Quickie Melody - ezMobilityBatteries.com
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1. 3 Then slide the wheel off the shaft 2 Remove the two screws mounting the freewheel handle to the motors fig 5 4 3 Unplug motor from the controller fig 59 2 4 Use a four mm hex key and an eight mm wrench to remove the four bolts and nuts mounting the motor to the frame figs5 6 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 14 Disassembly Reassembly and Adjustment cont Step 6 Caster removal 1 Remove caster cap fig 57 1 2 Use a 19mm socket wrench to remove the caster nut fig 7 2 Step 7 Anti tip removal 1 Use two 10 mm wrenches to remove the bolt and nut retaining the anti tip wheel fig 57 1 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 15 Disassembly Reassembly and Adjustment cont Step 8 Main wiring harness removal 1 Remove the two screws mounting battery plug to the frame fig 58 1 Step 9 Rear bumper removal 1 Use an 11mm wrench to remove the two bolts secur ing the rear bumper to the frame fig 55 2 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 162. Battery Voltage 6 3 2 Two Bars Left Motor Disconnected 6 3 3 Three Bars Left Motor Wiring Trip 7 3 4 Four Bars Right Motor Disconnected 8 3 5 Five Bars Right Motor Wiring Trip 9 3 6 Six Bars Charger 9 3 Seven Bars Possible Joystick Trip 9 3 8 Eight Bars Possible Control System Trip 9 3 9 Nine Bars Solenoid Brake 10 3 10 Ten Bars High Battery Voltage 10 3 11 Eleven Bars Communication Error 10 Section 4 Disassembly Reassembly and Adjustment 11 Step 1 Seat removal amp Frame Separation 11 Step 2 Shroud 12 Step 13 Step 4 Battery 13 Step 5 Motor 14 Step 6 Caster 15 Step 7 Anti tip 15 Step 8 Main wiring harness 16 Step 9 Rear bumper 16 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
3. 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 Measure the resistance from the bottom contact of the red thick wire on the 4 pin left motor connector to each of the top contacts of the connector see 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 Test3 4 5 If all of the readings are open then replace the controller If any of the readings are short then replace the left motor SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 7 Understanding Controller Diagnostics Codes cont 3 4 Four Bars Right Motor Disconnected 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 Otherwise check the brushes on the right motor Ensure that they are not excessively worn replace as required as shown in Figure 4 1 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 t
4. 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 is intended as a troubleshooting guide for the Quickie Melody P hoto graphs and content may differ from the actual products in some cases due to changes in specifications and other factors There are warning symbols used in this document to fo cus attention on any hazard that could effect the safety of the in dividual troubleshooting the chairs covered in this Service Manual 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 trou bleshooting 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 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 0 1 VR2 Controller VR2 Controller Buttons Battery Gauge CP A series of t
5. screwdriver 2 18mm combination wrench Flat blade screwdriver 19mm socket wrench e 5mm socket wrench Wiring Diagram for VR2 Controller Package It 24 L SOLENOID LEFT MOTOR E LEFT BATTERY SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 0 4 Troubleshooting No Power 1 1 Circuit Breaker Reset If On off button is pressed and no light or bar is shown check for tripped circuit breaker see figure 1 1 1 and make sure all connections are clean and tight including the batteries If the problem persists then perform the following diagnostics 1 2 Test Joystick Check that the voltage is going to the controller set the me ter 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 VR2 joystick see figure Al 2 1 If the voltage meter reads approximately 24 volts replace the controller the meter reads less than 12 volts proceed to the next step Note Make sure the polarity is correct If the read ing is intermittent there is a connection or Control ler problem If polarity is reversed proceed to step 1 6 1 3 Battery Test Check that the batteries are fully charged and in good condi tion Remove the battery box and the battery cover use the meter to check the voltage across the battery terminals see figure Al 3 1 Ifthe voltage meter reads be
6. Quickie Melody Service Manual 2006 Sunrise Medical Inc 101975 Rev A Quickie Melody Service Manual Contents Introduction 0 1 VR2 Controller 0 2 Plugs Connectors 0 3 Basic Tool List amp Wiring Diagram 0 4 Section 1 Troubleshooting No 1 1 1 Circuit Breaker Reset 1 1 2 Test Joystick 1 1 3 Battery 1 1 4 2 1 5 Battery Connection 3 1 6 Check Battery Wire 4 1 7 Battery Fuse 4 1 8 Circuit Breaker 4 1 9 Main Harness 4 Section 2 Understanding Controller 5 5 2 1 The Maximum Speed Indicator Ripples 5 2 2 The Maximum Speed Indicator Flashes 5 2 3 Battery Gauge is 1 5 2 4 Battery Gauge Flashes Slowly 5 2 5 Battery Gauge Steps 5 2 6 Battery Gauge Blinks Once Every 2 5 Seconds 5 2 7 Battery Gauge Flashes Rapidly 5 Section 3 Understanding Controller Diagnostics Codes 6 3 1 One Bar Low
7. SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 10 Disassembly Reassembly and Adjustment Step 1 Seat removal amp Frame Separation Disassembly 1 Unplug joystick connector figure 51 1 2 Push seat lever forward and lift off seat figure 51 2 3 Lift and remove battery case figure 51 3 4 Lift T handle and separate front frame assembly from rear frame assembly figure 51 4 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 11 Disassembly Reassembly and Adjustment cont Step 2 Shroud removal Rear shroud 1 Remove the two screws fg 52 1 holding rear shroud CR 2 Remove the rear shroud fj 52 2 to access motor controller Front shroud 1 Remove the ten screws mounting the front shroud fg 52 3 2 Remove the front shroud SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 12 Disassembly Reassembly and Adjustment cont 1 Remove the rubber mat from the footplate fy 53 1 2 Remove the three screws mounting the footplate to the shroud 0 53 2 3 Remove the bolt mounting the footplate to the frame M f 53 3 Step 4 Battery removal 1 Remove the 11 screws mounting the top battery case to the bottom battery case fp 54 1 2 Remove 4 spade connectors from batteries fj 54 2 SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 13 Disassembly Reassembly and Adjustment cont 1 Use a 17mm socket wrench to remove wheel nut fig 55
8. ck there will be a long beep The wheelchair is now locked 2 2 The Maximum Speed Indicator Flashes VR2 This indicates that the chair is charging via on board charger The chair will be ready to drive as soon as the char ger is unplugged 2 3 Battery Gauge is Steady This indicates that all is well 2 4 Battery Gauge Flashes Slowly The control system is functioning correctly but you should charge the battery as soon as possible At 21 5 V the red light Starts to blink Each bar represents a 5V value The controller requires 18V to start and a minimum of 16V to work once started 2 5 Battery Gauge Steps Up Indicates the wheelchair batteries are being charged with the off board charger You will not be able to drive the wheel chair until the charger is disconnected and you have reset the control system by switching off the power and then power ing up again 6 Battery Gauge Blinks Once Every 2 5 Seconds The control system has gone to sleep because the wheelchair has not been driven for a period of time The time period depends on the programming of the system To re start reset the system by switching off the power and then powering up Battery Gauge Flashes Rapidly w N Make sure the J oystick is completely released The control system safety circuits have been activated and the control system has been prevented from moving the wheelchair This indicates a system trip i e the VR2 has detected a problem somewher
9. e in the wheelchair s electrical system Please refer to Section 3 VR2 Controller Diagnostics SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 5 Understanding 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 bat teries and then refer to Section 1 to check batteries and connections 3 2 Two Bars Left Motor Disconnected 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 pu Otherwise check the brushes on the left motor Ensure that they are not excessively worn replace as required as shown in Figure 2 1 Use the meter to check the resistance across the two bot tom contacts thicker wires on the 4 pin motor connector as shown in 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 DIGITAL MUL TDMETER meter reads between 0 to 1 5 ohms then replace the controller none of the above corrects the problem replace the left motor SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 6 Understanding Controller Diagnostics Codes cont 3 3 Three Bars Left Motor Wiring Trip Check that the batteries are fully
10. en LED s which O O indicate charge level F N On Off Key Press to power on or off the power chair or Control 2 ler Horn Key Activates a warning horn Speed Profile indicator A se ries of five LED s which display speed and profile settings Speed Profile Decrease Used to decrease the Speed Profile setting Speed Profile Increase Used to Increase the Speed Profile setting SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 0 2 Plugs Connectors charger port 4 Red 1 24 3 Yellow 2 0 3 Inhibit 1 Programmer Charger port Outside View Motor Plug MOTOR 1 Brake ve Brake ve Cu Motor ve Motor ve VR2 Controller M1 RIGHT SIDE MOTOR M2 LEFT SIDE MOTOR J SM OYSTICK MODULE INH 2 INHIBIT 2 A1 ACTUATOR 1 A2 ACTUATOR 2 OBC ON BOARD CHARGER BATTERY AOOO 2 A SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 0 3 Basic Tool List amp Main Wiring Diagram Basic Tool List The following list of tools should enable any task to be dealt with Some will only occasionally be needed but it is advisable to own or have access to them 17mm Deep Socket wrench 10mm combination wrench 13mm combination wrench Cutter for zip tie Needle nose pliers 4mm Allen wrench 5mm Allen wrench 3 8 combination wrench Phillips
11. eplace the joy stick module If the voltage meter reads zero voltage measure the cor responding 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 mea Sure the Battery Connector as shown in fig 1 5 3 If the voltage meter reads full voltage then replace the con troller or else proceed to the next step If the voltage meter reads full voltage then replace the controller SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 3 Troubleshooting No Power cont 1 6 Check Battery Wire Harness Check that the battery wire harness has the polarity cor rect Set the meter to dc volts and measure the connector with the red lead on the positive terminal and the black lead on the negative terminal as shown in figure 1 6 1 If both the battery wire harness have full voltage and correct polar ity then proceed to circuit breaker test If the voltage is ab sent proceed to battery fuse test If the polarity is reversed correct battery wiring If polarity is reversed correct battery wiring 1 7 Battery Fuse Check that the battery fuse is in good condition Inspect the fuse to see if the fuse is blown Set the meter to ohms and measure the resistance across the fuse Measure the negative terminal of the battery box and the positive termi nal of the battery harness Measure the positive terminal o
