Maintenance Manual
Contents
1. Double Cane Holder F Mechanical Adjustments dd Height oeat pin under the battery Release both secure bolt and cover level bolt Change pin Level hole as required Rescuer both level bolt and secure bolt Adjustments 3 x 20 mm see attached assembling drawing Armrest x Adjust the angle Front lights Release the screw and adjust The angle of the front lights 6 Front Electronics Board Setup The Horns can be setup to work in one of the follows options Controller alarms Tiller push button Reverse alarm Blinkers alarms The front board include setup options for the Horn This can be done with the dipswitch DSW1 that is on the front board Deep switch User Modes setup with relate to user needs Dip Switches Setup is as follows Shown the Default oet Up State Description 5 f Controller Programming Setup If the user cannot find a position on the half speed limit switch control that suits him the controller can be programmed to meet his needs Ihe controller can be programmed in two ways with an SP1 Programmer or specialist PC software and interface cable The SP1 is a small hand held unit which can be plugged into your controller to alter the program or into the charger Socket 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 the2. Revision 3 19 7 2013 PRC4014b BKEEZE The Senior Class Lifestyler Maintenance Manual AFIKIM ELECTRIC VEHICLES Contents 10 10 1 10 2 11 12 13 1 1 1 Safety instructions Specific Tools for technicians Specific Parts Options Accessories assembling Mechanical Adjustments Front Electronics Board Setup Controller Programming Setup Periodic maintenance Check Mechanical Fault troubleshooting Control and Electronics system fault troubleshooting General control system and Front Board Troubleshoots Controller Troubleshoots Mechanical assembly drawings Spare parts list General Wiring diagram Safety instructions General 11 12 14 14 15 17 17 17 Technicians who are servicing the scooter should be authorized to service the scooter Technicians who are servicing the scooter should be aware and follow all safety instructions within the User Manual Technician should follow general safety instruction like using gloves safety glasses when needed The scooter weight with batteries is about 100 kg even lifting 1 wheel is about 30 kg Always use other people help or an appropriate lifting device When lifting always use your legs and not your back The battery weight is about 14 kg The power unit weight is about 15 kg The seat weight is about 20kg Never do any change in the product before consulting the manufacturer engineering Remember the products are a
3. 4M 430 J26 Mikroswitch L C fas LEL 429 q gt i ce o m o A 4 C O e C5 GL c E u E a 6 0 mm2 6 0 mm2 Cherge Fuse F2 2 1 10A FUSE 12V Batt Q t COMPANY Breeze C wiring diagram Update Add slow fast switch DRAWN DATED SHMUKLER ANATOLY 03 09 CHECKED DATED Avner Fishbain 31 08 10 QUALITY CONTROL RELEASEO Avner Fishbein
4. absorbers if needed Rear suspension Check user weight and the fit of Replace if needed not functionin the absorbers vite Replace if needed Faulty shock absorbers travel between current Also might be noisy current and replace if chargin needed Replace the battery Ing Battery low voltage Check the charger Unsecured screws and gas Check secure of piston faulty Screws Replace gas piston if needed Scooter does not Wear in motor brushes Replace motor have power or brushes does not brake well or go to high C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 13 speed downhill T 421 4 a an Er hb X phat t IPA Noises from motor Wear of brushes Check brushes and replace if needed Faulty motor Replace motor Flat tire and Flat tire Repair replace tire s uneven and not tube ONENE Take out the cover Open the central nut Take out the air Open the 4 screws Replace the tube Inflate the tub a little bit before assemble After assemble inflate to 25 2 psi C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 14 10 Control and Electronics system fault troubleshooting 10 1 General
