Sunrise Medical Little Gem 2 Technical Manual

1

Service and Maintenance
for Scooters

Technical Manual
Little Gem 2

Info:1

Sunrise Medical is ISO 9001 certied, which ensures quality at all
stages of the development and production of this scooter.
This product is manufactured to comply with the requirements of
EEC directives 89/336/EEC

IMPORTANT:

It is potentially hazardous to t or use any parts other than
genuine Sterling parts.
The company disclaims all liability for the consequences of such
use, which in addition voids the machine warranty.

USAGE:

This vehicle is for the carriage of ONE PERSON and must not be
used for any other purpose.

CERTIFICATION:

PRODUCT INFORMATION

DESCRIPTION:

The Little Gem 2 is designed to be a exible four-wheel, highly
transportable scooter and Rear Wheel Drive, Single Transaxle
conguration.

Features include:

Fold down, height adjustable swivel seat with ip up width
adjustable armrests. Battery box tted with ergonomically
designed handle for easy removal/transport. Easily detachable
rear drive pack tted with twin handles for secure lifting, Fold
down, innitely adjustable tiller to accommodate comfortable ride
position and luggage compartment or cupboard storage.
All parts interconnect in a logical sequence, ultimately combining
to create an elegant yet simple modular construction.
It is this simplicity that makes the Little Gem 2 easy to understand
therefore quick and easy to service.

Wty:1

WARRANTY

WARRANTY CONDITIONS

1. The repair or replacement will be carried out by an authorised Sunrise

Medical dealer/service agent.

2. To apply the warranty conditions, should your scooter require attention under these

arrangements, notify the designated Sunrise Medical service agent immediately

giving full information about the nature of the difculty. Should you be operating the

scooter away from the locality of the designated Sunrise Medical service agent,
work under the “Warranty Conditions” will be carried out by any other service agent
designated by the manufacturer.

3. Should any part of the scooter require repair or replacement, as a result of a

specic manufacturing or material defect, within twenty four months from the date

on which the possession of the scooter was transferred to the original purchaser,
and subject to it remaining within that ownership, the part or parts will be repaired or
replaced completely free of charge if returned to the authorised servicing agent.

NOTE: This guarantee is not transferable.

4. Any repaired or replaced part will benet from these arrangements for the balance

of the warranty period applicable to the scooter.

5. Parts purchased after the original warranty has expired are covered for

twelve months.

6. Items of a consumable nature will not generally be covered during the normal

warranty period, unless such items have clearly suffered undue wear as a direct result
of an original manufacturing defect. These items include amongst others: batteries,
upholstery, tyres, inner tubes and similar parts.

7. The above warranty conditions apply to all scooter parts for models purchased at

full retail price.

8. Under normal circumstances, no responsibility will be accepted where the scooter

has required repair or replacement as a direct result of:

a) The scooter or part not having been maintained in
accordance with the manufacturer’s recommendations, where

such exist, or failing to use only the specied original

equipment parts.
b) The scooter or part having been damaged by neglect,
accident or improper use.
c) The scooter or part having been altered from the

manufacturer’s specications, or repairs being attempted prior
to the service agent being notied.

Cont:I

Table of Contents

1 Health & Safety .......................................................... 1.1-1.2

2 Tool Box...................................................................... 2.1

Service Information Note ............................................. SN1

3 Annual Service & Inspection .................................... 3.1

Service Information Note ............................................. SN2

4 Technical Specications ........................................... 4.1-4.2

Service Information Note ............................................. SN3-4

Mechanical Tasks

5 Batteries & Battery Box

Checking the Voltage .................................................. 5.1

Changing the Batteries ................................................ 5.2-5.3

Checking the Fuses ..................................................... 5.4

Checking the Wiring ..................................................... 5.5-5.6

6 Battery Charger

Connection & Charge LED ......................................... 6.1

Troubleshooting ........................................................... 6.2

7 Tiller

Console & Fuse ........................................................... 7.1

Console & Throttle Pot (Wigwag Pot) ........................ 7.2

Panels .......................................................................... 7.3

Air Strut ........................................................................ 7.4

Tiller Bar Removal ....................................................... 7.5

Connecting Bracket ..................................................... 7.6

.

8 Wheels

Front Removal ............................................................. 8.1

Rear Removal .............................................................. 8.2

Continued overleaf ........................................................

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Cont:II

Table of Contents

9 Front Frame

Floor Panel & Mat ........................................................ 9.1

Steering Rods & Stub Axles ........................................ 9.2-9.3

Steering Stem .............................................................. 9.4-9.5

Adjusting the Steering Track ........................................ 9.6-9.7

Control Box & Looms ................................................... 9.8-9.9

Docking & Lock ............................................................9.10

Service Information Note ............................................. 9.11

10 Programming

Port Access .................................................................. 10.1

Parameter List ............................................................. 10.2-10.3

On-board Diagnostics .................................................. 10.4

11 Rear Drive Assembly

Checking the Motor Brake ........................................... 11.1

Panel ........................................................................... 11.2

Motor & Brake Removal ............................................. 11.3

Transaxle Removal ...................................................... 11.4

12 Seat Assembly

Armrest Pads .............................................................. 12.1

Covers ......................................................................... 12.2

Seat Plate .................................................................... 12.3

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1:1

CHAPTER

Health & Safety

CHAPTER ONE

HEALTH & SAFETY

Whilst working on powered mobility products, it is
essential to observe good working practice.
Below are a series of safety guidelines and recom­mendations.
Please note that these precautions are intended
to serve only as a guide and are not intended to
supersede or replace any safety statute, NHS or
other safety regulations.

