-- Revision 2, 14/12/2011 –
Contents
1. 20 needed 14 The LCD does not keep the LCD battery end of life Replace the LCD Battery time after 3 5 years of use 15 No power or main fuse pop out Over load Try to reset 2 times Mechanical fault Troubleshoot the fault Fault controller Replace the controller Faulty power unit Replace the power unit Short circuit occur Find and repair short circuit 12 3 Controller Drive Troubleshoots The controller is the center of all driving functions of the Breeze S Speed control acceleration deceleration EMB Electro Magnetic Brake used as parking brake Reverse drive Speed limiting etc But still the functions of the controller are all connected to all the wiring connectors and as well the Front board power units and batteries Elimination troubleshoots The controller wiring connections are all quick connectors If you suspect the controller to be faulted we recommend as a quickest and way to find if the controller is faulty Doing it by elimination Just replace temporarily the controller with another working one and thus make sure if the problem is within the controller or somewhere else Check all connection of the controller following the wiring diagram that can be found within this maintenance manual 12 4 Controller Fault codes using the LCD Count the number of flashes in the battery indicator of the LCD and see the code in the follows Table Each cycle there is a short stop2. Remark The Adjust should fit the comfort of the user Front Electronics Board Setup There are 2 horns in the Breeze S One is main Buzzer external located at the front of the tiller Second is Internal Buzzer located on the front board Each one of the Horns can be setup to work in one of the follows options Controller alarms Tiller push button Reverse alarm Blinkers alarms The front board include setup options for the Horn This can be done with the dipswitch DSW1 that is on the front board Dip Switches Setup is as follows Shown the Default Set Up DSW NO Cont Alarm Tiller Main Buzzer Reverse Blink Cont Alarm On Board Tiller Buzzer Reverse Blink 2 5 4 5 7 m jJ u u m mm 7 LCD Display Set Up and User Manual a LCD Display Main Light Signal Direction Digital MM Da 1 ff 7 Speed Units information COGO CREDO milekm Distance Units ANC LLL Time Units A E 1 2 Warning Battery Capacity Half Speed Push buttons b Right Mode Use to change between different display modes and to Reset the Distance and Time Every push changes the display mode cyclic Speed Trip Distance Trip Time Clock Return automatically to initial Speed after 5 seconds Long Push more than 7 seconds when change Modes Trip Time Reset Trip time Trip Distance Reset Trip Distance Time Enter to C
3. Revision 2 14 12 2011 I RD Breeze S 2 Maintenance Manual Breeze S Maintenance Manual version 14 12 2011 docx BREEZE S The Senior Class Lifestyler Maintenance Manual AFIKIM ELECTRIC VEHICLES Contents N X ue 11 12 12 1 12 2 12 3 12 4 12 5 12 6 13 14 Safety instructions Specific Tools for technicians Specific Parts Options Accessories assembling drawing instructions Mechanical Adjustments Front Electronics Board Setup LCD Display Set Up and User Manual Controller Programming Setup Controller Parameters List Periodic maintenance Check Mechanical Fault troubleshooting Control and Electronics system fault troubleshooting General control system and Front Board Troubleshoots Trouble Shoot Table Controller Drive Troubleshoots Controller Fault codes using the LCD Controller Trip codes using programmer SP1 amp actions to repair Possible Faults symptoms and repair actions Mechanical assembly drawings Electrical diagrams General Wiring diagram c fF FR 11 12 15 18 20 20 20 21 21 22 22 24 32 32 1 Safety instructions 1 1 General 1 1 1 1 1 2 1 1 3 1 1 4 1 1 5 1 1 6 1 1 7 Technicians who are servicing the scooter should be authorized to service the scooter Technicians who are servicing the scooter should be aware and follow all safety instructions within the User Manual Technician
4. 0 15 m a 7 Es 50 2 Forward Decel n fast 0 15 14 12 16 10 15 14 2 Forward Decel n slow 0 1s 15 15 18 15 15 20 3 Reverse Accel n fast 0 1s 40 40 40 40 40 25 3 Reverse Accel n slow 0 1s 40 40 40 40 40 60 4 Reverse Decel n fast 0 1s 20 20 25 25 25 20 4 Reverse Decel n slow 0 1s 25 25 25 25 25 20 5 Max Fwd Speed fast 96 100 100 100 100 100 100 5 Max Fwd Speed slow 96 60 60 50 60 60 100 6 Min Fwd Speed fast 50 50 50 50 50 30 6 Min Fwd Speed slow 96 30 30 30 30 30 30 7 Max Rev Speed fast 50 50 30 50 50 40 7 Max Rev Speed slow 96 35 35 20 35 35 30 8 Min Rev Speed fast 96 30 30 10 30 30 30 8 Min Rev Speed slow 96 30 30 10 30 30 30 inv 9 Invert Throttle throttle No No No No No No 10 Sleep Timer time m 0 0 0 0 0 0 11 Read System Log 12 Read Timer elapsed h 13 Engineer Menu 14 Current Limit min A 130 130 130 130 130 130 15 Current Limit max A 130 130 130 130 130 130 16 Output Voltage output V 24 24 24 24 24 24 17 Drive Boost current A 140 140 140 140 140 140 18 Drive Boost time S 10 10 10 10 10 10 19 Drive Foldb k 1 threshold A 130 130 130 130 130 130 20 Drive Foldb k 1 time S 20 20 20 20 20 20 21 Drive Foldb k 2 level 96 100 100 100 100 100 100 22 Drive Foldb k 2 temp 80 80 80 80 80 80 23 Motor Cooling time S 120 120 120 120 120 120 motor 24 Compansation cmp 55 50 45 20 20 20 25 3 124
