Technical Specification - Mobility Scooters Plus
Contents
1. STERLING EMERALD 4 WHEEL Scooters Workshop Manual SUNRISE MEDICAL EMERALD WORKSHOP MANUAL The Emerald mobility scooter isa 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 amp 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 Safety Information Recommended Tools Service Inspection Technical Specifications Front Wheels Rear Wheels Tyres amp Tubes Seating Seat Stem Batteries amp Charger Separating the Scooter Rear Drive Assy Ties amp Plugs Rear Lights Main Control Box Drive Train Assy Motor amp Brake Assy Rear Chassis Assy Tiller Assy Front Body Panel Assy Front Body Panel Lights Front Body Panel Bumper Main Frame Assy Steering Rods Steering Head Stub Axles Front Suspension Assembly Reference Photographs IMPORTANT Itis 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 ONE2. 3 The nut spring washer and large 4 The Front Bumper Assy washer 5 Overview of the Tiller Parts 6 Overview of the Front Body Panel parts EMERALD MAIN FRAME ASSY 1 Cut any remaining tie wraps still 2 Feed the soll vem the holei in securing the Main Loom to the the front chassis member chassis 3 Retract the plug through the hole at 4 The two front Suspension Struts the back of the front chassis member and the two nuts securing the Steering and remove the Main Loom Cover 5 Use a 10 00 socketto undothe 6 Lift the Steering Cover away from two nuts the chassis EMERALD STEERING RODS 1 Connection of the Steering Rodsto 2 Use a 13 00mm socket to un the Steering Head Note thatthereis locking nut adjustment at the ends of each Steer ing Rod 4 Remember to make a note of the ing Head and lift the spacer off spacer positions to aid refitting 5 The connection with the left hand 6 Use a 13 00mm spanner socket to Stub Axle undo the bolt and self locking nut EMERALD 10 Use a 13 00mm spanner socket to undo the bolt and self locking nut on the other Stub Axle 11 Drop the rods away from the Stub 12 Lift the small spacer off the bolt Axle EMERALD 16 The Steering Rod Set showing the positions of the nuts spacers and bolts EMERALD STEERING HEAD 1 Usea 30 00mm spannertoloosen 2 Once loosened use the fingers to the Steering Head Retaining Nut undo
3. 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 RECOMMENDED TOOLS Metric socket set Imperial socket set Hexagon wrenches imperial amp metric 3 5 8mm flat screwdriver No 0 cross head screwdriver No 1 cross head screwdriver No 2 cross head screwdriver Metric combination spanner set 5 25mm Imperial combination spanner set 1 8 1 Mole grips Long nose pliers Adjustable Spanner Combination pliers Ciclip pliers Hammer small amp large Soft hammer rubber hide or nylon Feeler gauges metric amp imperial Stanley knife Pin punches Electric drill mains battery Drill bits metric amp imperial Hacksaw standard amp junior Toque wrench Steel engineering rule Tape measure Tyre pump Tyre pressure gauge Personal safety gear Wire strippers cutters Tag crimper Multi meter Battery tester Hand held electronic programmers Parts manuals amp wokshop ma
4. completely 3 Note that there is a shoulder at the 4 The larger Bearing Retaining Nut should top of the nut undo using hand pressure but mole grips can be used if this is tight i 5 Use a pair of thin nosed pliers to 6 As the Steering Head is lowered remove the top bearings the bottom bearings can be seen Note also the position of the Steering Stop Bolt EMERALD STUB AXLES 1 Use a 15 00mm spanner and a sturdy 15 00mm socket to undo the Stub Axle nut and square headed bolt 4 Lift the Stub Axle away from its mount Note that there is an adjustable steering stop bolt attached to the Stub 5 Remove the two spacers Repeat the process for the other Stub Axle EMERALD FRONT SUSPENSION 1 Use a 13 00mm socket to undo the 2 Remove the Hexagon Flange top bolt Note that there is no nut with head bolt this bolt as the bolt locates into a threaded hole 3 Use two 13 00mm spanners to undo the bottom fixing 5 and bolt 6 Remove the Suspension Strut Do the same for the other side EMERALD ASSEMBLY REFERENCE PHOTO s MAIN FRAME ASSEMBLY EMERALD ASSEMBLY REFERENCE PHOTO s MAIN BODY ASSEMBLY EMERALD ASSEMBLY REFERENCE PHOTO s TILLER ASSEMBLY EMERALD ASSEMBLY REFERENCE PHOTO s REAR DRIVE ASSEMBLY Please use this Wokshop Manual in conjunction with the Emmerald Owners Manual amp Parts Manual
