S142/S145 Service Manual
Contents
1. e w On completion of programming unplug the programmer to save the new information to the controller un Wait until the controller status light comes on about two seconds before turning the scooter off Programmable Settings The following settings can be modified so that a scooter can meet user s needs Not all of these settings are available from the Scooter Programmer 7 2 1 Setup Menu These settings customize the scooter to user preferences and or environment 27 Setting Accel eration Decel eration Maximum Speed Forward Speed Reverse Speed Values 1 10 3 es es 1 10 es es 7 Description Sets the acceleration of the scooter The higher the settmg the greater the acceleration rate A low acceleration gives softer performance and a less sensitive throttle response Sets the deceleration of the scooter The higher the setting the greater the deceleration rate Low settmgs should only be used with very low Forward Speed settings This should be set higher than the Acceleration parameter Allows fine adjustment of the RHINO controller s maximum motor output and thus of the motor s maximum speed Usually set to meet local regulatory requirements Y Y Yi Yi 12 255 255 Sets the maximum forward speed of the scooter The higher the setting the higher the maximum forward speed Sets the maximum reverse speed of the scooter The higher the setting the2. Release lever the speed at which the scooter can be pushed will be to this value the Push Speed 15 exceeded the scooter will execute a controlled stop Defines the scooter response to throttle movement If set to 0 moving the throttle half of its travel will result m the scooter travellng at half programmed speed If set to 100 movmg the throttle half of its travel will result m the scooter travelling at around 25 of its programmed speed mcreasmg speed as the throttle 1s moved further Values 0 50 No Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP 7 2 2 Options Menu These settings are adjustable using a hand held programmer Settings via the programmer can be either ON or OFF 32 Setting Description Default Single If ON the throttle controls speed only and direction 15 selected OFF Ended with a forward reverse switch Pot If OFF speed and direction are controlled by the throttle No forward reverse switch 15 required For the DS72KA this option should be OFF otherwise the actuator function will be unavailable Motor If ON the polarity of the motor pms on the motor connector is Reverse reversed and the motor tums m the direction opposite to normal Pot If ON the polarity of the throttle is rev
3. has severed To check the connection between output connector and the battery To check if having made a correct connection for the battery polarity To check the battery is connected completely 4 If the fuse is burned out as soon as the power switch has been turned on and no effect at all After having been replaced with another new same fuse Please do not dismantle 40 the charger or replace with other larger fuse by yourself 5 The charge time continues for a long duration abnormal To check if the battery has been broken down or aged 6 The yellow green LED have flashed over 40 minutes during charging To check if the battery is broken down 7 The battery heats abnormal To stop charging and check if there are troubles occurred on the charger Caution 1 If there is a ground wire for the power cord of charger for safety purpose please be sure to make a good ground connection job 2 To make sure the DC output corresponding with the battery which will be charged and the voltage value otherwise it may cause battery explosion and hurt someone 3 To keep the power on off switch in o position before the charge circuitry and battery have been connected completely 4 Do not expose the charger to the rain water or store it at humid place 41 9 Diagnostic flow Chart 1 1 Main flow chart 1 Scooter can not move speed gauge O Dash board failure ight steag 42 Replace dash board ead l
4. Merits 91 53 sere Rhino Service Manual 51 83 series Rhino Service manual Introduction 1 1 guide 1 2 Battery 1 2 1 When to replace the batteries 1 2 2 To remove the batteries 1 2 3 To install the batteries 2 2 4 Check battery charge 2 3 Motor brush and Parking brake 2 3 1 Motor 2 3 2 Brushes 4 3 3 Parking Brake 4 4 Tiller Instrument 10 4 1 Tiller disassembly assembly procedure 11 4 2 Throttle Potentiometer 13 4 3 Dash board 15 4 3 1 Analog Dash board 15 4 3 2 Digital Dash board 16 5 Examples of Electrical illustrated parts bre
5. aced easure resistanc between l and 3 of throttle resistor Throttle VR eplace throttle failure esistor Measure resistance between 1 and 2 neutral position is within 2 3 2 70 test drive 48 i mo Remark POT 4 4 4 8VDC 0 2 0 6VDC FROM 1 2 of POT and POT on controller See remark Controller 1 replace failure and POT control cable ee 120161 Replace controller cable ontroller cabl broken and POT on main cable ec emark Replace main cable main voltage is OK broken cable YES Replace resistor 49 FROM 1 2 heck insulatio between motor coil and case Controller failure controller Motor broken Replace Motor 50 Horn failure Dismantle tiller head and check horn switch Dash board PCB broken Horn switch broken Replace PCB Replace horn switch 51 o 2 head Mort failure FROM 1 1 Replace the bulb Dismantle tiller head and check head light switch Dash board PCB broken switch Replace PCB Replace switch 52 5 5 Left indicator failure Replace the bulb Dismantle tiller head and check indicator switch Dash board PCB broken switch Replace PCB Replace switch 53 Dismantle tiller head and check indicator switch Replace switch 5 4 Right indicator failure Replace the bulb Dash board PCB