5. 116 122 200 115 140 26 4 4 300 300 300 300 300 300 27 Bridge Hold bridge hld cs 300 300 300 300 300 300 28 Soft Stop soft stop On On On On On On 29 Freewheel threshold 100 100 100 100 100 100 30 Freewheel timeout cs 20 20 20 20 20 20 31 Throttle Gain gain 300 300 300 300 300 300 32 Throttle D band deadband 96 3 3 3 3 3 3 33 ISO Tests ISO tests Off Off Off Off Off Off 34 Throttle Type thrtl type 0 0 0 0 0 0 35 Displaced Mode Dspl 1 1 1 1 1 1 12 mode 36 Check Refs check refs On On On On On On ot 37 Speed Limit Pot brake 38 Brake Time time ms 750 850 750 500 500 1000 brake 39 Brake Check check On On On On On On brake 40 Brake Alarm alarm On On On On On On brake 41 Brake Light light Off Off Off Off Off Off 42 Status Output type 0 0 0 0 0 0 43 Diagnostic Flash flesh 2 2 2 2 2 2 diag 44 Diagnostic Alarm alarm On On On On On On 45 Inhibit 1 Mode Mode 1 1 1 1 1 1 46 Inhibit 1 Speed speed 0 0 0 0 0 0 Non Non Non Non Non Non 47 Inhibit 1 Latch latched Latching Latching Latching Latching Latching Latching 48 Inhibit 2 Mode Mode 1 1 1 1 1 1 49 Inhibit 2 Speed speed 0 0 0 0 0 0 50 Inhibit 2 Latch latched Latching Latching Latching Latching Latching Lat
6. LIGHTS mr 25 T GREEN JR9 RSS Left LLED BUZZER RIT Front lights harness 6x0 5mm2 Breeze S w AFIKIM ELECTRIC VEHICLES Kibbutz Afikim 15148 Tel 972 4 6754814 Fax 972 4 6751456 E mail mainbox afiscooters com www afiscooters com 33
7. of few seconds 1 Flashes The battery needs charging or there is a bad connection to the battery Check the connections to the battery If the connections are good try charging the battery 2 Flashes There is a bad connection to the motor Check all connections between the motor and the controller 3 Flashes The motor has a short circuit to a battery connection Contact your service agent 4 Flashes The freewheel switch is activated or the manual brake cisengagement mechanism is operated Check the position of the switch or lever 5 Flashes used 6 Flashes The S drive is being inhibited from driving Inhibit 2 is active This may be because the battery charger is connected or the seat is not in the driving position 7 Flashes throttle fault is indicated Make sure that the throttle is in the rest position before switching on the scooter 8 Flashes controller is indicated Make sure that all connections are secure 9 Flashes The parking brakes have a bad connection Check the parking brake and motor connections Make sure the controller connections are secure 10Flashes An excessive voltage has been applied to the controller This is usually caused by a poor battery connection Check the battery connections 21 12 5 Controller Trip codes using programmer SP1 amp actions to repair When the fault exists connect the SP1 programmer s connector directly to the controller SDRIVE140 or
8. should follow general safety instruction like using gloves safety glasses when needed The scooter weight with batteries is about 150 kg even lifting 1 wheel is about 40 kg Always use other people help or a appropriate lifting device When lifting always use your legs and not your back The battery weight is about 24 kg The power unit weight is about 25 kg The seat weight is about 15kg Never do any change in the product before consulting the manufacturer engineering Remember the products are approve as they are any chage remove the manufacturer responsibility for the safety of the product 1 2 Drive 1 2 1 Technicians who are drivinging the scooter should be aware and follow all safety instructions within the User Manual 1 3 Mechanic 1 3 1 It is possible that a technician will need to operate the scooter when he is standing on the side working on different assemblies 1 3 2 When no electric power and operation needed always Stop the power by Switch OFF and disconnecting the battery terminals 1 3 3 Never put any part of your body under the scooter parts 1 3 4 If necessary first place a wood block under to make sure no injure will happen 1 3 5 Use standard tools Use them according to their safety instructions 1 4 Electric 1 4 1 If necessary to operate the scooter when you are not seating on it In such cases you should be aware to the parts that can move by power Power unit shafts and wheels 1 4 2