5. and safety glasses 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 2 3 Specific Tools for technicians otandard 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 v 2 blocks 20 22 centimeters height to place beneath the batteries box v 2 blocks 14 16 centimeters height to place beneath the foot rest area v Remark Always before operating a lifted Breeze make sure that the 2 rear wheels are free to turn so that the scooters will not move Specific Parts We recommend the availability of the following set of test and repair assemblies D ue un ee SUB ue rect Front Board Main Harnesses Cable Main Lights Harness Cable Main Supply Harnesses Controller S Drive 120A P amp G Motor Power Unit Also it is very much recommended hold and use P amp G SP1 Programmer for S Drive possible to upgrade old model of SP1 programmer to fit the S Drive free of charge 4 Options Accessories assembling Most accessories based on the rear square pipe The accessories are 4 1 Rear Basket 4 2 Seat safety belt 4 3 Walker Holder 4 4 Cane Clip Attachment 4 6
6. special interface cable Ihe controller can then be programmed using a windows type environment The programming tools may be included with your scooter If they are not the scooter distributor or service agent or scooter manufacturer will are able to program the controller If you have a programmer read the user guide before you use it If you re program your controller make sure that you observe any restrictions given in your scooter user manual Note any changes you make for future reference Programming should only be conducted by healthcare professionals with in depth knowledge of PGDT electronic controllers Incorrect programming could result in an unsafe set up of a scooter for a user PGDT accept no liability for losses of any kind if the programming of the controller is altered from factory pre set values 7 1 Controller Programming with hand programmer SP1 The list of parameters fit to power units 950W 12km h 10km h and 15km h The parameters refer to S Drive 120 controller with hand programmer SP1 To program through the Charge Socket use the adaptor Programmer SP1 Adaptor to the Charger Socket Instructions to change the parameters ile 2 3 Connect the adaptor to the programmer and connect to the Charge Socket the programmer will start working The up down arrows let you choose the parameters In order to change a parameter stand on the parameter press enter the values will
7. C or after a long time parts and damaged not using it parts Use the figures 5 Check secure of all Technician Once a year by technician screws and parts Batteries replacing Technician Every 2 3 years after about 300 400 full cycles of charge discharge When short travel distance and or technician check Note To Replace the batteries the Seat and Battery Cover located under the Seat must be NO C2 removed N External when needed Technician Internal Once a year Check power unit Technician Check noise clearance current on surface should be 12 to 14 Amp Removing the Turn the Seat by using the lifting Lever so that the Lever will point 45 Right Seat and the or Left The Seat can be removed only at this position Batteries 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 Cover 2 Warning The seat weight is 20 Kg 44lbs 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 Replacing the The replacement of the Cover is done in reverse order MAKE SURE that the Batteries Cover 2 fits onto it s place Secure with the 4 screws 2 6 Cover 2 Batteries Batteries weight each is 14 Kg 30 Ibs and over Lift each battery only with the a
8. R VLLL ok eK RK ko k o Sarai fault Replace the Controller the Controller Ld hold IS Vidc dl display and Locos EN known fault of the ara s INN follows Fault Bars table and a code is shown controller has been found repair the according scooter does not drive display control system system habe shoot a a Weak Old batteries replace if needed C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 16 10 3 The fault code from the SP1 Programmer More codes you can see on the hand programming SP1 When the fault exists connect the SP1 programmer s connector directly to the controller SDRIVE or to the charging socket using a special wiring adaptor The fault will be displaed on the SP1 programmer display Table 1 Check the solenoid brake s wiring amp connections to the controller then retest Check the batteries wiring amp connections to the controller then retest Also possible a condition of high load driving downhill 1E09 Check the wiring amp connections to pin 6 of the 14 way tiller connector then retest Inhibit 2 check EMB manual brake micro switch 1EOA N A for Breeze C 2CO00 Check the batteries wiring amp connections to the controller then retest 2F01 Check the throttle is not displaced on start up or does not return to natural condition then