Good Working Practice

General

· Always wear suitable protective clothing when

handling batteries.

· Always wear suitable eye protection when

drilling or inspecting.

· When safe to do so, wear protective gloves

when handling the running gear or batteries,
as these parts are exposed to paths, parks
etc..

· If the drive wheels have to be raised off the

oor, always use a pair of axle stands to se­cure the vehicle correctly.

Batteries

· Always make sure that the batteries are

disconnected from the vehicle before
commencing work.

· Always check that the battery charger is
disconnected from the vehicle / batteries
before commencing work.

· Do not smoke.

· Keep batteries away from all sources of
ignition.

· Do not place objects on the battery tops.

· Always try to keep someone within
earshot of your work area so that they
may come to your assistance if needed.

· Always wear personal protection when
handling batteries, including eye / face
protection and gloves.

· Make sure there is easy access to soap
and water in case of acid spills.

· Avoid touching eyes or unprotected
parts of the body while working on
batteries.

· Remember that non-sealed batteries can
contaminate any packaging, housing or
boxes they may have been transported
in, so handle all packaging with care

especially when disposing of.

If battery acid should come into contact
with bare skin or clothing, be sure to
wash immediately using plenty of soap
and water. If battery acid enters the eyes,

ush with running cold water for as long

as possible while medical help is sought.

All work carried out on batteries or battery
boxes should demand a degree of extra
caution.

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1:2

CHAPTER ONE

HEALTH & SAFETY

Batteries continued

Battery Chargers

· When the tops of batteries are

exposed, take extra care when
working on or around the terminals.

· 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.

· Remove personal items of jewel

lery such as rings, watches, chains
etc. before commencing work on
batteries.
If such items were to cause short
circuit whist being worn, very seri
ous burns would result.

· Batteries are constructed using very

heavy materials. Because of this it
is essential that correct lifting tech
niques be employed when moving
batteries around. It is also recom
mended that safety footwear be
worn.

· When disposing of old batteries,

please ensure that correct disposal
procedures are followed. Contact
your local authority for their recom
mendations.

Remember battery chargers are con

nected to Mains Electricity

· Always observe all guidelines
and laws relating to mains-connected
installations and equipment.

· Never operate the battery charger in wet
or damp conditions.

· If you suspect that the charger has been
exposed to water or excessive damp,
do not use it Return the unit back to
the dealer/supplier for inspection.

· If the battery charger is suspected of
being defective or is visibly damaged,
return the unit back to the dealer for
inspection.

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CHAPTER

Tool Box

CHAPTER TWO

TOOL BOX

The following list of tools will enable any task
covered by this module to be carried out
quickly, effectively and safely.
The order in which tasks are executed can
vary depending on individual circumstances.

Be Aware!

It is the responsibility of the Servicing Engineer
to use their own judgement as to the suitability of a
particular work area for the task in hand.
If the safety of the engineer or others close by
is in question, we recommend that the vehicle is
removed to a more suitable safe area or workshop.

1. Metric socket set.

2. Hexagon wrenches (Allen Keys).

3. 3.5 - 8mm at screwdriver.

4. No. 0 cross-head screwdriver.

5. No. 1 cross-head screwdriver.

6. No. 2 cross-head screwdriver.

7. Metric spanner set 5 - 25mm

8. Mole grips.

9. Long nose pliers.

10. Adjustable spanner.

11. Combination pliers.

12. Circlip pliers.

13. Soft hammer, (rubber, hide or nylon).

14. Stanley knife.

15. Pin punches.

16. Torque wrench.

17. Steel engineering rule.

18. Tape measure.

19. Tyre pump.

20. Tyre pressure gauge.

21. Personal safety gear.

22. Wire strippers/cutters.

23. Tag crimper.

24. Multi-meter.

25. Battery tester.

26. PC programmer.

27. Parts, Owners & Workshop Manuals.

Tool Box

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SN:1

IMPORTANT

SERVICE INFORMATION

All scooter components should be regularly checked for loose, damaged or
corroded connectors, terminals or cabling. All cables should be restrained to
protect them from damage. Damaged components should be replaced.

All switchable functions on the electronics system should be regularly tested to
ensure they function correctly.

All electronic components should be kept free of dust, dirt and liquids. If
necessary, wipe with a cloth dampened with warm water. Do not use solvents or
abrasive cleaners.

There are no serviceable parts in the Main Control Box, Batteries or Battery
Charger.
Do not attempt to open the case or undertake any repairs whatsoever, as safety
critical systems could be compromised.

Use Sunrise Medical spare parts only.
When replacing fasteners be sure to tighten to the correct torque settings.
All fasteners must be replaced like for like using the correct length, tensile
strength and materials.
Never use nylok nuts twice.

Any drive testing should take place in a clear safe space.
It is recommended that the servicing of this equipment is best undertaken in a
controlled workshop environment away from children, animals and the general
public.
Failure to comply with this recommendation is the sole responsibility of the
servicing agent.

3:1

CHAPTER

Annual Service
& Inspection

CHAPTER THREE

ANNUAL SERVICE & INSPECTION

Controller

• Plug Connections

• Switches & Buttons

• External Connections

• Dynamic Braking (See Test Run).