9. to the charging socket using a special wiring adaptor Trip Code Action A01 Quick switch ON OFF Switch OFF wait few seconds and ON again 0300 Check the tiller amp throttle wiring to the controller then retest 0815 Check the tiller amp throttle wiring to the controller then retest 0A00 Check the sleep mode parameter is set correctly then retest 0 07 Check the tiller amp throttle wiring to the controller then retest 0 08 Check the tiller amp throttle wiring to the controller then retest 1501 Check the solenoid brake s wiring amp connections to the controller then retest 1502 Check the solenoid brake s wiring amp connections to the controller then retest 1600 Check the batteries wiring amp connections to the controller then retest 1601 Check the batteries wiring amp connections to the controller then retest 1705 Internal faults in relay 1E08 Check the wiring amp connections to pin 4 of the programming socket then retest 1E09 Check the wiring amp connections to pin 6 of the 14 way tiller connector then retest 1 Check the wiring amp connections to 14 of the 14 way tiller connector then retest 2C00 Check the batteries wiring amp connections to the controller then retest 2F01 Check the throttle is not displaced on start up then retest 2F01 Check the tiller amp throttle wiring to the controller then retest 3100 B
10. 44 Units setup Europe or US State Speed Distance Date in Clock mode Off Europe kmh km DD MM On USA mph mile MM DD i 6 Pulses per km State curve product Off 740 pulse km Breeze S wheel diameter 430 mm On 1044 pulses km Breeze C wheel diameter 305 mm j Clock Adjust Every push on Mode change different time unit and this unit is Flashing When Flashing every push on Setup increase 1 unit Stage Display Flashing 1 HH mm mm 2 HH mm HH 3 DD MM DD or MM DD 4 DD MM MM or MM DD 5 20 6 Save of Updated Time and Date k Controller Fault Code wiHbe shewr iegether with Speed changed every 2 seconds 3 Will be shown on Batt Icon upon controller fault code l Technician state active when Mode button is pressed a Will show software version before it returns to regular work mode b LED will flash constant until the LCD board is OFF Note it needs a complete OFF not only Power signal change 10 8 Controller Programming Setup If the user cannot find a position on the half speed limit switch control that suits him the controller can be programmed to meet his needs The controller can be programmed in two ways with an SP1 Programmer or specialist PC software and interface cable The SP1 is a small hand held unit which can be plugged into your contr
11. CD Board Main Harnesses Cable Main Lights Harness Cable Main Supply Harnesses Controller SDrive 140A P amp G Motor Power Unit Also itis very much recommended hold and use P amp G SP 1 Programmer for S Drive possible to upgrade old model to modified free of charge 4 Options Accessories assembling drawing instructions See attached accessories assembling drawing Breeze S accessories1 pdf 5 Mechanical Adjustments Description Where How to Adjust 1 Seat Height Seat pin under the battery Release both secure bolt and cover level bolt Change pin Level hole as required Resecure See attached assembling bote level bolt and secure bolt drawing Breeze S 4W assembling pdf AGUS Ines 22 20 min 2 Tiller Height Tiller bottom adaptor under Release the secure nut and the rubber cover screw adjust height and resecure again the screw and See attached assembling 9 the nut drawing Breeze S 4W assembling pdf Adjustments continues 3 Rear Shock Rear Shock absorber under It is possible to replace the absorber Load the battery cover See attached assembling drawing Breeze S 4W assembling pdf whole shock absorber for persons until 120 Kg and above Also it is possible to adjust the the load rate by changing the oprint pretention 5 stages are possible 20 40 5096 80 10096 Should be fit to user weights 80 100 120 140 160 kg
12. NT TILLER BREEZE 5c 4055 HAND SHIELD BACK TILLER BREEZE 53 4 IPS4025 HAND SHIELD FRONT TILLER BREEZE 53 4 IPS4024 NAME PART NO REMARK tolerance Part name AFIKIM ELECTRIC MOBILIZERS Page 7 DATE Scale holesd linear aneular Drawing no Cat No KIBUTZ AFIKIM 15148 ISRAEL BREEZE S ASSY TEL 972 4 6754814 FAX 972 4 6751456 E mail mainbox lt 500mm 0 5mm Website www al 30 xI RD Breeze S DRAWINGS BREEZ Page 8 DATE Scale 8 2 4 10 X S ASSY PART WIRING ASSY 4w tolerance holes linear angular gt 500mm 1mm o 20 0 S 05 1 Drawing nor br s 8 6c 1 BASE SEAT BREEZE NEW MPBRO87 6b 1 SLIDERS ROODIN SET 1 SEAT BREEZE ARMREST 10 SEBROO ITEM PART NO REMARK Part name AFIKIM ELECTRIC MOBILIZERS Cat No KIBUTZ AFIKIM 15148 ISRAEL BREEZE S ASSY 31 diagram lagram Id ica Electr General Wirin 14 a 31 FRONT BOARD 1 1 5 Pot Wiper Forward Reverse open Pot High d7 Tiller Harness 18 0 5 2 Pot Wiper Pot High Audio Alarm Mode Speed ON OFF switch Inhibit 2 7 24V B Poten Low RIGHT SIDE edel dole toffee f F R COMM ON OFF switch WHITETYELLOW TATE HED BUZZERPB BU
