the open contact of the end of stroke micro switch and should be open 10 Example 2 the tilt is in the full down position If the readings are not correct replace the tilt actuator Refer to Tilt Actuator and Micro Switch Removal section this manual Retest as necessary Note ...

Page 42: ...teries are either over charged or the batteries have just been disconnected from the battery charger and contain a surface charge If the batteries are not freshly charged and the voltage is excessive inspect the battery charger for correct operation 2 Load test the batteries using either a commercial load tester or the following procedure To use the power chair s motors as a load complete the foll...

Page 43: ...ication at the end of a 5 minute rest is typically the starting voltage or no more than 1 VDC less R net Fault Codes cont fig 5 21 Notes A rapid drop of approximately 1 5 or more during the first 5 seconds indicates a shorted cell in one or both of the batteries The battery terminals should be checked to ensure that they are tight and clean and then the test should be repeated If the terminals are...

Page 44: ...ries typically read within 1 to 2 VDC c 13 VDC or more indicates an overcharged battery or one that has a surface charge from being recently removed from the charger Verify correct operation of the battery charger if the batteries have not recently been removed from charge d 11 9 to 12 VDC indicates a discharged battery Recharge as necessary e Lessthan11 9VDCindicatesanexcessively discharged batte...

Page 45: ...akage fig 6 1 2 Inspect the cotter pin connecting the gearbox release arm to the motor gearbox assembly Ensure that it is tight and not damaged fig 6 2 3 Manually operate each gearbox release lever to ensure that they operate easily and fully engage and disengage Note When removing the brush assemblies remove one brush assembly at a time Note its orientation so that it can be inserted into the bru...

Page 46: ...rush and spring has not over heated and that the ends of the brush are sharp and clean 6 Inspect the motor s commutator fig 6 5 Verify that it is clean not overheated and does not show signs of excessive arcing Normal color is bright copper to dull brown copper Contact Sunrise Medical Technical Service if in doubt of its condition 7 Inspect the motor connector at both the motor end and the control...

Page 47: ...ugh the motor brush assembly and motor by connecting a Multimeter to the large pins of the 4 pin connector fig 6 8 Normal resistance is approximately 5 to 9 ohms Note New brush readings may be different than those recorded above The new brush assemblies should be run in prior to measuring their resistance Contact Sunrise Technical Service if the readings are either significantly higher or lower th...

Page 48: ...der the front of the seat fig 7 1 2 Inspect the power chair base at the back and disconnect any connectors that may be damaged before tilting the seat back fig 7 2 3 Flip back the arms to prevent damage to the arms as the seat back is tilted fig 7 3 Removal Procedures Section 7 fig 7 1 fig 7 2 fig 7 3 ...

Page 49: ...one of the cables attached to the electronics are damaged fig 7 4 5 Locate and remove the 6 plastic inserts that secure the shroud to the base fig 7 5 6 Locate the two batteries mounted in the base fig 7 6 Note the battery connectors 7 Disconnect the battery connectors fig 7 7 8 Remove the batteries 9 Replace the batteries by reversing the previous procedures Removal Procedures cont fig 7 4 fig 7 ...

Page 50: ...and disengage the connector leading from the motor to the control module fig 7 8 3 Elevate the wheelchair by placing wood blocks under the battery box fig 7 9 4 Remove the wheel s hubcap by prying it off using a common screw drive fig 7 10 5 Remove the wheel by removing the 4 bolts using a 6 mm Allen wrench fig 7 11 Removal Procedures cont fig 7 8 fig 7 9 fig 7 10 fig 7 11 ...

Page 51: ... lever Note For the next procedure use either a ball type 5 mm Allen wrench or a cut down 5 mm Allen wrench 7 Remove the 4 bolts securing the motor gearbox assembly to the motor mount using a 5 mm Allen wrench fig 7 13 8 Lift the motor out from the side of the power chair fig 7 14 9 Replace the motor gearbox assembly by reversing the previous procedures Removal Procedures cont fig 7 12 fig 7 13 fi...