• Programmable Settings

• Multi Prole Settings (Where Used).

• Drive Prole (See Test Run).

• Disable functions (safety circuits).

• Rubber Gaiters/Grommets

• Check for Water Incursion

• Fasteners & Brackets

Batteries

• Physical Inspection

• Check Type

• Charger Operation & Output Power

• Charger Type (GEL, WET, Automatic etc.).

• Connections

• Discharge Test

• Fuses & Resets

Wheels & Tyres

• Tyre Wear/cuts

• Pressure (Pneumatic Tyre).

• Bonding to Rim (Solid Tyre).

• Bearings (where appropriate).

• Wheel/Hub Nuts & Rim Studs

• Drive Key & Key-ways

Motors & Actuators

• Wiring

• Brushes

• Noise

• Connections & Looms

• Brake & Freewheel

• Micro Switch(s)

• Seals (leaks).

• Performance (Up -Down & See Test Run)

Chassis & Seat

• Condition (Welded Joints etc.).

• Alignment (Twists etc.).

• Bearing Housing

• All Fasteners & Brackets

• Handles & Grips

• Arm Rests & Upholstery

• Seat Post & Securing Pin

Electrical

• Looms

• Micro Switches

• Cable Ties

• Connections

• Lights/Indicators

• Unauthorised Modications?

Full Drive Prole (Test Run)

• Forward Speed (max - min)

• Reverse Speed (max - min)

• Acceleration (fwd - rev)

• Deceleration (fwd - rev)

• Stopping Distance

• Brake

• Emergency Stop

• Drive a Straight Line

• Left/Right Arc Turn

• Ascend Slope

• Stop on Ascent

• Pull Away on Ascent

• Descend Slope

• Stop on Descent (Dynamic Braking).

• Pull Away on Descent

• Over obstacles

• Freewheel Push

Accessories

• Posture Belts

• Head Rest

• Dining Tray

• Auxiliary Equipment & Brackets

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SN:2

IMPORTANT

SERVICE INFORMATION

The Technical Specications shown on the facing page are intended for
information purposes only. Small differences may occur.
Sunrise Medical reserve the right to alter any specication without notice.

The range gures are calculated to the Industry Standard ISO 7178 Part 4:
Scooter Energy Consumption Theoretical Range.

*User weight, terrain, environmental conditions, battery condition/age and other
factors, can all affect the maximum range of the vehicle.

4:1

CHAPTER

Technical Specications
General

CHAPTER FOUR

TECHNICAL SPECIFICATIONS

LENGTH 98 cms (38.5”)
WIDTH 51 cms (20”)
MAXIMUM USER WEIGHT 113kg (248.6 lbs)
BATTERIES (Test @ 5hr discharge) 12 AH (AGM)
BATTERIES (Dimensions in mm.) W = 98.1, L = 151.2, H = 103.2
MAXIMUM SAFE ANGLE 6 degrees (Dynamic)
TURN RADIUS 115 cms (45.25”)
BASE to SEAT HEIGHT 39.5 - 49 cms (15.5” - 19.25”)
MOTOR POWER 120 Watts (@ rated load)
MAXIMUM SPEED 6 kph (4 mph)
WHEEL SIZE FRONT 17.5 cms (6.875“)
WHEEL SIZE REAR 19 cms (7.5”)
CHARGER OFF-BOARD 2.0 A
MAXIMUM RANGE* 15.7 km (9.8 mls)
OVERALL WEIGHT 47.5 kg (104.5 lbs)
SEAT WEIGHT 10.4 kg (22.9 lbs)
BATTERY WEIGHT (each) 4.31 kg (9.5 lbs)
DRIVE UNIT WEIGHT 10.7kg (23.6 lbs)
HEAVIEST PART (Footboard/Tiller) 15 kg (33 lbs)
TYRE PRESSURE Solid
GROUND CLEARANCE 6 cms (2.4”)
MAX OBSTACLE CLIMB 5 cms (2”)

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Technical Specications
Torque

CHAPTER FOUR

TECHNICAL SPECIFICATIONS

FASTENER SIZE TORQUE SETTING (Nm)

M3 Bolt / Stud 1
M4 Bolt / Stud 2.5 - 3
M5 Bolt / Stud 5 - 6
M6 Bolt / Stud 9 - 10
M8 Bolt / Stud 19 - 20
M10 Bolt / Stud 30
M12 Bolt / Stud 47.5
M16 Bolt / Stud 54
No6 Screw 1.5

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Generic Settings

Specic Settings

FASTENER SIZE TORQUE SETTINGS (Nm)

GIMBLE BOLT
(Through Front Axle)

36 - 37

WHEEL NUTS 33 - 34
TILLER HINGE BOLTS 6.15 - 6.4
AIR STRUT HINGE BOLTS 6.15 - 6.4
STEM BEARING CUP ASSY. 3.5 - 3.6
STEM BOLT 26 - 27

SN:3

IMPORTANT

SERVICE INFORMATION

The service and maintenance of any mobility scooter or powered wheelchair
should only be undertaken by qualied or experienced engineering personnel.

This document is not intended for use by the general public.

This Technical Manual may recommend the use of certain tools/equipment during
maintenance procedures. It requires that the servicing engineer has, by means
of qualication or experience, the skills necessary to use such tools/equipment
correctly and safely.
It is highly recommended that all specic instruction manuals and safety
recommendations supplied with the tools/equipment, should be read and
understood before such equipment is used.

