Sunrise Medical Little Gem 2 Technical Manual
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Sunrise Medical Little Gem 2 Technical Manual

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Service and Maintenance
for Scooters
Technical Manual
Little Gem 2
1

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Summary of Contents for Sunrise Medical Little Gem 2

  • Page 1 Service and Maintenance for Scooters Technical Manual Little Gem 2...

  • Page 3: Product Information

    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. Info:1...

  • Page 5: Warranty Conditions

    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.

  • Page 7: Table Of Contents

    Table of Contents Chptr. Subject Page Health & Safety ............1.1-1.2 Tool Box..............2.1 Service Information Note ..........SN1 Annual Service & Inspection ........3.1 Service Information Note ..........SN2 Technical Specifications ........... 4.1-4.2 Service Information Note ..........SN3-4 Mechanical Tasks Batteries &...
  • Page 9 Table of Contents Chptr. Subject Page 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 ..........

  • Page 11: Health & Safety

    CHAPTER ONE HEALTH & SAFETY Sunrise Training and Education Programmes Health & Safety Good Working Practice Batteries All work carried out on batteries or battery Whilst working on powered mobility products, it is boxes should demand a degree of extra essential to observe good working practice.
  • Page 12 CHAPTER ONE HEALTH & SAFETY Sunrise Training and Education Programmes Batteries continued Battery Chargers Remember battery chargers are con · When the tops of batteries are nected to Mains Electricity exposed, take extra care when working on or around the terminals. ·...

  • Page 13: Tool Box

    CHAPTER TWO TOOL BOX Sunrise Training and Education Programmes Tool Box Tool Box The following list of tools will enable any task Metric socket set. covered by this module to be carried out Hexagon wrenches (Allen Keys). quickly, effectively and safely. 3.5 - 8mm flat screwdriver.

  • Page 14: Service Information Note

    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.

  • Page 15: Annual Service & Inspection

    CHAPTER THREE ANNUAL SERVICE & INSPECTION Sunrise Training and Education Programmes Annual Service & Inspection Chassis & Seat • Condition (Welded Joints etc.). Controller • Alignment (Twists etc.). • Bearing Housing • Plug Connections • All Fasteners & Brackets • Switches &...

  • Page 16: Service Information Note

    The Technical Specifications shown on the facing page are intended for information purposes only. Small differences may occur. Sunrise Medical reserve the right to alter any specification without notice. The range figures are calculated to the Industry Standard ISO 7178 Part 4: Scooter Energy Consumption Theoretical Range.

  • Page 17: Technical Specifications

    CHAPTER FOUR TECHNICAL SPECIFICATIONS Sunrise Training and Education Programmes Technical Specifications General 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...
  • Page 18 CHAPTER FOUR TECHNICAL SPECIFICATIONS Sunrise Training and Education Programmes Technical Specifications Torque Generic Settings FASTENER SIZE TORQUE SETTING (Nm) M3 Bolt / Stud M4 Bolt / Stud 2.5 - 3 M5 Bolt / Stud 5 - 6 M6 Bolt / Stud 9 - 10 M8 Bolt / Stud 19 - 20...

  • Page 19: Service Information Note

    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.
  • Page 20 SERVICE INFORMATION IMPORTANT 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.

  • Page 21: Batteries & Battery Box Checking The Voltage

    CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes Batteries & Battery Box Checking the Voltage This is only an approximate field test. The true battery state should be determined by using a proprietary battery test unit. Carefully insert the probes into the charging socket Set the Multimeter to dc voltage on a suitable on the battery box as shown.

  • Page 22: Changing The Batteries

    CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes 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.
  • Page 23 CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes Batteries & Battery Box Changing the Batteries Open the top & hinge it back for access. Turn the battery box back upright. Retrieve the 7 screws as they fall out. Disconnect the right hand battery.

  • Page 24: Checking The Fuses

    CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes Batteries & Battery Box Checking the Fuses The Multimeter should be set to read DC VOLTS for photo’s 3 - 6. Place the battery box on its front as shown. Ensure both sockets are orientated as above.

  • Page 25: Checking The Wiring

    CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes Batteries & Battery Box Checking the Wiring The Multimeter should be set to read RESISTANCE for the following tasks. For no continuity or open circuit (bad reading) the For good continuity (reading is OK) the meter should read close to Zero as above.
  • Page 26 CHAPTER FIVE BATTERIES & BATTERY BOX Sunrise Training and Education Programmes Batteries & Battery Box Checking the Wiring The Multimeter should be set to read RESISTANCE for the following tasks. Place one probe top left of the 4 pin socket & the Place one probe bottom right of the 4 pin socket other top right on the 8 pin socket.

