Sunrise Medical Little Star Workshop Manual Download | Manualshive

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Workshop Manual
Little Star (4 Wheel)

Service and Maintenance

for Scooters

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Summary of Contents for Little Star

Page 1: ...1 Workshop Manual Little Star 4 Wheel Service and Maintenance for Scooters ...

Page 2: ...ives 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 Transa...

Page 3: ...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 ...

Page 4: ...nnected from the vehicle before commencing work Always check that the battery charger is disconnected from the vehicle bat teries 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 ...

Page 5: ...rrect 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 proce dures 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 i...

Page 6: ...mbination 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 Tyr...

Page 7: ...y 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 Park...

Page 8: ...us 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 ...

Page 9: ...ad 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 ...

Page 10: ...ocket 3 Remove the centre bolt noting the posi WLRQV RI WKH VSULQJ ZDVKHU DQG ÀDW ZDVKHU 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 ...

Page 11: ...ld 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 ...

Page 12: ...rests 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 ORFDWLRQ DQG UH W WKH SLQ 12 Ensure the pin is pushed fully into place CHAPTER THREE SEAT ARMRESTS ...

Page 13: ...ower lead connected to the battery 3 remove the power lead by pressing in the metal tab on the battery socket 4 Use the handle to lift the Battery Box away from the scooter 5 The battery box removed CHAPTER FOUR BATTERY BOX Battery Box CHAPTER ...

Page 14: ...illips screwdriver LWK WKH DWWHU R RQ D ÀDW VXUIDFH carefully lift the lid up 4 The Batteries in situ 5 Use thin nosed pliers to release the posi tive terminals CAUTION Take care not to short out the terminals 6 and the negative terminals on both bat teries CHAPTER FIVE BATTERIES BATTERY BOX Batteries Battery Box CHAPTER ...

Page 15: ...ODGH IXVHV ÀLS up the lid on the fuse holder and pull the fuse out 10 View of the battery main lead and socket 11 The battery connection charging socket is secured by 2 small bolts 12 Using long nosed pliers undo the small bolts on the battery connection charging CHAPTER FIVE BATTERIES BATTERY BOX ...

Page 16: ...e fuse holder 15 Once removed carefully lift the tab on the connectors ready for re assembly 16 Using a 14mm ring spanner undo the power cut out nut 17 Remove the power cut out from inside the battery box lid 18 Shows the batteries fuses power cut out and connection charger socket CHAPTER FIVE BATTERIES BATTERY BOX ...

Page 17: ... phillips screwdriver to undo the rear panel retaining screw 2 Slide out the rear panel by angling it slightly through the rear frame 7KH UHDU SDQHO DQG LQJ VFUHZ CHAPTER SIX REAR DRIVE ASSEMBLY PANEL Rear DriveAssembly Panel CHAPTER ...

Page 18: ...17 1 Using long nosed pliers bend open the clip around the power terminal plug 2 Disconnect the power plug socket CHAPTER SEVEN REAR DRIVE ASSEMBLY MOTOR LEADS Rear DriveAssembly Motor Leads CHAPTER ...

Page 19: ... 3 To release the motor studs a combination of 5 0mm hex driver 4 and a 5 00mm hex key is required 5 Note that the motor loom clamp is at tached to one of the motor studs 6 Shows the position of the rear panel bracket on the motor CHAPTER EIGHT REAR DRIVE ASSEMBLY MOTOR BRAKE Rear DriveAssembly Motor Brake CHAPTER ...

Page 20: ...KDIW FRXSOLQJ RQ the motor must line up with the drive shaft coupling inside the transaxle see over 10 Shows the position of the freewheel extension lever held by 2 phillips screws Coupling 11 Use a 10 00mm spanner and a screw driver 12 to remove the stabiliser wheels CHAPTER EIGHT REAR DRIVE ASSEMBLY MOTOR BRAKE ...

Page 21: ...saxle mounting bolts 3 Location of the other 2 transaxle mounting bolts 4 Use a 13 00mm socket spanner to undo the four mounting bolts 5 Remove the motor bolts carefully taking care not to damage the rubber mounts 6 Carefully lift the transaxle out of the chas sis CHAPTER NINE REAR DRIVE ASSEMBLY TRANSAXLE Rear DriveAssembly Transaxle CHAPTER ...

Page 22: ...21 7 Carefully remove the rubber mounts for inspection 8 The transaxle assembly without motor brake CHAPTER NINE REAR DRIVE ASSEMBLY TRANSAXLE ...

Page 23: ...ng the black screw anti clockwise 4 Shows the tiller locking screw and lock ing plate removed 5 Undo the lower tiller mounting studs using a 4 00mm hex key and a 10 00mm spanner 6 To release the tiller cable remove the battery and lift the rear panel from the frame CHAPTER TEN TILLER ASSEMBLY TillerAssembly ...