5. prevents the Pot body turning against the securing nut EMERALD TILLER ASSY 19 Press outthe two plastic pop rivets to remove the Bar Graph PCB 21 Use a 22 00mm spanner to loosen the Key Switch retaining nut 23 Withdraw the Key Switch idy 20 The two wires on ihe back of the Key Switch have to be de soldered for removal and soldered back on Jis 22 Once loosened it is easier to use the fingers to undo the nut and remove the plastic spacer 24 Use a small X head screwdriver for the outer screws on the Charger Socket EMERALD TILLER ASSY 25 Use a pair of long or snipe nosed 26 Withdraw the Charger Socket pliers to hold the small self locking assy from the Tiller Panel nuts at the back of the Charger Socket 27 The two Tiller securing bolts are 28 Usea 10 00mm socket amp spanner located just above the Tiller Adjust to undo the two bolts ment Mechanism W SE m3 4 AE 29 The two bolts can be withdrawn 30 Lift the Tiller Shaft off the Tiller easier if the Tiller Shaft is gently Adjustment Mechanism rocked back and forth whilst pulling the bolts out EMERALD FRONT BODY PANEL 1 Peel up one corner of the carpetto 2 Lift the carpet mat off its velcro get a good grip pads 3 This exposes the six body panel screws 6 Lift up the rubber Tiller Gaiter to expose the two lower fixing bolts EMERALD FRONT BODY PANEL 1 Use a 10 00mm socket am
6. screwdriver to 2 carefully prize off the chrome hubcap 3 Use a 13 00mm socket wrench to 4 Note the use of thread lock on the undo the centre wheel securing bolt bolt Be careful not to breath in the powder residue 5 Note the sequence of washer split 6 Make sure the scooter is firmly washer and bolt supported by axle stands or wooden blocks before removing the wheel EMERALD WHEELS FRONT 7 Carefully remove the wheel assem bly Note that there is no drive shaft key onthe front wheels Var 9 Use a 13 00mm socket to loosen the nuts but do not try to undo them fully yet 11 Use your thumb to apply gentle pressure preventing the heads turn ing 8 Th the wheel bearing hub 10 The bolt heads are enclose in the hub but will drift upwards as the nuts are loosened 1 Us 1E B k E i 7 1 31 1 i 7 b kaggi i 1 12 The nuts now be removed EMERALD WHEELS FRONT 13 Remove the bolts amp carefully lift out the wheel hub 15 View of the enclosed ball race bearings 17 Before undoing the five wheel rim studs be sure to deflate the tyre through the air valve 16 Location of t The numbers indicate the re tightening sequence D PX id 18 Use a 5 00mm hexagon wrench to undo each of the studs When re tightening use the sequence shown above EMERALD WHEELS REAR 1 Use a flat blade screwdriver to 3 Note t
7. 6 Loosen the two armrest adjustment position carefully liftthe seat assem knobs bly off the seat stem EMERALD SEATING 7 To retract the armrest simply pull it out 9 Use a 13 00mm socket wrench to undo the nuts 11 Lift the swivel plate assy away from the seat 8 Turn the seat assy up side down to expose the 4 bolts securing the swivel 10 Remove the nuts amp washers 12 This exposes the armrest adjuster bracket EMERALD SEATING 14 With the seat slides set fully for ward the two rear studs can be accessed 15 Use a sturdy 5 00mm hex wrench 16 The blue thread lock is the reason to undo all four studs Note thatthese the studs are so tight are firmly held amp some force is re 17 Press the seat slide lever downto 18 the slides are pushed back move the slide to the rear The other the other two studs are exposed slide can be pushed back freely EMERALD SEATING to undo these N aN i 21 Once the studs have been re moved lift off the seat slide 23 Finally remove the four spacer washers EMERALD SEAT STEM 2 liftthe Rear Cover off its velcro mount and clear of the scooter Loosen off the Seat Post securing 4 Un hook the Securing Pin spring stud There is no need to remove it 5 Before pulling the Securing Pin out 6 Lift the Seat Stem out of the Seat Post make sure the Seat Stem is held firm because it will drop
8. PERSON And must not be used for any other purpose 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 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 com mencing work Always check that the battery charger is disconnected from the vehicle batteries be fore 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 protec tion and gloves Make sure there is easy
