Afikim Breeze User manual

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Breeze
Maintenance Manual
Afikim Electric Mobilizer
Kibbutz Afikim 15148, Israel
Tel.: [phone]
Fax : [phone]
Customer Service : 972-4-6754180
E-mail: [email protected]
Website: www.afiscooters.com p/n – PRBR003

2
November 2003
Revision : 03
Product: Breeze - all models
Warning
Please read this manual carefully before engaging in any maintenance operations of the
Breeze. If you have any questions about the contents of this manual, please do not
hesitate to call the company for clarification.
Maintenance operations should be carried out only by authorized technicians of Afikim
Electric Vehicles or its representatives.
Remember - any product which does not functional properly may cause harm to either
property or persons.
Warning
Electro-Magnetic Interference may cause the vehicle to perform in an unanticipated
manner, endangering the user. For your safety, before using the Breeze, it is strongly
recommended to read Chapter 4 "Electro-Magnetic Interference " carefully.
The serial number and manufacturer details are on a label adjacent near the cellular cabin
.

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TABLE OF CONTENTS
Chapter 1 – Maintenance 1
1.1 General and Safety Instructions to the Technician 1.1
1.2 List of Recommended Tools for a technician 1.2
1.3 Periodic Maintenance 1.3
1.4 Handling (Wet) Batteries 1.4
1.5 Basic Cleaning of the Breeze 1.5
1.6 Shock Absorbers Adjusting to the User Weight 1.6
Chapter 2 –Troubleshooting and General Faults Repairing 2
Chapter 3 - Electrical and Electronic Systems 3
3.1 Main Electric Wiring Diagram 3.1
3.2
Main Electric and Electronic System Description 3.2
3.3 Troubleshooting Electric and Electronic Faults 3.3
3.3.1 General instructions for Electric troubleshooting 3.3.1
3.3.2
Troubleshooting Electric and Electronic Faults 3.3.2
3.3.3
Troubleshooting Charging Problems 3.3.3
3.3.4
Voltage supply measurements 3.3.4
3.3.5 No Load Test and Driving Test 3.3.5
3.3.6 Potentiometer Tests and Calibration 3.3.6
3.3.7 Status Indicator - Fault Diagnosis 3.3.7
3.3.8 Programmer SP-1 Fault Diagnosis 3.3.8
3.4 Controller Parameters Set-Up 3.4
3.5
Front Board Alarms / Horn Dip switches Adjusting 3.5
3.6
SP-1 Programmer Manual 3.6
3.7 SOLO 130A Controller Manual 3.7
3.8 True Charge Battery Gauge Manual 3.8
Chapter 4 – EMI Warnings 4
Appendix A - List of Recommended Spare Parts/Assemblies A
Appendix B - Exploded Drawings of Parts and Assemblies B

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CHAPTER 1 – MAINTENANCE
1.1 GENERAL AND SAFETY INSTRUCTIONS TO THE TECHNICIAN
Warnings
1. When handling the Breeze mechanical systems such as the motor, transaxle, wheels and
electro-magnetic unit, the main supply should be disconnected by removing the battery
cables in order to prevent accidental operation.
2. When conducting electrical tests, elevate the rear wheels using a jack or stable block of
wood. Avoid touching moving parts such as wheels and axels.
3. Any maintenance operations must be carried our by a trained and authorized technician
only.
The following instructions are directed to the technician responsible for the maintenance or repair of the
Breeze :
1. Always ensure that the Breeze is positioned on a straight horizontal surface, the key is removed
from the key switch and the handbrake is locked in the parking position.
2. Before commencement of any operations, perform a visual examination of the Breeze for a
preliminary identification of problems.
3. Before replacing or repairing front wheel, elevate the front section of the Breeze .
4. Always before operating a lifted Breeze make sure that the 2 rear wheels are free to turn , so that
the scooters will not move .
5. Always before operating a lifted Breeze make sure that any person hands , legs , chains etc. are
away out from possible moving parts . Also make sure that no object is placed so that when start
operation of the scooter , it might move and injure anybody .
6. When a Breeze is brought for repair, the fault should be identified using the table in Chapter 2 –
Troubleshooting and Repair of General Faults.
7. When a Breeze is brought for a routine check or regular maintenance work, use this chapter for
information.
8. Before lifting up the scooter or any of it’s parts , make sure about it’s weight , And if needed ask
for an assistance help . Here are Breeze main parts weight :
Weight
Part
Kg lbs
Complete Breeze 130 286
Front Section 40 88
Rear Section (2 wheels) 90 198
Each Rear wheel 45 99
Battery (each) 22-24 48-53
Seat 15-17 33-37
Transaxle Power Unit 20-22 44-48

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1.2 RECOMMENDED TOOLS AND REPLACEMENT ASSEMBLIES
Specific Tools:
•Standard tool box (wrenches, socket-head cap screw , hexagon keys, Phillips (crosshead) tip
and/or screwdrivers, etc.)
•Voltmeter (To measure 24VDC)
•Air pressure gauge (To measure 35 psi)
•Batteries tester (under load)
•Density meter
•Valve Wrench
•Wooden blocks to elevate the Breeze during checks, maintenance and repairs:
92 blocks 20-22 centimeters height to place beneath the batteries box .
92 blocks 14-16 centimeters height to place beneath the foot rest area .
9Remark : 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:
°Handlebars switches – Left and Right
°Front Board
°Display Board
°Main Driving Harness Cable .
°Main Lights Harness Cable .
°Mail Supply Harnesses
°Rear Board
°Controller SOLO 130A - P&G
°Controller Control cable
°Motor
°Also it is very much recommended hold and use P&G SP-1 Programmer .