6. akdown 17 5 1 S1 series 17 5 2 S3 SerleS 18 6 Scooter troubleshooting 19 Typical problems and solution 7 Controller 22 7 1 Rhino connection and wiring 22 7 2 Programming Rhino 24 7 2 1 Setup Menu 27 7 2 2 Option Menu 32 7 2 3 Common programming errors 34 7 3 Rhino Diagnostics and fault finding 35 7 3 1 Diagnose fault 35 7 3 2 flash code 38 8 Charger 39 8 1 Operation instruction 39 8 2 LED indication 40 8 3 Troubleshooting 40 9 Scooter diagnostic flow chart 42 Introduction The purpose of this manual is to provide dealers and or distributors with the product information
7. amp wire color white and black 12 7 Loosen the four screws of top cover B Tiller assembly procedure You can just backward the disassembly procedure to assemble the tiller Remember to tighten every screw and make sure every connector is plugged firmly 4 2 Throttle Potentiometer POT In some cases scooter can not move results from POT problems There are three typical POT problems 1 Speed POT wire broken or short circuited Rhino flash code 7 13 Check if wires shorted or connector loose 2 Speed POT out of range Rhino flash code 7 Measure the resistance between 1 3 of the potentiometer It must be 5KQ 10 If not Replace the potentiometer 3 Speed POT not in neutral position Rhino flash code 6 Measure the resistance between 1 2 of the potentiometer It must be 2 5KQ 10 If not recalibrate the neutral position Measure the resistance between 2 and 3 of the potentiometer It must be 2 5 10 If not recalibrate the neutral position Follow the wire color allocation as picture below to solder the wire to the potentiometer 14 4 3 Dash board PCB Dash board handles all accessories of the scooter like lighting system buzzer switches battery gauge charging inlet keypad speed adjust throttle potentiometer Sometimes the accessory problems may turn out to be caused by dash board PCB Make sure all wires are not loose and all conn
8. and instructions that are required for servicing the S1 S3 series electrical scooter 1 Service Guide Batteries Motors Brush and brake Tiller instrument Electrical illustrated parts breakdown Troubleshooting Dynamic Rhino controller Charger Scooter diagnostic flow chart WARNING Before performing any maintenance or service turn the power off NEVER allow tools and or battery cable s to contact BOTH the battery terminal s or the post s at the same time An electrical short may occur resulting in serious personal injury and or damage It is strongly recommended that battery installation and or replacement should be done only by a qualified technician 2 Batteries B Battery type Lead acid 2 pieces 2 1 When to replace the batteries The batteries may have to be replaced should one of the following conditions occurs B The scooter s driving distance decreases significantly B Incomplete charge B The Charging cycle becomes significantly longer or shorter than before 2 2 To Remove the Batteries 1 Remove the seat and shroud and unplug rear lights connector 2 Disconnect the wiring harness from the batteries removing the screws 3 Remove the batteries from the scooter base 2 3 To install the Batteries 1 Install two new batteries into the power chair base 2 Connect the wiring harness to the batteries Refer to Electrical illustrated parts breakdown diagram 3 Confirm the battery supply vo
9. broken Replace PCB 54 5 5 Hazard indicator failure FROM 1 1 Replace the bulb Dismantle tiller head and check hazard switch Dash board PCB broken switch Replace PCB Replace switch 55
10. drive system functions correctly 4 Ensure that the scooter s power system is equipped with a circuit breaker or fuses Testing Check the motors and control system when the installation is completed Note the following points The circuit breaker or fuses must be included in the power circuitry B Lift the wheels off the ground B Do not arc cables to check for power B Use a multimeter to check the voltage Operation of Brake lever When it is desired to manually push the scooter the brake lever is easily released Simply push pull the lever on the magnetic brake Labels are available for indicating the status of the brake lever Maintenance and Servicing The motor is a low maintenance required motor and except for periodic checkup requires no further maintenance under normal conditions The batteries should be disconnected during any maintenance procedure and in fact their complete removal from the scooter may help access B Check system regularly B Check for loose damaged or corroded connectors and terminals B Replace damaged cabling B Check motor mountings for tightness B Clean motor and control system components with a damp cloth B The cover may be removed to check the brush length B Check for oil or grease leaks around the seals output shaft and brake lever B Check motor for increased backlash or play excessive noise or other indications of the gear wear out Warning Do not use the motor if there is any i