9. Rear Suspension Struts 8 Withdraw the bolt but be aware that if the strut on the other side has been removed the frame top section will drop on its hinges 12 The Rear Frame Assy EMERALD TILLER ASSY E 1 1 Undo the single screw on the inside 2 The Orange Main Loom Plug is cover of the Tiller and lift the cover exposed away 4 Undo the two screws that secure the Basket Bracket to the front of the Tiller 6 Undo screws at the top of the Tiller next to the handle bar on the left EMERALD TILLER ASSY m j 8 Unclip the 3 way molex plug located behind the Tiller Panel 11 Undo the small brass screws that 12 Liftthe Tiller Panel away from the secure the Throttle PCB to the handle handle bar assy bar assy EMERALD TILLER ASSY 13 Undo the two small brass screws 14 Remove the WigWag assy from securing the WigWag assy the handle bar 16 Use an 11 00mm spanner to either min or max then remove the partially loosen the securing nut Be pointer knob by pulling it upwards careful not to tear the min max decal When refitting align the pointer tothe below When refitting do not over chosen min or max position tighten 17 To avoid damage to the min 18 Withdraw the Pot Note that there max decal use the fingers to remove is alow tack glue used on the Pot the loosened nut face Itis advisable to use a low tack compound or a star washer when refitting This
10. 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 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 com mencing 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 recom mended 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
11. ear tail amp indicator tail lamp if required lights are sealed If a bulb blows the complete assembly has to be changed EMERALD MAIN CONTROL BOX 1 Release all the tie wraps holding the looms emanating from the Main Control Box 4 Aview of the Main Control Box the Main Control Box upwards until it Mounting Bracket slides off it s guide 5 A view of the V shape 6 The Main Control Box amp Loom Box Receiver Bracket Note that there are no serviceable parts in the Main Controller If a fault is suspected please return it to Sunrise Medical for repair replace ment EMERALD DRIVE TRAIN ASSY 1 There are four bolts securing the 2 Use a 13 00m Drive Train Assembly securing nuts 3 On the long drive shaft side use a screwdriver to undo the bolts 2 0 5 Remove the two bolts 6 Carefully remove the rubber gasket EMERALD DRIVE TRAIN ASSY 8 Usea 13 00mm s plete with the rubber gaiter nuts on the U bolt side of the drive 11 Carefully lift out the U bracket by moving the Drive Train until the bolts sleeve that is positioned at the inside are clear of the frame top of the U bolt a a Sa uh MEO ue 1 EMERALD DRIVE TRAIN ASSY 1 Pus 13 Retract the Drive Train Assy 14 The left hand Drive Train fixings caution as this part is heavy 15 The right hand Drive Train fixings 16 The complete Drive Train Assy amp fi
12. hat the centre nut has an extra spacer fitted 5 Carefully remove the drive key 2 carefully prize off the chrome hub cap E 1 4 Onthe rear wheel hub there is a key way cut which corresponds to the key way on the drive shaft 6 Make a note of the number of shims used behind the rear wheels on each axle EMERALD WHEEL TYRE amp INNER TUBE a wo e 1 Remove the valv 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 4 Press down on the tyre with the ball five rim studs of the hands and use a tyre lever to gently lift the rim away from the tyre gt 5 Liftthe rim away from the tyre 6 View of the wheel with the first rim removed EMERALD WHEEL TYRE amp INNER TUBE 7 Itis now possible to carefully re 8 If the inner rim is to be removed move and replace the inner tube use a suitable tyre lever as before 10 When be sure not to pinch the inner tube between the rims 11 To help avoid pinching with the 12 The inner tube should then seat rim studs half tightened partially itself behind both rims Re tighten the inflate the inner tube studs in the sequence shown previ ously and then inflate the tyre as normal EMERALD SEATING 1 Lift the armrests up for easy ac cess 4 Stand behind the seat amp lift the seat swivel lever up 5 With the seat swivelleverinthe up
13. nuals Tyre levers Service amp Inspection ANNUAL Controller On off Switch PCB Plug Connections Operation Dynamic Braking Programmable Settings where applicable Test Run Batteries Physical Inspection Connections Discharge Test Up Down Slope Wheels amp Tyres Wear Pressure Pneumatic Only Bearings Where appropriate Wheel Nuts Castors Where appropriate Stub Axles Motors Wiring Noise Connections Brake Brushes Chassis e Condition Welded Joints etc e Steering Twists etc Upholstery Seat Seat Back Arm pads Seat Slide Mechanism where fitted Set Post Assy Electrical Loom Connections Lights Indicators Drive Forwards Reverse Emergency Stop Left Turn Right Turn Over Obstacles Parking Brake TECHNICAL SPECIFICATIONS Overall Length 48 122 cm Overall Width 22 55 cm Maximum user weight 300 Ibs 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 Ibs 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 EMERALD WHEELS FRONT 1 Use a flat blade
