Sunrise Medical Sterling Pearl User manual

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Workshop ManualWorkshop Manual
Workshop ManualWorkshop Manual
Workshop Manual
Pearl ScooterPearl Scooter
Pearl ScooterPearl Scooter
Pearl Scooter
ST PS
Sunrise Training and Education Programmes

Sunrise Medical is ISO 9001 certified, which ensures quality at allSunrise Medical is ISO 9001 certified, which ensures quality at all
Sunrise Medical is ISO 9001 certified, which ensures quality at allSunrise Medical is ISO 9001 certified, which ensures quality at all
Sunrise Medical is ISO 9001 certified, which ensures quality at all
stages of the development and production of this scooter.stages of the development and production of this scooter.
stages of the development and production of this scooter.stages of the development and production of this scooter.
stages of the development and production of this scooter.
This product is manufactured to comply with the requirements of EECThis product is manufactured to comply with the requirements of EEC
This product is manufactured to comply with the requirements of EECThis product is manufactured to comply with the requirements of EEC
This product is manufactured to comply with the requirements of EEC
directives 89/336/EECdirectives 89/336/EEC
directives 89/336/EECdirectives 89/336/EEC
directives 89/336/EEC
IMPORTANT:IMPORTANT:
IMPORTANT:IMPORTANT:
IMPORTANT:
It is potentially hazardous to fit or use any parts other than genuineIt is potentially hazardous to fit or use any parts other than genuine
It is potentially hazardous to fit or use any parts other than genuineIt 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 suchThe company disclaims all liability for the consequences of such
The company disclaims all liability for the consequences of suchThe company disclaims all liability for the consequences of such
The company disclaims all liability for the consequences of such
use, which in addition voids the machine warranty.use, which in addition voids the machine warranty.
use, which in addition voids the machine warranty.use, which in addition voids the machine warranty.
use, which in addition voids the machine warranty.
USAGE:USAGE:
USAGE:USAGE:
USAGE:
This vehicle is for the carriage of ONE PERSON and must not be usedThis vehicle is for the carriage of ONE PERSON and must not be used
This vehicle is for the carriage of ONE PERSON and must not be usedThis vehicle is for the carriage of ONE PERSON and must not be used
This vehicle is for the carriage of ONE PERSON and must not be used
for any other purpose.for any other purpose.
for any other purpose.for any other purpose.
for any other purpose.
CERTIFICATION:CERTIFICATION:
CERTIFICATION:CERTIFICATION:
CERTIFICATION:
PRODUCT INFORMATION
Pearl

Table of Contents
Chptr.Chptr.
Chptr.Chptr.
Chptr. SubjectSubject
SubjectSubject
Subject PagePage
PagePage
Page
1 Health & Safety........................................................... 1- 2
2 Tool Box..................................................................... 3
3 Service Schedule......................................................... 4
4 Technical Specifications............................................. 5
5BatteriesBatteries
BatteriesBatteries
Batteries
Battery Box ................................................................ 6 - 7
Battery Charger .......................................................... 8
6WheelsWheels
WheelsWheels
Wheels
Front Wheels ............................................................. 9
Rear Wheels .............................................................. 10
7Rear Drive Assembly.Rear Drive Assembly.
Rear Drive Assembly.Rear Drive Assembly.
Rear Drive Assembly.
Panels ........................................................................ 11
Motor Loom & Terminals ........................................... 12
Transaxle & Fixings ................................................... 13
Motor / Brushes ........................................................ 14
Motor / Brushes Test ................................................. 15
Brake / Micro-switch Test ......................................... 16
8Tiller & Footboard Removal.Tiller & Footboard Removal.
Tiller & Footboard Removal.Tiller & Footboard Removal.
Tiller & Footboard Removal.
Front Basket .............................................................. 17
Tiller Adjuster............................................................ 18
Lifting The Footboard................................................. 19 - 21
9Tiller AssemblyTiller Assembly
Tiller AssemblyTiller Assembly
Tiller Assembly
Tiller Assembly Panels .............................................. 22
Tiller Assembly Pod ................................................... 23
Tiller Assembly Key Switch ........................................ 24
Tiller Assembly WigWag ............................................ 25
10 Main Control BoxMain Control Box
Main Control BoxMain Control Box
Main Control Box
Main Control Box ....................................................... 26
11 Main FrameMain Frame
Main FrameMain Frame
Main Frame
Main Frame Front Bumper .......................................... 27
Main Frame Steering Rods ......................................... 28 - 30
Main Frame Stub Axle ................................................ 31
Steering Head, Bearings & Bump Stops ...................... 32 - 33
Gem-Lock ................................................................. 34
Power Output Terminals ............................................ 35
12 SeatSeat
SeatSeat
Seat
Adjustments -Armrests & Height .............................. 36
Seat Covers ................................................................. 37
Seat Positional Adjustment ......................................... 38

