1
Workshop Manual
Little Star (4 Wheel)
Service and Maintenance
for Scooters
1
1
The Little Star mobility scooter is a versatile indoor/occasional outdoor, 4-wheeled
machine.
Features include;
Folding tiller assembly, moulded lightweight padded seat with width
adjustable armrests, 2” seat height adjustment, 2-Amp off-board automatic charger,
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This product is manufactured to comply with the requirements of
EEC directives 93/42/EEC and 89/336/EEC
Chapter Subject Page
-- Product Information ................................................................. 2
-- Safety Information ................................................................... 3
-- Recommended Tools............................................................... 5
-- Service/Inspection ................................................................... 6
-- Technical Specifications........................................................... 7
1 Front Wheels (4-Wheel)........................................................... 8
2 Rear Wheels ............................................................................ 9
3 Seat & Armrests..................................................................... 10
4 Battery Box ............................................................................ 12
5 Batteries & Battery Box.......................................................... 13
6 Rear Drive Assembly Panels ................................................. 16
7 Rear Drive Assembly Motor Leads........................................ 17
8 Rear Drive Assembly Motor/Brake......................................... 18
9 Rear Drive Assembly Transaxle............................................. 20
10 Tiller Assembly ....................................................................... 22
11 Main Controller ....................................................................... 25
12 Front Panel............................................................................. 26
13 Steering Head ........................................................................ 27
14 Main Frame Steering.............................................................. 29
15 Main Frame Stub Axle............................................................ 31
16 Front Frame Bump Stops....................................................... 32
17 Tiller Assembly ....................................................................... 33
Table of Contents
It is potentially hazardous to fit or use any parts other than genuine
Sunrise Medical parts.
The company disclaims all liability for the consequences of such use,
which in addition, voids the machine warranty.
This vehicle is for the carriage of
ONE PERSON
And MUST NOT be used for any other purpose.
Product Information
2
3 3
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.
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 of the floor, always use a pair of axle
stands to secure the vehicle correctly.
Batteries
All work carried out on batteries or battery boxes should demand a degree of
extra caution.
• 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 personnel 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 none 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, flush with running cold water for as long as possible while medical help
is sought.
Safety Information
4
Batteries
• 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 personnel items of jewellery such as rings, watches, chains etc. before commencing work on batteries. If such items were to cause short circuit
whist being worn, very serious burns would result.
• Batteries are constructed using very heavy materials, because of this it is
essential that correct lifting techniques be employed when moving batteries
around. It is also recommended that safety footwear be worn.
• When disposing of old batteries, please ensure that correct disposal procedures are followed. Contact your local authority for their recommendations.
Battery Chargers
• Remember battery chargers are Mains Driven Units.
• 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.
Safety Information
5 5
Recommended Tools
• 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.
1. Metric socket set
2. Imperial socket set
3. Hexagon wrenches, (imperial & metric)
4. 3.5 - 8mm flat screwdriver
5. No. 0 cross-head screwdriver
6. No. 1 cross-head screwdriver
7. No. 2 cross-head screwdriver
8. Metric combination spanner set 5 - 25mm
9. Imperial combination spanner set 1/8 - 1”
10. Mole grips
11. Long nose pliers
12. Adjustable Spanner
13. Combination pliers
14. Circlip pliers
15. Hammer, (small & large)
16. Soft hammer, (rubber, hide or nylon)
17. Feeler gauges, (metric & imperial)
18. Stanley knife
19. Pin punches
20. Electric drill, (mains/battery)
21. Drill bits, (metric & imperial)
22. Hacksaw, (standard & junior)
23. Toque wrench
24. Steel engineering rule
25. Tape measure
26. Tyre pump
27. Tyre pressure gauge
28. Personal safety gear
29. Wire strippers/cutters
30. Tag crimper
31. Multi-meter
32. Battery tester
33. Hand held electronic programmers
34. Parts manuals & workshop manuals
35. Tyre levers
Tools Required
6
Controller
• On/off Switch
• PCB Plug Connections
• Operation
• Dynamic Braking
• Programmable Settings, (where applicable)
• Test Run
Batteries
• Physical Inspection
• Connections
• Discharge Test
• Up/Down Slope
Wheels & Tyres
• Wear
• Pressure, (Pneumatic Only)
• Bearings, (Where appropriate)
• Wheel Nuts
• Castors, (Where appropriate)
• Stub Axles
Motors
• Wiring
• Noise
• Connections
• Brake
• Brushes
Chassis
• Condition, (Welded Joints etc.)
• Steering, (Twists etc.)
Upholstery / Seat
• Seat
• Back
• Arm pads
• Seat Slide Mechanism, (where fitted)
• Set Post Assy
Electrical
• Loom
• Connections
• Lights/Indicators
Drive
• Forwards
• Reverse
• Emergency Stop
• Left Turn
• Right Turn
• Up/Down Slope
• Over Obstacles
• Parking Brake
Service & Inspection (Annual)
7
Little Star
Overall length 38” / 96cm
Overall width 20” / 50cm
Maximum user weight 250lbs / 18st / 113kg
Maximum gradient 6 degrees
Range 8m / 12km
Speed 4mph / 6kph
Turning radius 43” / 110cm
Weight 77lbs / 35kg including batteries.
Heaviest part 44lbs / 20kg chassis.
Battery capacity 10AH
Adjustable seat height 14” / 16”- 35cm / 41cm
Front wheel diameter 7” / 18cm
Rear wheel diameter 7.5” / 19cm
Range given represents test conditions. Please note that temperature, user weight, terrain and
battery capacity may affect overall performance.
7
Technical Specifications
8
1. Use a thin-blade knife to.....
3. Use a cross-head screwdriver to undo
the centre wheel securing bolt.
4. Pull the Front Wheel from the Stub Axle.
5. Note the number of shims behind the
front wheels.
6. Front Wheel assembly.
2. carefully prize off the hubcap.
Front Wheels
CHAPTER ONE FRONT WHEELS
CHAPTER
9
1. Use a thin-blade knife to lift the hub cap.
2. Undo the centre bolt using a 13.00mm
socket.
3. Remove the centre bolt, noting the posi-
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4. Carefully remove the wheel, taking care
not to lose the Drive Key.
5. Use a pair of thin-nosed pliers to remove
the Drive Key.
6. The Rear Wheel assembly & parts.
CHAPTER TWO REAR WHEELS
Rear Wheels
CHAPTER
10
1. Shows the seat in operating position.
2. Fold the Backrest down.
3. Loosen the seat locking lever by turning
anti-clockwise.
4. Lift the Seat assembly off.
5. The Seat assembly clear of the scooter.
6. The underside of the Lightweight Seat
Assembly.
CHAPTER THREE SEAT & ARMRESTS
Seat & Armrests
CHAPTER
11
7. Undo the hand-wheel by tuning it anticlockwise.
8. Remove the Armrests or adjust them to
the desired width.
9. Hold the top of the Seat Stem & grab
hold of the securing pin.
10. Pull the securing pin out.
11. Move the securing pin to the desired
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12. Ensure the pin is pushed fully into place.
CHAPTER THREE SEAT & ARMRESTS
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