Sunrise Medical Rhapsody User manual

Quickie Rhapsody Service Manual
©2006 Sunrise Medical Inc.
101976 Rev A

Quickie Rhapsody Service Manual Contents
Introduction...................................................... 0.1
VR2 Controller................................................. 0.2
Plugs/Connectors............................................ 0.3
Basic Tool List & Main Wiring Diagram .......... 0.4
Section 1
Troubleshooting: No Power................................ 1
1.1 Circuit Breaker Reset ....................................1
1.2 Test Joystick..................................................1
1.3 Battery Test....................................................1
1.4 Not Charging ...............................................2
1.5 Battery Connection Test ...............................3
1.6 Check Battery Wire Harness........................4
1.7 Battery Fuse.................................................4
1.9 Main Harness ...............................................4
1.8 Circuit Breaker Test......................................4
Section 2
Understanding VR2 Controller Display................5
2.1 The Maximum Speed Indicator Ripples.......5
2.2 The Maximum Speed Indicator Flashes.......5
2.3 Battery Gauge is Steady...............................5
2.4 Battery Gauge Flashes Slowly .....................5
2.5 Battery Gauge Steps Up...............................5
2.6 Battery Gauge Blinks Once Every 2.5 Sec-
onds.....................................................................5
2.7 Battery Gauge Flashes Rapidly ...................5
Section 3
Understanding VR2 Controller Diagnostics
Codes...............................................................6
3.1 One Bar - Low 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 Connected..................9
3.7 Seven Bars - Possible Joystick Trip ........9
3.8 Eight Bars - Possible Control System Trip 9
3.9 Nine Bars - Solenoid Brake Trip................10
3.10 Ten Bars - High Battery Voltage .............10
3.11 Seven Bars + Speed Profile Indicator Com-
munication Error .............................................10
Section 4
Disassembly/Reassembly, and Adjustment.... 11
Step 1 - Seat removal......................................11
Step 2 - Footrest adjustment and removal .....12
Step 3 - Shroud removal..................................12
Step 4 - Battery removal..................................13
Step 5 - Controller removal..............................13
Step 6 - Motor removal....................................14
Step 7 - Shock removal...................................15
Step 8 - Caster removal...................................15
Step 9 - On-Board Charger removal................16
Step 10 - Suspension adjustment....................16

RHAPSODY SERVICE MANUAL PAGE 0.1
2006SUNRISE MEDICAL
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. 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 Rhapsody. Pho-
tographs and 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 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.
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.
Introduction

RHAPSODY SERVICE MANUAL PAGE 0.2
2006SUNRISE MEDICAL
VR2 Controller
VR2 Controller Buttons
Battery Gauge
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 Control-
ler.
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.

RHAPSODY SERVICE MANUAL PAGE 0.3
2006SUNRISE MEDICAL
Plugs/Connectors
1 = 24 Vdc
2 = 0 Vdc
3 = Inhibit 1/ Programmer
1 = Black (-)
2 = White
3 = Yellow
4 = Red (+) 21
3
charger port
Motor Plug
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
1 = 24 Vdc
2 = 0 Vdc
3 = INHIBIT 1/ PROGRAMMER
VR2 Controller

RHAPSODY SERVICE MANUAL PAGE 0.4
2006SUNRISE MEDICAL
Basic Tool List & Main Wiring Diagram
Wiring Diagram for VR2 Controller Package
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
• 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

RHAPSODY SERVICE MANUAL PAGE 1
2006SUNRISE MEDICAL
Section 1
Troubleshooting: No Power
Checkthatthevoltageisgoingtothecontroller,setthemeter
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 A1.2.1) If the voltage meter
readsapproximately 24volts, proceedto BatteryConnection
Test, if 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
1.2 Test Joystick
1.1 Circuit Breaker Reset
A1.2.1
IfOn/offbuttonispressed andnolightor barisshown,check
for tripped circuit breaker (see figure A1.1.1) and make sure
all connections are clean and tight (including the batteries). If
the problem persists, then perform the following diagnostics.
A1.1.1
21
3
1.3 Battery Test
Check that the batteries are fully charged and in good condi-
tion. Remove the seat, and the battery cover, with controller
connected and turned on, use the meter to check the volt-
age across the battery terminals (see figure A1.3.1). If the
voltage meter reads between 12 -13.5 volts, then proceed to
next step. If the voltage meter reads below 12volts,charge
the batteries.
Note: To find a bad battery, use a battery load tester. A1.3.1
If the voltage meter reads below 12 volts, charge the batteries.