9. 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 LEDS on the display Elimination troubleshoots The Front Board wiring connections are all quick connectors If you suspect the Front Board to be faulted we recommend as a quickest way to find if the Front Board is faulty Doing by elimination Just replace temporarily the Front Board with another working one and thus make sure if the problem is within the Front Board or somewhere else Check all connection of the Front Board following the wiring diagram that can be found at the end chapter of this maintenance manual Check main and Charge fuse located under the seat Also always check related function switch as an example Light does not work first check the light switch for continuity when it is in ON position Use the wiring diagram to figure the proper terminals to check each function switch terminals Trouble Shoot Table f Description Probablecause _ Repairaction FrontBoardfauty Replace Frond Board FrontBoardfauly Replace Frond Board Front Board faulty Replace Frond Board Front Board faulty Replace Frond Board Hornig faulty Replace Frond Board Front Board faulty Replace Frond Board 6 Hazarddoesn twork Hazardswitchfault Check switch and
10. ections 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 Note Make sure the controller have the rights parameters setup Check all connection of the controller following the wiring diagram that can be found within this maintenance manual Controller inform faults Codes in 2 ways 1 The main LED ON Fault indication 2 SP1 programmer Trouble Shoot Table for the ON Fault LED ol ume Probable cause Power is On in the LED Controller fault Replace controller display but Scooter Wiring connectors fault Check repair wiring connector does not drive No code Front board fault Replace front board shown The LED On Off Indicate the problem By flash code sequence 2 2 Low battery Battery empty need to recharge Change the charger Replace the battery Se 2b x ed SER OUR wis aR EME wire from E M B peer qmm 26 x Throttle trip The accelerate lever pressed while turn the key switch to On Check the wires to the controller 2 k x Throttle trip The accelerate lever pressed while turn the key switch to On Check the wires to the controller DPDIJMASALAAJN x k k k k RK ok Motor disconnect Check the wires to the Motor Spe R
11. m 17 18 A 6 5 4 5 PCBRO22 breeze Front blinkers Front Lights PCBRO on EBAN P P Lamp r 22 5reeze Front blinkers 4 L Blink R Blink i A 5Kohm 6 x 0 5 mm2 Speed Limit Potentiometer JR17 JRIB Ciis URIs JRiglrottle Potentiometer Reor Lights Harness 6 x 0 2 mm2 4 R blink LER lA Biel re RI E 744 Bat ot High PS a Key Switch A P Main Harness 18 x 0 5 mm2 Pot Wiper M Pot High Audio Alarm Siow Fast 24V QN On Of inhibi totus Led 12v er t Pot Low Pot Limit pig t x Qutpu Reverse ov D flosh L inhib 3 Freawnee 14 PCC4001 Breeze C Front Board Indicators n i C i 2 connector or Lu i wires option a a R blinker m x GREEN i A t h 7 i gt 43 3 c i ort t s i L blinker i GREEN gt o 4 e Dd yee devs de di de i 5 2 z S z a I zd b 1 A i 1 e ale da fe fo I PCC4003 Breeze C butions PCB XLR Program Adaptor o 9 a gt a Main Fuse Z F1 1 2 6 0 mm2 FUSE SOA i9 O 12V Batt O XLR Charqe Program E H 2 5 mm2 2 5 mm2 Charger Plug Q 2 1 REVSON RECORD O O OOO O OAE EE E QM R Rear Lights L Rear Lights PCC4002 8reeze C rear lights x 4 Bote Batt pra Inhibitt Preg LiT 120A Programmer t I Tiller Interface LELLLLUPEEL Aux Output Reverse 0 Y Inhib 3 Freewheel
12. ppropriate handle Keep lifting with your Knees legs and not loading your Back Tires Correct air pressure in the tires is essential for optimal steering and stability of the Breeze C Check air pressure every two weeks Inflate to the proper air pressure 25 2 psi Breeze 4W front tires 25 2 psi Golf wheels tires 25 2 psi Cleaning Use only a damp cloth and mild detergent Never use a hose for cleaning This may severely damage the power and electronic components C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 12 9 Mechanical Fault troubleshooting apon Probable cause Noises from front Check front suspension for Replace wear parts steering and clearances and secure of bolts secure bolts suspension system Check front shock absorbers Replace if needed Check the rod end for clearance 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 P Un adjusted steering system Hear suspension Wear in power unit absorbing Replace the Noisy Rubbers absorbing rubbers if Check for clearances and needed unsecured parts secure parts Check the shock absorbers Replace shock
