Sunrise Medical EMERALD Instruction manual

Workshop Manual
EMERALD 4-WHEEL
ENGLISH
Scooters

EMERALD
WORKSHOP MANUAL
The Emerald mobility scooter is a versatile outdoor/indoor, 4-wheeled
machine.
Features include;
Adjustable Tiller assembly, Padded seat with width adjustable armrests,
Seat slide, Seat swivel, Headrest, 3-Amp off-board automatic charger,
Integrated lights & indicators,
Hazard warning lights, Front shopping basket
and Carpeted floor matt.
Sunrise Medical is ISO 9001 certified.
This product is manufactured to comply with the requirements of
EEC directives 89/336/EEC
CE
CONTENTS
Product Information 1-1a
Safety Information 2- 3
Recommended Tools 4
Service/Inspection 5
Technical Specifications 6
Front Wheels 7- 9
Rear Wheels 10
Tyres & Tubes 11-12
Seating 13-16
Seat Stem 17
Batteries & Charger 18
Separating the Scooter 19
Rear Drive Assy. Ties & Plugs 20
Rear Lights 21- 22
Main Control Box 23
Drive TrainAssy. 24- 26
Motor & Brake Assy. 27- 28
Rear Chassis Assy. 29- 30
TillerAssy. 31- 35
Front Body Panel Assy. 36- 37
Front Body Panel- Lights 38- 39
Front Body Panel- Bumper 40
Main FrameAssy. 41
Steering Rods 42- 44
Steering Head 45
StubAxles 46
Front Suspension 47
Assembly Reference Photographs 48- 51
1

IMPORTANT
Itis potentiallyhazardoustofitoruseany partsotherthangenuine
SunriseMedicalparts.
Thecompany disclaimsall liabilityfor theconsequences ofsuch use,
whichin addition,voids themachinewarranty.
This vehicle is for the carriage of
ONE PERSON
And must not be used for any other purpose.
1a

EMERALD
Safety
Whilstworkingon poweredmobility products,itis essentialto observegoodworking
practice.
Belowarea seriesof safetyguidelinesand recommendations.
Please note that theseprecautions are intended to serveonly as a guide andare not
intendedto supersedeor replaceany safetystatute, NHSor othersafety regulations.
General
•Alwayswear suitableprotective clothingwhenhandlingbatteries.
•Alwayswear suitableeye protectionwhen drillingor inspecting.
•Whensafe todo so,wear protectivegloves whenhandling therunning gearor batter-
ies, as these parts are exposed to paths, parks etc.
•Ifthedrive wheelshave tobe raisedofthe floor,alwaysuse apairof axlestandsto
securethe vehiclecorrectly.
Batteries
Allworkcarried outon batteriesor batteryboxesshould demanda degreeofextra caution.
•Alwaysmake surethatthe batteriesare disconnectedfrom thevehicle before com-
mencingwork.
•Alwayscheck thatthebatterychargerisdisconnectedfrom thevehicle /batteries be-
forecommencingwork.
•Do not smoke.
•Keepbatteriesaway fromall sourcesofignition.
•Donotplaceobjectson thebattery tops.
•Alwaystry tokeepsomeonewithinearshotofyour workarea sothat theymay cometo
yourassistance ifneeded.
•Alwayswear personnelprotection whenhandling batteriesincluding, eye/ faceprotec-
tionand gloves.
•Make sure there is easy access to soap and water in case of acid spills.
•Avoidtouching eyesorunprotectedpartsof thebody whileworking onbatteries.
•Rememberthat nonesealed batteriescancontaminateanypackaging,housing,or
boxesthey mayhave beentransportedin,sohandleallpackagingwithcareespecially
whendisposing of.
•Ifbattery acidshouldcomeintocontact withbare skinor clothing,be suretowash
immediatelyusing plentyof soapand water.If batteryacid entersthe eyes,flushwith
runningcold waterforas longas possiblewhile medicalhelpis sought.
2