ST PS
Sunrise Training and Education Programmes
CHAPTER
Health & Safety
CHAPTER ONE HEALTH & SAFETY
Whilst working on powered mobility products,
it is essential to observe good working prac-
tice.
Below are a series of safety guidelines and
recommendations.
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 PracticeGood Working Practice
Good Working PracticeGood Working Practice
Good Working Practice
GeneralGeneral
GeneralGeneral
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 batter-
ies, as these parts are exposed to paths,
parks etc.
· If the drive wheels have to be raised of the
floor, always use a pair of axle stands to
secure the vehicle correctly.
BatteriesBatteries
BatteriesBatteries
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 personnel 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 bat-
teries.
·Remember that none 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,
flush 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 cau-
tion.
11
11
1

CHAPTER ONE HEALTH & SAFETY ST PS
Sunrise Training and Education Programmes
Batteries continuedBatteries continued
Batteries continuedBatteries continued
Batteries continued
·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 personnel items of jewellery
such as rings, watches, chains etc.
before commencing work on batteries.
If such items were to cause short circuit
whist being worn, very serious burns
would result.
·Batteries are constructed using very
heavy materials, 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 ChargersBattery Chargers
Battery ChargersBattery Chargers
Battery Chargers
Remember battery chargers are
connected to Mains Electricity
·Always observe all guidelines and laws
relating to mains-connected installa-
tions 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.
22
22
2

CHAPTER
Tool Box
CHAPTER TWO TOOL BOX ST PS
Sunrise Training and Education Programmes
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!Be Aware!
Be Aware!Be Aware!
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 work-
shop.
1. Metric socket set.
2. Imperial socket set.
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 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. Tyre pump.
27. Tyre pressure gauge.
28. Personal safety gear.
29. Wire strippers/cutters.
30. Tag crimper.
31. Multi-meter.
32. Battery tester.
33. Hand held electronic programmers.
34. Parts manuals & workshop manuals.
35. Tyre levers.
Tool BoxTool Box
Tool BoxTool Box
Tool Box
33
33
3

