Guardian Aspire Service Manual ©2003 Sunrise Medical Inc.
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 Step Step Step Step Step Step Step Step Step 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.
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.
VSI Controller SMASP0X01 VSI Controller Buttons VSI Controller 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.
Plugs/Connectors 1 = 0 Vdc 1 3 2 1 = 24 Vdc 1 2 3 2 = 0 Vdc 2 = Inhibit 3 3 = Inhibit 1/ Programmer 3 = 24 Vdc Charger port Outside View 3-pin connect Outside View 3pin charger port 9pin Controller and Harness +24 Vdc Solenoid Brake Input 0 Vdc 24 Vdc 7 8 5 6 24 Vdc 9 LH Motor - 3 4 Motor Plug 0 Vdc LH Motor + 1 2 3 4 4-pin connect 1 = Brake Solenoid RH Motor - 1 2 RH Motor + 2 = Brake Solenoid 3 = Motor 4 = Motor 9-pin Connect Harness Socket Face SUNRISE MEDICAL ASPI
Main Wiring Diagram/Tool List Wiring Diagram BLACK FUSE BLACK RED RED ORANGE BLACK FUSE RED Basic Tool List ORANGE WIRE_DGM1 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.
Section 1 Troubleshooting: No Power 1.0 Circuit Breaker Reset 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. A1.0.1 1.
1.3 Re-Charging the Batteries 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. 1.4 Not Charging 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.
1.6 Battery Wire Harness Check that the battery wire harness has the polarity correct. Set the meter to dc volts and measure the connector with the red lead on the red wire contact (top of the connector) and the black lead on the black wire contact (bottom of the connector) as shown in (figure A1.6.1). If both battery wire harnesses have full voltage and correct polarity, then proceed to step 1.8. If voltage is absent proceed to step 1.7. If polarity is reversed correct battery wiring. A1.6.
Section 2 Understanding Controller Display 2.1 The Maximum Speed Indicator Ripples 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.
Section 3 Understanding VSI Controller Diagnostics Codes 3.1 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. 3.2 Two Bars - Left Motor Disconnected The left hand motor has a bad connection. Check the connections to the left hand motor.
Understanding VSI Controller Diagnostics Codes (cont.) 3.3 Three Bars - Left Motor Wiring Trip The left hand motor has a short circuit to a battery connection. Test Left Motor Short 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. Take a resistance reading from pin 3 to pin 9 and pin 3 to pin 7 or pin 8, see (figure A3.3.1) and (A3.3.
Understanding VSI Controller Diagnostics Codes (cont.) 3.4 Four Bars- Right Motor Disconnected The right hand motor has a bad connection. Check the connections to the right hand module. Test Right Motor Open 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. Remove the 9-pin Beau plug and check the resistance across pin 1 and pin 2 as shown on (figure A3.4.1).
Understanding VSI Controller Diagnostics Codes (cont.) 3.5 Five Bars - Right Motor Wiring Trip The right hand motor has a short circuit to a battery connection. Test Right Motor Short 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. Take a resistance reading from pin 2 to pin 9 see (figure A3.5.1). Take a resistance reading from pin 2 to pin 7 or pin 8 see (figure A3.5.
Understanding VSI Controller Diagnostics Codes (cont.) 3.6 Seven Bars - Possible Joystick Trip A joystick trip is indicated. Make sure that the 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 controller.
Understanding VSI Controller Diagnostics Codes (cont.) 3.8 Nine Bars - Solenoid Brake Trip (cont.) Test Motor Connections If either or both readings are incorrect, then measure the resistance on the two small contacts on the 4-pin motor connector see (figure A3.8.3). If both motor connectors read approximately 60 ohms, then replace the main harness. Otherwise, replace the motor that does not read approximately 60 ohms. A3.8.
