Workshop Manual Pearl Scooter 0 4.5h 12.0h ST PS
PRODUCT INFORMATION CERTIFICATION: Sunrise Medical is ISO 9001 certified, 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 fit or use any parts other than genuine Sunrise Medical 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. Pearl
Chptr. Table of Contents Subject Page 1 Health & Safety... 1-2 2 Tool Box... 3 3 Service Schedule... 4 4 Technical Specifications... 5 5 Batteries Battery Box... 6-7 Battery Charger... 8 6 Wheels Front Wheels... 9 Rear Wheels... 10 7 Rear Drive Assembly. Panels... 11 Motor Loom & Terminals... 12 Transaxle & Fixings... 13 Motor / Brushes... 14 Motor / Brushes Test... 15 Brake / Micro-switch Test... 16 8 Tiller & Footboard Removal. Front Basket... 17 Tiller Adjuster... 18 Lifting The Footboard... 19-21 9 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... 26 11 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 Seat Adjustments -Armrests & Height... 36 Seat Covers... 37 Seat Positional Adjustment... 38
CHAPTER ONE CHAPTER HEALTH & SAFETY Health & Safety ST PS Good Working Practice Whilst working on powered mobility products, it is essential to observe good working practice. 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. 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 of the floor, always use a pair of axle stands to secure the vehicle correctly. Batteries All work carried out on batteries or battery boxes should demand a degree of extra caution. 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 batteries. 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. 1
CHAPTER ONE HEALTH & SAFETY ST PS 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 authority for their recommendations. Battery Chargers Remember battery chargers are connected 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. 2
CHAPTER TWO TOOL BOX ST PS CHAPTER Tool Box 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. 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. 3
CHAPTER THREE CHAPTER ANNUAL SERVICE & INSPECTION Annual Service & Inspection Genral Service Instruction for Mobility Vehicles Controller Plug Connections External Connections Dynamic Braking (See Test Run). Programmable Settings Multi Profile Settings (Where Used). Drive Profile, (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). 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 Castor Wheels, Forks & Bearings Drive Key & Key-ways Chassis Condition, (Welded Joints etc.). Alignment, (Twists etc). Bearing Housings Fasteners & Brackets Full Drive Profile (Test Run) Forward Speed, (max - min) Reverse Speed, (max - min) Acceleration, (fwd - rev) Deceleration, (fwd - rev) Stopping Distance Brakes Synchronised Emergency Stop Drive a Straight Line Left/Right Arc Turn Left/Right Spin Turn Ascend Slope Stop on Ascent Pull Away on Ascent Descend Slope Stop on Descent, (Dynamic Braking). Pull Away on Descent Over obsticles Freewheel Push Repeat for Multi Profile Settings (Where Used) Motors Wiring Brushes Noise Connections & Looms Brake & Freewheel Micro Switch Seals, (leaks). Performance (See Test Run) 4
CHAPTER FOUR TECHNICAL SPECIFICATIONS ST PS CHAPTER Technical 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. Pearl Scooter Specifications 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. 5
CHAPTER FIVE BATTERIES ST PS CHAPTER Batteries Battery Box 1 2 3 2 1 4 + _ 12 11 5 6 10 9 8 7 Undo & remove the 12 fixing screws. Carefully lift the battery box lid away from the body. + _ 3 4 The battery terminals are screw stud type. Undo the + & - terminals first as shown. The other two terminals are the link via the circuit breaker. 5 The batteries have velcro pads securing them to the battery box. A reasonable amount of force is necessary to lift each battery. 6 Cut the tie-wrap around the two insulated spade connectors leading to the charger socket. Disconnect the charger socket. 6
CHAPTER FIVE BATTERIES ST PS Batteries Battery Box 7 8 Use a 10mm spanner to disconnect the black charger inhibit lead. Pull the two insulated spade terminal connectors off the back of the circuit breaker. 9 10 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. 11 12 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
CHAPTER FIVE BATTERY CHARGER ST PS Batteries Battery Charger 13 14 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. 15 16 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. 17 The charging sequence is as follows; STEADY RED = MAINS ON FLASHING RED = FAULT/NO CONNECTION FLASHING GREEN STEADY GREEN = NORMAL CHARGE = FULLY CHARGED 8
CHAPTER SIX WHEELS ST PS CHAPTER Wheels Front Wheels 1 2 Use a thin knife blade or similar to carefully prise off the plastic hub cap. Remove the cap to expose the fixing stud. 3 4 Use a X-head screw driver to loosen the stud screw. Steady the front of the scooter and remove the wheel. 5 6 Make a note of the number of shim washers fitted behind the wheel. The front wheel assembly. 9
CHAPTER SIX WHEELS ST PS Wheels Rear Wheels 7 8 Lift off the plastic cap to expose the bolt. Use a 13.0mm socket to undo the bolt. 9 10 Withdraw the bolt, spacer, washer & spring washer. Lift the wheel away from the rear axle taking care not to lose the drive key. 11 12 Use a pair of snipe-nose pliers to remove the drive key. The rear wheel assembly. 10
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS CHAPTER Rear Drive Assy. Panels 1 2 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. 3 4 Use a X-head screw driver to undo the six panel screws. Undo screws 1-4 and lift the handle off. 5 6 Undo the remaining screws, (5&6) and lift the panel clear of the chassis. The rear panel set. 11
