Sunrise Medical Little Gem 2 Technical Manual Download Page 55

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11:3

ST PS

Sunrise Training and Education Programmes

CHAPTER ELEVEN

REAR DRIVE ASSEMBLY

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.

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 refitting, the insert must be aligned with the

slot in the gearbox coupling.

Drive Coupling Key

Summary of Contents for Little Gem 2

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

Page 2: ......

Page 3: ...TION DESCRIPTION The Little Gem 2 is designed to be a flexible four wheel highly transportable scooter and Rear Wheel Drive Single Transaxle configuration Features include Fold down height adjustable swivel seat with flip up width adjustable armrests Battery box fitted with ergonomically designed handle for easy removal transport Easily detachable rear drive pack fitted with twin handles for secur...

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Page 5: ...his guarantee is not transferable 4 Any repaired or replaced part will benefit 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 wea...

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Page 7: ...chanical 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 ove...

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Page 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 Chptr Subject Page ...

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Page 11: ...he 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...

Page 12: ...sential 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 main...

Page 13: ...emoved to a more suitable safe area or workshop 1 Metric socket set 2 Hexagon wrenches Allen Keys 3 3 5 8mm flat 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 pun...

Page 14: ... 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...

Page 15: ... 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 Modifications Full Dri...

Page 16: ...rences 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 User weight terrain environmental conditions battery condition age and other factors can all affect the maximum range of the vehicle ...

Page 17: ...SE 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 PRESSU...

Page 18: ...ud 9 10 M8 Bolt Stud 19 20 M10 Bolt Stud 30 M12 Bolt Stud 47 5 M16 Bolt Stud 54 No6 Screw 1 5 ST PS Sunrise Training and Education Programmes Generic Settings Specific 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 ...

Page 19: ...lification or experience the skills necessary to use such tools equipment correctly and safely It is highly recommended that all specific 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 M...

Page 20: ...s 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 ...

Page 21: ...4 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...

Page 22: ...he 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 ...

Page 23: ...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 ...

Page 24: ...f 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 low...

Page 25: ... 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...

Page 26: ...e 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 ...

Page 27: ...ts 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...

Page 28: ...k the mains lead is pushed home into its sockets Confirm 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 Perfo...

Page 29: ...sole 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 ...

Page 30: ...le 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 wi...

Page 31: ...s 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 ...

Page 32: ...TER 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 fixing Use a 13 0 mm socket 10 0 mm spanner to undo the bottom bolt Remove the shoulder bolt from the bottom fixing The Air Strut assembly ...

Page 33: ...e 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 ...

Page 34: ...raw the bracket When refitting 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 fit tings 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 con necting bracket The segment is part of the friction f...

Page 35: ... tip it on one side to remove the wheel With the wheel on the floor 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 refitting use thread lock Lift the wheel off the stub axle When refitting ensure that the inner guide is aligned with the stub axle The Front Wheel assembly remove...

Page 36: ...d 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 refitting Gently remove the wheel Take care not to lose the drive shaft key The Rear Wheel ...

Page 37: ...met from the floor 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 floor panel using a Phillips screwdriver Remove the remaining 7 screws using a Phillips screwdriver Carefully lift the floor panel off the frame feeding the main loom through at the same time The Floor Panel removed ...

Page 38: ... 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 t...

Page 39: ...e 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 6 7 8 ...

Page 40: ...o 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 ...

Page 41: ...ck 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 knurle...

Page 42: ...dent Below are some examples to identify this problem The tyre exhibits scuffing 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 scuffin...

Page 43: ...etween 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...

Page 44: ...N Using a 7 0 mm spanner turn the flat on the main steering connecting rod to adjust tracking Pushing downwards increases TOW OUT Pushing upwards increases TOW IN When tracking is correct finger 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 finishing 14 ...

Page 45: ...ut the 3 cable ties on the frame Remove the tiller floor 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 ...

Page 46: ...s 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 ...

Page 47: ...cured 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 ...

Page 48: ...ments must be carried out by competent personnel and a full function test should be performed to confirm 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...

Page 49: ...emoved 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 Refit the battery box seat Programme using the SP1 hand held programmer or the PGDT PC mobility programmer ...

Page 50: ...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...

Page 51: ...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 1...

Page 52: ...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 connection...

Page 53: ...he 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...

Page 54: ...anner 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 ...

Page 55: ...te 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 refitting the insert must be aligned with the slot in the gearbox coupli...

Page 56: ...xle 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...

Page 57: ... 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 ...

Page 58: ...e 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...

Page 59: ...ly 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 ...

Page 60: ...Sunrise Medical Limited High Street Wollaston Stourbridge West Midlands DY8 4PS England Phone 44 0 1384 446666 ...

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