P320 Service Manual - Merits Health Products
Contents
1. 15 5 4 5534 16 6 Scooter troubleshooting 17 Typical problems and solution 7 Controller Rhino C40 and S drive 19 7 1 Connection and wiring 19 7 2 Programming 22 7 2 1 Setup Menu For Rhino and C40 22 7 2 2 Option Menu For Rhino and C40 28 7 2 3 S Drive programming setting 31 7 2 4 Common programming errors 32 7 3 Diagnostics and fault finding 33 7 3 1 Diagnose fault 33 7 3 2 flash code 36 8 Charger 37 8 1 Operation instruction 37 8 2 LED indication 38 8 3 Troubleshooting 38 9 Scooter diagnostic flow chart 40 Introduction The purpose of this manual is to provide dealers and or2. If set to ON C40 will automatically stop driving after it Current limit has been in current limit for 15 seconds A flash code 4 l timer will be displayed and the scooter must be turned off and on again to reset Set to ON to reverse the polarity of the motor pins on the Motor reverse Motor connector The motor will turn in the opposite direction ON OFF OFF to normal Load Allows C40 to maintain a constant speed regardless of oa ies changing driving conditions This should be ON for ON OFF ON Compensation normal operation 7 2 3 S drive programming settings 31 0 1 to 10s Fast Slow 0 1 to 10s Fast Slow 0 1 to 10s Fast Slow 0 1 to 10s Fast Slow 0 to 100 Fast Slow 0 to 100 Fast Slow Yes No 0 to 20 minutes On line help text Trip codes from controller Mew stored diagnostic codes Mew elapsed running time 20A to max rating Oto 10 100 to 420 0 to 100 1 to 255s Oto 1s 0 1 to 10s Fast Slow Hi Lo 1 t0 6 0 to 5s 0 to 1250 Yes No Yes No Yes No On Off 3 to 100 20 to 40V 10 to 250mQ TruCharge Cal 1 to 200 Max Charge Amps Oto 12A Min Charge Amps 0 to 12A Erase System Log Clears stored diagnostic codes Clear Timer Resets run timer lt O RJC BAC LIC ORIO Li EJ ORIO R 7 2 4 Common Programming Errors Sometimes after changing certain parameters in particular wh
3. 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 8 1 Operating Instruction 1 To assure the charged batteries are lead acid batteries 37 2 To unplug the AC power input before the charge circuitry and battery have been connected completely 3 To check if the output end of charger corresponds with the positive negative pole of battery 4 After the above sequences have been finished please plug the AC power input When LED turns yellow it means the charger has been under normal charging condition If the abnormal phen
4. aged 6 The yellow green LED have flashed over 40 minutes during charging To check if the battery is broken down 38 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 AC power unplugged 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 39 9 Diagnostic flow Chart 1 1 Main flow chart 1 Scooter can not move s speed gauge O Dash board failure ight steag 40 Replace dash board ead ligh 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 41 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 42 Full charge the battery Battery failu
5. distributors with the product information and instructions that are required for servicing the S2 S5 series electrical scooter 1 Service Guide Batteries Motors Brush and brake Tiller instrument Electrical illustrated parts breakdown Troubleshooting Rhino C40 and S Drive 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 Scooter without battery box 1 Remove the seat and shroud 2 Disconnect the wiring harness from the batteries by removing the screws 3 Remove the batteries from the scooter base Scooter with battery box 1 Remove the seat and battery box 2 Follow specific scooter service manual to dismantle battery box 3 Remove the batteries from the battery box 2 3
6. 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 Scooter can Loose Check if wire connection is tight move but the wire connection battery gauge does not work Battery gauge Battery gauge is bad Replace new ones 7 Controller Rhino Controller C40 Controller and S Drive controller 7 1 Connections and Wiring Controller 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 the controller 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 19 Typical Wiring Diagram for RHINO DS72K 25730A z ON OFF SWMTCH For variant Tier interface connection ations efe fo TILLER INTERFACE section Typical Wiring Diagram for S drive 21 Forsord Reverse 7 2 Programming Using a hand held programmer the controller settings can be modified if desired Programming Warning Only qualified personnel
7. Merits S 2 S 5 series Rhino C40 and S Drive Service Manual S2 S5 series 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 5 4 Tiller Instrument 10 4 1 Dash board 11 4 2 Throttle Potentiometer 11 5 Examples of Electrical illustrated parts breakdown 13 5 1 52353 13 5 2 5541 14 5 3 5538 5548
8. To install the Batteries Scooter without battery box 1 Install two new batteries into the power chair base 2 Connect the wiring harness to the batteries 3 Confirm the battery supply voltage the battery voltage to the controller should be at least 25VDC 4 Cover the shroud and install the seat Scooter with battery box 1 Install two new batteries into the battery box 2 Follow specific scooter service manual to install battery box 3 Confirm the battery supply voltage the battery voltage to the controller should be at least 25VDC 4 Put the battery box into scooter and install the seat 24 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 motor may have to be replaced should one of the following conditions occurs B The scooter s driving power decreases significantly B Loud noise from motor B Motor screwed up and fail ex Harness connector or case damaged The 24V motors are specifically designed for use on electrical scooter The m
