Sunrise Medical Sterling Pearl, Service Maintenance Manual

Page 1: ... 12 0h 0 Workshop Manual Workshop Manual Workshop Manual Workshop Manual Workshop Manual Pearl Scooter Pearl Scooter Pearl Scooter Pearl Scooter Pearl Scooter ST PS Sunrise Training and Education Programmes ...

Page 2: ... is potentially hazardous to fit or use any parts other than genuine It is potentially hazardous to fit or use any parts other than genuine It is potentially hazardous to fit or use any parts other than genuine Sunrise Medical parts Sunrise Medical parts Sunrise Medical parts Sunrise Medical parts Sunrise Medical parts The company disclaims all liability for the consequences of such The company di...

Page 3: ...rd Removal Tiller Footboard Removal Tiller Footboard Removal Tiller Footboard Removal Tiller Footboard Removal Front Basket 17 Tiller Adjuster 18 Lifting The Footboard 19 21 9 Tiller Assembly Tiller Assembly Tiller Assembly Tiller Assembly Tiller Assembly Tiller Assembly Panels 22 Tiller Assembly Pod 23 Tiller Assembly Key Switch 24 Tiller Assembly WigWag 25 10 Main Control Box Main Control Box Ma...

Page 4: ...teries 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 ass...

Page 5: ...rials 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 author ity for their recommendations Battery Chargers Battery Chargers Battery Chargers Battery Chargers Battery Chargers Reme...

Page 6: ... 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 ga...

Page 7: ...m Studs Wheel Hub Nuts Rim Studs Wheel Hub Nuts Rim Studs Castor Wheels Forks Bearings Castor Wheels Forks Bearings Castor Wheels Forks Bearings Castor Wheels Forks Bearings Castor Wheels Forks Bearings Drive Key Key ways Drive Key Key ways Drive Key Key ways Drive Key Key ways Drive Key Key ways Motors Motors Motors Motors Motors Wiring Wiring Wiring Wiring Wiring Brushes Brushes Brushes Brushes ...

Page 8: ...t Ht 16 5 42cm Max Gnd Seat Ht 21 5 55cm Min F board Seat Ht 12 30cm Max F board Seat Ht 17 43cm Effective Gnd Clearance 1 5 4cm Tot Weight C W Batts 114lbs 52kg Wieght of Battery Box 35lbs 16kg Batteries Rated at 21A h Max User Wieght 21st 136kg Max Range 15m 24km Max Speed 4mph 6kph Max Obsticle Ht 2 5cm Max Gradient 8 degrees Turn Radius 46 2 117cm Footwell Toe to Seat Front edge adjust 17 5 18...

Page 9: ...he body The battery terminals are screw stud type Undo the terminals first as shown The other two terminals are the link via the circuit breaker _ _ _ _ _ _ _ _ _ _ The batteries have velcro pads securing them to the battery box A reasonable amount of force is necessary to lift each battery Cut the tie wrap around the two insulated spade connectors leading to the charger socket Disconnect the char...

Page 10: ...rminal connec tors off the back of the circuit breaker Use a 14mm spanner to carefully undo the circuit breaker nut Undo the two screws securing the charging socket Note that there are two small self locking nuts on the back of the screws There are two fuse holders To access the fuse press the plastic clip flip up the lid of the fuse holder Withdraw the 40A blade fuse and check for continuity 7 7 ...

Page 11: ... plug to the power outlet and switch on The battery box can be removed from the scooter for off board charging if required The charging sequence is as follows STEADY RED STEADY RED STEADY RED STEADY RED STEADY RED MAINS ON FLASHING RED FLASHING RED FLASHING RED FLASHING RED FLASHING RED FAULT NO CONNECTION FLASHING GREEN FLASHING GREEN FLASHING GREEN FLASHING GREEN FLASHING GREEN NORMAL CHARGE STE...

Page 12: ...hin knife blade or similar to carefully prise off the plastic hub cap Remove the cap to expose the fixing stud Use a X head screw driver to loosen the stud screw Steady the front of the scooter and remove the wheel Make a note of the number of shim washers fitted behind the wheel The front wheel assembly 9 9 9 9 9 ...

Page 13: ...7 Lift off the plastic cap to expose the bolt Use a 13 0mm socket to undo the bolt Withdraw the bolt spacer washer spring washer Lift the wheel away from the rear axle taking care not to lose the drive key Use a pair of snipe nose pliers to remove the drive key The rear wheel assembly 10 10 10 10 10 ...