It is recommended that all mandatory safety procedures are strictly adhered to.

No responsibility is accepted by Sunrise Medical for any consequence, directly
or indirectly resulting from incorrect use of tools/equipment during any service
procedure pertaining to this or other Technical/Workshop Manual issued by
Sunrise Medical.

SN:4

Use extreme care when working on batteries.
Take all precautions and observe all safety rules and best working practice.
Use suitable protective gear.

When using electronic measuring devices be sure to read, understand and follow
the product instruction booklet.

Do not touch the metal portion of the probes or allow them to touch each other
when measuring voltage.

IMPORTANT

SERVICE INFORMATION

5:1

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CHAPTER

CHAPTER FIVE

BATTERIES & BATTERY BOX

Batteries & Battery Box
Checking the Voltage

2

1

4

6

3

5

Set the Multimeter to dc voltage on a suitable
range to measure up to 30v or more.

Carefully insert the probes into the charging socket
on the battery box as shown.

Take note of the reading obtained. If it is less than

24.5v, charge the batteries & start again.

Now switch the scooter ON. Drive/run the scooter
for a couple of minutes. Stop the scooter, but don’t
turn it off.

Note the reading. If there is a difference of more
than 1.5v the batteries may be worn out.
22v = Deep Cycle Discharge.
23v = Full Discharge.
24v = Discharged.
24v - 24.5v = Partial Discharge.
25v and above = Fully Charged.

If the initial voltage reading is 0v check the fuses,
reset button & wiring in the battery box.

This is only an approximate eld test. The true battery state should be determined by using a proprietary

battery test unit.

5:2

CHAPTER FIVE

BATTERIES & BATTERY BOX

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4

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5

Batteries & Battery Box
Changing the Batteries

Push the seat lever forward & lift the seat off.

Remove the battery box securing pin.

Lift the battery box off the scooter.

Place the battery box on a suitable work surface.

Invert the battery box to expose the 7 screws. Note
that screws 3 & 4 are shorter than the rest.

1

2

3

4

5

6

7

Use a Phillips screwdriver to undo the screws.

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7

10

12

CHAPTER FIVE

BATTERIES & BATTERY BOX

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Batteries & Battery Box
Changing the Batteries

9

11

Turn the battery box back upright. Retrieve the 7
screws as they fall out.

Open the top & hinge it back for access.

Disconnect the right hand battery.

To aid re-assembly, mark or tie the leads together.

Repeat for the other battery.

The batteries are held by Velcro. To release them
invert the box & gently shake until the seal is
overcome & the batteries drop out. Do not try to
lever the batteries out from the top.

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CHAPTER FIVE

BATTERIES & BATTERY BOX

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Batteries & Battery Box
Checking the Fuses

3

5

Place the battery box on its front as shown.

Ensure both sockets are orientated as above.

Place BLACK probe in top left & RED in bottom left
sockets of the 8 pin plug . Do not short the probe
pins.

A reading of at least 24.5V should be obtained. If
lower charge the batteries. If reading is zero, check
for blown main fuses, reset button or broken leads.

The Multimeter should be set to read DC VOLTS for photo’s 3 - 6.

Place BLACK probe in pin 2 & RED in pin 1 as
shown. Do not short the probe pins.

A reading of at least 24.5V should be obtained. If
reading is lower, charge the batteries. If reading
is zero, check for blown charging fuse or broken
leads.

2

1

4

6

CHAPTER FIVE

BATTERIES & BATTERY BOX

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Batteries & Battery Box
Checking the Wiring

3

5

5:5

The Multimeter should be set to read RESISTANCE for the following tasks.

Place one probe into pin 3 on the charging socket.

Place the other probe second from top left on the 8
pin plug as shown. Meter reads close to Zero.

For good continuity (reading is OK) the meter
should read close to Zero as above.

For no continuity or open circuit (bad reading) the
meter will read similar to above. In this case, check
for broken wires etc.

Place one probe top right of the 4 pin socket & the
other second from top right on the 8 pin socket.
Meter reads close to Zero.

Place one probe bottom left of the 4 pin socket &
the other bottom right on the 8 pin socket. Meter
reads close to Zero.

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CHAPTER FIVE

BATTERIES & BATTERY BOX

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Batteries & Battery Box
Checking the Wiring

8

7

The Multimeter should be set to read RESISTANCE for the following tasks.

Place one probe top left of the 4 pin socket & the
other top right on the 8 pin socket. Meter reads
close to Zero.

Place one probe bottom right of the 4 pin socket
& the other second from bottom right on the 8 pin
socket. Meter reads close to Zero.

15 A

12v dc
12Ah

+

-

12v dc
12Ah

+

-

30A

30A

7A

9

Battery Box Wiring Diagram

A = Viewed from
Outside Battery
Box (as in Photo’s

Above).

A

1

2

3

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CHAPTER SIX

BATTERY CHARGER

Battery Charger
Connection & Charge LED

2

1

4

6

3

5

The battery charger has a detachable mains lead.

The charger output plug connects to the battery
box.

Always connect the charger to the scooter before switching on the mains power. Observe all safety
recommendations when charging batteries. This charger is for Indoor Use Only. Do not expose to
moisture. Allow space around the casing.

The power lead connects to the socket on the
bottom of the charger.

