Sunrise Medical Quickie Pulse 6 Service Manual
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Sunrise Medical Quickie Pulse 6 Service Manual

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Quickie Pulse 6 Service Manual
©2011 Sunrise Medical Inc.
111425 Rev B

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Summary of Contents for Sunrise Medical Quickie Pulse 6

  • Page 1 Quickie Pulse 6 Service Manual ©2011 Sunrise Medical Inc. 111425 Rev B...

  • Page 2: Table Of Contents

    Quickie Pulse 6 Service Manual Contents Introduction Three Bars - Left Motor Wiring Trip Basic Setup Four Bars- Right Motor Disconnected Motor - Drive Gear engaged Five Bars - Right Motor Wiring Trip Motor - Free-wheel Six Bars - Charger Connected...

  • Page 3: Introduction

    This Service Manual is intended as a troubleshooting guide for the Quickie Pulse 6. Photographs and content may differ from the actual products in some cases due to changes in specifications and other factors.

  • Page 4: Basic Setup

    If no - Follow checklist a second time, then refer to the section on Diagnostics. If yes – The Power Wheelchair is ready to drive! Motor - Drive Gear engaged Motor - Free-wheel fig. 4.3.4 fig .2.1 PAGE 0.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 5: Multimeter Tutorial

    “fused”, so that you don’t end up melting the meter’s circuits. Current up to 10A. Same as above, except it can take more cur- rent, as the name suggests. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.3...

  • Page 6: Symbols

    The feature found on some multimeters enables you to check for shorts without taking your eyes off your work. Other meters signify this with a small fl ashing light. PAGE 0.4 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 7: Health And Safety

    Do not allow metal tools to drop on to or touch the exposed terminals of the batteries or other exposed connections, as this could cause a short circuit, which may result in an explosion. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011...

  • Page 8: Battery Chargers

    • Move in unintended directions. If any of these occur, severe injury could result. 2. EMI can damage the control system of a power chair, resulting in a safety hazard and/or costly repairs. PAGE 0.6 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 9 Quickie control systems: • Breath Control (“Sip n Puff”) • Tri-Switch Head Array • Proximity Head Array • Proportional Mini-Joystick/Chin Control • Buddy Button • Wafer Board SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.7...

  • Page 10: Electro Static Discharge

    Do not place the printed circuit board on a hard surface. • Tighten board mounting screws only hand tight (torque12.4 in lbs/1.4Nm) in a cross pattern to reduce stress on mounting holes and PCB board material. PAGE 0.8 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 11: Batteries

    ACID = H2O ACID = H2SO2 H2SO2 Recharge As battery discharges, the sulfate from the electrolyte forms on the plates. As battery recharges, the sulfate is driven back into the electrolyte SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.9...

  • Page 12: Battery Diagnostics

    The problem with this test is that it is time consuming. • with a regular interval check - Another way of truly knowing how much Current / Voltage check time your battery will last, but it is also time consuming. PAGE 0.10 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 13: Battery Types

    SUNRISE MEDICAL SEPT 2011 PULSE 6 SERVICE MANUAL PAGE 0.11...

  • Page 14: Vr2 Remote Controller

    Speed/Profile indicator- A series of five LED’s, whichdisplay speed and profile settings Speed/ Profile Decrease. Used to Used to Speed/ Profile Increase. decrease the Speed/ Profile setting. Increase the Speed/ Profile setting. PAGE 0.12 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 15: Vr2 Plugs/Connectors

    M1 = LEFT SIDE MOTOR M2 = RIGHT SIDE MOTOR JSM = JOYSTICK MODULE INH-2 = INHIBIT 2 A1 = ACTUATOR 1 A2 =ACTUATOR 2 OBC = ON BOARD CHARGER + - =BATTERY SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.13...

  • Page 16: R-Net Remote Controller

    On/Off Key- Press to power on or off the power chair or Controller. peed/ Profile Increase. Speed Profile Decrease. Used to Increase the Used to decrease the Speed/ Profile setting. Speed/ Profile setting. PAGE 0.14 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 17: R-Net Remote Controller W/Display

    Controller. Horn Key- Activates a warning horn. peed/ Profile Increase. Speed Profile Decrease. Used to Increase the Used to decrease the Speed/ Profile setting. Speed/ Profile setting. SUNRISE MEDICAL SEPT 2011 PULSE 6 SERVICE MANUAL PAGE 0.15...