CHAPTER
Annual Service &
Inspection
CHAPTER THREE ANNUAL SERVICE & INSPECTION
ControllerController
ControllerController
Controller
•Plug ConnectionsPlug Connections
Plug ConnectionsPlug Connections
Plug Connections
•External ConnectionsExternal Connections
External ConnectionsExternal Connections
External Connections
•Dynamic Braking (See Test Run).Dynamic Braking (See Test Run).
Dynamic Braking (See Test Run).Dynamic Braking (See Test Run).
Dynamic Braking (See Test Run).
•Programmable SettingsProgrammable Settings
Programmable SettingsProgrammable Settings
Programmable Settings
•Multi Profile Settings (Where Used).Multi Profile Settings (Where Used).
Multi Profile Settings (Where Used).Multi Profile Settings (Where Used).
Multi Profile Settings (Where Used).
•Drive Profile, (See Test Run).Drive Profile, (See Test Run).
Drive Profile, (See Test Run).Drive Profile, (See Test Run).
Drive Profile, (See Test Run).
•Disable functions, (safety circuits).Disable functions, (safety circuits).
Disable functions, (safety circuits).Disable functions, (safety circuits).
Disable functions, (safety circuits).
•Rubber Gaiters/GrommetsRubber Gaiters/Grommets
Rubber Gaiters/GrommetsRubber Gaiters/Grommets
Rubber Gaiters/Grommets
•Check for Water IncursionCheck for Water Incursion
Check for Water IncursionCheck for Water Incursion
Check for Water Incursion
•Fasteners & BracketsFasteners & Brackets
Fasteners & BracketsFasteners & Brackets
Fasteners & Brackets
BatteriesBatteries
BatteriesBatteries
Batteries
•Physical InspectionPhysical Inspection
Physical InspectionPhysical Inspection
Physical Inspection
•Check TypeCheck Type
Check TypeCheck Type
Check Type
•Charger Operation & Output PowerCharger Operation & Output Power
Charger Operation & Output PowerCharger Operation & Output Power
Charger Operation & Output Power
•Charger Type, (GEL, WET).Charger Type, (GEL, WET).
Charger Type, (GEL, WET).Charger Type, (GEL, WET).
Charger Type, (GEL, WET).
•ConnectionsConnections
ConnectionsConnections
Connections
•Discharge TestDischarge Test
Discharge TestDischarge Test
Discharge Test
•Fuses & ResetsFuses & Resets
Fuses & ResetsFuses & Resets
Fuses & Resets
Wheels & TyresWheels & Tyres
Wheels & TyresWheels & Tyres
Wheels & Tyres
•Tyre Wear/cutsTyre Wear/cuts
Tyre Wear/cutsTyre Wear/cuts
Tyre Wear/cuts
•Pressure, (Pneumatic Tyre).Pressure, (Pneumatic Tyre).
Pressure, (Pneumatic Tyre).Pressure, (Pneumatic Tyre).
Pressure, (Pneumatic Tyre).
•Bonding to Rim (Solid Tyre).Bonding to Rim (Solid Tyre).
Bonding to Rim (Solid Tyre).Bonding to Rim (Solid Tyre).
Bonding to Rim (Solid Tyre).
•Bearings, (Where appropriate).Bearings, (Where appropriate).
Bearings, (Where appropriate).Bearings, (Where appropriate).
Bearings, (Where appropriate).
•Wheel/Hub Nuts & Rim StudsWheel/Hub Nuts & Rim Studs
Wheel/Hub Nuts & Rim StudsWheel/Hub Nuts & Rim Studs
Wheel/Hub Nuts & Rim Studs
•Castor Wheels, Forks & BearingsCastor Wheels, Forks & Bearings