Page 52: ...The control module is mounted under the rear cover of the power chair fig 7 15 1 Remove the rear cover by lifting the two quick release pins from the cover fig 7 16 2 Carefully disconnect the connectors leading to the control module fig 7 17 Removal Procedures cont fig 7 15 fig 7 16 fig 7 17 ...

Page 53: ...g two 3 mm Allen screws fig 7 18 Note It may be necessary to remove the batteries to gain access to the nuts on the other side of the control module 4 Slide the control module up to remove it fig 7 19 5 Reverse the above procedures to install the control module Removal Procedures cont fig 7 18 fig 7 19 ...

Page 54: ...his manual 2 Remove the motor gearbox assembly from the side on which you are removing the shock Refer to Motor Gearbox Removal section of this manual 3 Use a 17 mm wrench and remove the top bolt securing the shock to the base fig 7 20 4 Use two 19 mm wrenches and remove the bottom nut and bolt securing the shock to the base fig 7 21 7 22 5 Lift the shock from the base 6 Reverse the previous proce...

Page 55: ...ection of this manual 2 Remove the motor gearbox assembly Refer to the Motor Gearbox Removal section of this manual 3 Remove the two braces connecting the front caster arm to the rear caster arm using 19 mm wrenches fig 7 23 7 24 4 Remove the coupler that connects to the two braces fig 7 25 Removal Procedures cont fig 7 23 fig 7 24 fig 7 25 ...

Page 56: ...n the rear of the motor mount assembly to allow clearance for the front caster arm assembly to slide out fig 7 26 6 Remove the front caster arm assembly fig 7 27 7 Reverse the previous procedures to install the front caster arm assembly Removal Procedures cont fig 7 26 fig 7 27 ...

Page 57: ... Battery Removal section of this manual 2 Remove the two braces connecting the front caster arm to the rear caster arm using 19 mm wrenches fig 7 28 7 29 3 Remove the rear caster arm assembly fig 7 30 4 Reverse the previous procedures to install the rear caster arm assembly Removal Procedures cont fig 7 28 fig 7 29 fig 7 30 ...

Page 58: ...with one hand while removing the caster fork nut with a 19 mm socket wrench fig 7 33 4 Remove the caster fork from the caster arm assembly fig 7 34 Note If either of the bearings needs to be replaced it may be necessary to use a bearing puller on the lower bearing to separate it from the fork stem and a brass drift to drive out the upper or lower bearings from the caster arm assembly if they are s...

Page 59: ... Elevate the caster fork to be removed by placing wood blocks under the battery box of the power chair fig 7 35 2 Remove the caster using two 13 mm wrenches fig 7 36 3 Reverse the previous procedures to install the caster fig 7 37 Removal Procedures cont fig 7 35 fig 7 36 fig 7 37 ...

Page 60: ...to be replaced or the micro switch replaced separately Reverse the procedures to install the tilt actuator or micro switch and retest as necessary 1 Disconnect the 6 pin connector located on the rear of the tilt system fig 7 38 2 Remove the cover over the 6 pin connector on the rear of the tilt system using a 3 mm Allen wrench fig 7 39 3 Locate the micro switch assembly and remove using a 3 mm All...

Page 61: ... replaced separately 6 Locatethemicro switchassemblyattherear of the tilt fig 7 42 Note the connections leading to the micro switch Separate the wires leading to the micro switch Reverse the procedures to replace it and retest as necessary Warning The tilt system is free to fall during the next step Secure the seating system prior to removing the tilt actuator 7 Use two 13 mm wrenches and remove t...

Page 62: ...ro switch assembly as one part if the entire assembly is to be replaced fig 7 44 Reverse the procedures to install and retest as necessary Note Perform this step if only the actuator is to be replaced 9 Note the connections of the wires and separate them fig 7 45 Remove the actuator 10 Reverse the previous procedure to install the actuator micro switch assembly Retest as necessary Removal Procedur...

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