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS Motor Loom & Terminals 7 8 Cut any plastic tie-wraps, making a note of their location for replacement later. Unclip any metal cable tags to free the loom. 9 10 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. 11 12 Pass the terminals back through the mountings. The power terminals and loom. 12
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS Transaxle & Fixings 13 14 There are four fixing nuts securing the Transaxle assembly. 15 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. 16 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. 17 18 Use caution when lifting the transaxle assembly away from the frame as it is quite heavy. The transaxle assembly and fixings. 13
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS Motor/Brushes 19 20 Use a 6.00mm hex key or driver to undo the four motor studs. Note that there is blue locktight used on the threads. 21 Carefully lift the motor/brake assembly away from the transaxle. 22 The motor drive coupling has to be lined up with the gearbox drive coupling when refitting. The gearbox drive coupling. 23 24 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
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS Motor/Brushes Test 25 26 1 2 3 Hold the cap firmly when removing as it is under spring tension. Gently lift the motor brush out of it s housing. 27 Inspect the cap, (1), for burning, the lead, (2) for continuity, (see next) & carbon brush, (3) for cracks/wear etc. 28 To check for continuity, set the multi-meter to the lowest number in the RESISTANCE position. The display says, 1 or OC 29 Put one prong on the cap of the motor brush. 30 Put the other prong on the carbon brush. If the connection is OK, the meter will show 000 000 or similar. If the meter has a continuity buzzer, a buzzing or beeping sound may be heard. 15
CHAPTER SEVEN REAR DRIVE ASSEMBLY ST PS Brake/Micro-switch Test 31 32 The brake micro-switch is secured with two small screws. The switch actuator is located at the side of an operating cam which is connected to the brake lever. To test the micro-switch, (ms), first set the multimeter to the lowest RESISTANCE setting. As before, 1or OC is displayed. 33 BRAKE CONNECTIONS 34 Hold the motor connector block firmly. The brake/ms connections are as shown above, located next to the clip lock. 35 Carefully place one prong in each of the terminals as shown above. 36 With the brake release lever in the DRIVE position, the meter will read, 058 058 or similar. This is an indication of the brake coil resistance and that the switch is operating normally. 16 With the lever in the FREEWHEEL position, the meter will read, 1or OC. If the readings are nothing like the above, there may be a fault in the ms, the brake or the plug/wires.
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS CHAPTER Front Basket 1 2 The basket bracket has two hooks fixing the basket. Lift the basket off the bracket and away from the tiller assembly 3 4 Use a X-head screw driver to undo the two screws securing the bracket. 5 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. 6 To remove the clamp take the screws out. The clamp is in two halves. 17
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS Tiller Adjuster 7 8 Release the tiller lock. Locate the two mounting studs in the lowest position. 9 10 Use a 4.00mm hex key and a 10.00mm spanner to undo the two studs. The tiller lock receiver and studs. 11 12 Repeat the process for the upper set of bolts & lift the tiller off. Lift the tiller adjustment assembly off the steering shaft. 18
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS Lifting The Footboard 13 14 To remove the tiller it is necessary to 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. 15 16 Remove the plastic cover off the tiller lock. Use a flat-blade screw driver to undo the tiller lock handle. 17 18 Drop the spring and plunger out of the housing. Gently lift the front of the footboard over the steering head. 19
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS Lifting The Footbard 19 20 Lift the back of the footboard clear of the Gem-lock mechanism. Lift the footboard and rest it on the chassis to access the loom & plugs. 21 22 Locate the main tiller loom as shown. Cut the plastic tie wraps making a note of their position. 23 24 Cut the tie wrap at the other end of the loom. Disconnect the loom plug from the main control box. 20
CHAPTER EIGHT TILLER & FOOTBOARD REMOVAL ST PS Lifting The Footboard 25 26 Feed the loom & plug through the hole in the front of the footboard. Remove the tiller assembly complete. 27 28 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. 29 30 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
CHAPTER NINE TILLER ASSEMBLY ST PS CHAPTER Tiller Assembly Panels 1 2 Remove the tiller assembly as previously shown. Remove the loom clip. 3 4 Undo the two screws in the bottom of the tiller panel. Slide the panel down the shaft to access the top of the loom. 5 6 Cut the plastic tie wrap securing the top of the loom. Feed the white plug through the hole and into the tiller tube. 22
CHAPTER NINE TILLER ASSEMBLY ST PS Tiller Assembly Pod 7 8 Carefully pull the loom through the tube and out through the top hole. With the lower panel removed the pod fascia is easily accessed. 9 10 Disconnect the white plug. The tiller pod fascia can now be removed. 11 12 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