The top of the charger shows the charge status.
RED LED = POWER ON

AMBER LED = CHARGING

GREEN LED = CHARGED

CHAPTER SIX

BATTERY CHARGER

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4

Battery Charger
Troubleshooting

3

6

5

RED LIGHT when batteries & mains are connected.

NO LIGHT when batteries & mains are connected.

Lever the fuse carrier out & check the 3A fuse.
Check the mains lead is pushed home into its

sockets. Conrm mains wall socket is OK

Check charging socket for battery voltage. If below
17V change batteries. If zero check reset button,
charging fuse, main fuses & wiring in battery box
(Ch 5).

AMBER LIGHT stays on for longer than 24 hours.

Check the charger plug & socket for moisture or
dirty contacts. If burning is evident change the
socket AND the charger. Perform discharge test on
batteries as they may be worn out or faulty.

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CHAPTER SEVEN

Tiller

Console & Fuse

TILLER

Release the locking clip on the large white plug &
disconnect.

The Tiller Console is sold as a complete assembly for spares. Only Keys & Fuses are
sold separately

Release the top screw using a Phillips screwdriver.

Do the same with the front screw.

Lift the top off the console.

Peel off the splash guard & keep it in a safe place.

If the battery gauge does not illuminate when the
key is turned, open the in line fuse holder to gain
access to the 2A fuse & check for continuity.

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CHAPTER SEVEN

TILLER

Tiller

Console & Throttle Pot (Wigwag)

To ret the Tiller Console, reverse this process. Ensure that the battery box is removed from the scooter

when working on the Tiller Console to prevent accidental short circuits.

Disconnect the 2 pin plug attached to the preset
speed control.

The top console is now disconnected.

If the wigwag throttle control needs replacing, use a

1.5 mm allen key to loosen the 2 set screws on the

wigwag lever.

Slide the lever off the stem together with the small
washer.

Use thin nosed pliers & small Phillips screwdriver
to undo the 2 small bolts on the wigwag throttle
control.

Lift out the wigwag throttle assembly.

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CHAPTER SEVEN

TILLER

Tiller

Panels

Use a Phillips screwdriver to undo the 3 screws
under the console panels.

Lift off the 2 console panels.

Use a Phillips screwdriver to undo the 2 basket
bracket screws.

Remove the bracket. Note that the top screw is
shorter.

Use a Phillips screwdriver to undo the lower screw.

Lift away the bottom panel.

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CHAPTER SEVEN

TILLER

Tiller
Air Strut

Use a 13.0 mm socket & 10.0 mm spanner to undo
the top bolt.

Remove the shoulder bolt from the top xing.

Use a 13.0 mm socket & 10.0 mm spanner to undo
the bottom bolt.

Remove the shoulder bolt from the bottom xing.

The Air Strut assembly.

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CHAPTER SEVEN

TILLER

Tiller

Tiller Bar Removal

Cut the tie wrap at the top of the tiller.

Pull the grommet out & slip it over the end of the
main loom.

Feed the main loom into the opening in the tiller
bar.

Use a 13.0 mm socket & 10.0 mm spanner to
remove the lower tiller mount bolt.

Pull the 2 bushes out of the way to allow the main
loom to be withdrawn.

The Tiller Bar removed.

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CHAPTER SEVEN

TILLER

Tiller

Connecting Bracket

The connecting bracket is secured by one long
bolt.

Turn the bracket against the steering stop then use
a 13.0mm socket & extension to undo the bolt ap­proximately 3 - 4 turns. Do not undo completely.

Withdraw the bracket. When retting ensure the

drive wheels are front & parallel to each other & the
tiller connecting bracket is facing straight ahead.

The bracket relies on the tightening of friction t­tings & may require the seal breaking by turning
with a “tommy” bar as shown.

The Tiller Connecting Bracket.

Notice the small segment at the foot of the con­necting bracket. The segment is part of the friction

t. As the bolt tightens the segment moves in a

shear motion that wedges it inside the tube of the
steering head.

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CHAPTER EIGHT

Wheels
Front Removal

WHEELS

If a clean safe space is available, it is a good idea to remove the seat & batteries
from the scooter, loosen the axle stud & tip it on one side to remove the wheel.

With the wheel on the oor, use a 5.0mm allen key

to loosen the axle stud.

Tip the scooter on to its side for better access to
the wheel.

Remove the axle stud taking care not to lose the

washer. When retting use thread lock.

Lift the wheel off the stub axle.

When retting ensure that the inner guide is aligned

with the stub axle.

The Front Wheel assembly removed.

Store all xings in a safe place.

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CHAPTER EIGHT

WHEELS

Wheels
Rear Removal

The scooter can be tipped on its side for rear wheel removal, or the rear drive assembly can be detached
and worked on as a separate assembly.

Place the scooter into drive to stop the wheels
turning.

With the wheel on the ground, use a 19.0mm
socket to loosen the centre nut.

Either turn the scooter on one side or split the drive
assembly & turn that on end, then remove the nylok

nut & washer. Always use a new nut when retting.

Gently remove the wheel.

Take care not to lose the drive shaft key.

The Rear Wheel assembly.

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CHAPTER NINE

Front Frame
Floor Panel & Mat

FRONT FRAME

1

2

3

4

5

6

7

Release the grommet from the oor panel & slide it

off the end of the main loom.

Peel the rubber mat back to remove it.

Remove the 2 screws at the front of the oor panel

using a Phillips screwdriver.