13. Never put your hands close to a part that is moving or turning Be aware that your cloth will not be trapped into one of the moving parts 1 4 3 Batteries contain a large electric energy inside This energy can cause sparks and heat metals when short circuiting 1 4 4 When working on the battery terminals make sure no to short circuit between any 2 terminals This can cause strong spars and make the tools very hot 1 4 5 When working on the batteries use protecting gloves and safety glasses 1 4 6 Battery contains acid Never open any of the battery case If you see any liquid or Gel aside beware of it It might be Acid 3 2 Specific Tools for technicians Standard tool box wrenches socket head cap screw hexagon keys Phillips crosshead tip and or screwdrivers etc Voltmeter To measure 24VDC Air pressure gauge To measure 35 psi Batteries tester under load Density meter Valve Wrench Wooden blocks to elevate the Breeze during checks maintenance and repairs 2 blocks 20 22 centimeters height to place beneath the batteries box 2 blocks 14 16 centimeters height to place beneath the foot rest area Remark Always before operating a lifted Breeze make sure that the 2 rear wheels are free to turn so that the scooters will not move 3 Specific Parts We recommend the availability of the following set of test and repair assemblies Handlebars switches Left and Right Front Board Display L
14. Page 1 2 4 10 Oft 8 X 24 I RD Breeze S DRAWINGS BREEZ 5 ASSY PART WIRING ASSY 4w HWS4004 PAGE 2 IPS4007 PAGE2 ASS4027 PAGE 2 FRONT PLASTIC COVERS REAR SUCPENSION 19 PAGE 8 ASS4020 PAGE7 ASS4024 PAGE 6 PAGE 5 9 8 7 6 5 4 3 2 FRONT STEERING PAGE 4 1 5 55 2 3 PART NO tolerance holes d linear angular gt 500mm 1mm 0 S sites 1 DATE Scale 2 4 10 X Page 2 Of 8 Drawing no Cat No nor br s p 1 2 4w x Part name BREEZE S ASSY AFIKIM ELECTRIC MOBILIZERS KIBUTZ AFIKIM 15148 ISRAEL TEL 972 4 6754814 972 4 6751455 E mail mainbox afiscooters com Website www afiscooters com 25 xI RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w lo BATTERY 70AH 12V 9000602 FRAME WELDING BREEZE 54 54001 Im REAR LIGHT COVER ASSY ASS4025 BUMPER REAR BREEZE 53 4 IPS4001 COVER CONTROLLER BREEZE 54 MPS4007 PIN SEAT BREEZE 53 4 MPS4036 COLUMN SEAT BREEZE 53 4 PCBRO1 MPS4012 CANAL CABLES LEFT BREEZE S4 MPS4004 CANAL CABLES RIGHT BREEZE 54 MPS4005 CARPET BREEZE S4 COVER SIDE LEFT FLOOR BREEZE 54 HWS4004 IPS4010 COVER SIDE RIGHT FLOOR BREEZE 54 ABZORB ENERGY FRONT BREEZE 54 2 1 1 1 1 1 1 CONTROLLER P amp G SDRI
15. VE 140A 1 1 1 1 1 1 1 1 BUMPER FRONT BREEZE 54 tolerance holesd linear angular Page 5 DATE Scale Of 8 2 4 10 0 3 500mu tnm lt 500mm 0 5mm 54009 54019 PART NO REMARK Drawing no ape nor br s p 5 Cat No BREEZE S ASSY AFIKIM ELECTRIC MOBILIZERS KIBUTZ AFIKIM 15148 ISRAEL TEL 972 4 6754814 FAX 972 4 6751456 E mail mainbox afiscooters com Website www aliscoolers com 26 xI RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w 2 1 SHOK ABSORB FRONT RIGHT BRZ 4W ASSY 2008 SHOCK ABSORB FRONT LEFT BREEZE 4W ASSY 2008 SCREW SHAFT 8 10 35 SHAFT KING PHI BREEZE 4W 2008 BUSHING IGUS GFM 1820 32 BUSHING CHROME 10 18 102 BREEZE 4W 200 HEX SOC DIN 912 51 12 9 GALV 10 130 SC00340 STEERING GUIDE BREEZE 4W 2008 4 059 TUBE 3 00 3 50 10 90 DEG VALVE HWBROO4 TIRE 928 300 10 HW00124 RIM FOR FRONT WHEEL 3 10 BREEZE MPBROO2 KING PIN RIGHT BREEZE 4W 2008 MP4W067 TRAIL ARM RIGHT BREEZE 4W 2008 AS4W056 LINK JOINT M10 LONG NOR ASSY AS4WO69 LINK JOINT M10 SHORT NOR ASSY AS4W070 TRAIL ARM LEFT BREEZE 4W 2008 4 062 KING PIN LEFT BREEZE 4W 2008 MP4WO057 SHOK OBSORB FRONT BREEZE 4AW MP4WO54 STR SH PIS HAND BR 4W IMP4W035 THREADAD HEAD SET 7 1 1 8 26T ACBRO I NAME PART NO tolerance Page 4 DATE Scale holes d linear angular Of 8 2 4 10 X 46 spooom
16. ZZER COMM Inhibit 7 24VDC it Pot Yellow Black BLUE Status Indicator 10 1 Aux Dutput m 1 ENB Speed F R Poten Low Reverse switch IH 12 Reverse switch S Drive controller Be P82 key switch throtle throtle wiper thratle buzzer speed limit pot Forw Rev Inhibit Speed Made 5 EL 8 82 re TI RACKS 4 Inhibit 1 Tiller Right Switches Rhina controller RIGHT SIDE J COMM 2 TTL Freewheel Sle ie ELT EEA WHITE BLACK Removed wire PBS a Hazzard JR29 JR27 JR5 JR4 Thermistor In 3 Thermistar Out B E Wheel speed out 9 RS4B5 Wheel speed in 10 rrr JRI6 JRIS 140 J2 EMERG LIGHT COMM LIGHT COMM BUZZER COMM Charge max 124 LIGHT Program connector 20 BUZZERPB 2 2 1 1 BLUE BLACK S Drive LEFT SIDE 0 0 PT Buzzer Pad Tiller Left Switches 5 JR71 speed dry
