Sunrise Medical Little Gem 2 User manual

1
Service and Maintenance
for Scooters
Technical Manual
Little Gem 2

Info:1
Sunrise Medical is ISO 9001 certied, which ensures quality at all
stages of the development and production of this scooter.
This product is manufactured to comply with the requirements of
EEC directives 89/336/EEC
IMPORTANT:
It is potentially hazardous to t or use any parts other than
genuine Sterling parts.
The company disclaims all liability for the consequences of such
use, which in addition voids the machine warranty.
USAGE:
This vehicle is for the carriage of ONE PERSON and must not be
used for any other purpose.
CERTIFICATION:
PRODUCT INFORMATION
DESCRIPTION:
The Little Gem 2 is designed to be a exible four-wheel, highly
transportable scooter and Rear Wheel Drive, Single Transaxle
conguration.
Features include:
Fold down, height adjustable swivel seat with ip up width
adjustable armrests. Battery box tted with ergonomically
designed handle for easy removal/transport. Easily detachable
rear drive pack tted with twin handles for secure lifting, Fold
down, innitely adjustable tiller to accommodate comfortable ride
position and luggage compartment or cupboard storage.
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.

Wty:1
WARRANTY
WARRANTY CONDITIONS
1. The repair or replacement will be carried out by an authorised Sunrise
Medical dealer/service agent.
2. To apply the warranty conditions, should your scooter require attention under these
arrangements, notify the designated Sunrise Medical service agent immediately
giving full information about the nature of the difculty. 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.
3. Should any part of the scooter require repair or replacement, as a result of a
specic manufacturing or material defect, within twenty four months from the date
on which the possession of the scooter was transferred to the original purchaser,
and subject to it remaining within that ownership, the part or parts will be repaired or
replaced completely free of charge if returned to the authorised servicing agent.
NOTE: This guarantee is not transferable.
4. Any repaired or replaced part will benet 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 wear as a direct result
of an original manufacturing defect. These items include amongst others: batteries,
upholstery, tyres, inner tubes and similar parts.
7. The above warranty conditions apply to all scooter parts for models purchased at
full retail price.
8. Under normal circumstances, no responsibility will be accepted where the scooter
has required repair or replacement as a direct result of:
a) The scooter or part not having been maintained in
accordance with the manufacturer’s recommendations, where
such exist, or failing to use only the specied original
equipment parts.
b) The scooter or part having been damaged by neglect,
accident or improper use.
c) The scooter or part having been altered from the
manufacturer’s specications, or repairs being attempted prior
to the service agent being notied.

Cont:I
Table of Contents
1 Health & Safety .......................................................... 1.1-1.2
2 Tool Box...................................................................... 2.1
Service Information Note ............................................. SN1
3 Annual Service & Inspection .................................... 3.1
Service Information Note ............................................. SN2
4 Technical Specications ........................................... 4.1-4.2
Service Information Note ............................................. SN3-4
Mechanical 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 overleaf ........................................................
Chptr. Subject Page

Cont:II
Table of Contents
9 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 ............................................. 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

1:1
CHAPTER
Health & Safety
CHAPTER ONE HEALTH & SAFETY
Whilst working on powered mobility products, it is
essential to observe good working practice.
Below are a series of safety guidelines and recom-
mendations.
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.
Good Working Practice
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 off the
oor, always use a pair of axle stands to se-
cure the vehicle correctly.
Batteries
· 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 personal 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 non-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,
ush with running cold water for as long
as possible while medical help is sought.
All work carried out on batteries or battery
boxes should demand a degree of extra
caution.
ST PS
Sunrise Training and Education Programmes

1:2
CHAPTER ONE HEALTH & SAFETY
Batteries continued Battery Chargers
·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 personal items of jewel
lery such as rings, watches, chains
etc. before commencing work on
batteries.
If such items were to cause short
circuit whist being worn, very seri
ous burns would result.
·Batteries are constructed using very
heavy materials. Because of this it
is essential 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 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.
ST PS
Sunrise Training and Education Programmes