13. pprove as they are any change remove the manufacturer responsibility for the safety of the product 1 2 Drive 1 2 1 Technicians who are driving the scooter should be aware and follow all safety instructions within the User Manual 1 3 Mechanic 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 It is possible that a technician will need to operate the scooter when he is standing on the side working on different assemblies When no electric power and operation needed always Stop the power by owitch OFF and disconnecting the battery terminals Never put any part of your body under the scooter parts If necessary first place a wood block under to make sure no injure will happen Use standard tools Use them according to their safety instructions 1 4 Electric 1 4 1 1 4 2 1 4 3 1 4 4 1 4 5 1 4 6 If necessary to operate the scooter when you are not seating on it In such cases you should be aware to the parts that can move by power Power unit shafts and wheels 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 Batteries contain a large electric energy inside This energy can cause sparks and heat metals when short circuiting 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 When working on the batteries use protecting gloves
14. repair L Front Board faulty Replace Frond Board Z Reverse function does work Reverse switch fault Check switch and repair _ 5 EEan EMB release function EMB release Switch Check switch and repair does not work faulty No Charge start Charger fault Replace charger Charge fuse popup or Heset Replace charge fuse faulty Travel distance very low Charger fault Replace charger Old Weak batteries Check Batteries charge batteries Replace if needed 13 No ON Supply power to the Over load Try to reset 2 times control system Mechanical fault Troubleshoot the fault Faulted controller Replace the controller Faulty power unit Replace the power unit Find and repair short circuit Note Main Fuse is located under the seat Short circuit occur C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 15 10 2Controller 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 If any driving misbehave occur Elimination troubleshoots The controller wiring conn
15. retest Check the tiller amp throttle wiring to the controller then retest Table 2 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 ocooter drives slowly Check the controller is programmed correctly then retest ocooter drives slowly Check the speed limiting function is not active e g seat raised then retest ocooter drives slowly Check the solenoid brakes are not jammed then retest otatus 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 Reverse 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 ocooter will not drive in reverse Check the reverse switch is working correctly then retest C Users avner Desktop holland conference Breeze C 9 MAINTENACE 3 Service Manaul Service manual Eng Breeze C Maintenance 19 7 2013 PRC4014b doc 17 11 Mechanical assembly drawings See attached assembling drawings Breeze C 3 4W assembling pdf 12 Spare parts list Can be found using the assembling drawings 13 General Wiring diagra
16. then appear in the display window With the help of the arrows you can change the values After changing the value push enter the scooter will beep turn key switch off and then on The programmer will display the next parameter To make further changes repeat step 5 Press enter again to return to the parameter menu When you get to the Engineer Menu press enter to get to the sub menu How to improve and to adjust parameters to the customer Change the acceleration of the scooter forward Line 1 Change the deceleration of the scooter forward Line 2 Change the acceleration of the scooter reverse Line 3 Change the deceleration of the scooter reverse Line 4 Change the max speed forward Line 5 Change the max speed reverse Line 7 Change the direction of travel of the Wig Wag Invert Throttle Line 9 The time until entering into sleep mode when the key switch is On Sleep Timer Line 10 9 Reads the Code number of faults and how many times they occurred Read System Log Read System Log Line 11 10 Working time of the scooter Read timer Line 12 pee s 7 2 Controller Parameters List for manual and PC programmer See external separated file 10 11 8 Periodic maintenance Check Check air pressure in User Every week all tires Check normal drive Every Month and stop Check tires wear Every Month Check for missing User When receiving the Breeze
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