  • Page 18: R-Net Plugs/Connectors

    Rnet Controller M1 = LEFT SIDE MOTOR M2 = RIGHT SIDE MOTOR INH-2 = INHIBIT 2 A1 = ACTUATOR 1 A2 =ACTUATOR 2 OBC = ON BOARD CHARGER + - =BATTERY PAGE 0.16 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 19: Main Wiring Diagram Vr2 (Pls)

    SB50 Dual-Toggle Left 3.5 mm Stereo Right DUAL-TOGGLE 4-Way Amp Single Actuator Black Mate-N-Loc Phone Jack Switch HARNESS Driver Circuit Fuse Fuse Breaker Black Black Battery Battery SEE NOTE "A" SUNRISE MEDICAL SEPT 2011 PULSE 6 SERVICE MANUAL PAGE 0.17...

  • Page 20: Main Wiring Diagrams Rnet (Pls)

    Mate-N-Loc Phone Jack Switch HARNESS Driver Circuit Fuse Fuse Breaker Black Black R-NET DUAL-TOGGLE SINGLE ACTUATOR Battery Battery NOTE: HARNESS 108277-100 IS INCLUDED IN RETRO ASSEMBLY 110842 SEE NOTE "A" PAGE 0.18 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 21: Main Wiring Diagram Vr2 And Rnet (Pls6A/Pls6B)

    Connector Connector Intellegent PGD Bus PGD Bus Seating OMNI 108316-120 Right or Left Module Universal Specialty Infrared (ISM) Hand Mount Control Interface Device(s) 108316-030 112731 108316-120 4-Way PGD SEAT BASE SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.19...

  • Page 22: Main Wiring Diagrams Actuators (Pls6A/Pls6B)

    Power Module Inhibit3 Mate-N-Loc Inhibit3 4-Way Amp 3.5 mm Stereo 020063-070 Mate-N-Loc Phone Jack 6-Way Mini-Fit Jr. Dual-Toggle TILT: Single Actuator 104977-020 ACTUATOR Thru-Drive 112563 ADAPTER Driver PM Driven Tilt HARNESS PAGE 0.20 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 23: Vr2 Dual Attendant System Connection

    • 17mm Open End wrench • 13mm combination wrench • 13mm" Socket wrench • 10mm open end wrench • 13mm Open End wrench • 5mm socket wrench • 3/8 combination wrench SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 0.21...

  • Page 24: Battery Connection Test

    Battery Connector as shown in (fig 1.1.3) If the voltage meter reads full voltage, replace the controller, or proceed to Fig 1.1.2 the next step. Fig 1.1.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 1.1...

  • Page 25: Check Battery Wire Harness

    1 ohm, then change the circuit breaker, otherwise proceed to next step. Fig 1.2.3 Main Harness If the above steps did not correct the problem, change the main harness. PAGE 1.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 26: Vr2 Remote Controller Display

    This indicates a system trip, i.e. the VR2 has detected a problem somewhere in the wheelchair's electrical system. Please refer to Section 3 (VR2 Controller Diagnostics). SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011...

  • Page 27: Vr2 Controller Diagnostic Codes

    (figure 3.1.3) Ensure that they are not excessively worn, Fig 3.1.3 see curvature on brush (figure 3.1.4) Replace as required. Fig 3.1.4 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 3.1...

  • Page 28: Three Bars - Left Motor Wiring Trip

    4-pin motor connector as shown in (figure 3.3.1). If the meter reads between 0 to 1.5 ohms, Fig 3.2.2 then replace the controller. If none of the above corrects the problem, replace the right motor. PAGE 3.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 29: Five Bars - Right Motor Wiring Trip

    (below right). If all of the readings are open, then replace the controller. If any of the Test 3 Test 4 readings are short, then replace the right motor. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 3.3...

  • Page 30: Six Bars - Charger Connected

    If this does not correct the problem,disconnect the power to the controller for 2 minutes, replug in to reboot the module. If the condition still exits, then replace the controller. PAGE 3.4 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 31: Nine Bars - Solenoid Brake Trip

    1 and pin 2 of the charger port of the VR2 controller, see (figure 3.5.2) If the meter reads more than 30 volts, then check the charger. Otherwise, replace your controller. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 3.5...

  • Page 32: R-Net Troubleshooting Procedures

    The connectors are designed to visually indicate when they are not mated correctly. If yellow is showing between the halves (A), push them closer together until only black is visible. Retest as necessary. Fig. 4.1.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 4.1...

  • Page 33: R-Net Troubleshooting Procedures (Cont.)