Page 14: ...ge the rear drive body panel first seperate the rear drive from the main scooter body using the Gem lock lever The rear drive assembly Use a X head screw driver to undo the six panel screws Undo screws 1 4 and lift the handle off Undo the remaining screws 5 6 and lift the panel clear of the chassis The rear panel set 11 11 11 11 11 ...

Page 15: ...of their location for replacement later Unclip any metal cable tags to free the loom Disconnect the motor plug by pressing down on the plastic clip to unlock it then pull the two plugs apart Mark the top of the power terminals to aid re assembly and undo the four screws Pass the terminals back through the mountings The power terminals and loom 12 12 12 12 12 ...

Page 16: ... 13 0mm socket on the nuts and a x head screw driver on the right hand studs The left hand side is a U bolt Remove the nut washer and rubber washer on all four of the threads Remove the studs and U bolt taking care not to damage the rubber pads Use caution when lifting the transaxle assembly away from the frame as it is quite heavy The transaxle assembly and fixings 13 13 13 13 13 ...

Page 17: ...ght used on the threads Carefully lift the motor brake assembly away from the transaxle The motor drive coupling has to be lined up with the gearbox drive coupling when refitting The gearbox drive coupling Move the rubber cap to gain clear access to the motor brush housing and or brake Using a flat blade screw driver carefully undo the brush cap Be aware of the spring located under the cap 14 14 1...

Page 18: ...the lead 2 for continuity see next carbon brush 3 for cracks wear etc 1 2 3 To check for continuity set the multi meter to the lowest number in the RESISTANCE position The display says 1 1 1 1 1 or OC OC OC OC OC Put one prong on the cap of the motor brush Put the other prong on the carbon brush If the connection is OK the meter will show 000 000 000 000 000 or similar If the meter has a continuit...

Page 19: ...e above there may be a fault in the mS the brake or the plug wires The brake micro switch is secured with two small screws The switch actuator is located at the side of an operating cam which is con nected to the brake lever To test the micro switch mS first set the multimeter to the lowest RESISTANCE setting As before 1 1 1 1 1or OC OC OC OC OC is displayed BRAKE CONNECTIONS BRAKE CONNECTIONS BRA...

Page 20: ...t the basket off the bracket and away from the tiller assembly Use a X head screw driver to undo the two screws securing the bracket With the bracket removed loosen the four screws securing the clamp The position of the clamp can be changed and the screws tightened or the clamp can be removed To remove the clamp take the screws out The clamp is in two halves 17 17 17 17 17 ...

Page 21: ...8 Release the tiller lock Locate the two mounting studs in the lowest position Use a 4 00mm hex key and a 10 00mm spanner to undo the two studs The tiller lock receiver and studs Repeat the process for the upper set of bolts lift the tiller off Lift the tiller adjustment assembly off the steering shaft 18 18 18 18 18 ...

Page 22: ...o lift the footboard There are two screws holding the rear of the footboard to the chassis Use a X head screw driver to undo both screws Remove the plastic cover off the tiller lock Use a flat blade screw driver to undo the tiller lock handle Drop the spring and plunger out of the housing Gently lift the front of the footboard over the steering head 19 19 19 19 19 ...

Page 23: ...he back of the footboard clear of the Gem lock mechanism Lift the footboard and rest it on the chassis to access the loom plugs Locate the main tiller loom as shown Cut the plastic tie wraps making a note of their position Cut the tie wrap at the other end of the loom Disconnect the loom plug from the main control box 20 20 20 20 20 ...

Page 24: ...the front of the footboard Remove the tiller assembly complete The blue power plug has to be disconnected before the footboard can be lifted clear of the chassis To change the contacts loom first mark the terminals with a felt pen or similar Hold the lower nut with a 10 00mm spanner Use a 10 00mm socket to undo the top nut and release the terminal tag 21 21 21 21 21 ...

Page 25: ...6 5 Remove the tiller assembly as previously shown Remove the loom clip Undo the two screws in the bottom of the tiller panel Slide the panel down the shaft to access the top of the loom Cut the plastic tie wrap securing the top of the loom Feed the white plug through the hole and into the tiller tube 22 22 22 22 22 ...

Page 26: ... loom through the tube and out through the top hole With the lower panel removed the pod fascia is easily accessed Disconnect the white plug The tiller pod fascia can now be removed Note that the main loom is hard wired to the tiller fascia pod as part of the assembly The bottom panel can be slid off the tiller tube 23 23 23 23 23 ...

Page 27: ...17 Cut the small tie wrap located near to the black plug Disconnect the black key switch plug Use long nose pliers to undo the key switch nut Remove the nut and pull the key switch through the front of the panel The key switch assembly The preset speed knob is a push fit and can easily be removed by hand 24 24 24 24 24 ...