11. ector are connected firmly If everything is fine but the problem still remains replace the dash board PCB and test 4 3 1 Analog dash board PCB Following picture shows function of each connector on analog dashboard PCB 1 Main cable connector 2 Key switch connector 3 Speed POT Connector 4 Charger connector 5 Status LED connector 6 Hazard switch connector 7 Direction switch connector 8 Head light switch connector 9 Horn switch connector 10 Reduce speed switch connector 11 Turning reduce speed sensor connector 12 Lighting system connector 13 Speed adjust VR Connector 15 4 3 2 Digital dash board PCB 1 Main cable connector 2 Key switch connector 3 Speed POT Connector 4 Charger connector 5 Lighting system connector 6 Key pad connector 7 Turning reduce speed sensor connector 8 Reduce speed switch connector 16 5 Examples of electrical illustrated parts breakdown 5 1 Sl series scooter 5 2 S3 series scooter NAME CONTROLLER 0 181 MAIN CABLE KEYPAD CONTROLLER POT WIRE RY CABLE P CABLE REAR LIGHT CABLE REAR LAMP POTENTIOMETER KEY SW HEAD LIEHT FT INDICATOR POWER CABLE MOTOR ICHARBING INLET 16 inpicator CHARGER AD CORD HALF SPEED SENSOR R SPEEU SETTING MRE HORN SWIIC HEAD LICHT SWITCH BATTER 12 2 18 6 Scooter troubleshooting Typical problems and
12. ed mode the speed both forward and reverse will always be Imited to the Reduce Speed setting Set to OFF if the input is from a speed lmit such as a steermg sensor slope sensor or seat position switch 7 2 3 Common Programming Errors Sometimes after changing certain parameters in particular when customizing the Motor Reverse and Pot Reverse settings the scooter might not drive in the way that was intended Following is a matrix of Motor Reverse and Pot Reverse 34 settings and the impact they have the motion of the scooter Setting Result Driving Forward Driving Backward Reverse Reverse Slow reverse speed O OFF Fast forward speed with buzzer with buzzer Fast forward speed with buzzer O ON Siop forward Fast reverse speed with buzzer FF ON FF 7 3 RHINO Diagnostics amp Fault Finding RHINO provides diagnostics information to assist technicians with diagnosing and correcting faults within the scooter system A fault in the scooter will cause the RHINO Status Light to flash separated by a pause The number of flashes in each burst also referred to as the flash code indicates the nature of the fault Depending on the severity of the fault and its impact on user safety RHINO will react differently It can Display the flash code as a warning but allow normal driving and operation Display the flash code as a warning but allow limited driving and operati
13. ersed Moving the throttle OFF Reverse m the direction that normally causes forward movement results m reverse movement When used with Single Ended Pot ON this option will reverse the directions of the Forward Reverse switch Speed Enables the Reduce Speed option on the Setup Menu ON ting Brake Set to ON if the motor has a park brake ON Checking Allows RHINO to mamtam a constant speed despite changing ON drivmg conditions for example chmbing from a flat surface on to ON ON 2 5 slope This setting should be ON for normal operation It uses the Motor Resistance settmg m the Setup Menu Motor This option is set to ON Derating Enable If ON Sleep Mode is enabled and RHINO goes to sleep Sleep after the Sleep Time specified with the Setup Menu Check for IFON stoppmg performance tends to be harsher than normal OFF Slope The Park Brake Delay settmg the Setup Menu 1s bypassed when stoppmg on a slope Beep mode Sleep RHINO will beep three times when it goes into Skep 33 Description Current Having this setting turned ON 1 a regulatory requirement m some Limit countries If ON RHINO will automatically stop driving after the Timer amount of time set m the Current Limit Time settmg Flash Code 4 1s displayed and the scooter must be tumed off then on agam to reset When set to ON RHINO might tum off after a time under heavy load for example gomg up a long steep hill This wi
14. f position before the charge circuitry and battery have been connected completely 4 To check if the output end of charger corresponds with the positive negative pole of battery 5 After the above sequences have been finished please turn on the AC power switch to I and the fan will begin to run When LED turns red yellow it means the charger has been under normal charging condition If the abnormal phenomena occurs please turn off the charger immediately and check the 1 4 sequences repeatedly then turn on the charger again 6 When LED turns to red green that means the batteries have been finished for complete charge 7 Under the condition of yellow green LED It may have a temporary alternating phenomenon around 1 60 seconds during switching please note this is a normal feature 8 2 LED Indication LED POWER RED LIGHT ON Power On LED CHARGE LIGHT OFF Battery Disconnect YELLOW LIGHT ON Charging GREEN LIGHT ON Full Charged 8 3 Troubles Shooting 1 When the power switch sites on but no LED light up To check the connection of power cord To check the connection of socket To check if the fuse is under normal condition 2 When the power switch sites on but red yellow LED do not light up completely and the fan does not run To check if the output wire occurs short circuit 3 When the power switch sites on red LED light up but green LED flashes and no charging action To check if the output fuse