Remove the remaining 7 screws using a Phillips
screwdriver.

Carefully lift the oor panel off the frame feeding

the main loom through at the same time.

The Floor Panel removed.

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CHAPTER NINE

FRONT FRAME

Front Frame
Steering Rods & Stub Axles

This process is best carried out with the oor panel & front wheels removed.

There are 3 bolts securing the connecting rods.

1

2

3

Use a 13.0 mm spanner/socket to undo the right
hand, single connection bolt.

Lift the connecting rod out of the stub axle. Note the
positions of the washers & spacers.

Use a 13.0 mm spanner/socket to undo the left
hand, double connection bolt.

Lift the connecting rods out of the stub axle. Note
the positions of the washers & spacers.

Slip the long connecting rod off the bolt.

2

2

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CHAPTER NINE

FRONT FRAME

Front Frame
Steering Rods & Stub Axles

The short connecting rod is bolted to the steering
stem.

Use a 13.0 mm spanner/socket to undo the bolt.

Lift the connecting rod off the bolt. Turn the steering
to one side to remove the bolt.

The connecting rods showing the washer & spacer
sequence.

Use a 13.0 mm spanner/socket to undo the bolt
securing the stub axle.

The stub axle removed showing the top to bottom
sequence of nut, washers bearings & bolt.

1

2

3

4

5

67

8

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CHAPTER NINE

FRONT FRAME

Front Frame
Steering Stem

Undo the steering rod stub axle connections using
a 13.0 mm spanner/socket.

Undo the connection to the steering stem using the
same tools.

Cut the cable ties attached to the steering stem.

Use a 13.0 mm spanner/socket to undo the stub
axle pivot bar.

Remove the assembly.

Use an adjustable spanner to loosen the top
steering nut.

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CHAPTER NINE

FRONT FRAME

Front Frame
Steering Stem

On retting, check that the steering is fully free to move from left hand lock to right hand lock without

stiffness & that there is no up & down play in the steering head.

Remove the top nut by hand.

Remove the locking ring by hand.

Remove the knurled ring by hand.

Slide the steering stem out of the head. The lower
bearing should come with it, if not use thin nosed
pliers to extract it from the head.

Use thin nosed pliers to extract the top bearing.

The steering stem showing the nut, locking ring,
knurled ring & bearings.

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CHAPTER NINE

FRONT FRAME

Front Frame
Adjusting the Steering Track

4

2

6

Above is an example of TOW IN.

If the steering is not set up correctly severe tyre wear and low range become evident. Below are some
examples to identify this problem.

The tyre exhibits scufng or a lightening of the tread

colour on the outside half of the tyre.
View from front of scooter.

Above is an example of TOW OUT.

The tyre exhibits similar wear patterns as the tow in
fault, but the damage is on the inside edge.
View from front of scooter.

Above is an example of correctly set tracking.

The tyre has no scufng & any signs of normal

wear are symmetrical.

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CHAPTER NINE

FRONT FRAME

Front Frame
Adjusting the Steering Track

The easiest way to check for correct tracking is
to measure the distance between the tyre centre
tread line. Start at the back of the tyres.

The steering should be turned straight ahead during this process.

Then measure the front of the tyres. The
measurement should be the same (380mm).

8

These are the nuts that control the tracking.

Loosen the left hand nut using a 13.0 mm spanner.

Loosen the right hand nut using a 13.0 mm
spanner.

Give the nuts a few turns by hand to allow free
movement.

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CHAPTER NINE

FRONT FRAME

Front Frame
Adjusting the Steering Track

TOW OUT

TOW IN

Using a 7.0 mm spanner, turn the at on the main

steering connecting rod to adjust tracking.

Pushing downwards increases TOW OUT.

Pushing upwards increases TOW IN.

When tracking is correct, nger tighten the nuts.

Carefully tighten the left hand nut using the 13.0
mm spanner.

Do the same for the right hand nut. Recheck the

steering before nishing.

14

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CHAPTER NINE

FRONT FRAME

Front Frame
Control Box & Looms

4

2

6

Cut the 2 cable ties on the steering head.

Cut the 3 cable ties on the frame.

*

*

*

*

*

Remove the tiller & oor panel as previously shown (Ch 7 & 9).

Feed the main loom into the hole at the front of the
frame.

Simultaneously pull from the rear of the frame until
the loom is through.

Use a small Phillips screwdriver to undo the 2
screws on the controller cover.

Carefully remove the cover taking care not to
damage the gasket.

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CHAPTER NINE

FRONT FRAME

Front Frame
Control Box & Looms

Make a note of the wiring layout before
disconnecting any plugs.

Depress the clip & remove the 14 pin plug.

The Main Loom.

BATS. MOT.

BRK.

CHG./PROG.

Use a Phillips screwdriver to undo the 2 screws
securing the controller to the frame.

BATS. MOT.

BRK.

CHG.

LOOM

Lift the controller off the frame.

The S-Drive controller & Power Loom.

11

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CHAPTER NINE

FRONT FRAME

Front Frame
Docking & Lock

4

2

De-dock the Drive assembly.

The docking lock is secured to the front frame by 4
screws.

1

2 3

4

Use a Phillips screwdriver to undo the 4 screws.

The Docking Lock Assembly.

5 6

If docking is loose or rattles it can be adjusted via
2 adjuster bolts on the mating surface of the drive
assembly.