17. all tires 2 Check emergency User Every week brakes 15 Check normal drive and Every Month stop 4 Check tires wear User Every Month 5 Check for missing parts User When receiving the Breeze S or after a long and damaged parts time not using it Use the figures 1 2 3 4 Check emergency User Every Month brake 7 Check secure of all Technician Once a year by technician screws and parts Batteries replacing Technician Every 2 3 years after about 300 400 full cycles of charge discharge When short travel distance and or technician check Note To Replace the batteries the Seat and Battery Cover located under the Seat must be removed Cleaning User External when needed Technician Internal Once a year 10 Check power unit Technician Check noise clearance current on surface should be 12 to 15 Amp 11 Check Emergency Technician Once a year Brake Removing the Seat and the Turn the Seat by using the lifting Lever 7 5 so that the Batteries Cover 2 Lever will point 45 Right or Left The Seat can be removed only at this position Remove the Seat 7 Hold the Seat in your two hands one hand on the backrest and a second hand at the front lower part of the seat and lift the seat up from its pivot 16 Replacing the Batteries Cover 2 Batteries Cleaning Warning The seat weight is 15 Kg 33lbs Keep lifting with your Knees legs and not loading your Back Release Batte
18. attery connected whilst scooter is switched on Turn off wait 10 seconds then retest 3B01 Check the motor wiring amp the connections to the controller then retest 3D02 Check the motor wiring amp the connections to the controller then retest 3D03 Check the motor wiring amp the connections to the controller then retest 3600 Internal un expected fault in the controller 4401 Internal controller fault 5300 Programmable parameter changed Turn the scooter off then on again then retest 7000 Push at startup 7001 Push at drive 7C00 High temperature in the controller Others wiring amp connections to the controller then retest Try replacing the 12 6 Possible Faults symptoms and repair actions Symptom Action No power to programmer Check the wiring amp connections to the batteries then retest No power to programmer Check the wiring amp connections to the programmer then retest Scooter drives slowly Check the controller is programmed correctly then retest Scooter drives slowly Check the speed limiting function is not active e g seat raised then retest Scooter drives slowly Check the solenoid brakes are not jammed then retest Status indicator does not light Check the wiring amp connections to the status indicator then retest Reverse alarm does not sound Check the wiring amp connections to the buzzer then retest Reverse alarm does not sound Check the buzzer is working correctly then retest Rever
19. ching 51 Inhibit Mode Mode 1 1 1 1 1 1 52 Inhibit 3 Speed speed 0 0 0 0 0 0 Non Non Non Non Non Non 53 Inhibit Latch latched Latching Latching Latching Latching Latching Latching 54 Clear SystemLog erase log clear 55 Clear Timer timer 56 Reverse Alarm Alarm On On On On On On 57 Pulse Rev Alarm pulsed On On On On On On 58 TruCharge Cable cable res mQ 20 20 20 20 20 20 59 TruCharge Cal calibration 100 100 100 100 100 100 60 Low Batt Flash flash level 2 2 2 2 2 2 Low bat 61 Low Batt Alarm alm Off Off Off Off Off Off 62 Back To Root PC programmer revision 9 8 1 setup 25 10 2011 Power Unit Afikim10 Afikim12 AMT10 12 15 Afikim15 Speed Settings 13 Forward Acceleration Fast Profile 0 1 Seconds 35 35 40 35 35 40 Forward Acceleration Slow Profile 0 1 Seconds 40 40 40 40 40 50 Forward Deceleration Fast Profile 0 1 Seconds 14 12 16 10 15 14 Forward Deceleration Slow Profile 0 1 Seconds 15 15 18 15 15 20 Reverse Acceleration Fast Profile 0 1 Seconds 40 40 40 40 40 25 Reverse Acceleration Slow Profile 0 1 Seconds 40 40 40 40 40 60 Reverse Deceleration Fast Profile 0 1 Seconds 20 20 25 25 25 20 Reverse Deceleration Slow Profile 0 1 Seconds 25 25 25 25 25 20 Max Forward Speed Fast Profile 96 100 100 100 100 100 100 Max Forward Speed Slow Profile 96 60 60 50 60 60 100 Min For
20. contact WHITE BLACK 1 on middle aff Blinkers JRIU 1 BROWN BLINK COMM BLINK R Bm Blink R indicator PDWER ind INHIBIT ind LIGHTS ind 5485 OF mode In 1 Wheel speed STATUS 2 0 24 R2 H GND 0 V Wr Det 1815 2 ee EMSTOP2 LEFT SIDE I L 4 rev8 11 3 2010 S emen fear tion ino op Pot Panic sw D4 Key switch KARTAU Rear lights 8 0 34 2 Blink R Els Pilot light L Brake Light L x D2 Blink L Right blink 1 41 Head Light H d HEADLIGHT QUT Right JRS JR32 Key Switch Rear Lights 1 REAR LIGHTS SDrive 140 controller Rh RIGHT CH OUT LEFT CH OUT le iring FRONT
21. emains on or flashes slowly after half a second Go to drive the scooter slowly in the forwards direction until you hear the parking brake operate The scooter may start to move Immediately release the throttle You must be able to hear the parking brake operate within a few seconds Repeat the test in the reverse direction Cables and connectors Check that all connectors on the scooter are securely mated and ensure that all cables are free from damage 23 drawings 13 Mechanical assembl See attached assembling drawings Breeze S 4W assembling pdf I RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w CARPET HWS4004 PAGE 2 lt 54007 2 2 554027 4 1 1 1 1 1 1 1 1 6 SEAT ASBRO19 PAGE 8 5 TILLER ASS4020 PAGE7 4 FRONT PLASTIC COVERS ASS4024 PAGE 6 3 REAR SUSPENSION PAGE 5 LIMEN cu i Se 2 FRONT STEERING PAGE 4 1 1 FRAME S ASSY 2 3 QTY NAME PART NO REMARK Do not scale from drawing Draw Checked Approved only with stamp 2 4 10 Date X Production Confirme d Tolerance b Linear Angular MICHAEL 500mmsimm Conf Update 900mm 0 5mm 21 AFIKIM ELECTRIC MOBILIZERS Drawing no KIBU sy E mail nor br s pl 2 4w Website www afiscooters com Part name BREEZE S ASSY Date Scale