Castor Wheels, Forks & BearingsCastor Wheels, Forks & Bearings
Castor Wheels, Forks & Bearings
•Drive Key & Key-waysDrive Key & Key-ways
Drive Key & Key-waysDrive Key & Key-ways
Drive Key & Key-ways
MotorsMotors
MotorsMotors
Motors
•WiringWiring
WiringWiring
Wiring
•BrushesBrushes
BrushesBrushes
Brushes
•NoiseNoise
NoiseNoise
Noise
•Connections & LoomsConnections & Looms
Connections & LoomsConnections & Looms
Connections & Looms
•Brake & FreewheelBrake & Freewheel
Brake & FreewheelBrake & Freewheel
Brake & Freewheel
•Micro SwitchMicro Switch
Micro SwitchMicro Switch
Micro Switch
•Seals, (leaks).Seals, (leaks).
Seals, (leaks).Seals, (leaks).
Seals, (leaks).
•Performance (See Test Run)Performance (See Test Run)
Performance (See Test Run)Performance (See Test Run)
Performance (See Test Run)
Chassis
•Condition, (Welded Joints etc.).
•Alignment, (Twists etc).
•Bearing HousingsBearing Housings
Bearing HousingsBearing Housings
Bearing Housings
•Fasteners & BracketsFasteners & Brackets
Fasteners & BracketsFasteners & Brackets
Fasteners & Brackets
Full Drive ProfileFull Drive Profile
Full Drive ProfileFull Drive Profile
Full Drive Profile (Test Run)(Test Run)
(Test Run)(Test Run)
(Test Run)
•Forward Speed, (max - min)
•Reverse Speed, (max - min)
•Acceleration,Acceleration,
Acceleration,Acceleration,
Acceleration, (fwd - rev)(fwd - rev)
(fwd - rev)(fwd - rev)
(fwd - rev)
•Deceleration,Deceleration,
Deceleration,Deceleration,
Deceleration, (fwd - rev)(fwd - rev)
(fwd - rev)(fwd - rev)
(fwd - rev)
•Stopping DistanceStopping Distance
Stopping DistanceStopping Distance
Stopping Distance
•Brakes SynchronisedBrakes Synchronised
Brakes SynchronisedBrakes Synchronised
Brakes Synchronised
•Emergency Stop
•Drive a Straight LineDrive a Straight Line
Drive a Straight LineDrive a Straight Line
Drive a Straight Line
•Left/RightArc Turn
•Left/Right Spin Turn
•Ascend SlopeAscend Slope
Ascend SlopeAscend Slope
Ascend Slope
•Stop on AscentStop on Ascent
Stop on AscentStop on Ascent
Stop on Ascent
•Pull Away on AscentPull Away on Ascent
Pull Away on AscentPull Away on Ascent
Pull Away on Ascent
•Descend SlopeDescend Slope
Descend SlopeDescend Slope
Descend Slope
•Stop on Descent, (Dynamic Braking).Stop on Descent, (Dynamic Braking).
Stop on Descent, (Dynamic Braking).Stop on Descent, (Dynamic Braking).
Stop on Descent, (Dynamic Braking).
•Pull Away on DescentPull Away on Descent
Pull Away on DescentPull Away on Descent
Pull Away on Descent
•Over obsticlesOver obsticles
Over obsticlesOver obsticles
Over obsticles
•Freewheel PushFreewheel Push
Freewheel PushFreewheel Push
Freewheel Push
•Repeat for Multi Profile SettingsRepeat for Multi Profile Settings
Repeat for Multi Profile SettingsRepeat for Multi Profile Settings
Repeat for Multi Profile Settings
(Where Used)(Where Used)
(Where Used)(Where Used)
(Where Used)
44
44
4
Genral Service Instruction for Mobility Vehicles