  • Page 27: Battery Charger Connection & Charge Led

    CHAPTER SIX BATTERY CHARGER Sunrise Training and Education Programmes Battery Charger Connection & Charge LED 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.

  • Page 28: Troubleshooting

    CHAPTER SIX BATTERY CHARGER Sunrise Training and Education Programmes Battery Charger Troubleshooting Lever the fuse carrier out & check the 3A fuse. NO LIGHT when batteries & mains are connected. Check the mains lead is pushed home into its sockets. Confirm mains wall socket is OK RED LIGHT when batteries &...

  • Page 29: Tiller Console & Fuse

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes Tiller Console & Fuse 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.

  • Page 30: Console & Throttle Pot (Wigwag Pot)

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes Tiller Console & Throttle Pot (Wigwag) To refit 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 The top console is now disconnected.

  • Page 31: Panels

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes Tiller Panels Lift off the 2 console panels. Use a Phillips screwdriver to undo the 3 screws under the console panels. Use a Phillips screwdriver to undo the 2 basket Remove the bracket. Note that the top screw is bracket screws.

  • Page 32: Air Strut

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes Tiller Air Strut Use a 13.0 mm socket & 10.0 mm spanner to undo Remove the shoulder bolt from the top fixing. the top bolt. Use a 13.0 mm socket & 10.0 mm spanner to undo Remove the shoulder bolt from the bottom fixing.

  • Page 33: Tiller Bar Removal

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes 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 Use a 13.0 mm socket &...

  • Page 34: Connecting Bracket

    CHAPTER SEVEN TILLER Sunrise Training and Education Programmes Tiller Connecting Bracket The connecting bracket is secured by one long Turn the bracket against the steering stop then use bolt. a 13.0mm socket & extension to undo the bolt ap- proximately 3 - 4 turns. Do not undo completely. The bracket relies on the tightening of friction fit- Withdraw the bracket.

  • Page 35: Wheels Front Removal

    CHAPTER EIGHT WHEELS Sunrise Training and Education Programmes Wheels Front Removal 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 floor, use a 5.0mm allen key Tip the scooter on to its side for better access to to loosen the axle stud.

  • Page 36: Rear Removal

    CHAPTER EIGHT WHEELS Sunrise Training and Education Programmes 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 With the wheel on the ground, use a 19.0mm turning.

  • Page 37: Front Frame Floor Panel & Mat

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Floor Panel & Mat Release the grommet from the floor panel & slide it Peel the rubber mat back to remove it. off the end of the main loom. Remove the 2 screws at the front of the floor panel Remove the remaining 7 screws using a Phillips using a Phillips screwdriver.

  • Page 38: Steering Rods & Stub Axles

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Steering Rods & Stub Axles This process is best carried out with the floor panel & front wheels removed. There are 3 bolts securing the connecting rods. Use a 13.0 mm spanner/socket to undo the right hand, single connection bolt.
  • Page 39 CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Steering Rods & Stub Axles The short connecting rod is bolted to the steering Use a 13.0 mm spanner/socket to undo the bolt. stem. Lift the connecting rod off the bolt. Turn the steering The connecting rods showing the washer &...

  • Page 40: Steering Stem

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Steering Stem Undo the steering rod stub axle connections using Undo the connection to the steering stem using the a 13.0 mm spanner/socket. 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.
  • Page 41 CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Steering Stem 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.

  • Page 42: Adjusting The Steering Track

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Adjusting the Steering Track If the steering is not set up correctly severe tyre wear and low range become evident. Below are some examples to identify this problem. Above is an example of TOW IN. The tyre exhibits scuffing or a lightening of the tread colour on the outside half of the tyre.
  • Page 43 CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Adjusting the Steering Track The steering should be turned straight ahead during this process. Then measure the front of the tyres. The The easiest way to check for correct tracking is measurement should be the same (380mm).
  • Page 44 CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Adjusting the Steering Track TOW OUT Using a 7.0 mm spanner, turn the flat on the main Pushing downwards increases TOW OUT. steering connecting rod to adjust tracking. TOW IN Pushing upwards increases TOW IN.

  • Page 45: Control Box & Looms

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Control Box & Looms Remove the tiller & floor panel as previously shown (Ch 7 & 9). Cut the 2 cable ties on the steering head. Cut the 3 cable ties on the frame. Feed the main loom into the hole at the front of the Simultaneously pull from the rear of the frame until frame.
  • Page 46 CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Control Box & Looms BATS. MOT. BRK. CHG. LOOM Depress the clip & remove the 14 pin plug. Make a note of the wiring layout before disconnecting any plugs. BATS.