    (figure 4.2.2). Reset if it is tripped and retest. fig. 4.2.2 Disconnect the batteries. (also see Sub- section 7.1) PAGE 4.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 34 4.3.3 12. If the above tests pass, replace the wiring harness leading from the batteries through the circuit breaker and control module. Retest as necessary. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 4.3...

  • Page 35: R-Net Fault Codes

    A latch function has exceeded it preset time. Brake Lamp Short Left Lamp Short Right Lamp Short L Ind Lamp Short R Ind Lamp Short L Ind Lamp Failed R Ind Lamp Failed SUNRISE MEDICAL SEPT 2011 PULSE 6 SERVICE MANUAL PAGE 5.1...
  • Page 36 The predetermined sleep time has been exceeded due to inactivity by the user. Charging This indication is present when the battery charger is connected. There may also be an error in the control module. Contact Sunrise Technical Service for assistance. PAGE 5.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 37 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.

  • Page 38: Example Of R-10 Fault Isolation

    Omni. 1. “Creep” speed as indicated by the turtle on the hand control ("A" fi gure 5.4.2). 2. Tilt the seating system to the rear. fig. 5.4.2 PAGE 5.4 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 39 Omni for the turtle symbol to go on and go off with the micro-switch operation. If the symbol changes, the problem is in the programming. Contact Sunrise Medical Technical Service for assistance. If the symbol fig. 5.5.1 does not change, proceed to step 5.

  • Page 40: Power Chair Will Not Drive In Creep Speed When Tilted

    If it is open, replace the micro-switch assembly. fig. 5.6.2 Refer to Tilt Actuator and Micro-Switch Removal section 7 of this manual. d. Retest as necessary. Closed fig. 5.6.3 PAGE 5.6 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 41: Tilt Will Not Operate

    Disconnect the 6-pin cable leading to the control module. 5. Select tilt on the hand control and place a rubber band around the joystick to hold it displaced (fi gure 5.7.2). fig. 5.7.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 5.7...
  • Page 42 8. At the 6 pin connector "B" (fi gure 5.8.2) on the rear of the tilt, check continuity between the indicated pins (fi g. 5.8.3). fig. 5.8.2 Voltage to 1 to 3 ohms the actuator fig. 5.8.3 PAGE 5.8 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 43 (fi gure 5.9.3). If the readings are not correct, replace the tilt actuator. Refer to Tilt Actuator *SEE NOTE* and Micro-Switch Removal section this manual. fig. 5.9.3 Retest as necessary. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 5.9...
  • Page 44 Note: in this example, a small surface charge is present. After the voltage has stabilized, record the voltage. Typical value for a fully charged pair of batteries is 25.6 VDC (12.8 VDC each). fig. 5.10.3 PAGE 5.10 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 45 If the voltage does not return to .1 VDC of the starting voltage at the end of the 5 minute test, evaluate the age of the batteries and the use they have received, and consider replacing them. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011...
  • Page 46 Less than 11.9 VDC indicates an excessively discharged battery. f. Values larger than 13 VDC indicate either an overcharged battery or one that has just been removed from charge, as in the example (fi gure 5.12.1) PAGE 5.12 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 47: Motor/Gearbox Inspection

    Caution: Use care not to damage the brush cap with excessive force in the next step. Remove the brush by using a common screwdriver to unscrew the cap (fi gure. 6.1.3). fig. 6.1.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 6.1...
  • Page 48 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. fig. 6.2.2 7. Inspect the motor connector at both the motor end and the control module end for signs of over heating (fi...
  • Page 49 The new brush assemblies should be run-in prior to measuring their resistance. Contact Sunrise Technical Service if the readings are either signifi cantly higher or lower than those recorded above. fig. 6.3.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 6.3...

  • Page 50: Removal Procedures

    (fi gure 7.1.2). fig. 7.1.2 3. Flip back the arms to prevent damage to the arms as the seat back is tilted (fi gure 7.1.3). fig. 7.1.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.1...
  • Page 51 6. Locate and remove the 4 thumb screws that secure the shroud to the base (fi gure 7.2.3) effective on chairs with s/n prefi x PLS6A and PLS6B fig. 7.2.3 PAGE 7.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

  • Page 52: Battery Installation

    Battery Installation Batteries installed incorrectly can blow the fuse for this system. Pay careful attention to install the battery harness across both batteries instead of to each of the batteries individually. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.3...