9. ator 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 B Ensure the springs seat properly on the brush and the brush wire is placed properly Note Ensure correct insulation between motor case and motor wires refer ISO 7176 14 B Always replace all the brushes in both motors at the same time B 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 The parking brake may have to be replaced should one of the following conditions occurs B Poor parking brake holding ability B Parking brake screwed up and fail ex Harness connector or case damaged 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 B Cut solder the wires of the parking brake Avoid 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 B 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 orientati
10. e 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 Battery needs to be recharged If after full charging the 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 C It is too cold to operate 18 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 required This is normal for chargers and is no warm during response to cause for concern Ifthe charger does not get warm during use charger use use it does not mean that it is not working properly Scooter can not Magnetic brake Possibly the brake lining is worn out Replace the magnetic stop on a slope are not working brake properly Scooter takes Throttle Ifthe 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
11. ease 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 inhibited 34 If 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 pre
12. en 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 32 settings and the impact they have on the motion of the scooter Setting Result Motor Pot ae T eee Driving Forward Driving Backward O OFF Fast forward speed with buzzer OF O ON erp Fast forward speed with buzzer O ON Siop forward Fast reverse speed with buzzer 7 3 Diagnostics amp Fault Finding FF E ON F Fast reverse speed cm with buzzer FF N Controller provides diagnostics information to assist technicians with diagnosing and correcting faults within the scooter system A fault in the scooter will cause the controller 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 controller 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 operation 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 controller programmer Detailed descriptions of what each
13. espond 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 output 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 24 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 off 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 f
14. flash code means and the probable cause and remedy for each are described in flash code table 7 3 1 Diagnosing controller Faults Use the following troubleshooting guide if the scooter fails to operate The guide will help identify whether the fault exists within controller 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 33 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 If you can hear the solenoid or the relay the problem is 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 following Throttle pins Battery Throttle 0 5 0 1V Battery Throttle Wiper 2 5 0 1V Battery Throttle 4 5 x 0 1V When the Throttle is moved in the forward and reverse directions the voltage on Throttle Wiper should incr
15. for IFON stoppmg performance tends to be harsher than normal OFF Slope The Park Brake Delay settmg m the Setup Menu 1s bypassed when stoppmg on a slope Beep mode Sleep RHINO will beep three times when it goes into Skep 29 Current Limit Timer Enable Slam Brake Description Having this setting turned ON 1 a regulatory requirement m some countries If ON RHINO will automatically stop driving after the 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 will be undesirable for some users If driving resumes before the motor cools or if this option is tumed 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 altemative park brake release switch This parameter is not available on the DS72KA If ON when the controller senses the Mode Select switch 1s 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 If ON moving the throttle significantly m the opposite direction to which the scooter is currently moving causes the scooter to decelerate immediately at maximum deceleration rate as per the Deceleration settm
16. 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 indication 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 The motor brushes may have to be replaced should one of the following conditions occurs B The scooter s driving power decreases significantly B Loud noise from the brush 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 B Disconnect the motor B Remove the end cover to allow access B Remove the brush B Check the commut
17. g 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 Speed 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 C40 OPTION MENU 30 Setting Description Value Default If set to ON the throttle will control speed only with direction Single ended selected by the position of a Forward Reverse switch ON OFF OFF POT If set to OFF speed and direction are controlled by the throttle and no Forward Reverse switch 15 required Brake Checking Set to ON if the motor has a park brake ON OFF ON If set to ON Sleep Mode will be enabled and C40 will oto sleep after the sleep time specified in the Sleep mode gt E p p ON OFF ON Setup Menu
