Workshop Manual
ELITE XS 3 & 4 WHEEL,
ONYX
ENGLISH
Scooters
ELITE XS, ONYX
WORKSHOP MANUAL
The ELITE XS range is a rear wheel drive, three or four - wheeled electric powered
scooter with pneumatic tyres, rake adjustable
tiller, upholstered seat with folding back and flip up-wid th adjust able
armrests, shopping basket, horn, battery gauges
and security key on/off switch.
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
CE
TITLE CONTENTS P AGES
Safety 1 to 2
Recommended T ools 3
Service & Inspection 4
T echnical S pecifications 5 to 7
Programme 8
Bumper, Brakes & Wheels
Front Bumper (3W). 9
Front Wheel & Brake (3W) 10 to 12
Rear Wheel Elite XS 13 to 14
Front Wheel Onyx, XL8 15
Rear Wheel Onyx, XL8 16
T yres & Tube Onyx, XL8 17 to 19
T yres & Tube Elite 20
Front Brake Elite (4W), Onyx, XL8 21 to 22
Seat, Batteries & Rear Panel
Seat Removal (All) 23
Seat Post Removal (All) 24
Seat Assembly (All) 25 to 29
Batteries & Battery Charger (All) 30 to 31
Rear Panel (All) 32
Rear Lights & Indicators 33 to 35
Rear Chassis
Brake Lever/Loom 36
Panels & Bolts 37 to 40
Transaxle 41 to 43
Suspension Struts 44
Struts/Stabilisers 45
Stabilisers/Bumper 46
Bumper/Frame 47
Main Fuse 48
Main Fuse/Fuse Panel/Programme Skt. 49
Main Control Box 50 to 51
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 .
This scooter is for the carriage of
ONE PERSON
And must not be used for any other purpose.
ELITE XS, ONYX
WORKSHOP MANUAL
TITLE CONTENTS P AGES
Tiller Fascia Panel 52
Tiller Fascia Panel & Tiller Back Panel 53 to 54
Hand Brake & Tiller Front Panel 55
Tiller Front & Top Panel 56
Tiller Horn & Reflector 57
Tiller-Indicators-Bulbs 58
Tiller Charging Socket 59
Tiller Loom 60
Tiller Adjustment & Weld Assy. 61 to 62
Tiller Bracket 63
H’lamps, Fnt Body Panel & Main Loom
Gaiter & Front Bumper 64
Headlamp & Bulb (4-Wheel) 65 to 66
Headlamp (3-Wheel) 67
Fnt. Body Panel (4-Wheel) 68
Fnt. Body Panel (3-Wheel) 69
Main Loom 70 to 72
Front Suspension & Steering
Stub Axles 73 to 75
Steering Rods 76 to 77
Front Suspension Struts 78
Swinging Arm 79
Steering Head (4-Wheel) 80 to 81
Steering Head & Forks 82 to 83
SAPPHIRE
GENER AL SAFETY
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 s u it a b le e ye protection w h e n d r illin g or inspec tin g .
•
When safe to do s o, wear p rote ctive gloves whe n h and ling the run n ing gea r
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
commen cing work.
•
Always check that the battery charger is disconnected from the vehicle /
batteries before comm encing work.
•
Do not smoke.
•
Keep batteries away from all sources of ignition.
•
Do not place objects on the battery tops.
•
Always try to k e ep so m e o n e within e ar shot 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 acce ss to soap and wa ter 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.
ELITE/ONYX
SAFETY
1
SAPPHIRE
GENERAL SAFETY
Batteries
· 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 Mains Driven Units.
· 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
ELITE/ONYX
SAFETY
RECOMMENDED TOOLS
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 S panner .
13. Combination pliers.
14. Ciclip pliers.
15. Hammer , (small & large).
16. Soft hammer,(rubber , hide or nylon).
17. Feeler gauges, (metric & imperial).
18. St anley knife.
19. Pin punches.
20. Electric drill, (mains/battery).
21. Drill bits, (metric & imperial).
22. Hacksaw , (standard & junior).
23. T oque wrench.
24. Steel engineering rule.
25. Tape measure.
26. T yre 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.
3
Service & Inspection
ANNUAL
Controller Electrical
• On/off Switch • Loom
• PCB Plug Connections • Connections
• Operation • Lights/Indicators
• Dynamic Braking
• Programmable Settings, (where applicable).
• T est Run
Drive
Batteries • Forwards
• Reverse
• Physical Inspection . • Emergency Stop
• Connections • Left Turn
• Discharge T est • Right Turn
• Up/Down Slope • Over Obstacles
• Parking Brake
Wheels & Tyres
• Wear
• Pressure, (Pneumatic Only).
• Bearings, (Where appropriate).
• Wheel Nuts
• Castors, (Where appropriate).
• Stub Axles
Motors
• Wiring
• Noise
• Connections
• Brake
• Brushes.
Chassis
• Condition, (W elded Joints etc.).
• Steering, (T wists etc.).
Upholstery / Seat
• Seat
• Back
• Arm pads
• Seat Slide Mechanism, (where fitted).