2:1
CHAPTER
Tool Box
CHAPTER TWO TOOL BOX
The following list of tools will enable any task
covered by this module to be carried out
quickly, effectively and safely.
The order in which tasks are executed can
vary depending on individual circumstances.
Be Aware!
It is the responsibility of the Servicing Engineer
to use their own judgement as to the suitability of a
particular work area for the task in hand.
If the safety of the engineer or others close by
is in question, we recommend that the vehicle is
removed to a more suitable safe area or workshop.
1. Metric socket set.
2. Hexagon wrenches (Allen Keys).
3. 3.5 - 8mm at 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 punches.
16. Torque wrench.
17. Steel engineering rule.
18. Tape measure.
19. Tyre pump.
20. Tyre pressure gauge.
21. Personal safety gear.
22. Wire strippers/cutters.
23. Tag crimper.
24. Multi-meter.
25. Battery tester.
26. PC programmer.
27. Parts, Owners & Workshop Manuals.
Tool Box
ST PS
Sunrise Training and Education Programmes

SN:1
IMPORTANT
SERVICE INFORMATION
All scooter components should be regularly checked for loose, damaged or
corroded connectors, terminals or cabling. All cables should be restrained to
protect them from damage. Damaged components should be replaced.
All switchable functions on the electronics system should be regularly tested to
ensure they function correctly.
All electronic components should be kept free of dust, dirt and liquids. If
necessary, wipe with a cloth dampened with warm water. Do not use solvents or
abrasive cleaners.
There are no 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.
Never use nylok nuts twice.
Any drive testing should take place in a clear safe space.
It is recommended that the servicing of this equipment is best undertaken in a
controlled workshop environment away from children, animals and the general
public.
Failure to comply with this recommendation is the sole responsibility of the
servicing agent.

3:1
CHAPTER
Annual Service
& Inspection
CHAPTER THREE ANNUAL SERVICE & INSPECTION
Controller
• Plug Connections
• Switches & Buttons
• External Connections
• Dynamic Braking (See Test Run).
• Programmable Settings
• Multi Prole Settings (Where Used).
• Drive Prole (See Test Run).
• Disable functions (safety circuits).
• Rubber Gaiters/Grommets
• Check for Water Incursion
• Fasteners & Brackets
Batteries
• Physical Inspection
• Check Type
• Charger Operation & Output Power
• Charger Type (GEL, WET, Automatic etc.).
• Connections
• Discharge Test
•Fuses & Resets
Wheels & Tyres
• Tyre Wear/cuts
• Pressure (Pneumatic Tyre).
• Bonding to Rim (Solid Tyre).
• Bearings (where appropriate).
• Wheel/Hub Nuts & Rim Studs
• Drive Key & Key-ways
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 Modications?
Full Drive Prole (Test Run)
• Forward Speed (max - min)
• Reverse Speed (max - min)
• Acceleration (fwd - rev)
• Deceleration (fwd - rev)
• Stopping Distance
• Brake
• Emergency Stop
• Drive a Straight Line
• Left/Right Arc Turn
• Ascend Slope
• Stop on Ascent
• Pull Away on Ascent
• Descend Slope
• Stop on Descent (Dynamic Braking).
• Pull Away on Descent
• Over obstacles
• Freewheel Push
Accessories
• Posture Belts
• Head Rest
• Dining Tray
• Auxiliary Equipment & Brackets
ST PS
Sunrise Training and Education Programmes

SN:2
IMPORTANT
SERVICE INFORMATION
The Technical Specications shown on the facing page are intended for
information purposes only. Small differences may occur.
Sunrise Medical reserve the right to alter any specication without notice.
The range gures 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.

4:1
CHAPTER
Technical Specications
General
CHAPTER FOUR TECHNICAL SPECIFICATIONS
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 115 cms (45.25”)
BASE 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 PRESSURE Solid
GROUND CLEARANCE 6 cms (2.4”)
MAX OBSTACLE CLIMB 5 cms (2”)
ST PS
Sunrise Training and Education Programmes

4:2
Technical Specications
Torque
CHAPTER FOUR TECHNICAL SPECIFICATIONS
FASTENER SIZE TORQUE SETTING (Nm)
M3 Bolt / Stud 1
M4 Bolt / Stud 2.5 - 3
M5 Bolt / Stud 5 - 6
M6 Bolt / Stud 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
Specic 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

SN:3
IMPORTANT
SERVICE INFORMATION
The service and maintenance of any mobility scooter or powered wheelchair
should only be undertaken by qualied or experienced engineering personnel.
This document is not intended for use by the general public.
This Technical Manual may recommend the use of certain tools/equipment during
maintenance procedures. It requires that the servicing engineer has, by means
of qualication or experience, the skills necessary to use such tools/equipment
correctly and safely.
It is highly recommended that all specic 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 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.

SN:4
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.
IMPORTANT
SERVICE INFORMATION