14. p spanner 2 With to undo the two bolts bolts a 3 Lift up the body panel to expose the 4 Mark the loom plug and socket front light connections Temporarily rest sides to aid refitting the panel on the Tiller Adjuster to gain access to the plugs i 5 Mark the other side also and 6 Lift the Front Panel clear of the disconnect the two plugs chassis EMERALD FRONT BODY PANEL amp LIGHTS 1 Liftthe Tiller Adjustment Mechanism 2 Pull the Rubber Gaiter off the Main off the Steering Head Loom 3 The Front Light Cluster is held in 4 Note the position of the springs before place by mounting springs and undoing the self tapping screw screws 5 Remove the screw and the spring 6 Do the same for the other screw EMERALD FRONT BODY PANEL amp LIGHTS 7 Withdraw the Front Light Cluster from the front of the panel 9 The Headlamp and Indicator sock 10 Pull the plastic bulb mounts out of ets are accessible from the back of the cluster body to access the bulbs the cluster 11 To release the bulb gently pullon 12 Make sure that the copper termi the glass envelope care asthe nals do not touch as this will cause a bulb is cap less and the glass and short circuit After changing bulbs break always try the lights prior to returning to the customer EMERALD FRONT BODY PANEL amp BUMPER 2 Use a 10 00mm socket to undo the nut When refitting do not over tighten n
15. sharply into the Seat Post once the pin is out EMERALD BATTERIES amp CHARGER 3 Undo the two velcro straps that secure the batteries Carefully lift the batteries out 6 Batteries Battery Leads amp Battery Charger EMERALD SEPARATING THE SCOOTER 1 Unplug the Main Loomatthe Motor 2 Grab the Securing Pin by the loop at end of the scooter the top 4 Pull the front amp rear sections of the scooter in opposite directions 5 The two sperate sections of the scooter EMERALD REAR DRIVE ASSY TIES amp PLUGS 1 Undo the two screws securing the 2 Release the loom tie holding the plastic cover to the rear frame amp lift main loom the cover off 3 Cut the tie wrap holding the Red amp 4 Release th rol the Black wires to the rear frame ler Loom 6 Disconnect the white Motor Plug tors on the Power Breaker Remember to press the hook lock down to release the plug halves EMERALD REAR LIGHTS 3 There are two White plugs mating to one Green socket and one White socket On the other side there is the same but it is a Yellow socket 5 Release the tie wrap which goes to the Green socket Yellow on the other side to aid reassembling Do this before disconnecting them 6 Carefully sque lugs together using a pair of long nosed pliers EMERALD REAR LIGHTS 7 Pull the bracket Fo de 7 UNE 9 Mark the position of the indicator or 10 Note that the r
16. xings EMERALD MOTOR ELECTRONIC BRAKE ASSY 1 A6 00mm hex wrench is the basic 2 Some of the studs may require tool required for undoing the four extra force That may require a Motor Studs cranked hex key or tool h 3 Limited room may alsorequirethe 4 Itis a good idea to mark the top of use of a hex key driver tool If the the Motor and Transaxle for refitting Drive Train has to be removed do purposes that first and then take the Motor off 5 Carefully withdraw the Motor from 6 The Motor Electronic Brake Assy the Transaxle EMERALD MOTOR ELECTRONIC BRAKE ASSY 7 When refitting the Motor be sure to line up the Motor drive coupling with the drive coupling in the Transaxle E TEE 7 A Fd 9 To inspect the Brushes undo the housing cap using a flat blade screw driver 11 Inspect the Carbon for cracks or excessive wear down Check the Copper terminal and wire for broken connections or green discolouration If any of the above are found replace the Motor Brushes as a set EMERALD REAR CHASSIS ASSY 3 Check that there are no broken terminals or cracks in the Power breaker body wn 6 The top of one of the struts Note that there are no nuts just a bolt into a threaded housing 5 The Rear Suspension Struts EMERALD REAR CHASSIS ASSY 7 Use a 13 00mm socket to undo the top bolt 9 Use the 13 00mm socket to undo the bottom bolt 11 One of the two
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