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2006SUNRISE MEDICAL
Section 1
If the chair is not charging through the rear charging
port,check that the circuit breaker is not triped. Insure the
three pin charger is properly connected and in good condi-
tion. Measure the voltage across pin one and pin two (fig
1.4.1)
If the voltage meter reads approximately 24 volts, replace
the charger, if the meter reads less than 12 volts, check the
coresponding pins ont the controller (fig 1.4.2) if the meter
reads less than 12 volts, proceed to the next step.
1.4 Not Charging
A1.4.1
If all of the measurements read full voltage, then replace the controller.
Troubleshooting: No Power (cont.)
A1.4.2
Troubleshooting: No Power (cont.)

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2006SUNRISE MEDICAL
1.5 Battery Connection Test
Check that the female VR2 Bus plug on the chair
has voltage. 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 (figA1.5.1)
A1.5.1
A1.5.2
If the voltage meter reads full voltage, then replace 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.
Troubleshooting: No Power (cont.)
If all of the measurements read full voltage, then replace the controller.
A1.5.3

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2006SUNRISE MEDICAL
Section 1
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 + 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 polarity,
then proceed to circuit breaker test. If the voltage is absent
proceed to battery fuse test. If the polarity is reversed cor-
rect battery wiring. A1.6.1
If polarity is reversed correct battery wiring.
Check that the battery fuse is in good condition. With the
batteries disconnected remove the fuse cap, inspect the
fuse to see if the fuse is blown. To make sure the fuse is
not blown, set the meter to ohms and measure the resis-
tance across the fuse. see (figureA1.7.1). If the meter
reads more than one ohm, change the wiring harness, or
else proceed to the next step.
1.7 Battery Fuse
A1.7.1
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 (figureA1.8.1). If the meter reads more than 1 ohm,
then change the circuit breaker, otherwise proceed to next
step.
A1.8.1
If the meter reads more than 1 ohm, then change the circuit breaker.
If the above steps did not correct the problem, change the
main harness.
1.9 Main Harness
If the previous steps did not correct the problem, change the main harness.
Troubleshooting: No Power (cont.)

RHAPSODY SERVICE MANUAL PAGE 5
2006SUNRISE MEDICAL
Section 2
Understanding VR2 Controller Display
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 chirp. 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 joystick, there will be a long beep. The wheelchair is now locked.
This indicates that the chair is charging via on-board charger. The chair will be ready to drive as soon as
the charger is unplugged.
This indicates that all is well.
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
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 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 again.
Make sure the Joystick 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
somewhere in the wheelchair's electrical system. Please refer to Section 3 (VR2 Controller Diagnostics).
2.1 The Maximum Speed Indicator Ripples
2.2 The Maximum Speed Indicator Flashes
2.3 Battery Gauge is Steady
2.4 Battery Gauge Flashes Slowly
2.5 Battery Gauge Steps Up.
2.6 Battery Gauge Blinks Once Every 2.5 Seconds
2.7 Battery Gauge Flashes Rapidly

RHAPSODY SERVICE MANUAL PAGE 6
2006SUNRISE MEDICAL
Section 3
Understanding VR2 Controller Diagnostics Codes
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.
Use the meter to check the resistance across the two bot-
tom contacts (thicker wires) on the 4-pin motor connector
as shown in (figureA3.2.2). 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.
3.2 Two Bars - Left Motor Disconnected
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.
A3.2.1
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.
Otherwise, check the brushes on the left motor. Ensure
that they are not excessively worn, (replace as required) as
shown in (FigureA3.2.1).

RHAPSODY SERVICE MANUAL PAGE 7
2006SUNRISE MEDICAL
Section 3
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.
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 (figureA3.3.1). 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.
3.3 Three Bars - Left Motor Wiring Trip)
A3.3.1
Test 1 Test 2
Test 3 Test 4
Understanding VR2 Controller Diagnostics Codes (cont.)
If any of the readings are short, then replace the left motor.
If all of the readings are open, then replace the controller.

RHAPSODY SERVICE MANUAL PAGE 8
2006SUNRISE MEDICAL
Section 3
Understanding VR2 Controller Diagnostics Codes (cont.)
Check that the batteries are fully charged and in good con-
dition; and check all cables and
connections. Check the connections to the right motor, look
for a loose or damaged
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 (figureA3.4.2). 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. Ensure
that they are not excessively worn, (replace as required) as
shown in (FigureA3.4.1).
3.4 Four Bars- Right Motor Disconnected
A3.4.1
A3.4.2
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.

