Sunrise Medical EMERALD, EMERALD 4-WHEEL Workshop 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 adjust able armrest s,
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 Train Assy . 24- 26
Motor & Brake Assy. 27- 28
Rear Chassis Assy. 29- 30
Tiller Assy . 31- 35
Front Body Panel Assy. 36- 37
Front Body Panel- Lights 38- 39
Front Body Panel- Bumper 40
Main Frame Assy . 41
Steering Rods 42- 44
Steering Head 45
Stub Axles 46
Front Suspension 47
Assembly Reference Photographs 48- 51
1
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 vehicle is for the carriage of
ONE PERSON
And must not be used for any other purpose.
1a
EMERALD
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 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 p air 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.
2
EMERALD
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.
3
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. Sof t 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.
4
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
Wheels & Tyres • Over Obstacles
• Parking Brake
• Wear
• Pressure, (Pneumatic Only).
• Bearings, (Where appropriate).
• Wheel Nuts
• Castors, (Where appropriate).
• Stub Axles
Motors
• Wiring
• Noise
• Connections
• Brake
• Brushes.
Chassis
• Condition, (Welded Joints etc.).
• Steering, (T wists etc.).
Upholstery / Seat
• Seat
• Back
• Arm pads
• Seat Slide Mechanism, (where fitted).
• Set Post Assy.
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 a flat-blade screwdriver to 2. carefully prize off the chrome hubcap
3. Use a 13.00mm socket wrench to
undo the centre wheel securing bolt.
4. Note the use of thread-lock on the
bolt. Be careful not to breath in the
powder residue.
5. Note the sequence of washer, split
washer and bolt.
6. Make sure the scooter is firmly
supported by axle stands or wooden
blocks, before removing the wheel.
7
EMERALD
WHEELS FRONT.....
7. Carefully remove the wheel assembly . Note that there is no drive shaft
key on the front wheels.
8. There are 4 nuts & bolts securing
the wheel bearing hub.
9. Use a 13.00mm socket to loosen
the nuts, but do not try to undo them
fully yet.
10. The bolt heads are enclose in the
hub, but will drift upwards as the nuts
are loosened.
1 1. Use your thumb to apply gentle
pressure, preventing the heads turning.
12. The nuts can now be removed.
8
EMERALD
WHEELS FRONT.....
13. Remove the bolts & carefully lift
out the wheel hub.
14. The wheel, bearing hub and bolts.
15. View of the enclosed ball-race
bearings.
16. Location of the five wheel rim studs.
The numbers indicate the re-tightening
sequence
1
3
4
5
17. Before undoing the five wheel rim
studs, be sure to deflate the tyre
through the air valve.
18. Use a 5.00mm hexagon wrench to
undo each of the studs. When retightening, use the sequence shown
above.
2
9
EMERALD
WHEELS REAR
1. Use a flat-blade screwdriver to 2. carefully prize off the chrome hub cap.
3. Note that the centre nut has an
extra spacer fitted.
4. On the rear wheel hub there is a
key-way cut which corresponds to the
key-way on the drive shaft.
5. Carefully remove the drive key .
6. Make a note of the number of
shims used behind the rear wheels on
each axle.
10
EMERALD
WHEEL, TYRE & INNER TUBE
1. Remove the valve dust cap.
2. Use a small screwdriver or similar,
to depress the valve pin and let out as
much air as possible.
3. Use a 5.0mm Hex Key , to undo the
five rim studs.
4. Press down on the tyre with the ball
of the hands and use a tyre lever to
gently lift the rim away from the tyre.
5. Lift the rim away from the tyre.
6. View of the wheel with the first rim
removed.
11
EMERALD
WHEEL, TYRE & INNER TUBE
7. It is now possible to carefully remove and replace the inner tube.
8. If the inner rim is to be removed,
use a suitable tyre lever as before.
9. Lift the rim away from the tyre. 10. When refitting, be sure not to pinch
the inner tube between the rims.
1 1. T o help avoid pinching, with the
rim studs half tightened, partially
inflate the inner-tube.
12. The inner tube should then seat
itself behind both rims. Re-tighten the
studs in the sequence shown previously and then inflate the tyre as
normal.
12
EMERALD
SEATING
1. Lift the armrests up for easy access.
2. Pull the seat recline lever upwards.
3. Allow the backrest to fold flat.
4. Stand behind the seat & lif t the seat
swivel lever up.
5. With the seat swivel lever in the up
position, carefully lift the seat assembly off the seat stem.
6. Loosen the two armrest adjustment
knobs.
13
EMERALD
SEATING.....
7. T o retract the armrest, simply pull it
out.
8. Turn the seat assy . up side down to
expose the 4-bolts securing the swivel
pate.
9. Use a 13.00mm socket wrench to
undo the nuts.
10. Remove the nuts & washers.
1 1. Lift the swivel plate assy . away
from the seat.
12. This exposes the armrest adjuster
bracket.
14
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