22. lock setup Left Setup Use to adjust the clock d Internal LED Use for a technician Can be seen only from the bottom side of the LCD board When LCD board active flashes to indicate OK e Display Legend Signal Direction Use to show Blinkers working Main Light Use to show Front lights and rear Pilot lights are working Digital information Shows Speed Distance of Trip Time of Trip Time or Faults Codes Speed Units Show mph miles per hour or kph kilometers per hour Distance Units Shows mile miles or km kilometers Time Shows Hour HH mm hours minuts Half Speed shows 1 full or 1 2 half speed Battery Capacity 8 Bars full 1 bar empty between is proportional Also flashes at a CODE when there is a controller fault CODE Warning Inhibit Indicate when the motor is heated and when the EMB is opened Dip Switches f 1 2 5 User Modes setup with relate to user needs State Description 0 Regular Speed Distance Time Clock 1 Off On On Minimal No Digital Information 2 Off On Speed only 9 On Speed and Distance only 4 On Off Hour only Controller Type setup State Description Remark Off PG SDrive Battery status from Controller On Dynamic Rhino Battery status calculated upon Algorithm 22 24 VDC
23. m 28 xI RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w 29 4k 1 MUD GUARD BREEZE 54 IPS4011 PLATE HEATSINK FRONT HEAD LIGHT 1 BREEZE 53 4 54023 SEAL RUBBER HEAD LIGHT BREEZE 53 4 54001 FRONT LEDS LIGHT TESTED PCBRO25 REFLECTOR HEADLIGHT REEZE 53 4 5401 COVER HEADLIGHT BREEZE 53 4 54018 BASKET FRONT BREEZE 53 4 MPS4032 BRACKET LIGHT BLINKER SIDE FRONT BREEZE 53 4 54013 FRONT LED BLINKER TESTED PCBRO22 COVER LIGHT BLINKER SIDE FRONT IPS4014 REEZE 53 4 COVER FRONT BREEZE 54 54015 PART NO REMARK tolerance Part name AFIKIM ELECTRIC MOBILIZERS Page 6 DATE Scale holes d linear angular Drawing no GENS BREEZE S ASSY UN Of 8 2 4 1 0 X 0 5 gt 500mm mm 1 nor br iS p 6 E mail main conten adn lt 500mm 0 5mm Website www al xI RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w 5q 1 MIRROR RIGHT F BREEZE 1 LCD DISPLAY F BREEZE E BUTTON OPERATING TILLER BREEZE 53 4 COVER TOP TILLER BREEZE 53 4 IPS4021 COVER TILLER TOP ASSY ASS4022 MIRROR LEFT F BREEZE ACBRO17 HARNESS CHARGING SOCKET BREEZE 53 4 ASS4003 KEYSWITCH BREEZE ASSY 5 008 a BACK TILLER BREEZE IPS4023 COVER TILLER INSIDE ASSY 554021 5 2 SP HANDL BRZ 93 FRONT BOARD BREEZE 5 54001 TILLER 55 BRZ S 3 4 ASS4020 BUZZER BREEZE ASSY ASBROO7 aa FRO
24. mrtum nor br s p 4 x lt 500mm 0 5mm 54 050 NO 1 AS4W051 5 00330 MP4W058 HW4W022 MP4W066 MIMI Part name AFIKIM ELECTRIC MOBILIZERS Drawing no Cat No KIBUTZ AFIKIM 15148 ISRAEL BREEZE S ASSY TEL 972 4 6754814 FAX 972 4 6751456 voolers com Website www aliscoolers com 27 xI RD Breeze S DRAWINGS BREEZ S ASSY PART WIRING ASSY 4w Page Of 5 Bi BK Bd Bd DATE 2 4 10 Scale X tolerance holesd linear 500mm 1mm 0 5 lt 500 0 5 angular Drawing nor br s p 5 CLAMP FOR POWER UN SE MP00329 3l POWER UNIT AFIKIM 1OKMH BRZ ASBR132 RIM REAR WHEEL 2 5 10 MPBROO6 WHEEL REAR 4W F NOR AS4W029 REAR SUSPENSION POWER UNIT BREEZE 53 SCREW SHAFT M10 12 40 MPS4013 5 00356 SHOCK ABSORBER BACK BREEZE ACBRO39 BRAK REAR BRZ 4W ASSY AS4W011 TUBE 3 00 3 50 10 90 DEG VALVE HWBROO4 TIRE 3 5 10 HF 203 2 DURO F BRZ 3 4W NOR HWBRO27 RIM RE WH 10 2 5 BRAK MP4WO017 WHEEL RE LEF 4W F NOR ASAWOSO PART NO REMARK BREEZE S ASSY AFIKIM ELECTRIC MOBILIZERS KIBUTZ AFIKIM 15148 ISRAEL TEL 972 4 6754814 FAX 972 4 6751456 E mail mainbox afiscooters com Website www afiscooters co
25. n On On Diagnostic Alarm On On On On On On Diagnostic Alarm Tone 0 0 0 0 0 0 Brake Disconnected Alarm On On On On On On Brake Disconnected Alarm Tone 0 0 0 0 0 0 Brake Fault Detect On On On On On On Brake Light Off Off Off Off Off Off Freewheel Speed Limit 100 100 100 100 100 100 Freewheel Time out 0 01 Seconds 20 20 20 20 20 20 Freewheel Enable Enable Enable Enable Enable Enable Enable Horn Input Enable Tag Off Off Off Off Off Off Horn Tone Motor Settings Current Limit Max Amps Boost Drive Current Amps Boost Drive Time Seconds Current Foldback Threshold Amps Current Foldback Time Seconds Current Foldback Level 96 Motor Cooling Time Seconds Current Foldback Temp Deg C Current Limit Min Amps Motor Compensataion milli Ohms AntiRollback Level Pull away Delay centi Seconds parameter 4 10 Slope Factor Anti Rollback Velocity Braking Current Limit Amps Timed Foldback Braking Current Amps Timed Foldback Speed 96 Enhanced Motor Compensation Value parameterar 3 Bridge Hold Time Factory Settings Throttle Settings Throttle Type Throttle Deadband Throttle Gain Throttle Operated at Power Up Throttle Reference Test ISO Test Resistor 10 Periodic maintenance Check 1 Check air pressure in User Every week