Section 4 Disassembly/Reassembly, and Adjustment Step 1 - Controller and Seat Note: When using the terms “Right Hand, Left Hand” this is referenced as if seated in the chair. Disassembly a. Squeeze down the locking legs of the 3 pin charger plug and unplug it from the rear of the chair. (figure s1.1). b. Rock the controller plug back and forth until it is loose and then unplug it (figure s1.1). Note: Remember to lay cables on the seat otherwise they may become tangled when taking off the seat. c.
Disassembly/Reassembly, and Adjustment (cont) Step 2 - Cog Release Disassembly a. Turn each of the two cog release handles counter-clockwise to unscrew them. Note: For better access, pull the cog release handle to the free-wheel position (figure s2.1). Reassembly a. Hold the cog release pivot joint, and thread the cog release handle back to the pivot joint. Adjustment Tighten the Jam nut to set the cog release handle to the correct orientation. Note: It is recommended that the handles end up facing outward.
Disassembly/Reassembly, and Adjustment (cont) Step 4 - Shroud Disassembly Note: Make sure the cog release pivot joints are in a position that matches the shroud cutout. a. Use a #2 Phillips screw driver to remove the four mounting screws and slide out while lifting off the top shroud from the back of the chair. (figure s4.1). b. Use a #2 phillips screw driver to remove the six mounting screws on the inside of the shroud to remove the side shroud fairing (figure s4.2) c.
Disassembly/Reassembly, and Adjustment (cont) Step 5 - Front Caster Cover Disassembly a. Use a #2 Phillips screw driver to remove the two mounting screws on the side of the front caster cover. (figure s5.1). b. Use a #2 phillips screw driver to remove the two mounting screws and the caster cover mounting bracket (figure s5.2). c. Repeat steps a and b on the other side. Reassembly a. Perform the reverse of instructions above. s5.1 s5.
Disassembly/Reassembly, and Adjustment (cont) Step 6 - Charger Disassembly a. Peel the velcro strip apart, and remove the on-board charger (figure s6.1). b. Slide the female charger plug out of the beau plug bracket (figure s6.2) c. Depress the locking tabs and unplug the A/C plug and charger light indicator plug. (figure s6.1) Reassembly a. First insert the velcro strip through the support ring before starting reassembly. b. Perform the reverse of instructions above.
Disassembly/Reassembly, and Adjustment (cont) Step 8 - Motor/Wheel Disassembly Note: For ease of disassembly, set the base frame on a block where all six wheels are at least 1 inch above the ground. a. Unwrap the wire looms from the motor and pull the motor connector out (figure s8.1). b. Depress the motor connector locking tab and unplug it (figure s8.1). c. Use a 5mm hex key to remove the six mounting screws (figure s8.2). d.
Disassembly/Reassembly, and Adjustment (cont) Step 9 - Motor Mounts Disassembly a. Use a 5mm allen wrench and 13mm wrench to remove the mounting bolt connecting the linkage to the caster arm (figure s9.1). b. Use a 16mm wrench and 19mm wrench to remove the motor mount pivot bolt(figure s9.2). c. Slide the motor mount out from the base frame pivot bracket. Reassembly a. Reverse above instructions.
Disassembly/Reassembly, and Adjustment (cont) Step 10 - Front and Rear Caster Assembly Disassembly a. Straighten the locking washer tabs on the front (figure s10.1) and/or rear (figure s10.2) caster assemblies. b. Use the 13mm wrench and 13mm socket wrench to remove the mounting bolts. c. Slide the caster assemblies out from the base frame tubes. Reassembly a. Reverse above instructions. Note: Torque specification on the mounting bolts is 13 ft-lbs. Note: Bend locking tabs against bolt head flats. s10.
Disassembly/Reassembly, and Adjustment (cont) Step 11 - Wire Harnesses Disassembly a. Remove all the zip ties on the base frame. b. Unwrap all the wire loom ties securing the harness to the frame. c. For the main harness, remove the two screws that holding the female beau plug (figure s11.1). d. Remove the circuit breaker locking nut and push it through the bracket (figure s11.2), then remove the main wire harness. e.