Use a 13.0 mm spanner/socket. First loosen the
lock nut, adjust the bolt, then retighten the lock nut.
Repeat for both sides.

1

2

SN:5

IMPORTANT

SERVICE INFORMATION

Sunrise Medical recommend and support the factory installed programme only.
Details of the recommended programme are set out in this Technical Manual
within Chapter 10.

Any deviation from this programme is deemed to be a third party t and as
such the responsibility for any modication lies with the person amending the
programme.

Any alterations or amendments must be carried out by competent personnel
and a full function test should be performed to conrm suitability and safety of
the installed programme. All parameters should comply with acceptable safety
standards.

It is strongly recommended that any person likley to be required to programme
any Sunrise Medical equipment, should attend the relevant STEPS training course
offered by Sunrise Medical.
Contact Sunrise Medical for details.

If in any doubt, do not change anything as a wrongly installed programme could
lead to a dangerous drive prole.

Contact Sunrise medical for further advice.

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CHAPTER TEN

Programming
Port Access

PROGRAMMING

This process starts with the seat, batteries & drive assembly removed.
Use SP 1 Hand Held Programmer or PGDT PC Programming Software.

Remove the S-Drive cover & disconnect the 4 pin
plug (Ch 9).

Insert the programmer plug into the 4 pin socket.

Route the programmer wire as shown.

Carefully dock the drive assembly ensuring the
cable is not trapped.

Ret the battery box & seat.

Programme using the SP1 hand held programmer
or the PGDT PC mobility programmer.

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CHAPTER TEN

PROGRAMMING

Programming
Parameter List

SPEED SETTINGS FAST SLOW

FWD ACCEL (0.1Sec. Increments) 18 10
FWD DECEL (0.1Sec. Increments) 6 8
REV ACCEL (0.1Sec. Increments) 12 12
REV DECEL (0.1Sec. Increments) 8 4
MAX FWD SPEED % 100 50
MIN FWD SPEED % 30 30
MAX REV SPEED % 40 40
MIN REV SPEED % 30 30
SPEED LIMIT POT ENABLED OFF

OPERATION SETTINGS

SLEEP TIMER (Minutes) 10
THROTTLE INVERT NO

BATTERY SETTINGS

LOW BATTERY FLASH LEVEL (BARS) 0
CABLE RESISTANCE (mΩ) 40
CALIBRATION FACTOR 85
LOW BATTERY ALARM OFF

INHIBIT SETTINGS

INHIBIT 1 MODE 1
INHIBIT 1 OPERATION LATCHING
INHIBIT 1 SPEED % 0
INHIBIT 2 MODE 1
INHIBIT 2 OPERATION NON-LATCHING
INHIBIT 2 SPEED % 100
INHIBIT 3 MODE 1
INHIBIT 3 OPERATION NON-LATCHING
INHIBIT 3 SPEED % 100
AUX OUTPUT: MODE 0

GENERAL SETTINGS

SOFT STOP ON
BRAKE TIME (mS) 1100
OUTPUT VOLTAGE 24V
STATUS OUTPUT TYPE 2 (Analogue)
DIAGNOSTIC FLASH SEQUENCE 4

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CHAPTER TEN

PROGRAMMING

Programming
Parameter List

GENERAL SETTINGS CONT. MAX MIN

REVERSE ALARM ON
PULSED REVERSE ALARM ON
DIAGNOSTIC ALARM ON
BRAKE DISCONNECTED ALARM OFF
BRAKE FAULT DETECT ON
BRAKE LIGHT OFF
FREEWHEEL SPEED LIMIT 100
FREEWHEEL TIME OUT (0.1Sec.) 2
FREEWHEEL ENABLE ENABLE

MOTOR SETTINGS

CURRENT LIMIT MAX 45A
BOOST DRIVE CURRENT 45A
BOOST DRIVE TIME (Sec.) 0
CURRENT FOLDBACK THRESHOLD 30A
CURRENT FOLDBACK TIME (Sec.) 20
CURRENT FOLDBACK LEVEL % 90
MOTOR COOLING TIME (Sec.) 120
CURRENT FOLDBACK TEMP. ( C ) 80
CURRENT LIMIT MIN 10A
MOTOR COMPENSATION (mΩ) 210
ANTI ROLLBACK LEVEL 12
PULL-AWAY DELAY (0.1 Sec) 30
SLOPE FACTOR 90
ANTI ROLLBACK VELOCITY 0

FACTORY SETTINGS

ACCELERATION (0.1 Sec) 100 1
DECELERATION (0.1 Sec) 100 1
FORWARD SPEED % 100 0
REVERSE SPEED % 100 0

THROTTLE SETTINGS

THROTTLE TYPE 1 (WIGWAG)
THROTTLE DEADBAND % 10
THROTTLE GAIN % 110
THROTTLE OPERATED AT POWER UP 2 (TRIP)
THROTTLE REFERENCE TEST ON

ISO TEST RESISTOR OFF

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CHAPTER TEN

PROGRAMMING

Programming
On-board Diagnostics

No.

Pulses

Description Remedy

None All is OK ----

Slow Beep Batteries deeply discharged

Charge batteries as soon as pos-

sible

1 x Pulse

per 5 Sec.