RHAPSODY SERVICE MANUAL PAGE 9
2006SUNRISE MEDICAL
Section 3
Understanding VR2 Controller Diagnostics Codes (cont.)
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
connector. Measure the resistance from the bottom contact
of the red thick wire on the 4-pin right motor connector
to each of the top contacts of the connectors see (figure
A3.5.3). Measure the resistance from the bottom contact
of the black thick wire on the 4-pin right motor connector to
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.
3.5 Five Bars - Right Motor Wiring Trip
A3.5.3
Test 1 Test 2
Test 3 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.
Ajoystick 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.
3.7 Seven Bars - Possible Joystick Trip
The Onboard Batteries are being charged with the off-board charger. You will not be able to drive the wheelchar 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 diconnected and the chair has been swithed off and powered up
again, the Joy stick module may be defective.
3.6 Six Bars - Charger Connected
If the joystick fails to center because it is bent or broken, replace the joystick module.
Controller Fault - Acontrol 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.
3.8 Eight Bars - Possible Control System Trip

RHAPSODY SERVICE MANUAL PAGE 10
2006SUNRISE MEDICAL
Section 3
Understanding VR2 Controller Diagnostics Codes (cont.)
3.9 Nine Bars - Solenoid Brake Trip
A3.8.3
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 (figureA3.9.1) If the meter reads more than 30 volts,
then check the charger. Otherwise, replace your controller.
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 connec-
tion. Check the battery connections.
A3.9.1
21
3
If the meter reads more than 30 volts replace the charger,
If the Batteries, connections, and voltage level are correct replace the controller.
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.
3.11 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.

RHAPSODY SERVICE MANUAL PAGE 11
2006SUNRISE MEDICAL
Section 4
Disassembly/Reassembly, and Adjustment
Disassembly
Unplug joystick at the base of the chair. (figure s1.1).1. Note: Remember to lay cables on the seat otherwise
they may become tangled when taking off the seat.
Fold seat back down (figure s1.2).2. Remove front hand screws (figure s1.3).3. Loosen knobs on rear seat posts4. (figure s1.4).
Pull rear pins and tilt seat forward5. (figure s1.5).
Slide seat back while lifting and remove6. (figure s1.6).
Step 1 - Seat removal
s1.1
s1.2
s1.3
s1.4
s1.5
s1.6

RHAPSODY SERVICE MANUAL PAGE 12
2006SUNRISE MEDICAL
Section 4
To adjust footplate position
Remove the clevis pin ( fig s2.1)1. Slide footrest assembly in or out to desired position2. and reinsert clevis pin.
To remove footplate
Remove clevis pin ( fig s2.1)1. slide footrest assembly out of frame ( fig s2.2).2.
Top shroud:
Remove four wing bolts (fig s3.1) holding top shroud1. and remove.
Front shroud
Complete step 2 (Footrest removal)1. Remove front shroud (fig s3.2) (attached with Velcro).2.
Step 2 - Footrest adjustment and removal
s2.1
s2.2
Step 3 - Shroud removal
Disassembly/Reassembly, and Adjustment
s3.1
s3.2

RHAPSODY SERVICE MANUAL PAGE 13
2006SUNRISE MEDICAL
Section 4
Disassembly/Reassembly, and Adjustment (cont)
Carefully lift rear battery and remove (fig s4.2), then4. front battery.
Remove the footrest (step 2)1. Remove front shroud (step 3)2. Disconect battery harnesses (fig s4.1)3. Unplug all connectors from the controller.4. Loosen and remove wing nuts5. Remove controller from frame( fig s5.1)6.
Remove seat (step 1)1. Remove top shroud (step 3)2. Disconnect battery harnesses (fig s4.1)3.
Step 4 - Battery removal
s4.1
s4.2
Step 5 - Controller removal
s5.1

RHAPSODY SERVICE MANUAL PAGE 14
2006SUNRISE MEDICAL
Section 4
Disassembly/Reassembly, and Adjustment (cont)
Complete steps 1-4, removal of seat, footrest,shrouds1. and batteries.
Unplug the motor connector (fig s6.1) from the control-2. ler and remove any zip ties holding the cable harness
to the frame.
Use a 17mm socket wrench to remove the drive wheel3. (fig s6.2)
Using two 13mm wrenches remove four bolts and nuts4. ( s6.3) holding motor plate to the frame.
Remove the cotter pin (A) (fig s6.4) holding the cog5. release handle (B) to the cog release lever arm (C).
Use a 5mm hex key to remove the six socket head6. capscrews hoding the motor gearbox housing to the
motor plate (fig s6.5).
s6.2
Step 6 - Motor removal
s6.1
Right motor Left motor
s6.5
s6.3
s6.4
C
A
B
Warning-When motor plate is removed the gear
box plate may come off