-- Revision 3, 18/7/2013 –
Contents
1. Revision 3 18 7 2013 S 9 MAINTENACE 3 SERVICE MANUAL Service manual Eng Breeze S Maintenance Manual version 18 7 2013 docx BREEZE S The Senior Class Lifestyler Maintenance Manual y 1 QF AFIKIM ELECTRIC VEHICLES Contents N 0o 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 20 O oa fF FR A 11 11 12 14 16 16 16 17 17 18 18 19 19 1 Safety instructions 1 1 General 1 1 1 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 U2. Time Enter to Clock setup c 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 3 On Speed and Distance only 4 On Off Hour only 3 Controller setup State Description Remark Off PG SDrive Battery status from Controller On Dynamic Rhino Battery status calculated upon Algorithm 22
3. 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 20 2 psi Use only a damp cloth and mild detergent Never use a hose for cleaning This may severely damage the power and electronic components 13 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 Rear suspension Wear in 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 Rearsuspension Check user weight and the fit of Replace if needed not functionin the absorbers 9 Replace needed Faulty shock absorbers 6 Noise from
4. 24 VDC 4 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 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 20YY YY 6 Save of Updated Time and Date k Controller Fault Code witbe shewntegether with Speed changed every 2 secends J Will be shown Batt Icon upon controller fault code 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 9 Controller Programming Setup lf 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 b
5. Audia Alarm Mode Speed ON OFF switch Inhibit 2 24 Poten Low Drive controller imit Pot Stotus Indicotor Aux Output Reverse switch Rhina controller 9 10 4816 0815 Charga max 12 JR5 JR4 JR29 JR27 Bat Inhibit 1 1 BRAKE 2 BRAKE THERMI connector 20 2 2 1 1 IS au area EPP PERE 2 JR70 JR71 speed dry contact S Drive 140 BI F3 YE 70 80 LCD Ca 12 Charging Kameaa 2x2 5m2 Rear lights harness 8x0 34mm2 4 50 852 Pilat light L Brake Light L Blink L Right 1 2 5 Rear Lights hope 1 07 mee ti AX 1 08 REAR LIGHTS SDrive 140 controller Rhino option rev8 11 3 2010 JRSS 20 iring Breez
6. Front Board Display LCD Board Main Harnesses Cable Main Lights Harness Cable Main Supply Harnesses Controller SDrive 140A P8G Motor Power Unit Also it is 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 2 Tiller Height Tiller bottom adaptor under Release the secure nut 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 I tis 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 Sprint pretention 5 stages are possible 20 40 50 80 100 Should be fit to user weights 80 1
7. one meter clear space around the scooter Switch the scooter on Check that the status indicator remains 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 seconas 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 13 Mechanical assembly drawinqs See attached assembling drawings Breeze S 4W 8 3W assembling 14 Electrical diagrams General Wiring diagram 19 5 8 LI L H 5 5 4 5 L L 51 PBI 2 555 1 Q Forward Reverse WHITE BLUE 1 YELL LUE 2 EMB BLACKS F R COMM RED 4 WHITE YELLOW 5 BUZZER COMM WHITE RED 6 Yelloy Black BLUE Buzzer 0 0 2 Speed Node 5 6 BUZZERPB Tiller Right Switches 52 WHITE BLACK Removed wire PBS Fre Hazzard COMM 2 TTL hh fan COMU 1 85485 3 WHITE BLACK YELL EMERG LIGHT
8. 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 14 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 15 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 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 on
9. 00 120 140 160 kg Remark The Adjust shoula fit the comfort of the user Front Electronics Board Setup There are 2 horns in the Breeze 5 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 DSWA 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 E E E __ E E E 2 3 4 5 T A 7 LCD Display Set Up and User Manual a LCD Display Main Light Signal Direction Digital Wa a 7 Speed Units information Mf lets _ Distance Units AN TO Time Units 20 Ce 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
10. COMM 1 ORANGE LIGHT COMM BUZZER COMM 1 2 BLUE 4 WHT LUE 5 BLACK EMERG LIGHT LIGHT a Buzzer PB4 Tiller Left Switches middle aff kers JRIO BUZZERPB BLINK COMM BLINK R BLINK L bascas T i f2 2 2K pa NC POT HIGH POT WIPER MAN 2 krenn ALE POT LOW 5 4 Panic switch gt T pas Pot Panic sw I I Key switch 4 1 55 EMSTOP2 Key Switch Right blink 4 t HEAGLIGHT_QUT RIGHT _CH_OUT LEFT CH OUT FRONT LIGHTS Left blink 4 gE 1 JRIB 487 Front ghts harness 6x0 5mm2 FRONT BOARD Pot Wiper Pot High Audio Alarm Mode Speed ON OFF switch Inhibit 2 Reverse switch Ground Inhibit 3 key switch throtle throtle wiper thratle E buzzer speed limit po Forw Rev Freewheel Ground 240 Inhibit Charge Inhibit EMB N C Thermistor In Thermistar Out 8 Wheel speed out Wheel speed in LIGHTS ind RS485 D Speed mode ind Wheel speed STATUS VD 24V GND G M 85485 D Pilat light R Brake Light R Blink R Tiller Harness 18x0 5mm2 Pot Wiper Pot High