• Set Post Assy .
4
TECHNICAL SPECIFICATIONS
maximum range* 57 km
forward speed maximum 12 km/h
reverse speed maximum 5 km/h
turning circle 115 cm
incline 1:4 (25%), max. user weight 115 kg
incline 1:5 (20%), max. user weight 150 kg
total weight (excl. batteries) 82 kg
total length 138 cm
total width 67 cm
weight heaviest part 64 kg
batteries 74 AH
weight batteries each (74 AH) 26.5 kg
adjustable seat height 48 - 55 cm
backrest height 52 cm
seat depth 43 cm
seat width 51 cm
Elite XS 3-Wheel
* Range is calculated under test conditions. Weight, terrain and weather conditions can
affect range and speed.
5
maximum range* 57 km
forward speed maximum 12 km/h
reverse speed maximum 5 km/h
turning circle 162 cm
incline 1:4 (25%), max. user weight 115 kg
incline 1:5 (20%), max. user weight 150 kg
total weight (excl. batteries) 87 kg
total length 138 cm
total width 67 cm
weight heaviest part 69 kg
batteries 74 AH
weight batteries each (74 AH) 26.5 kg
adjustable seatheight 48 - 55 cm
backrest height 52 cm
seat depth 43 cm
seat width 51 cm
Elite XS 4-Wheel
* Range is calculated under test conditions. Weight, terrain and weather conditions can
affect range and speed.
TECHNICAL SPECIFICATIONS
6
TECHNICAL SPECIFICATIONS
ONYX
*Range given represents test conditions. Please note that temperature,
user weight, terrain and battery capacity may affect overall performance.
Overall Length 54" / 138 cm
Overall Width 26" / 67 cm
Max.user weight 330 lbs / 150 kg / 23.5 st
Max.Gradient (1) 14 degrees - 115 kg user weight
Max.Gradient (2) 11 degrees - 150 kg user weight
Range* 24 m / 37 km
Speed 8 mph / 12 kph
T urning Radius 63" / 162 cm
Weight (excluding batteries) 190 lbs / 87 kg
Battery Capacity 50 AH
Adjustable seat height 19" - 23" / 48 cm - 58 cm
Front wheel diameter 12" / 31 cm
Rear wheel diameter 12" / 31 cm
7
Function Fast Slow 8kph 6kph
Forward acceleration 25 25
Forward deceleration 15 15
Reverse acceleration 20 20
Reverse deceleration 20 20
Forward speed with 2K5 resistor 100 100 66 50
Reverse speed 35 35
Invert throttle polarity yes
Power down timer 0 m
Accessible only with SP1b v2.2
Current limit 1 10A 1 10A
Motor compensation 60m&! 60m&!
Hold factor/hold comp 180% 180%
Mid current 0s
mid time 0%
Brake time 15
ISO tests on **
Bridge hold time 20
Throttle gain 100
Pulse reverse alarm yes
Wig-wag throttle yes
Low battery flash inhibit yes
Soft stop yes
Throttle deadband 10%
Output voltage 25V
Trucharge cable resist ance 40m&!
Trucharge cal 100
Max charge amps 30
Min charge amps *
Accessible only with SP1e To p Bottom
Profile 1 80
PROGRAMME FOR ELITE, ONYX
Accessible with SP1
8
ELITE-ONYX
FRONT BUMPER ELITE XS (3W)
1. The front bumper is secured at
each end by two hex stud bolts.
2. The nuts are between the outer
chassis member and the edge of the
foot board.
3. Use a 10.00mm open spanner and
a 5.00mm hex key , to undo the bolts.
4. Remove all four bolts.
5. Finally , remove the bumper.
6. Note that the bumper has a smooth
curved profile on the top surface and
an angled profile underneath.
9
ELITE-ONYX
FRONT WHEEL/BRAKE ELITE XS (3W)
1. With the bumper removed it is
easier to access the front brake.
2. Use a 4.00mm hex driver to release
the brake anchor stud.
3. The Brake Anchor Stud & W ashers. 4. Turn the brake adjuster and locking
wheel to align their slots with the slot
in the bracket.
5. Pull the brake cable cap out of the
adjuster.
6. Drop the cable through the slots.
10
ELITE-ONYX
11
FRONT WHEEL/BRAKE ELITE XS (3W)
7. Free the cable & it’s spring from
the bracket.
8. Aline the cable with the slot in the
actuator lever.
9. Pull the brake cable & nipple out of
the actuator lever.
10. Use a 10.00mm cranked hex key
to loosen the front axle.
1 1. Use a 19.00mm. socket to secure
the other end of the front axle.
12. Once the axle is loosened, jack the
front wheel up until it clears the floor.
ELITE-ONYX
12
FRONT WHEEL/BRAKE ELITE XS (3W)
13. Undo the dome nut and washer
using finger pressure.
14. Turn the other side ant-clockwise
and pull the axle slowly out.
15. Be careful not to lose the two shim
washers as the axle retreats through
the wheel.