Page 24: ...ring looms 9 Using long nosed pliers and wire cutters release the tiller cable from it ties 10 Do this all the way along to the control ler 11 Cut the cable ties holding the tiller con nector 12 Cut the cable ties around the tiller connector protective sheathing and slide it away CHAPTER TEN TILLER ASSEMBLY ...

Page 25: ...fully feed the tiller cable through the front panel and lift the tiller clear 15 Undo the upper tiller mounting studs using a 4 00mm hex key and a 10 00mm spanner 16 The tiller folding mechanism 17 The Tiller Assembly complete with Main Loom CHAPTER TEN TILLER ASSEMBLY ...

Page 26: ...e the motor and power cable from their ties 3 Unscrew the two screws visible from the top of the main controller Note Threadlock is used on these screws 4 Lift out the main controller 5 The main controller with tiller motor and battery wiring shown CHAPTER ELEVEN MAIN CONTROLLER Main Controller CHAPTER ...

Page 27: ...nd velcro 2 Move the panel away from the velcro and put in a position ready to lift clear 3 Lift the panel clear of the frame 4 Shows the position of the front panel velcro centre and 4 frame clips corners 5 Shows the position of the 2 front velcro pads on the panel CHAPTER TWELVE FRONT PANEL Front Panel CHAPTER ...

Page 28: ...V DV WKLV LV TXLFNHU 3 Undo the bearing retaining nut 4 Using long nosed pliers carefully remove the steering head upper bearing 5 Position the wheels to make access to the steering link possible 6 Use a 13mm spanner and socket to undo the steering link connector CHAPTER THIRTEEN STEERING HEAD Steering Head CHAPTER ...

Page 29: ...ng head bracket out of the frame NOTE This is only possible when the Front Frame Bump Stops have been removed See Chapter 16 10 The steering head bracket showing the lower bearing in position 8 Remove the spacer and bolt from the steering head bracket CHAPTER THIRTEEN STEERING HEAD ...

Page 30: ...ther end of the steering link 2 Remove the self locking nut from the top 4 Lift off the long spacer tube 5 Lower the bolt out of the stub axle and remove the short spacer tube 6 Remove the bolt from the steering link CHAPTER FOURTEEN MAIN FRAME STEERING Main Frame Steering CHAPTER ...

Page 31: ...r to undo the other end of the steering link 8 Remove the self locking nut from the top 9 Lower the bolt out of the stub axle and remove the short spacer tube 10 Lift the steering link off the bolt CHAPTER FOURTEEN MAIN FRAME STEERING ...

Page 32: ...spacer 3 The stub axle may need to be carefully tapped with a nylon hammer and rotated to aid removal 4 Remove the Stub Axle assembly Repeat the process for the other side 5 The Stub Axle assembly nut spacer CHAPTER FIFTEEN MAIN FRAME STUB AXLES Main Frame StubAxles CHAPTER ...

Page 33: ...ss member 3 Once loose it maybe quicker to use your QJHUV WR UHPRYH 4 Pull cross member forwards remember LQJ ZKHUH WKH VSDFHUV DUH WWHG 5 Show front axle cross member removed 6 Inspect bump stopr on frame for wear and damage replace if necessary CHAPTER SIXTEEN FRONT FRAME BUMP STOPS Front Frame Bump Stops CHAPTER ...

Page 34: ...with a ÀDW VFUHZGULYHU 3 Undo the four screws in the bottom of the tiller fascia box 4 Once removed feed the cable through the tiller section 5 Feed the white plug through the hole in the tiller shaft 6 The tiller fascia control box CHAPTER SEVENTEEN TILLER ASSEMBLY TillerAssembly CHAPTER ...

Page 35: ...lly lift open the fascia control box 9 Shows the position of the key switch 10 Disconnect the black connector from the key switch 11 Using an adjustable spanner undo the large retaining nut on the back of the key switch 12 Carefully slide the key assembly out of the fascia control box CHAPTER SEVENTEEN TILLER ASSEMBLY ...

Page 36: ...ndo the locking nut with a ring span ner 15 Remove the locking nut and washer from the speed potentiometer 16 Shows the speed potentiometer 17 Undo the locking nut on the horn button with a spanner or long nosed pliers 18 Slide out the horn button CHAPTER SEVENTEEN TILLER ASSEMBLY ...

Page 37: ... D ÀDW EODGHG VFUHZGULYHU FDUHIXOO OHYHU WKH ZLJ ZDJ IURP WKH SRWHQWLRPHWHU VKDIW 21 Using a small phillips screwdriver remove the 4 screw holding the wig wag potentiometer DUHIXOO OLIW RXW WKH ZLJ ZDJ SRWHQWLRPHWHU 23 The wig wag potentiometer CHAPTER SEVENTEEN TILLER ASSEMBLY ...

Page 38: ...37 Please use this Workshop Manual in conjunction with the Little Star Owners Manual and Parts Manual END ...

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