11. ccur 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 stop 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 Mere is a bad connection to the motor Check all connections between the motor and the controller 3 Flashes The motor has a short circui
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13. e 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 Front 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 doe
14. e plugged into your controller 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 lf you have a programmer read the user guide before you use it lf 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 Controller Parameters List See external separated file 11 10 maintenance Check 1 Check air pressure in User Every week all tires 2 Check emergency User Every week brakes 3 Check normal drive and Every Month stop Check tires wear Every Month 5 Check for missing parts User When receiving the Breeze 5 after a long and damaged parts time not using it Use the fig
15. nd wheels 1 4 2 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 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
16. p 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 1 09 Inhibit activated Can be caused by the electromagnetic brake lever micro switch panic sensor Check all wiring 8 connections to the controller then retest Try replacing the controller 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 Reve
17. rse 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 In cases that the scooter with transaxle 12 km hr is recoil Reduce the compensation parameter from 50 to 40 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 True Charge 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
18. ser Manual Technician 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 14 Electric 1 4 1 fnecessary 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 a
19. sn 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 16 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 o
20. t 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 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 A throttle fault is indicated Make sure that the throttle is in the rest position before switching on the scooter 8 Flashes A fault is indicated Make sure that all connections are secure 9 Flashes 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 17 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 to the charging socket using a special wiring adaptor oan Action A01 Quick switch ON OFF Switch OFF wait few seconds and ON again Possible fault of main key switch If hundreds time suspect the keyswitch 0300 Check the tiller 8 throttle wiring
21. to the controller then retest 0815 Check the tiller 8 throttle wiring to the controller then retest 0 00 Check the sleep mode parameter is set correctly then retest 0 07 Check the tiller 8 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 Check the batteries wiring amp connections to the controller then retest 1600 Possible high voltage due to high load downhill Possible to decrease the half speed parameter to 40 and instruct the user to drive 1 2 speed mode down hills 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 8 connections to pin 14 of the 14 way tiller connector then retest 2 00 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 Battery connected whilst scooter is switched on Turn off wait 10 seconds then retest 3B01 Check the motor wiring am
22. ures Check secure of all Technician Once a year by technician screws and parts 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 Check power unit Technician Check noise clearance current on surface should be 12 to 15 Amp 12 Periodic maintenance continue Removing the Seat and the Batteries Cover 2 Replacing the Batteries Cover 2 Batteries Cleaning Turn the Seat by using the lifting Lever 7 5 so that the 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 Warning The seat weight is 15 Kg 33lbs Keep lifting with your Knees legs and not loading your Back Release Battery 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
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