CHAPTER NINE TILLER ASSEMBLY ST PS Tiller Assembly Key Switch 13 14 Cut the small tie wrap located near to the black plug. Disconnect the black key switch plug. 15 16 Use long-nose pliers to undo the key switch nut. Remove the nut and pull the key switch through the front of the panel. 17 18 The key switch assembly. The preset speed knob is a push fit and can easily be removed by hand. 24
CHAPTER NINE TILLER ASSEMBLY ST PS Tiller Assembly WigWag 19 20 Undo the two small screws securing the potentiometer, (pot), to the tiller bar. Remove the plastic thumb pads. 21 22 Feed the wigwag assembly through the slot in the splash guard. The wigwag assembly removed. 23 Parts of the tiller assembly. 25
CHAPTER TEN MAIN CONTROL BOX ST PS CHAPTER Main Control Box 1 2 To gain access to the main control box the footboard has to be lifted up as previously explained. Unplug the main loom. Unplug the battery loom. 3 4 Unplug the motor/brake loom. Do not unscrew the two screws visible from the top of the control box. 5 6 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
CHAPTER ELEVEN MAIN FRAME ST PS CHAPTER Main Frame Front Bumper 1 2 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). 3 4 Loosen the grub screws. Pull the bumper forward and out of the tube-in-tube fitment. 5 6 The bumper removed. 27
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Steering Rods 7 8 Move the steering to access the steering link that joins with the steering head. Use a 13.00mm spanner to hold the lower bolt and a 13.00mm socket to undo the top nut. 9 10 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. 11 12 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
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Steering Rods 13 14 Remove the nut. Carefully lift the steering link off the bolt. 15 16 Lift the large spacer of the bolt. Lift the small spacer off the bolt. 17 18 Lift the washer off the bolt. Withdraw the bolt from the steering link. 29
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Steering 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. 21 22 Remove the nut. Drop the rod out of the stub axle and lift off the washer. 23 24 Remove the spacer. Remove the bolt. 30
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Stub Axle 25 26 The stub axle is secured by a 19.00mm nut. Use a 19.00mm socket to undo the nut. 27 28 Remove the nut and the spacer. 29 The stub axle is a tight fit. It may require tapping with a soft hammer whilst rotating the axle. 30 Remove the stub axle. Repeat the process for the other side. The stub axle assembly. Note that when ordering spares the stub axles are handed left or right. 31
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Steering Head, Bearings & Bump Stops 31 32 It is recommended to use an adjustable spanner to loosen the steering head locking nut. The locking nut is on a fine thread, it is advisable to use fingers to remove it completely. 33 34 With the locking nut off, the bearing retaining nut can be removed using finger pressure. 35 36 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. Once loosened, use fingers to remove the stud. 32
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Steering Head, Bearings & Bump Stops 37 38 When the stud thread is clear of the chassis, lift and pull the front frame clear. The front frame removed. 39 40 The rubber bump-stops can now be inspected or changed as required. Gently lower the steering head. 41 42 The lower bearings usually come down with the steering head, but if not, use a pair of thinnosed pliers as shown. 33 Steering head & bearings.
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Gem-Lock 43 44 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. 45 46 Remove both of the bolts. Pull the Gem-lock assembly out of the mounting bracket. 47 The Gem-lock assembly. 34
CHAPTER ELEVEN MAIN FRAME ST PS Main Frame Power Output Terminals 48 49 The power output terminals are fixed to a bracket located just below the Gem-lock. It is good working practice to mark the terminals to assist in re-assembly. 50 51 Undo the four mounting screws. Each block can be removed individually to check connections etc. 52 53 To replace the loom, undo both blocks. The motor/brake power output loom. 35
CHAPTER TWELVE SEAT ST PS Seat Adjustments Armrests & Height CHAPTER 1 2 1 2 The two armrest securing knobs are located under the seat, (1&2). Loosen each knob as required. 3 4 Slide the armrest to the desired width or remove completely. 5 To adjust the seat height, firstly remove the seat. Next, remove the set stem pin. 6 Aline the seat stem and receiver holes to correspond at the desired seat height and replace the pin. Or remove the seat stem completely. 36
CHAPTER TWELVE SEAT ST PS Seat Covers 7 8 The backrest cover has two pop-stud fasteners securing 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. 9 10 The seat cover is secured in the same way as the backrest cover. Undo the two pop-studs. 11 12 Lift the cover off the seat taking care not to lose the foam insert. The backrest and seat cushions. 37
CHAPTER TWELVE SEAT ST PS Seat Positional Adjustment 13 14 Forwards Middle Back Forwards Middle Back Top view of the seat pan showing the seat plate encapsulated nuts. There are 3 possible positions for the front and back fixings. Under view of the 4 seat plate fixing bolts. 15 16 Undo the bolts using a 13.00mm socket. Take the bolts out of the seat base. 17 18 3 2 1 3 2 1 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. 38