  • Page 53: Motor And Gearbox Removal

    (fi gure. 7.4.3) . fig. 7.4.3 5. Remove the wheel by removing the 4 bolts using a 6 mm Allen wrench (fi gure. 7.4.4). fig. 7.4.4 PAGE 7.4 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 54 9. When re-assembling be sure the holes for the spring pin are aligned and drive in the spring pin with a hammer. Reverse steps 1-7 to complete re-assembly. fig. 7.5.3 SUNRISE MEDICAL SEPT 2011 PULSE 6 SERVICE MANUAL PAGE 7.5...
  • Page 55 7.6.4 5. Final motor removal step requires disconnecting Motor connection from control module and cutting the Ty-wrap (Figure 7.6.5). Both parts should be re-attached when motor is re-installed.. fig. 7.6.5 PAGE 7.6 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 56 Note: The control module is mounted under the rear cover of the power chair (fi gure 7.7.2). fig. 7.7.2 2. Carefully disconnect the connectors leading to the control module (fi gure 7.7.3) fig. 7.7.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.7...
  • Page 57 7.8.1 4. Slide the control module up to remove it (fi gure. 7.8.2). 5. Reverse the above procedures to install the control module fig. 7.8.2 PAGE 7.8 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 58 (fi gures . 7.9.2 & 7.9.3). fig. 7.9.2 5. Lift the shock from the base. 6. Reverse the previous procedures to install the shock. fig. 7.9.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.9...
  • Page 59 19 mm wrenches (fi gures 7.10.1 & 7.10.2). fig. 7.10.1 fig. 7.10.2 Remove the coupler that connects to the two braces (fi gure 7.10.3). fig. 7.10.3 PAGE 7.10 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 60 (fi gure 7.11.1). fig. 7.11.1 Remove the front caster arm assembly. (fi gure 7.11.2) Reverse the previous procedures to install the front caster arm assembly. fig. 7.11.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.11...
  • Page 61 (fi gure 7.12.1 & 7.12.2) fig. 7.12.1 3. Remove the rear caster arm assembly (fi gure fig. 7.12.2 7.12.3). 4. Reverse the previous procedures to install the rear caster arm assembly fig. 7.12.3 PAGE 7.12 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 62 5. Reverse the previous procedures to install the caster fork. fig. 7.13.4 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.13...
  • Page 63 (fi gure 7.14.1). fig. 7.14.1 Remove the caster using two 13 mm wrenches (fi gure 7.14.2). fig. 7.14.2 Reverse the previous procedures to install the caster (fi gure 7.14.3). fig. 7.14.3 PAGE 7.14 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 64 3. Locate the micro-switch assembly and remove using a 3 mm Allen wrench (fi g. 7.15.3). Note: this step may be eliminated if the micro- switch is to be disconnected and left in place. fig. 7.15.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.15...
  • Page 65 7. Use two 13 mm wrenches and remove the nuts at both ends of the actuator (fi gure 7.16.3). Remove both pins from the tilt actuator. fig. 7.16.3 PAGE 7.16 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 66 9. Note the connections of the wires and separate them (fi gure 7.17.2). Remove the actuator. Reverse the previous procedure to install the actuator/micro-switch assembly. Retest as necessary. fig. 7.17.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 7.17...
  • Page 67 4. Remove the 5mm socket head bolts with a Hex key that are used to hold bottom seat in place (figure 8.1.3) – totally remove out of its position. fig. 8.1.3 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 8.1...
  • Page 68 7. Using a 5mm Hex Key and either a 13mm open end wrench or ratchet., Remove the nuts and bolts from the back bracket attached to the back cane assembly. fig. 8.2.3 PAGE 8.2 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 69 (figure 8.3.1) the final adjustment change, the nuts and bolts can be re-tightened in the reverse order of the steps listed. Make sure all bolts are tightened to appropriate Specifications. SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 8.3...
  • Page 70 4. Once desired height is achieved, Reset placement of bolts then tighten with 5mm Hex key and 13mm wrench. Tighten to 40 in/lbs of torque. fig. 8.4.4 PAGE 8.4 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...
  • Page 71 4° (figure 8.5.2) Then re-attach the nut and tighten bolt into place. make sure plastic saddles and 8° washers are in place behind the part. fig. 8.5.2 SUNRISE MEDICAL PULSE 6 SERVICE MANUAL SEPT 2011 PAGE 8.5...
  • Page 72 Multi meter to pins shown. (figure 8.6.4) connection prior to depression of switch. (figure 8.6.5) shows depression switch and what meter will read fig. 8.6.5 PAGE 8.6 PULSE 6 SERVICE MANUAL SEPT 2011 SUNRISE MEDICAL...

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