18. harger 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 overloaded 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 circ
19. in voltage is OK broken cable YES Replace resistor 47 FROM 1 2 heck insulatio between motor coil and case Controller failure controller Motor broken Replace Motor 48 Horn failure Dismantle tiller head and check horn switch Dash board PCB broken Horn switch broken Replace PCB Replace horn switch 49 head lion failure FROM 1 1 Replace the bulb Dismantle tiller head and check head light switch Dash board PCB broken switch Replace PCB Replace switch 50 5 3 Left indicator failure Replace the bulb Dismantle tiller head and check indicator switch Dash board PCB broken switch Replace PCB Replace switch 51 Dismantle tiller head and check indicator switch Replace switch 5 4 Right indicator failure Replace the bulb Dash board PCB broken Replace PCB 52 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 53
20. itch to Run Scooters powered by RHINO charge the batteries when traveling down slopes or deceleratmg Excessive charging m 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 again 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 is closed when powermg up 36 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 short 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
21. l flash code 7 Check if wires shorted or connector loose 2 Speed POT out of range control flash code 7 Measure the resistance between 1 and 3 of the potentiometer It must be 5KQ 10 If not Replace the potentiometer 3 Speed POT not in neutral position control flash code 6 Measure the resistance between 1 and 2 of the potentiometer It must be 11 2 5KQ 10 If not recalibrate the neutral position Measure the resistance between 2 and 3 of the potentiometer It must be 2 5KQO 10 If not recalibrate the neutral position Follow the wire color allocation as picture below to solder the wire to the potentiometer 12 5 Examples of electrical illustrated parts breakdown 5 1 S2353 scooter 9 NAME CONTROLLER b FUSE POWER CABLE 8 BATTERY WIRE 9 UNCTION BOARD 0 TET CHARGING 20 Por wre swen 0 Bini 13 5 2 S541 scooter ne ER 14 5 3 S538 S548 scooter 5 4 S534 scooter 6 Troubleshooting Typical problems and 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 c
22. mum 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 the higher the maximum reverse speed Anti tip wheels may be required if high Reverse Speed settings are used 23 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 A 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 for 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 r
23. n is 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 1s fitted Increases the amount of throttle Minimum movement required before the park Maximum brakes will disengage Helps to prevent Default rollback on slopes Dealer Prog HHP Push Speed If RHINO 1s turned on and the park Minimum Limit brakes have been electrically released Maximum using the Park Brake Release lever the Default speed at which the scooter can be Dealer Prog pushed will be limited to this value If HHP the Push Speed is exceeded the scooter will execute a controlled stop Defines the scooter response to throttle Minimum movement If set to 0 moving the Maximum throttle half of its travel will result in the Default scooter travellng at half its programmed Dealer Prog speed If set to 100 moving the HHP throttle half of its travel will result m the scooter travelling at around 25 of its programmed speed mcreasmg speed as the throttle is moved further C40 SETUP MENU Value Setting Description Max Min Sets the acceleration of the scooter A higher number gives a Acceleration greater acceleration rate A low acceleration will give softer 10 1 performance and give a less touchy throttle response 2 Deceleration As above but sets the deceleration of the scooter Lo
24. omena occurs please unplug the AC power immediately and check the 1 4 sequences repeatedly then plug the AC power again 5 When LED turns to green that means the batteries have been finished for complete charge 6 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 RED LIGHT ON Power On and Battery Disconnected YELLOW LIGHT ON Charging GREEN LIGHT ON Full Charged 8 3 Troubles Shooting 1 When the AC power plugged 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 AC power plugged but yellow LED do not light up completely To check if the output wire occurs short circuit 3 When the AC power plugged but green LED flashes and no charging action To check if the output fuse 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 AC power plugged and no effect at all After having been replaced with another new same fuse Please do not dismantle 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
25. on 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 c the brake 1n order to place back new brake correctly 4 Cut off the wires white and gray 5 Release the 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 Tiller instrument handles all accessories of the scooter like buzzer switches battery gauge charging inlet speed adjust throttle potentiometer Sometimes 10 the accessory problems may turn out to be caused by tiller instruments Make sure all wires are not loose and all connector are connected firmly 4 Dash Board PCB 250 Tiller Following picture shows function of each connector on dashboard PCB 1 Main cable connector 1 5 2 Key switch connector 3 Speed POT Connector 4 Charger connector 5 Status LED connector 6 Horn switch connector 7 Speed adjust VR Connector 8 Battery gauge connector 9 Horn connector 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 contro