CHAPTER
Technical
Specifications
CHAPTER FOUR TECHNICAL SPECIFICATIONS ST PS
Sunrise Training and Education Programmes
Technical SpecificationsTechnical Specifications
Technical SpecificationsTechnical Specifications
Technical Specifications
The technical specifications listed opposite
refer to general physical dimensions, weights
and drive profile capabilities of the Pearl
scooter.
Sunrise Medical reserve the right to make
changes to such specifications when required,
without giving prior notice.
•Drive Wheel Diameter 8.5” / 21.5cm
•Front Wheel Diameter 7.5” / 19cm
•Overall Length 40.5” / 103cm
•Overall Width 22” / 56cm
•Min. Gnd - Seat 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, 18.5, 19”
(via seat fixing bolts) 44, 46, 48cm.
*User weight, terrain, environmental conditions,
battery condition/age and other factors, can all
affect the maximum range of the vehicle.
The range quoted is compliant with the standard,
ISO 7176; Part 4
All measurements are approximate.
Pearl Scooter SpecificationsPearl Scooter Specifications
Pearl Scooter SpecificationsPearl Scooter Specifications
Pearl Scooter Specifications
55
55
5

CHAPTER
Batteries
Battery Box
CHAPTER FIVE BATTERIES ST PS
Sunrise Training and Education Programmes
12
34
6
5
Undo & remove the 12 fixing screws.
123
4
5
6
789
10
11
12
Carefully lift the battery box lid away from the
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 charger socket.
66
66
6

CHAPTER FIVE BATTERIES
78
910
11 12
ST PS
Sunrise Training and Education Programmes
Batteries
Battery Box
Use a 10mm spanner to disconnect the black
charger inhibit lead.
Pull the two insulated spade terminal 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.
77
77
7

CHAPTER FIVE BATTERY CHARGER
13 14
15 16
ST PS
Sunrise Training and Education Programmes
17
Batteries
Battery Charger
Open the charger socket cover to gain access
to the charging socket.
Plug the charger output plug into the charging
socket on the battery box.
Connect the charger mains 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 REDSTEADY RED
STEADY REDSTEADY RED
STEADY RED = MAINS ON
FLASHING REDFLASHING RED
FLASHING REDFLASHING RED
FLASHING RED = FAULT/NO CONNECTION
FLASHING GREENFLASHING GREEN
FLASHING GREENFLASHING GREEN
FLASHING GREEN = NORMAL CHARGE
STEADY GREENSTEADY GREEN
STEADY GREENSTEADY GREEN
STEADY GREEN = FULLY CHARGED
88
88
8

CHAPTER
Wheels
Front Wheels
CHAPTER SIX WHEELS ST PS
Sunrise Training and Education Programmes
12
34
6
5
Use a thin 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.
99
99
9

CHAPTER SIX WHEELS ST PS
Sunrise Training and Education Programmes
Wheels
Rear Wheels
8
910
11 12
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.
1010
1010
10

CHAPTER
Rear Drive Assy.
Panels
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
12
34
6
5
To change 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.
1111
1111
11

CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
78
910
12
11
Motor Loom
& Terminals
Cut any plastic tie-wraps, making a note 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.
1212
1212
12

CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
13 14
15
18
17
Transaxle &
Fixings
16
There are four fixing nuts securing the
Transaxle assembly.
Use a 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.
1313
1313
13

CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
19 20
21
24
23
Motor/Brushes
22
Use a 6.00mm hex key or driver to undo the
four motor studs. Note that there is blue lock-
tight 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.
1414
1414
14

CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
25 26
27
30
29
Motor/Brushes Test
28
Hold the cap firmly when removing as it is
under spring tension. Gently lift the motor
brush out of it’s housing.
Inspect the cap, (1), for burning, 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, “ 11
11
1 or OCOC
OCOC
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
“000000
000000
000” or similar. If the meter has a continuity
buzzer, a buzzing or beeping sound may be
heard.
1515
1515
15

CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS
Sunrise Training and Education Programmes
31 32
33
36
35
Brake/Micro-switch Test
34
With the brake release lever in the DRIVE posi-
tion, the meter will read, “058058
058058
058” or similar. This is
an indication of the brake coil resistance and that
the switch is operating normally.
With the lever in the FREEWHEEL position,
the meter will read, “11
11
1or OCOC
OCOC
OC”. If the readings
are nothing like the 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, “11
11
1or OCOC
OCOC
OC” is displayed.
BRAKE CONNECTIONSBRAKE CONNECTIONS
BRAKE CONNECTIONSBRAKE CONNECTIONS
BRAKE CONNECTIONS
Hold the motor connector block firmly.
The brake/mS connections are as shown above,
located next to the clip lock.
Carefully place one prong in each of the termi-
nals as shown above.
1616
1616
16

CHAPTER
Front
Basket
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS
Sunrise Training and Education Programmes
12
34
6
5
The basket bracket has two hooks fixing the
basket.
Lift 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.
1717
1717
17