Guardian Aspire Service Manual - Sunrise Medical

1 Guardian Aspire Service Manual 2003 Sunrise Medical Rev AGuardian Aspire Troubleshooting Controller .. Wiring Diagram/Tool List .. - No 1 Step Circuit Breaker Reset ..1 Step Test Joystick ..1 Step Battery Test ..1 Step Recharging the Not Charging ..2 Step Battery Connection Check ..2 Step Battery Wire Harness ..3 Step Battery Fuse ..3 Step Circuit Breaker Test ..3 Step Main Harness ..3 Understanding Controller Maximum Speed Indicator Ripples .. Maximum Speed Indicator Flashes .. Battery Gauge is Battery Gauge Flashes Slowly .. Battery Gauge Steps Battery Gauge Blinks Every Seconds .. Battery Gauge Flashes VSI Controller Diagnostics Codes ..Section 1 Bar (1 Red) Low Battery Voltage .. 2 Bars(2 Red) -Left Motor Disconnected.

2 3 Bars(3 Red) -Left Motor Wiring Trip .. 4 Bars(3 Red,1 Yellow) Right Motor Disconnected .. 5 Bars(3 Red, 2 Yellow)Right Motor Wiring Trip .. 7 Bars(3 Red, 4 Yellow)Possible Joystick Trip .. 8 Bars(3 Red, 4 Yellow, 1 Green)Possible Control System Trip .. 9 Bars(3 Red, 4 Yellow, 2 Green)Solenoid Brake Trip .. 10 Bars (3 Red, 4 Yellow, 3 Green)High Battery Voltage ..10 Disassembly/Reassemblyand 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 MANUALPAGE MEDICALINTRODUCTIONP lease read and follow instructions in this Service Manual before attempting to troubleshootor repair this product for the first there is anything in this Service Manual that is notclear, or if you require additional Technical assistance, contact Sunrise Medical at: (800)333-4000 option 2, then option troubleshooting and/or repair of this product depends on your diligence in followingthe instructions within this Manual .

3 Sunrise Medical is not responsible for injuries or dam-age resulting from a person s failure to exercise good judgement and/or common Service Manual has been compiled as a troubleshooting guide for the Guardian and content may differ from the actual products in some cases due tochanges in specifications and other factors. This Service Manual is intended for use by persons with a basic working knowledge and theskills required in servicing and maintaining Power Wheelchairs. Persons without a GeneralWorking knowledge and expertise in the servicing of this product should not carry out trou-bleshooting procedures. This can result in problems with future servicing, and/or damageto the and configuration or specifications of Products included in this Service Manual are subject to change without prior are warning symbols used in this document to focus attention on anyhazard that could effect the safety of the individual troubleshooting thechairs covered in this Service Service MANUALPAGE MEDICALVSI ControllerVSI ControllerSMASP0X01 SMASP0P01 VSI Controller ButtonsBattery Condition Meter- Aseries of ten LED s, which indi-cate charge indicator- Aseries of five LED s, whichdisplayspeed and profile settingsOn/Off Key- Press to power onor off the power chair Key- Activates a Profile Decrease.

4 Usedto decrease the Speed/ Profilesetting. Speed/ Profile Increase. Usedto Increase the Speed/ Profilesetting. CNTRLLR BTNSASPIRE Service MANUALPAGE MEDICALP lugs/Connectors864275310 Vdc90 Vdc24 Vdc24 VdcLH Motor -LH Motor +1 = 24 Vdc2 = 0 Vdc3 = Inhibit 1/ Programmer1 = Brake Solenoid2 = Brake Solenoid3 = Motor 4 = Motor 1 = 0 Vdc2 = Inhibit 33 = 24 VdcRH Motor -RH Motor ++24 Vdc Solenoid Brake Input21321342139-pin Connect Harness Socket Face3-pin connectOutside View3pin9pincharger portMotor Plug4-pin connectCharger portOutside ViewController and HarnessBLACKFUSEFUSEBLACKBLACKORANGEORAN GEREDREDREDMain Wiring Diagram/Tool ListASPIRE Service MANUALPAGE MEDICALFor correct maintenence, adjustment, and fordisassembly/reassembly of the power chair youwill need the following tools:1.