15. gh the scooter will not achieve maximum speed no matter how much the throttle is deflected If set too low the scooter will reach maximum speed with only a small deflection of the throttle Sets the amount the throttle must be deflected before the scooter begins to drive 30 Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Wig Wag Fault Threshold Slope Current Battery Saver Threshold V Description Controls the threshold at which the controller will generate a fault if a short exists between the Wig Wag potentiometer wiper and either end terminal Use values greater than 10 if ISO resistors are fitted If RHINO s m current limit for this amount of time driving will be disabled and a Flash Code 4 displayed The scooter must be tumed off then on agam to reset The Current Limit Timer m the Options menu must be set to ON for this settmg to have any effect Sets the threshold at which the park brakes will be apphed when the Check for Slope settmg is set to ON Sets the threshold at which the Battery Discharge Indicator BDI shows low battery Sets the voltage at which the Battery Saver feature becomes active This feature protects the batteries by slowmg the scooter as the voltage decreases thereby extending batter
16. he scooter 1s left off for a few mmutes battery charge might recover enough to allow driving for a short time 3 Battery Drive Battery charge 1s too high If a charger is plugged m voltage too high inhibited unplug it or turn the Charge Run switch to Run Scooters powered by RHINO charge the batteries when traveling down slopes or deceleratmg Excessive charging this manner can cause this fault Turn the scooter power off then on If necessary reduce speed when descending the slope 4 Current limit Iv The scooter has drawn too much current for too time out inhibi long possibly because the motor has been over worked jammed or stalled Turn the scooter power off leave for a few mmutes and then tum the power back on agam The controller has detected a shorted motor Check the loom for shorts and check the motor Contact your service agent 5 Brake fault The Park Brake Release switch has been turned on when powermg up the scooter or while driving Check the park brake release lever is the engaged position Check the Park brake Release switch 15 closed when powermg up 38 Impact on Flash Code Fault Scooter 5 Brake fault Iv The park brake coil or wimg is faulty Check the park brake and wimmg for open or short circuits If necessary unplug the motor connector and check that all pms are m the correct position If this flash code does not appear until the throttle has been moved out of neutral check for a sho
17. higher the maximum reverse speed Anti tip wheels may be required if high Reverse Speed settings are used 28 Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Buzzer Volume Motor Resist ance Sleep Time Description Limits the maximum forward speed and maximum reverse speed of the scooter For example if Reduce Speed 1s set to 7 Forward Speed to 10 and Reverse Speed to 6 maximum forward speed will reduce to 7 but maxmum reverse speed will stay at 6 as it 1s already lower than Reduce Speed settmg of 1 tums the reversing buzzer off Any other value enables the reversmg buzzer with full volume Indicates the resistance of the motor to which RHINO 1s connected A correct value this setting is required to achieve good speed regulation Sets the length of time with no throttle movement before RHINO goes mto Sleep Mode When m Sleep Mode the Status Light turns OFF and the scooter will not respond to commands To exit Sleep Mode turn the power off then on agam Refer to Enable Sleep m the Options Menu for information about the Sleep Mode feature Sets the maximum output current from RHINO to the motor Lower values can affect scooter performance The maximum useable setting corresponds with the nominal current o
18. ibited 36 the Status Light is OFF Check whether the RHINO Programmer is plugged in The status light will be out and driving is not enabled when a Programmer is plugged in to the RHINO Confirm that the battery supply voltage is present on the RHINO Battery terminals Connect a voltmeter between Battery and Battery negative probe on Battery The voltmeter should measure between 23 and 27 volts If the voltage 1s negative check for correct battery wiring polarity If the voltage is OV check the circuit breaker and for open circuit wiring Confirm that the key switch is on and that its wiring and fuses are intact Confirm that the Status LED if present is fitted correctly Connect a voltmeter between the Key Switch terminal and Battery The voltmeter should read at least 20 volts If the voltage 15 OV use the voltmeter to check the wiring from Battery to the key switch itself and back to the Key Switch terminal If the External Indicator Light is FLASHING Count the number of flashes and refer to the following section RHINO Flash Codes Plug in the RHINO Programmer to determine the cause of the fault 37 7 3 2 RHINO Flashcodes Impact on Flash Code Fault Scooter l Battery needs W Battery charge 5 running low Recharge the batteries recharging as soon as possible All drive 2 Battery Drive Battery charge is empty Recharge the batteries If voltage too low inhibited t
19. id excess strain on the wires B Remove the screws that hold the parking brake assembly together B Reverse the process to install the new parking brake assembly Check the armature which must rotate freely with the parking brake disengaged Parking brake replacing procedure Electromagnetic brake change procedure 1 Loose the 2 screws out of the cover Remember the orientation of the cover in or to place back the cover correctly 2 Open the cover 3 Mark the position of the brake related to the motor Remember the orientation the brake 1n order to place back new brake correctly 4 Cut off the wires white and gray 5 Release clutch and loose the 4 screws out of the brake then remove the brake 6 Place the new brake onto the motor Before placing release the clutch first 7 Tighten the 4 screws 8 Solder the wires white wire to white wire gray wire to gray wire 4 9 Insulate the soldering point with heatshrink 4 Tiller Instrument In case tiller instruments are to be checked or replaced tiller shroud must be dismantled first to allow access 10 4 Tiller disassembly assembly procedure A Tiller disassembly procedure 1 Loosen the four screws of basket hangers 3 Push down the lever and remove the rear cover 11 4 Loosen the four screws of front cover 5 Remove the front cover 6 Unplug the lamp connectors Note right lamp wire l