26. or 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 high 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 25 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 brake
27. otors 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 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
28. re replace batteries 0 1 FROM 1 2 Controller being charged failure Stop charging and switch off on again If controller work Charger failure 43 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 44 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 45 2 6 Throttle out of neutral at FROM 1 2 Throttle neutral position displaced 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 46 i mo Remark POT 4 4 4 8VDC POT 0 2 0 6VDC FROM 1 2 of POT and POT on controller See remark Controller 1 replace failure controller and POT on control cable ee 120161 Replace controller cable ontroller cabl broken and POT on main cable ec emarK Replace main cable ma
29. re adjustable using a hand held programmer Settings via the programmer can be either ON or OFF Rhino OPTION MENU 28 Setting Description Default Single If ON the throttle controls speed only and direction 1s selected OFF Ended with a forward reverse switch Pot If OFF speed and direction are controlled by the throttle No forward reverse switch is 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 reversed 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 a 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
30. s will be apphed when the Check for Slope settmg is set to ON Sets the threshold at which the Battery Discharge Indicator BDI shows a 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 battery 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 26 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 Description Values Battery If the resistance of the battery circuit 5 0 Minimum Circuit entered the controller will be able to 50 Resistance calculate a far more accurate battery Default mOhm voltage used m features such as the No Prog Battery Saver HHP Speed Limits the maximum forward and 38 Minimum Limit reverse speed ofthe scooter If Digital 75 Pot Pot implementation is used the Reduce Default Minimum Speed setting determmes the reduce Dealer Prog speed parameters If Analog Pot HHP implementatio
31. sent 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 35 7 3 2 controller Flashcodes Impact on Flash Code Fault Scooter l Battery needs W Battery charge is 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 the 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 sw
32. should make alterations to controller programming Incorrect or inappropriate programming of controller 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 If the scooter is turned off during programming any changed settings are not saved and controller defaults back to the previously programmed settings 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 for Rhino and C40 These settings customize the scooter to user preferences and or environment Rhino SETUP MENU 22 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 maxi
33. uit happens If the scooter 17 suddenly stops running push the breaker to reset the circuit 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 per charge Undercharged battery Battery is old and will not accept full charge Charge the battery A new battery should have been charged for at least 12 hours before using the scooter for the first 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 Even with proper care a rechargeable battery does not last forever Battery life depends on scooter use and conditions Replace the battery if necessary Scooter runs sluggishly Tires are not properly inflated Scooter is overloaded Battery problem Make sure the tires have sufficient air but this usually is not 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 Make sure you do not overload the scooter by carrying too much weight going up a hill or towing objects behind the scooter If the scooter is overloaded the controller may go into protection mod
34. w values should only be used with very low Forward Speed values 10 Forward Speed The maximum forward speed of the scooter The higher this setting the higher the maximum speed 10 Reverse Speed As above the maximum speed of the scooter in reverse 10 Reduce Speed Limits the maximum forward and reverse speeds of the scooter to this value For example if Reduce Speed is set to 7 Forward Speed to 10 and Reverse Speed to 6 Forward Speed will reduce to 7 Reverse Speed will stay at 6 as it is already lower than Reduce Speed 10 Buzzer Volume A value of 1 turns the hom buzzer off Any other value gives full volume 10 Sleep time Sets the length of time with no throttle movement before C40 goes into Sleep Mode The status LED will turn off and the scooter will not respond to any commands Power must be turned off and on again to exit sleep mode See Enable sleep in the Option Menu to turn this feature ON or OFF 30 Current Limit This sets the maximum output current to the motor Lower value may affect scooter power 40 20 Brake Delay The delay between the scooter coming to a rest and the park brakes engaging A low value will minimise creep after stopping 15 Motor resistor Resistance of the motor to which C40 is connected Required to achieve good speed regulation 250 100 7 2 2 Options Menu For Rhino and C40 These settings a
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