Controller gone to sleep Switch OFF & ON again

Pulses 1 x Battery at or bad connection

Charge batteries - Check all

connections

Pulses 2 x Motor connection bad or intermittent

Check all connections between

Motor & Controller

Pulses 3 x Motor short-circuit to battery

Check all Motor & Battery

looms including plugs & sockets

Pulses 4 x Freewheel activated

Check freewheel lever, check

micro-switch & wiring

5 x Not

Used

---- ----

Pulses 6 x Battery charger inhibit activated Check charger is not plugged in

Pulses 7 x Throttle fault

Check wig-wag is central - check

throttle & preset speed pot

Pulses 8 x Possible controller fault

Check all connections between the

tiller console & main controller

Pulses 9 x Bad brake connection Check Brake & Motor connections

Pulses 10 x Over voltage detect

Check battery connections - check

battery charger - Check batteries

The on-board diagnostic status is indicated by a pulsed buzzer.
There will be a series of repeated pulses on the buzzer followed by a pause, then
repeated pulses again and so on. It is the number of pulses between pauses that
indicates the fault code.
Please refer to the table below for guidance.

The fault conditions can also be read by using the SP1 Hand Held programmer or
PGDT PC Programming Software.

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CHAPTER ELEVEN

Rear Drive Assembly
Checking the Motor/Brake

REAR DRIVE ASSEMBLY

To check the motor place the probes top right &
bottom left of the 4 pin plug.

Switch the meter to RESISTANCE. A reading of
approximately 8 - 12 Ohms is OK.

To check the brake & micro switch, place the
probes top left & bottom left of the 4 pin plug.

Switch the meter to RESISTANCE. With the
parking brake released an open circuit reading is
shown.

Leave the probes as they are.

Engage the parking brake lever. The meter will
read approximately 25 - 35 Ohms.

Please refer to Service Note on page 10

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CHAPTER ELEVEN

REAR DRIVE ASSEMBLY

Rear Drive Assembly
Panel

2

Use an 8.0 mm spanner & Phillips screwdriver to
undo the 2 bolts at the rear of the assembly.

Use a Phillips screwdriver to undo the 4 screws on
each handle.

Remove both handles.

Use a Phillips screwdriver to undo the 2 screws on
the 4 pin plug.

Carefully lift the rear panel off the drive assembly.

The Drive Assembly with the panel removed.

De dock the drive assembly.

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CHAPTER ELEVEN

REAR DRIVE ASSEMBLY

Rear Drive Assembly
Motor & Brake Removal

4

2

6

Please note that the motor, brushes, brake & micro switch are available as a complete assembly only.

*

*

*

1

2

3

Cut the 3 cable ties as shown above.

Disconnect the 2 plugs on the motor loom.

Use a 4.0 mm Allan Key to remove studs 1 & 2.
Note that stud 2 is the short stud.

Lift the drive assembly up to access stud 3.

Carefully pull the motor away from the transaxle.

Take care not to lose the drive coupling key insert.

When retting, the insert must be aligned with the

slot in the gearbox coupling.

Drive Coupling Key

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CHAPTER ELEVEN

REAR DRIVE ASSEMBLY

Rear Drive Assembly
Transaxle Removal

2

Remove the rear wheels (page 26) remove the panels (page 44) unplug the power loom (page 45).

There are 4 bolts securing the transaxle to the
frame. Note that bolts 3 & 4 are longer.

1

2

3

4

Mark the position of the bracket on the frame. Use
a 10.0 mm spanner/socket to loosen all 4 bolts but
do not remove the nuts completely.

Remove the nuts from the heavier gearbox side &
gently lower the transaxle. Release the nuts on the
other side.

Lift the bracket off the frame.

Lift the frame off the transaxle.

The Transaxle, Bracket & Frame. Note that the
motor can be removed at this point if preferred,
(see page 45).

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CHAPTER TWELVE

Seat Assembly
Armrest Pads

SEAT ASSEMBLY

Lift the armrest up.

Use a 10.0mm spanner/socket to undo the hinge
bolt.

Lift the armrest off the bracket taking care not to
lose the 2 plastic bushes on the inside edges.

Invert the armrest & use a Phillips screwdriver
to undo the 2 screws. Note that the countersunk
screw is towards the back.

Lift the armrest away from the arm pad.

The Armrest & Arm pad.

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CHAPTER TWELVE

SEAT ASSEMBLY

Seat Assembly
Covers

2

2

1

The cushion covers can be replaced while the seat
is still attached to the scooter.

To release the backrest cover, undo the 3 pop
studs at the back.

1

2

3

Peel the backrest cover upwards & back over the
backrest. The cover will turn inside-out; this is
normal.

Release the 2 pop studs on the seat cover

1

2

Peel the seat cover from the front, the cushion will
lift & the cover will pull clear.

The Backrest & Seat Covers.

To clean the upholstery, wipe down with a damp cloth using a mild detergent. DO NOT MACHINE WASH
the covers.

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CHAPTER TWELVE

SEAT ASSEMBLY

Seat Assembly
Seat Plate

4

2

6

Unscrew by approximately 2 turns, the 2 width
adjustment hand wheels.

Remove the armrests.

Use a 10.0mm spanner/socket to undo the 4 seat
plate bolts as shown.

Remove the bolts and lift the seat plate away from
the seat base.

The Seat Assembly.

The Armrest assemblies & Seat Plate assembly.

Sunrise Medical Limited
High Street, Wollaston
Stourbridge
West Midlands, DY8 4PS
England
Phone [phone]
446666