12. er Connected The Onboard Batteries are being charged with the off board charger You will not be able to drive the wheelchair until the charger is disconnected You will have to reset the control system by switching off the power and the Powering up again The On Board charger has no indication that the chair is charging and the chair will not move until complete If the condition still exists after the charger has been disconnected and the chair has been switched off and powered up again the J oy stick module may be defective 3 7 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 joystick mod ule If the joystick fails to center because it is bent or broken replace the joystick module 3 8 Eight Bars Possible Control System Trip Controller Fault A control system trip is indicated Make sure that all connections are secure Check that the batteries are fully charged and in good condition and check all joystick connections and cables If this does not correct the prob lem then replace the controller SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 9 Understanding VR2 Controller D
13. f the battery box and the negative terminal of the battery harness figure Al 7 1 If the meter reads more than ohm change the harness or else proceed to the next step If the meter reads more than one ohm change the Battery harness 1 8 Circuit Breaker Test To check the circuit breaker set the meter to ohms and measure the resistance across the circuit breaker as shown in figure Al 8 1 Ifthe meter reads more than 1 ohm then change the circuit breaker otherwise proceed to next step DIGITAL MUL TIMETER If the meter reads more than 1 ohm then change the circuit breaker 1 9 Main Harness If the above steps did not correct the problem change the main harness SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 4 Understanding Controller Display 2 1 The Maximum Speed Indicator Ripples Indicates that 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 chiro Now release the on off button deflect the joystick forwards until the control system chirps and deflect the joystick in reverse until the control system chirps Release the joysti
14. iagnostics Codes cont The parking brakes have a bad connection Check the parking break and motor connections Make sure the con trol 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 re place the controller Otherwise replace the motor that does not read approximately 60 ohms If both motor connectors read approximately 60 ohms then replace the controller Otherwise replace the motor that does not read approximately 60 ohms 3 10 Ten Bars High Battery Voltage An excessive voltage has been applied to the control system This is usually caused by a poor battery connection Check the battery connections Ea CA Battery Fault Check that the batteries are fully charged the correct volt age and in good condition Take a voltage reading from pin 1 and pin 2 of the charger port of the VR2 controller see figure A3 9 1 If the meter reads more than 30 volts then check the charger Otherwise replace your controller 2 3 meter reads more than 30 volts replace the charger Batteries connections and voltage level are correct replace the controller 3 11 Seven Bars Speed Profile Indicator Communication Error Inspect wiring between joystick module and controller Replace the jumper or joystick module with damaged wiring If the problem persists replace the controller
15. o 1 5 ohms then replace the controller If none of the above corrects the problem replace the right motor DIGITAL MUL TIMETER If the meter reads between 0 and 1 5 ohms then replace the controller If this does not correct the problem then replace the right motor SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 8 Understanding Controller Diagnostics Codes cont 3 5 Five Bars Right Motor Wiring Trip 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 If the reading is short resistance is less than 10 K ohms on any of the readings proceed to check the 4 pin motor _ a S DIGITAL connector Measure the resistance from the bottom contact 6 of the red thick wire on the 4 pin right motor connector to each of the top contacts of the connectors see figure 5 3 Measure the resistance from the bottom contact Test 1 Test 2 ms 5 of the black thick wire on the 4 pin right motor connector to ET each the top contacts of the connector below right If all of the readings are open then replace the controller If any of the readings are short then replace the right motor ESS Test 4 If all of the readings are open then replace the controller If any of the readings are short then replace the right motor 3 6 Six Bars Charg
16. tween 12 13 5 volts then proceed to next step If the voltage meter reads below 12 volts charge the batteries Note To find a bad battery use a battery load tester If the voltage meter reads below 12 volts charge the batteries SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 1 Troubleshooting No Power cont 1 4 Not Charging If the chair is not charging check the charging port fig 1 4 1 on the battery case If the meter reads less than 12 volts check the corresponding pins on the controller fig 1 4 3 if the meter reads less than 12 volts proceed to the next step DIGITAL MUL TIME TER If the charging port is OK check that the battery fuse 15 in good condition With the batteries disconnected remove the fuse cap inspect the fuse to see if the fuse 15 blown To make sure the fuse is not blown set the meter to ohms and measure the resistance across the fuse See figure 1 4 2 If the meter reads more than one ohm change the fuse or else proceed to the next step SUNRISE MEDICAL MELODY SERVICE MANUAL 2006 PAGE 2 Troubleshooting No Power cont 1 5 Battery Connection Test Check that the female VR2 Bus plug on the chair has volt age Set the meter to dc volts and measure pins 4 using the red lead of the meter and 1 using the black lead of the meter as shown in figure 1 5 1 If the voltage meter reads full voltage then r
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