EMERALD
Safety
Batteries
•Whenthe topsofbatteries areexposed, takeextra carewhen workingonor aroundthe
terminals.
•Donotallow metaltools todropon toor touchthe exposed terminalsof thebatteries or
otherexposed connectionsas thiscould causeashortcircuit,whichmayresultinan
explosion.
•Removepersonnel itemsof jewellerysuch asrings, watches,chains etc.before com-
mencingwork onbatteries.Ifsuchitemsweretocauseshort circuitwhist beingworn,
veryseriousburnswouldresult.
•Batteriesare constructedusingveryheavymaterials,becauseof thisit isessential that
correctlifting techniquesbe employedwhen movingbatteriesaround.Itisalsorecom-
mendedthat safetyfootwear beworn.
•Whendisposingof oldbatteries, please ensurethat correctdisposalprocedures are
followed.Contact yourlocalauthorityfortheir recommendations.
Battery Chargers
•Rememberbattery chargersareMainsDriven Units.
•Alwaysobserve allguidelines andlaws relatingto mains-connectedinstallations and
equipment.
•Neveroperate thebatterychargerinwet ordamp conditions.
•Ifyou suspectthatthechargerhas beenexposed towater orexcessive damp,donot
useit. Returnthe unitback tothe dealer/supplierfor inspection.
•Ifthe batterychargeris suspectedof beingdefective orisvisiblydamaged,return the
unitback tothedealer forinspection.
3

RECOMMENDEDTOOLS
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. Ciclippliers.
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 & wokshop manuals.
35. Tyre levers.
4

Service&Inspection
ANNUAL
Controller Electrical
•On/offSwitch •Loom
•PCBPlugConnections •Connections
•Operation •Lights/Indicators
•DynamicBraking
•ProgrammableSettings, (whereapplicable).
•TestRun Drive
Batteries •Forwards
•Reverse
•PhysicalInspection . •EmergencyStop
•Connections •LeftTurn
•DischargeTest •RightTurn
•Up/Down Slope
Wheels & Tyres •OverObstacles
•Parking Brake
•Wear
•Pressure,(PneumaticOnly).
•Bearings,(Whereappropriate).
•WheelNuts
•Castors,(Whereappropriate).
•StubAxles
Motors
•Wiring
•Noise
•Connections
•Brake
•Brushes.
Chassis
•Condition,(Welded Jointsetc.).
•Steering, (Twistsetc.).
Upholstery / Seat
•Seat
•Back
•Arm pads
•SeatSlide Mechanism,(wherefitted).
•Set PostAssy.
5

Overall Length 48" / 122 cm
Overall Width 22" / 55 cm
Maximum user weight 300 lbs / 137 kg / 21 st
Maximum Gradient 14 degrees - 115 kg user weight
11 degrees - 137 kg user weight
Range 22 m / 36 km
Speed 6 mph / 9.5 kph
Turning Radius 55" / 140 cm
Weight (excluding batteries) 158 lbs / 72 kg
Battery Capacity 36 AH
Adjustable seat height 17" - 20" / 43 cm - 51 cm
Front wheel diameter 11" / 28 cm
Rear wheel diameter 11" / 28 cm
Range given represents test conditions. Please note that temperature,
user weight, terrain and battery capacity may affect overall performance.
TECHNICAL SPECIFICATIONS
6

EMERALD
WHEELS FRONT
1.Use aflat-bladescrewdriverto 2.carefullyprizeoff thechrome hubcap
3.Usea 13.00mmsocket wrenchto
undothe centrewheelsecuring bolt. 4.Note theuse ofthread-lock onthe
bolt.Be carefulnot tobreathinthe
powderresidue.
5.Note thesequenceofwasher,split
washerand bolt. 6.Make surethescooter isfirmly
supportedby axlestands orwooden
blocks,before removingthe wheel.
7

EMERALD
WHEELS FRONT.....
7.Carefully removethewheelassem-
bly. Notethat thereis nodrive shaft
key onthe frontwheels.
8.There are4nuts &bolts securing
thewheel bearinghub.
9. Use a 13.00mm socket to loosen
thenuts,butdonot trytoundo them
fullyyet.
10.Theboltheadsare enclosein the
hub,but willdriftupwardsasthe nuts
areloosened.
11. Useyour thumbtoapplygentle
pressure,preventingtheheadsturn-
ing.
12.The nutscan nowbe removed.
8