20. igh is OK indicator is OK Replace fuse Yes Any fuse burn NO Replace 1 2 Main flow chart 2 FROM 1 1 Flash two Flash three Flash four Flash five Flash six Flash seven Flash eight 43 2 32 MOIS FROM 1 2 Meosure each battery voltage Compare voltage on controller and the sum of each batte voltage lt f difference gt 1 Measure resistance of power wire Wire broken Change wire Battery fail or over discharged Check connector 44 Full charge the battery Battery failure replace batteries 0 1 FROM 1 2 Controller being charged failure Stop charging and switch off on again If controller work Charger failure 45 controller gn 2 4 Current limit time out FROM 1 2 emove obstacle wheel stuck and switch obstacle off on again wheels off the ground and operate the transaxle failurg Replace transaxle between motor coil ane case Controller failure Replace controller Motor broken ese moer 46 FROM 1 2 Check brake lever Broke is released Measure circuit of magnetic brake Open circuit brake broken Replace the brake 2 5 Brake Engage the brake brake broken Controller failure Replace controller 47 2 6 Throttle out of neutral at FROM 1 2 Throttle neutral position displ
21. ired This is normal for chargers and is no warm during use response to charger use cause for concern If the charger does not get warm during use it does not mean that it is not working properly Scooter can not stop on a slope Magnetic brake are not working Possibly the brake lining is worn out Replace the magnetic brake properly Scooter takes Throttle If the scooter is moving when you release the throttle you off will not potentiometer will need to adjust the potentiometer neutral position or stop problem replace the throttle potentiometer After charging Charger Charger may be bad Replace charger This is the most for 8 hours the common scooter battery gauge does not Charger Charger connection on scooter is bad usually a wire on the show a full connection back of the charger socket is loose charge Battery Batteries are bad Replace new ones lights work Loose Check if wire connection is tight and scooter can wire connection move but the battery gauge Battery gauge Battery gauge is bad Replace new ones does not work Light is not Bulb Check Replace light bulb working Loose Check if wire connection is tight wire Connection Switch Check switch function If bad replace new one Dashboard PCB If light bulb wire connection and switch are all OK Replace dashboard PCB 21 7 Controller The Rhino Controller The RHINO scooter controllers include
22. ll be undesirable for some users If driving resumes before the motor cools or 1f this option is turned OFF the motor might be damaged under a heavy load If ON RHINO will ako signal Flash Codes with the buzzer If ON the Forward Reverse switch can be used as an altematrve park brake release switch This parameter is not available on the DS72KA when the controller senses the Mode Select switch 15 Open Reduce Speed mode will be entered If OFF the Reduce Speed mode will be entered when the controller senses the Mode Select switch is Closed Enable If ON moving the throttle significantly m the opposite direction Slam to which the scooter 15 currently moving causes the scooter to Brake decelerate immediately at maximum deceleration rate as per the Deceleration settmg RHINO checks the park brakes for open circuits before and while driving In some circumstances the park brake checking durmg driving may result m audible noise and or mcorrectly generates faults Set to OFF only if necessary If ON a drvmg mhibit condition typically removal of the key will cause the scooter to decelerate immediately at its maximum deceleration rate as per the Deceleration settmg If set to OFF the scooter will slow at its normal deceleration rate controlled stop If ON and the scooter is m Reduce Speed mode the speed of the scooter will operate as described m the Reduce Speed setting If OFF and the scooter is m Reduce Spe
23. lowing Throttle pins Battery Throttle 0 5 0 1V Battery Throttle Wiper 2 5 0 Battery Throttle 4 5 x 0 1V When the Throttle is moved in the forward and reverse directions the voltage on Throttle Wiper should increase and decrease by 2V If the throttle voltages are incorrect an incorrect throttle potentiometer is being used and or it 1s not correctly calibrated If the voltage swing does not occur check the potentiometer and wiring for open circuits Check the voltages on the Motor terminals Connect a voltmeter between Motor and Motor The voltmeter should measure 0V when the throttle is in neutral The voltmeter should measure 24V as the throttle is moved out of neutral to full forward If the voltage out of neutral is above OV but the motor 1s not driving check the motor motor wiring and connectors Check the voltages on the Park Brake terminals Connect a voltmeter between Park Brake and Park Brake The voltmeter should measure 0V when the throttle is in neutral The voltmeter should measure 24V when the throttle is out of neutral If the voltages are incorrect check the park brake and park brake wiring Check inhibit status Connect a voltmeter between Inhibit and Battery The voltmeter should measure 5V If the voltage is OV check that an inhibit switch is not engaged e g from a battery charger When OV 15 applied to this terminal driving will be inh