16. Remove the large spacer as the
axle withdraws from the wheel and
fork.
17. With the axle removed, lift the
front wheel clear of the forks.
18. Lift the brake assembly out from
the centre of the wheel.
ELITE-ONYX
REAR WHEELS ELITE XS
1. Use a small flat-blade screw driver
to get under the hub cap tag.
2. Carefully prize the hub cap off.
3. Use a 19.00mm socket to loosen
the hub nut.
4. Use a jack or blocks to lift the rear
wheel. Note that the jack should only
be placed under the chassis box
sections, not the flat panels.
5. Use the socket with hand pressure,
to undo the hub nut fully .
6. Remove the hub nut.
13
ELITE-ONYX
REAR WHEELS ELITE XS
7. Remove the large washer.
8. Because the rear wheel is keyed to
the drive shaft, a small ammount of
force may be carefully applied to
loosen the wheel.
9. Remove the wheel. 10. Remove the drive key .
1 1. Remove the spacer . Note that
there is a rebate cut into the end of the
inside face of the spacer .
12. The locating circlip that the spacer
rebate encloses. This circlip correctly
positions the rear wheel on the drive
shaft.
14
ELITE-ONYX
15
FRONT WHEELS ONYX
1. View of the front wheel.
2. With the wheel on the ground, use
a 19.00mm socket to loosen the
centre self-locking nut
3. Once the centre nut is loosened,
raise the wheel using a jack or axle
stands/blocks.
4. Remove the centre nut using finger
pressure only .
5. Remove the washer.
6. Carefully remove the wheel.
ELITE-ONYX
16
REAR WHEELS ONYX
1. Using a 19.00mm socket, loosen
the rear wheel while it is still on the
ground.
2. Use a jack or axle stands/blocks, to
elevate the wheel.
3. Use finger pressure to remove the
centre nut.
4. Remove the nut and washer.
5. Note that there is a key way cut in
the centre of the rear wheel.
6. Remove the corresponding key
from the drive shaft.
ELITE-ONYX
17
TYRES & TUBES ONYX
1. Remove the dust cap from the tyre
valve.
2. Depress the valve pin. T o release
as much of the air as possible,
squeeze the tyre.
3. Using a soft face hammer , carefully
tap around the circumference of the
back of the tyre.
4. Then tap around the front. This
action helps to break the seal on the
rims to aid removal.
5. The front face of the wheel has
4-dome nuts securing the hub.
6. The rear face of the wheel has 4 corresponding captured studs.
ELITE-ONYX
18
TYRES & TUBES ONYX
7. With the air out, loosen the four hub
nuts using the opposites sequence,
but don’t take them off.
8. Once the hub nuts are loosened,
use the socket shaft and finger pressure to fully remove them.
9. Remove the hub nuts.
10. Remove the washers.
1 1. Turn the wheel over . 12. Lift the hub away from the rims.
ELITE-ONYX
19
TYRES & TUBES ONYX
13. Lift the inner rim away from the
tyre. A non-corrosive release agent
will help.
14. Turn the wheel over and repeat for
the outer rim. Note; Be careful if using
metal tyre levers as excessive force
on the rim edge may cause fracture.
15. With the rims removed, reach into
the tyre and gently pull the tube out.
16. The Hub, Hub Nuts, W ashers and
Centre Wheel nut.
17. The Outer & Inner Rims.
18. The Tyre & T ube.
ELITE-ONYX
TYRES & TUBES ELITE XS
1. The five rim studs are accessed
from the back of the wheel.
The Elite XS has different types of wheel rims to the Onyx. The outer rim has
an integrated hub, but the basic process is the same.
2. Remove the valve dust cap and deflate the tyre as previously described.
3. Squeeze as much of the air out of
the tyre as is possible. At this st age,
use a non-corrosive releasing agent
between the tyre & rim.
4. Remove the five recessed rim
studs using a 4.00 mm hex key/driver.
5. Remove the inner rim from the tyre.
6. Lift the outer rim from the tyre & proceed as before to remove the tube. Note
that the outer rim has an integrated hub.
20
ELITE-ONYX
21
FRONT BRAKE ELITE XS(4) & ONYX
1. With the wheel removed the front
brake can be accessed.
2. Locate the brake actuator lever.
3. Push the brake actuator lever, so
that it releases the tension on the
cable.
4. Push the Nipple on the end of the brake
cable, out of the actuator lever.
5. Carefully turn the brake adjuster
until the slots line up with the slot in
the bracket.
6. Release the end of the brake cable.
ELITE-ONYX
22
FRONT BRAKE ELITE XS(4) & ONYX
7. The brake assembly is secured by
two bolts either side. The nuts are
visible from the front.
8. The bolt heads are accessed from
behind the brake assembly .
9. Use a 13.00mm open spanner on
the nuts.
10. Use a 13.00mm ring spanner on
the bolt heads.
1 1. Access is easier if the fingers are
used when the nuts are loose enough
to remove. Repeat for the other side.
12. Finally , remove the brake assembly
from the stub axle.
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