26. oller to alter the program The PC Programmer is a piece of PC software and an interface cable When the software is installed onto a PC it can then be connected to the controller by using the special interface cable The controller can then be programmed using a windows type environment The programming tools may be included with your scooter If they are not the scooter distributor or service agent or scooter manufacturer will are able to program the controller If you have a programmer read the user guide before you use it If you re program your controller make sure that you observe any restrictions given in your scooter user manual Note any changes you make for future reference Programming should only be conducted by healthcare professionals with in depth knowledge of PGDT electronic controllers Incorrect programming could result in an unsafe set up of a scooter for a user PGDT accept no liability for losses of any kind if the programming of the controller is altered from factory pre set values 11 9 Controller Parameters List Manual Programmer Breeze S S Drive 140 controller setup update 25 10 2011 Parameter Parameter Name Text AMT AMT T Afikim 15 1 Forward Accel n fast 0 1s 40 1 Forward Accel n slow
27. power unit absorbing Replace the Noisy Rubbers absorbing rubbers if needed Check for clearances and unsecured parts Secure parts Check the shock absorbers Replace shock absorbers if needed 5 HRearsuspension Check user weight and the fit of Replace if needed not functionin the absorbers 9 Replace if needed Faulty shock absorbers 6 Noise from power Wear in power unit Check and replace unit power unit if needed 7 Too short distance Power unit wear consume high Check noise and travel between current Also might be noisy current and replace charging if needed 8 Clearances in tiller Unsecured screws and gas Check scure of piston faulty Screws Replace gas piston if needed 9 Scooter does not Wear in motor brushes Replace motor have power or does not brake brushes 18 well or go to high speed downhill 10 Noises from motor Wear of brushes Faulty motor Check brushes and replace if needed Replace motor 11 Emergency handbrake does not stop The brake cable is not tight or brake drum disk is wear Tight cable and replace brake drum disk if needed 12 Flat tire and uneven and not smooth drive Flat tire Repair replace tire s tube 19 12 Control and Electronics system fault troubleshooting 12 1 General control system and Front Board Troubleshoots The front board is the center of all peripheral functions of
28. ront Board faulty Replace Frond Board 4 Front Blinker s doesn t work Front Blinker board faulty Replace front Blinker board Front Board faulty Replace Frond Board 5 Rear pilot s light does work Rear Blinker board faulty Replace Rear Blinker board Front Board faulty Replace Frond Board 6 Rear Blinker s doesn t work Rear Blinker board faulty Replace Rear Blinker board Front Board faulty Replace Frond Board 7 Horn does not work properly External Horn is faulty Replace Horn Internal Horn is faulty Replace Frond Board Front Board faulty Replace Frond Board 8 Hazard doesn t work Hazard switch fault Check switch and repair Front Board faulty Replace Frond Board 9 Reverse function doesn t work Reverse switch fault Check switch and repair Front Board faulty Replace Frond Board 10 Electric EMB release function does not work EMB release Switch faulty Check switch and repair Front Board faulty Replace Frond Board 11 LCD is not powered ON LCD board faulty Replace LCD board Front Board faulty Replace Frond Board 12 No Charge start Charger fault Replace charger Charge fuse popup or faulty Reset Replace charge fuse 13 Travel distance very low Charger fault Replace charger Old Weak batteries Check Batteries charge batteries Replace if