24. ltage the battery voltage to the controller should be at least 25 VDC 4 Plug rear lights connector and cover the shroud and install the seat 2 4 Checking Battery Charge 1 Connect the voltmeter negative probe to controller power 2 Connect the voltmeter positive probe to controller power 3 The voltmeter should measure 23 27 volts i e Battery Voltage 4 If the voltage is negative check for correct battery wiring polarity Ensure that batteries are connected correctly 5 If the voltage reading is zero check for wiring open circuits or battery wiring polarity 6 Charge the batteries completely before driving 3 Motor brush and parking Brake 3 1 Motor The 24V motors are specifically designed for use on electrical scooter The motors incorporate a metal cased parking brake The parking brake assembly and brushes are protected by a metal cover The motor frame is integral with the cast aluminum gearbox housing that forms a strong and compact unit An easy to operate brake lever engages releases the magnetic brake for manual pushing of the scooter Connections and Wiring 1 Each motor has four wires of two different sizes that require connection Note that the red and blue or black wire connections will affect the motor orientation 2 Upon completing all wirings the loom must be fastened to the frame to minimize strain on the connections 3 Lift the wheels before making the battery connection and check if the
25. ndication of damage or if abnormities such as damage to the case grease leakage abnormal response as well as excessive backlash or play noise heat smoke and or arcing are present Ensure that the motor is securely fastened to the transaxle and the wheel securely fastened to the transaxle 3 2 Motor Brushes Each motor contains two or four carbon brushes which may require replacement after operating the scooter a long period of time Brush replacement is a simple operation Note Disconnect the motor Remove the end cover to allow access Remove the brush Check the commutator for excessive wear or unusual burns or erosion marks Reverse the above processes to install the new brush ensuring that the brush is still able to slide in the brush guide Ensure the springs seat properly on the brush and the brush wire is placed properly Ensure correct insulation between motor case and motor wires refer ISO 7176 14 Always replace all the brushes in both motors at the same time Run brushes in for several hours in the forward direction Ensure that the parking brake is released when operating the motor This reduces brush bounce which causes arcing and in turn generates RFI and audible noise 3 3 Parking Brake Poor parking brake holding ability indicates the need for replacing the parking brake assembly B Disconnect the motor B Remove the cover to allow access Cut solder the wires of the parking brake Avo
26. ng Brake Checking Load Compensation Motor Derating Enable Sleep Check For Slope Sleep Upload Profile Download Profile Edit Programmer Profile Current Limit Time Slope Current BDI Threshold Battery Saver Threshold Battery Circuit Resistance Speed Limit Pot Minimum Creep Speed Push Speed Limit Demand Curve Rollaway Speed Limit I2T Capacity 12 Ramp Time I2T Refresh Rate I2T Threshoki Boost Current Boost Time Current Limit Timer Sound Flash Codes Enable PB Release2 Turn Input Sense Enable Slam Brake O C Drive Test Key Off Slam Brake Scale Turn Speed Brake Light Enable Reverse Light Enable Set Neutral Display Controller Micro controller Version Read Run Time Log Parameters available to DZ DS PD 0 162 Only RHINO Programming Warning Only qualified personnel should make alterations to RHINO programming Incorrect or inappropriate programming of RHINO can put the scooter into a dangerous state Manufacturer accepts no responsibility or liability for accidents caused by incorrect programming On completion of programming we recommend a drive test be carried out to ensure performance is as desired Note the scooter is turned off during programming any changed settings 25 are not saved and RHINO defaults back to the previously programmed settings 1 With the scooter turned on plug the programmer into the RHINO programming socket The startup screens appear for t
27. on Display the flash code stop the scooter and prevent driving until the scooter has been turned off and then back on again Descriptions of what each flash code means can be obtained by plugging in the RHINO programmer Detailed descriptions of what each flash code means and the probable cause and remedy for each are described in flash code table 7 3 1 Diagnosing RHINO Faults Use the following troubleshooting guide if the scooter fails to operate The guide will help identify whether the fault exists within RHINO or another part of the scooter system Required equipment Voltmeter Note Elevate the drive wheels before carrying out the following tests Turn the key switch on before beginning any diagnostics The voltages shown are nominal values Warning Testing should only be carried out by qualified service personnel 35 If the External Indicator Light is PERMANENTLY ON but the scooter does not move Check that the park brake solenoid or relay is working Move the throttle to the full speed position and listen carefully for the operation of the park brake solenoid or the relay 1n the RHINO f you can hear the solenoid or the relay the problem 15 not with the throttle or the inhibit circuitry f you can hear the solenoid but the motor does not turn look for an open circuit 1n the motor wiring Check the voltages on the Throttle terminals with the throttle in neutral Connect a voltmeter between Battery and the fol