  • Page 47: Docking & Lock

    CHAPTER NINE FRONT FRAME Sunrise Training and Education Programmes Front Frame Docking & Lock De-dock the Drive assembly. The docking lock is secured to the front frame by 4 screws. Use a Phillips screwdriver to undo the 4 screws. The Docking Lock Assembly. If docking is loose or rattles it can be adjusted via Use a 13.0 mm spanner/socket.

  • Page 48: Service Information Note

    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.

  • Page 49: Programming

    CHAPTER TEN PROGRAMMING Sunrise Training and Education Programmes Programming Port Access 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 Insert the programmer plug into the 4 pin socket.

  • Page 50: Parameter List

    CHAPTER TEN PROGRAMMING Sunrise Training and Education Programmes Programming Parameter List SPEED SETTINGS FAST SLOW FWD ACCEL (0.1Sec. Increments) FWD DECEL (0.1Sec. Increments) REV ACCEL (0.1Sec. Increments) REV DECEL (0.1Sec. Increments) MAX FWD SPEED % MIN FWD SPEED % MAX REV SPEED % MIN REV SPEED % SPEED LIMIT POT ENABLED OPERATION SETTINGS...
  • Page 51 CHAPTER TEN PROGRAMMING Sunrise Training and Education Programmes Programming Parameter List GENERAL SETTINGS CONT. REVERSE ALARM PULSED REVERSE ALARM DIAGNOSTIC ALARM BRAKE DISCONNECTED ALARM BRAKE FAULT DETECT BRAKE LIGHT FREEWHEEL SPEED LIMIT FREEWHEEL TIME OUT (0.1Sec.) FREEWHEEL ENABLE ENABLE MOTOR SETTINGS CURRENT LIMIT MAX BOOST DRIVE CURRENT BOOST DRIVE TIME (Sec.)

  • Page 52: On-Board Diagnostics

    CHAPTER TEN PROGRAMMING Sunrise Training and Education Programmes Programming On-board Diagnostics 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.

  • Page 53: Rear Drive Assembly Checking The Motor Brake

    CHAPTER ELEVEN REAR DRIVE ASSEMBLY Sunrise Training and Education Programmes Rear Drive Assembly Checking the Motor/Brake Please refer to Service Note on page 10 Switch the meter to RESISTANCE. A reading of To check the motor place the probes top right & approximately 8 - 12 Ohms is OK.

  • Page 54: Panel

    CHAPTER ELEVEN REAR DRIVE ASSEMBLY Sunrise Training and Education Programmes Rear Drive Assembly Panel De dock the drive assembly. Use a Phillips screwdriver to undo the 4 screws on Use an 8.0 mm spanner & Phillips screwdriver to each handle. undo the 2 bolts at the rear of the assembly.

  • Page 55: Motor & Brake Removal

    CHAPTER ELEVEN REAR DRIVE ASSEMBLY Sunrise Training and Education Programmes Rear Drive Assembly Motor & Brake Removal Please note that the motor, brushes, brake & micro switch are available as a complete assembly only. Cut the 3 cable ties as shown above. Disconnect the 2 plugs on the motor loom.

  • Page 56: Transaxle Removal

    CHAPTER ELEVEN REAR DRIVE ASSEMBLY Sunrise Training and Education Programmes Rear Drive Assembly Transaxle Removal 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 Mark the position of the bracket on the frame.

  • Page 57: Seat Assembly Armrest Pads

    CHAPTER TWELVE SEAT ASSEMBLY Sunrise Training and Education Programmes Seat Assembly Armrest Pads Use a 10.0mm spanner/socket to undo the hinge Lift the armrest up. bolt. Lift the armrest off the bracket taking care not to Invert the armrest & use a Phillips screwdriver lose the 2 plastic bushes on the inside edges.

  • Page 58: Covers

    CHAPTER TWELVE SEAT ASSEMBLY Sunrise Training and Education Programmes Seat Assembly Covers To clean the upholstery, wipe down with a damp cloth using a mild detergent. DO NOT MACHINE WASH the covers. The cushion covers can be replaced while the seat To release the backrest cover, undo the 3 pop is still attached to the scooter.

  • Page 59: Seat Plate

    CHAPTER TWELVE SEAT ASSEMBLY Sunrise Training and Education Programmes Seat Assembly Seat Plate Unscrew by approximately 2 turns, the 2 width Remove the armrests. adjustment hand wheels. Remove the bolts and lift the seat plate away from Use a 10.0mm spanner/socket to undo the 4 seat the seat base.
  • Page 60 Sunrise Medical Limited High Street, Wollaston Stourbridge West Midlands, DY8 4PS England Phone +44 (0)1384 446666...

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