5 3mm Allen wrench2. 5mm Allen wrench3. 13mm Open-end wrench4. 13mm Socket wrench5. 16mm Open-end wrench6. 17mm Deep Socket wrench7. 19mm Open-end wrench8. Phillips screwdriver #29. Flat blade screwdriver10. Cutter for the zip-tieWiring DiagramBasic Tool ListWIRE_DGM1 Aspire Service MANUALPAGE 12003 Sunrise MEDICALS ection 1 Troubleshooting: No PowerCheck that the voltage is going to the controller, set themeter to dc volts and take a voltage reading from pin 1(using the red lead) and pin 2 (using the black lead) to thecharger port of the VSI controller (see figure ) If thevoltage meter reads approximately 24 volts, replace the con-troller, if the meter reads less than 12 volts, proceed to the next : Make sure the polarity is correct. If the reading is inter-mittent, there is a connection or Controller polari-ty is reversed proceed to step Test Circuit Breaker On/off button is pressed and no light or bar is shown, checkfor tripped circuit breaker (see figure ) and make sureall connections are clean and tight (including the batteries).

6 Ifthe problem persists, then perform the following Battery TestIf the total Battery Voltage reads approx. 24 V, and the Polarity is correct, replace the that the batteries are fully charged and in good con-dition. Remove the seat, and the battery cover, with con-troller connected and turned on, use the meter to check thevoltage across the battery terminals (see figure ). Ifthe voltage meter reads between 12 volts, then pro-ceed to next step. If the voltage meter reads below12volts,charge the : To find a bad battery, use a battery load the voltage meter reads below 12 volts, charge the Service MANUALPAGE 22003 Sunrise Battery Connection CheckCheck that the female Beau plug on the chair has the meter to dc volts and measure pins 5 (using the redlead of the meter) and 7 (using the black lead of the meter)as shown in (figure ).

7 If the voltage meter reads full voltage, then measure pins 6(using the red lead of the meter) and 8 (using the blacklead of the meter) as shown in (figure ). If both themeasurements read full voltage, then replace the controller,or else proceed to the next both of the measurements read full voltage, then replace the the total Battery voltage is less than 8 Volts, charge each Battery separately with a 12 Volt Trickle Charger for a fewhours. This should bring the voltage back up to the level that the On-Board Charger will Re-Charging the BatteriesCheck the charger indicator light in the front shroud. If it is not lighted, check the connection from the light to the the Circuit Breaker Box and make sure it is not tripped. Make sure the 3 pin Charger plug is connected properlyand is in good condition.

8 Check all batteries and harness connections following steps and - Check the connection from the A/C charging outlet to the charger. If none of these actions have corrected the problem, then replacethe charger. Note: On Board Charger Indicator Light shows Amber color when charging, and Green when fully Not ChargingASPIRE Service MANUALPAGE 32003 Sunrise MEDICALIf the above steps did not correct the problem, change themain harness. Main Circuit Breaker TestTo check the circuit breaker set the meter to ohms andmeasure the resistance across the circuit breaker as shownin (figure ). If the meter reads more than 1 ohm,then change the circuit breaker, otherwise proceed to the meter reads more than 1 ohm, then change the circuit the previous steps did not correct the problem, change the main that the battery fuse is in good condition.

9 With thebatteries disconnected remove the fuse cap, inspect thefuse to see if the fuse is blown. To make sure the fuse isnot blown, set the meter to ohms and measure the resist-ance across the fuse. see (figure ). If the meterreads more than one ohm, change the fuse, or else pro-ceed to the next Battery the meter reads more than one ohm, change the Battery Battery Wire HarnessCheck that the battery wire harness has the polarity cor-rect. Set the meter to dc volts and measure the connectorwith the red lead on the red wire contact (top of the con-nector) and the black lead on the black wire contact (bot-tom of the connector) as shown in (figure ). If bothbattery wire harnesses have full voltage and correct polari-ty, then proceed to step If voltage is absent proceed tostep If polarity is reversed correct battery polarity is reversed correct battery Service MANUAL2003 Sunrise MEDICALS ection 2 Understanding Controller DisplayThe wheelchair is locked.

10 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, therewill be a long beep. The wheelchair is now lock the wheelchair, while the control system is switched on, depress and hold the on/off button. After1 second, the control system will chirp. Now release the on/off button, deflect the joystick forwardsuntil the control system chirps, and deflect the joystick in reverse until the control system chirps. Releasethe joystick, there will be a long beep. The wheelchair is now indicates that the chair is charging via on-board charger. The chair will be ready to drive as soon asthe charger is indicates that all is control system is functioning correctly, but you should charge the battery as soon as wheelchair batteries are being charged with the offboard charger.