28. res have sufficient air but this usually is not sluggishly properly inflated the problem The tires are inflated when shipped but they will lose some pressure between the point of manufacturing and delivery Check tire pressure and properly inflate the tires Scooter is Make sure you do not overload the scooter by carrying too overloaded much weight going up a hill or towing objects behind the Hand brake is not adjusted properly Battery problem scooter If the scooter is overloaded the controller may go into protection mode and even shut off power to the motor Correct the driving conditions that caused the overload wait a few seconds and then let the controller to recovery Avoid repeatedly overloading the scooter Adjust the handbrake neutral position to reduce the friction between brake disk and brake lining when brake is in neutral position Battery needs to be recharged If after full charging the 20 batteries the scooter still runs sluggishly Replace the batteries Sometimes it may be too cold to operate the scooter The battery does not output much current at low temperatures below 5 degree It is too cold to operate Sometimes the Loose wires or Check all wires and all connectors to make sure they are scooter doesn t connectors tight run but other times it does Switch bad Check ON OFF switch to make sure it is working properly Charger gets Normal No action requ
29. rloaded An excessive overload such as too heavy a rider or too steep a hill could cause the controller to overheat If the scooter suddenly stops running wait a few seconds and let the controller cool down Check all wires and connectors to make sure they are tight The circuit breaker or fuse will automatically shut off the power if overload or short circuit happens If the scooter suddenly stops running push the breaker to reset the circuit 19 or replace the fuse Correct the conditions that caused the breaker fuse to trip and avoid repeatedly tripping the breaker Short run time less than usual Undercharged battery Charge the battery A new battery should have been charged for at least 12 hours before using the scooter for the first per charge time and up to 8 hours after each subsequent use Check all wires and connectors Make sure the charger plug is tightly plugged into the charging socket and that the charger is plugged into the wall Make sure power flow to the wall outlet is on Battery is old Even with proper care a rechargeable battery does not last and will not forever Battery life depends on scooter use and conditions accept full Replace the battery if necessary charge Hand brake is Adjust the handbrake neutral position to reduce the friction not adjusted between brake disk and brake lining when brake is in neutral properly position Scooter runs Tires are not Make sure the ti
30. rt m the park brake circuit If this flash code appears at power up check for an open circuit in the park brake circuit Contact your service agent 6 Out of neutral Iv Throttle is not m neutral position when turnmg key at power up switch Return throttle to neutral turn power off and back on agam Throttle may need to be adjusted see Section 4 2 3 Check throttle winng 7 Speed Pot Ivi The throttle speed imitt pot or wiring may be error faulty Check for open or short circuits The throttle or speed lmit pot may not be correctly set up If no speed lmit pot is fitted the Speed Pot Limit parameter must be set to 255 Contact your service agent 8 Motor volts The motor its wirmg 1s faulty Check for short error circuits Contact your service agent 9 Other internal Drive Contact your service agent errors inhibited 10 Push Too Fast Iv The scooter has been pushed faster than the fault inhibr programmed Push Speed parameter when the Park Brake Release function has been operated The scooter has been pushed faster than the programmed Rollaway Speed parameter when the Park Brake has been mechanically released Tum the scooter off and then back on agam 8 CHARGER HP8204B 8 1 Operating Instruction 1 To select the input voltage 115V 230V and make a correct option by 115 230V option switch 39 2 To assure the charged batteries are lead acid batteries 3 To keep the AC power switch in of
31. s 70A model DS72K for small to medium size scooters 110A model DS112K for medium to large size scooters 160A model DS162K for large scooters 7 1 RHINO Connections and Wiring RHINO connections are located along the front of the case The illustration below indicates the different connectors and gives a section reference for specific installation instructions When all wiring has been completed it must be securely fastened to the scooter frame to ensure there is no strain on the connectors or any chance of snagging Before making any connections to RHINO disable the scooter by one of the following means to prevent accidental movement or arcing 1 place the battery circuit breaker in the open position or 2 disconnect the batteries 22 Typical Wiring Diagram for RHINO DS52K DS72K DS112K VOS 09L ONIHY Typical Wiring Diagram for RHINO DS162K the controller settings can be 2 held programmer DZ DS PM DZ DS PM Manufacturer Version Programmer Tree 7 2 Programming RHINO Using a hand modified if desired 24 Display Fault Information Acceleration Deceleration Maximum Speed Forward Speed Reverse Speed Reduce Speed Buzzer Volume Motor Resistance Sleep Time Maximum Current Soft Start Period Park Brake Delay Pot Neutral Alt Speed Pot FSD Alt Speed Pot Dead Band Wig Wag Fault Threshold Single Ended Pot Motor Reverse Pot Reverse Speed Derati