Page 28: ...n Programmes Tiller Assembly WigWag 23 Remove the plastic thumb pads Undo the two small screws securing the potentiometer pot to the tiller bar Feed the wigwag assembly through the slot in the splash guard The wigwag assembly removed Parts of the tiller assembly 25 25 25 25 25 ...

Page 29: ...oard has to be lifted up as previously explained Unplug the main loom Unplug the battery loom Unplug the motor brake loom Do not unscrew the two screws visible from the top of the control box The three mounting screws are accessed from underneath the chassis These are fixed with blue thread lock Remove the three screws and lift the control box off 26 26 26 26 26 ...

Page 30: ...1 2 3 4 5 The front bumper can be removed with the footboard still in place Use a 3 00mm hex key to undo the two grub screws Position of the two grub screws shown with the footboard removed Loosen the grub screws Pull the bumper forward and out of the tube in tube fitment The bumper removed 27 27 27 27 27 6 ...

Page 31: ...a 13 00mm spanner to hold the lower bolt and a 13 00mm socket to undo the top nut Carefully lift the link rod up to the top of the bolt but don t force it The steering may have to be gently rocked back and forth to allow the link rod to be lifted off the bolt Remove the washer pull the bolt through the steering head Use a 13 00mm socket spanner to undo the other end of the link rod 28 28 28 28 28 ...

Page 32: ...Education Programmes Main Frame Steering Rods 17 14 Remove the nut Carefully lift the steering link off the bolt Lift the large spacer of the bolt Lift the small spacer off the bolt Lift the washer off the bolt Withdraw the bolt from the steering link 29 29 29 29 29 ...

Page 33: ...ing Rods 19 20 The steering rod on the left hand side has the same nut and bolt connection as before Use the 13 00mm spanner to hold the lower bolt the 13 00mm socket to undo the nut Remove the nut Drop the rod out of the stub axle and lift off the washer Remove the spacer Remove the bolt 30 30 30 30 30 ...

Page 34: ... 19 00mm nut Use a 19 00mm socket to undo the nut Remove the nut and the spacer The stub axle is a tight fit It may require tapping with a soft hammer whilst rotating the axle Remove the stub axle Repeat the process for the other side The stub axle assembly Note that when order ing spares the stub axles are handed left or right 31 31 31 31 31 ...

Page 35: ...ad it is advis able to use fingers to remove it completely With the locking nut off the bearing retaining nut can be removed using finger pressure The upper bearing race can be lifted out of the steering head using thin nosed pliers Before the steering head can be removed the front frame stud has to be extracted Use a 10 00mm hex key to undo the large stud located directly below the steering head ...

Page 36: ...wer the steering head The lower bearings usually come down with the steering head but if not use a pair of thin nosed pliers as shown 42 When the stud thread is clear of the chassis lift and pull the front frame clear The front frame removed The rubber bump stops can now be inspected or changed as required Steering head bearings 33 33 33 33 33 ...

Page 37: ...ducation Programmes 43 44 45 46 47 The Gem lock assembly is located on the seat post Use a 4 00mm hex key and a 10 00mm spanner to undo the two securing bolts Remove both of the bolts Pull the Gem lock assembly out of the mounting bracket The Gem lock assembly 34 34 34 34 34 ...

Page 38: ...ower output terminals are fixed to a bracket located just below the Gem lock It is good working practice to mark the termi nals to assist in re assembly Undo the four mounting screws Each block can be removed individually to check connections etc To replace the loom undo both blocks The motor brake power output loom 35 35 35 35 35 ...

Page 39: ...obs are located under the seat 1 2 Loosen each knob as required Slide the armrest to the desired width or remove completely To adjust the seat height firstly remove the seat Next remove the set stem pin Aline the seat stem and receiver holes to corre spond at the desired seat height and replace the pin Or remove the seat stem completely 36 36 36 36 36 ...

Page 40: ...ecuring the fixing flap Pull the pop studs apart and fold the flap down Lift the cover off the backrest taking care not to lose the foam insert The seat cover is secured in the same way as the backrest cover Undo the two pop studs Lift the cover off the seat taking care not to lose the foam insert The backrest and seat cushions 37 37 37 37 37 ...

Page 41: ...he bolts using a 13 00mm socket Take the bolts out of the seat base Lift the seat plate off The corresponding seat plate mounting holes showing the possible 3 positions Set 1 Back Set 2 Middle Set 3 Forwards 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 Back Back Back Back Back Middle Middle Middle Middle Middle Forwards Forwards Forwards Forwards Forwards Back Back Back Back Back Mi...

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