EMERALD
WHEELS FRONT.....
13.Remove thebolts &carefully lift
outthewheelhub. 14.Thewheel,bearinghub andbolts.
15.Viewof theenclosed ball-race
bearings. 16.Location ofthefive wheelrim studs.
Thenumbers indicatethere-tightening
sequence
1
3
4
5
17.Before undoingthefivewheelrim
studs,be sureto deflatethe tyre
throughtheair valve.
18.Use a5.00mm hexagonwrenchto
undoeach ofthe studs.Whenre-
tightening,usethesequenceshown
above.
2
9

EMERALD
WHEELS REAR
1.Useaflat-bladescrewdriver to 2.carefully prizeoffthechromehub cap.
3.Note thatthecentrenuthas an
extraspacer fitted. 4.Ontherearwheelhubthere isa
key-waycut whichcorrespondstothe
key-wayonthedriveshaft.
5.Carefully removethedrivekey. 6.Make anote ofthenumber of
shimsused behindthe rearwheelson
eachaxle.
10

EMERALD
WHEEL, TYRE & INNER TUBE
1.Remove thevalvedustcap. 2.Usea smallscrewdriver or similar,
todepressthevalvepin andlet outas
much air as possible.
3.Use a5.0mmHex Key, toundothe
fiverim studs. 4.Press downon thetyre withthe ball
ofthe handsand usea tyreleverto
gentlylift therimaway fromthetyre.
5.Lift therim awayfrom thetyre. 6. Viewof thewheelwith thefirst rim
removed.
11

EMERALD
WHEEL, TYRE & INNER TUBE
7.It isnowpossibletocarefullyre-
moveand replacethe innertube. 8. Ifthe innerrimis tobe removed,
usea suitabletyrelever asbefore.
9.Lift therim awayfrom thetyre. 10. Whenrefitting, besure notto pinch
theinner tubebetweentherims.
11. Tohelp avoidpinching, withthe
rimstuds halftightened,partially
inflatetheinner-tube.
12.The innertubeshouldthenseat
itselfbehind bothrims. Re-tightenthe
studsin thesequenceshownprevi-
ouslyandtheninflatethe tyreas
normal.
12

EMERALD
SEATING
1.Liftthe armrestsup foreasyac-
cess. 2.Pull theseat reclinelever upwards.
3.Allowthebackrest tofold flat. 4.Standbehind the seat& liftthe seat
swivelleverup.
5.With theseat swivellever inthe up
position,carefully liftthe seatassem-
blyoff theseat stem.
6.Loosen thetwo armrestadjustment
knobs.
13

EMERALD
SEATING.....
7.To retractthe armrest,simplypullit
out. 8.Turntheseatassy. upside downto
exposethe 4-boltssecuring theswivel
pate.
9.Usea 13.00mmsocket wrenchto
undothenuts. 10.Removethenuts&washers.
11.Liftthe swivelplate assy. away
fromthe seat. 12.This exposesthe armrestadjuster
bracket.
14

EMERALD
SEATING .....
13.Lift offthe armrestadjuster
bracket. 14.With theseat slidessetfullyfor-
ward,the tworearstuds canbe
accessed.
15.Use asturdy5.00mmhexwrench
toundo allfourstuds.Notethat these
are firmly held & some force is re-
quired.
16.The bluethread-lock isthereason
thestuds aresotight.
17.Pressthe seatslidelever downto
movethe slideto therear.The other
slidecanbe pushedback freely.
18.Oncethe slidesare pushed back,
theother twostuds areexposed.
15

EMERALD
SEATING .....
19.Use a sturdy5.00mm hexwrench
toundo these. 20.Theyarealsoheldbythread-lock.
21.Once thestuds havebeen re-
movedlift offtheseat slide. 22.Andthe samewith theotherside.
23.Finally removethe fourspacer
washers.
16

EMERALD
SEAT STEM
1.ToremovetheSeatStem.. 2.lift theRearCoveroffits velcro
mountand clearof thescooter.
3.Loosenoff theSeat Post securing
stud.There isnoneed toremove it. 4.Un-hook theSecuring Pinspring.
5.Before pullingtheSecuringPinout,
makesurethe SeatStemis heldfirm,
becauseit willdropsharplyintothe
Seat Post once the pin is out.
6. Lift the Seat Stem out of the Seat Post.
17