29. ry Cover 2 securing screws 2 6 Lift the Battery Cover 2 until it is released from the Seat Pivot The replacement of the Gray Cover is done in reverse order MAKE SURE that the Gray Cover 2 fits onto it s place Secure with the 4 screws 2 6 Batteries weight each 23 Kg 50 Ibs and over Lift each battery only with the appropriate handle Keep lifting with your Knees legs and not loading your Back Correct air pressure in the tires is essential for optimal steering and stability of the Breeze S Check air pressure every two weeks 2 psi Breeze 4W Inflate to the proper air pressure 25 front tires 20 2 psi Golf wheels tires 2022 psi Use only a damp cloth and mild detergent Never use a hose for cleaning This may severely damage the power and electronic components 17 11 Mechanical Fault troubleshooting Description Probable cause Repair action 1 Noises from front Check front suspension for Replace wear parts steering and clearances and secure of bolts secure bolts suspension mien Check front shock absorbers Replace if needed system 2 Front suspension Check front shock absorbers Replace if needed not functioning properly Excessive wear of Wear of bushings that cause Replace wear parts front tires after clearances in the system Adjust the steering short period and secure Un adjusted steering system 4 HRearsuspension Wear in
30. se alarm does not sound Check the scooter is programmed correctly then retest Scooter will not drive in reverse Check the tiller wiring amp connections then retest Scooter will not drive in reverse Check the reverse switch is working correctly then retest 22 Slow Sluggish Movement If the scooter does not travel at full speed and the battery condition is good check the position of the speed limiting control If adjusting the speed limiting control does not remedy the problem then there may be a non hazardous fault Contact your service agent User Daily Checks Throttle With the scooter switched off check that the throttle mechanism is not bent or damaged and that it returns to the position when you push and release it If there is a problem do not continue with the safety checks and contact your service agent User Weekly Checks Throttle Put the throttle to the full speed forward position and switch the scooter on The scooter should not move show you that you have switched the scooter on with the throttle already pushed a TruCharge Trip type status indicator will display 7 Bars whereas a single bulb or LED type status indicator will flash seven times sequence If the scooter does move contact your service agent Parking brake This test should be carried out on a level surface with at least one meter clear space around the scooter Switch the scooter on Check that the status indicator r
31. the scooter Lights Horn Information goes to the LCD display Elimination troubleshoots The Front Board wiring connections are all quick connectors If you suspect the Front Board to be faulted we recommend as a quickest way to find if the Front Board is faulty Doing by elimination Just replace temporarily the Front Board with another working one and thus make sure if the problem is within the Front Board or somewhere else Check all connection of the Front Board following the wiring diagram that can be found within this maintenance manual Check main and Charging fuses located near the rear wheels Also always check related function switch as example Light does not work first check the light switch for continuity when is in ON position Use the wiring diagram to figure the proper terminals to check each function switch terminals 12 2 Trouble Shoot Table Description Probable cause Repair action 1 First check that Front Board internal LED flashes If it is not Flashing Front Board is faulty or no power supply to the board Check Supply If OK than Front Board is Faulty Replace it 2 If LCD is not working check if LCD internal LED flashes If it is not flashing LCD board is faulty or no power supply to the board Check supply If OK than LCD board is faulty Replace it 3 Front light doesn t work Front LED board faulty Replace front LED board F
32. ward Speed Fast Profile 96 50 50 50 50 50 30 Min Forward speed Slow Profile 96 30 30 30 30 30 30 Max Reverse Speed Fast Profile 96 50 50 30 50 50 40 Max Reverse Speed Slow Profile 96 35 35 20 35 35 30 Min Reverse Speed Fast Profile 96 30 30 10 30 30 30 Min Reverse Speed Slow Profile 96 30 30 10 30 30 30 Speed Limit Pot Enabled Off Off Off Off Off Off Operation Settings Sleep Timer Minutes Throttle Invert Battery Settings Low Battery Flash Level Bars Cable Resistance milli Ohms Calibration Factor Low Battery Alarm Battery Alarm Tone Tag Trucharge Reset Voltage Tag Battery Curve Scaler Inhibit Settings Inhibit 1 Mode Inhibit 1 Operation Latching Latching Latching Latching Latching Latching Inhibit 1 Speed 96 0 0 0 0 0 0 Inhibit Mode 2 1 1 1 1 1 1 Inhibit 2 Operation Latching Latching Latching Latching Latching Latching Inhibit 2 Speed 96 0 0 0 0 0 0 Inhibt Mode 3 1 1 1 1 1 1 Non Non Non Non Non Non Inhibit 3 Operation Latching Latching Latching Latching Latching Latching Inhibit Speed 96 0 2 0 0 Aux Output Mode 2 2 General Settings Soft Stop Brake Drive Time Seconds Output Voltage Volts Status Output Type Diagnostic Flash Sequence aure auris ania ane Reverse Alarm On Reverse Alarm Tone 0 0 0 0 0 0 Pulsed Reverse Alarm On On On O
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