32. solutions Problem Possible Causes Solution Scooter does Undercharged Charge the battery A new battery should have been charged not run battery for at least 12 hours before using the vehicle for the first time Scooter not moving and lights do not work using battery but lights do work when you plug the charger into the scooter and also plug the charger into the wall outlet Charger is not working Burned out fuse and up to 8 hours after each subsequent use Check all connectors Make sure the charger connector is tightly plugged into the charging inlet and that the charger is plugged into the wall Make sure power flow to the wall outlet is on You may check to see if your charger is working by using a volt meter Replace the fuse Scooter does not run Scooter not moving and lights do work using battery Controller diagnostic flashcode Status LED fail Follow controller section Chapter 7 3 2 to see flashcode meanings and Solutions If status LED is dimly light or not working replace with new one Scooter not moving and all lights do not work with only batteries Burned out fuse Loose wire Connection Replace the fuse Check if wires connections are tight Scooter was running but suddenly stopped Controller trip Tripped circuit breaker or burned out fuse The controller will automatically shut off the power if the motor is ove
33. utput for the controller type 1e 50A for the DS 52K Higher settings than the controller is capable of have no effect on the maximum current rating 29 Values Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default DS72K Dealer Prog HHP Soft Start Period Pot Neutral Alternative Speed Pot FSD Full Scale Deflection Alternative Speed Pot Dead Band Description Can be used to soften the 1nitial take when the throttle is moved out of neutral Set the length of time m steps of 16 milliseconds at which acceleration will be 50 of the maximum when starting from neutral The factory settmg generally gives the best performance Sets the tme between the scooter coming to a stop and the park brakes engaging Too high a value can cause excessive creep back when stoppmg on a slope too low a value can cause the scooter to lurch when stopping The factory default generally provides the best performance If the Check for Slope setting m the Options Menu 1s set to ON this setting is ignored Sets the neutral position of the throttle Care should be taken when changing this setting otherwise eratic operation may result if the throttle wiper becomes detached Sets the throttle position at which the RHINO reaches maximum speed If set too hi
34. wo seconds DYNAMIC CONTROLS XXX Programmer DS100Px VER The display then changes to the Main Menu screen Press ENTER to go to SETUP MENU If the scooter currently has a fault pressing the MENU button displays the Fault Menu screen FAULT fault description is displayed here MENU 2 Press MENU to return to the Main Menu 3 Press MENU while in the Main Menu screen to cycle through the available menus Setup Menu Allows the scooter to be customised for the user s driving preferences or environment Options Menu Allows the scooter manufacturer to optimise RHINO for a particular scooter model Can only be changed with a Manufacturer version Programmer Profiles Menu Allows the editing uploading and downloading of scooter profiles Available on Manufacturer version only Speed Lever in Neutral Allows calibration of the throttle about Menu neutral Controller Version Menu Gives controller version information 4 Select the required menu and press ENTER The selected menu screen 15 displayed 26 Setup and Options Menus The procedure for modifying settings in the Setup Menu and Options Menu is the same as outlined below 1 While in the Setup or Options Menu press NEXT to cycle through the available settings SETUP Acceleration 7 MENU NEXT VARY ENTER N Press VARY to change the value of the currently selected setting Press ENTER to confirm the new value
35. y Setting this to a higher value will cause the scooter to actrvate the Battery Saver feature earher providmg additional battery protection but lmutmg scooter performance particularly on slopes Setting this to a lower value will cause the scooter to contmue to perform optimally for longer but may shorten battery 31 Values Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog HHP Minimum Maximum Default Dealer Prog Minimum Maximum Default Dealer Prog HHP Battery Circuit Resistance mOhm Speed Limit Pot Minimum Push Speed Limit Description If the resistance of the battery circuit 5 entered the controller will be able to calculate a far more accurate battery voltage used m features such as the Battery Saver Limits the maximum forward and reverse speed of the scooter If Digital Pot implementation is used the Reduce Speed setting determmes the reduce speed parameters If Analog Pot implementation 5 used Speed Limit Pot ON allows the Reduce Speed Switch to let the speed potentiometer control the scooter speed Must be set to 255 if no speed reduction pot 15 fitted Increases the amount of throttle movement required before the park brakes will disengage Helps to prevent rollback on slopes If RHINO turned on and the park brakes have been electrically released using the Park Brake
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