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1.3 PERIODIC MAINTENANCE
Although the Breeze requires little periodic maintenance, careful compliance with pre-defined maintenance
operations will reduce the probability of faults and ensure regular and smooth operation of the Breeze .
During the maintenance operations, ensure that the Breeze is firmly positioned on a flat horizontal surface,
the key is removed from the key switch and the brake is locked in the parking position.
Periodic Maintenance
No. Nature of Maintenance Operation Frequency
1 Check air pressure/add air to tires. This operation
should be performed by user after receiving
instructions from the technician. See below.
Weekly
2 Check water level in batteries/add water (distilled
water only!).
Note! (for wet batteries only):
To be performed only by the technician or the user,
after receiving instructions from the technician. See
below.
Once in two months or
according to battery
manufacturer's instructions
3 Check emergency brake. This operation should be
performed by technician
Annually
4 General check for released screws, cracks and excess
clearance of axles. This should be made only by
trained technician .
Annually
Check Tires and Air
Pressure (may be
performed by the user)
Maintaining correct air pressure in the Breeze’s tires is
important to achieve a smooth ride and the stability of the
vehicle.
Checking the tires is extremely important. Perform a visual
check of the integrity and appearance of the outer tires and
ensure that tires are well placed along the entire circumference
of the wheel rim.
Check air pressure in the tires weekly and after any prolonged
period of storage.
Correct air pressure in PSI 35±5 (adjusted to passenger's
comfort).
Air pressure may be checked and air filled at gas station air
pumps or using a manual air pump equipped with a pressure
gage. Add air as necessary.

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1.4 BATTERY MAINTENANCE
Faulty batteries may cause many other faults in the Breeze. Although the user should provide
regular care of the batteries (recharging and filling water on wet batteries only), this is insufficient
to handle all problems which may arise. A technician should perform battery density tests and load
tests after recharging batteries.
Note: Checking a fully charged battery immediately after recharging may produce misleading
results. Checks should be performed on a charged yet not fully charged battery or after a short
travel.
Regular Care of Batteries (wet only)
Remark : Wet Battery are not aloud
for use in all markets were EN12184
and CE Mark approval are required.
Once every two months - water level in both
batteries should be checked, or according to
manufacture's instructions, if such exist.
Check (for wet batteries only):
oRemove the seat and the Battery cover.
oOpen the battery cells covers.
oUsing a flashlight, check the water
level in each of the battery's cells.
oCorrect water level should be app. 6 mm
above the plates.
oIf water level is less than the required
level, add distilled water only.
oAfter completing check, ensure all
battery cells covers have been properly
replaced and closed. Replace gray
cover and seat.
Notes:
1) Only distilled water should be used to
fill batteries.
2) Replacement of one battery necessitates
the replacement of the other. The
manufacture and Manufacturing Date
code should be identical for both
batteries.
3) When using battery Dry or GEL no
maintenance or check is necessary.
Any how refer to manufacture's
instructions.

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Acid Density Test (wet batteries
only)
Recommended
Remark : Wet Battery are not aloud
for use in all markets were EN12184
and CE Mark approval are required
oRemove the seat and gray cover.
oUsing a hydrometer, check the acid
concentration in each of the battery's
cells. Ensure correct density (gauge
indication in the green area).
oIf acid concentration is lower than
necessary in a battery cell - add acid or
refer to battery manufacturer agent.
oUpon completion of check, ensure that
all battery cells are closed. Replace
gray cover and seat.
Note: Acid concentration and water level in
battery chambers should be performed
whenever Breeze is brought for a
maintenance operation.
Battery Load Test This test should be performed after fully
recharging batteries and a short travel.
oRemove gray cover and seat.
oDisconnect all battery cables (negative
and positive poles).
oPerform the test for each battery
separately.
oOperate the Tester and check if
voltage reading matches the indication
of normal performance as specified on
the tester display.
oUpon completion of test, reconnect the
battery cables and ensure the correct
poles are replaced to their original
position. Replace gray cover and seat.

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1.5 BASIC CLEANING OF THE BREEZE
(only when basic cleaning is required)
Only use a cloth, soap and water to clean the Breeze.
Never spray a stream of water or steam directly on the
BREEZE and it’s systems .
Preparations oRemove the seat and gray cover
oDisconnect and remove the batteries from the Breeze.
Avoid causing short circuits when disconnecting the
batteries.
oCover the controller and Rear Electronics box well.
oCover the motor and Electromagnetic brake carefully.
Cleaning oClean the inner assemblies, especially the base of the
batteries.
oClean the gray cover on both sides.
oUse a cloth and water. Do not spray water directly on
the Breeze.
oClean the frame.
oUpon completing cleaning, wait for all parts to dry or
dry using air jets.
oReassemble removed parts and reconnect electric
circuits and Batteries .
Ensure correct assembling and reconnection. You
may refer to the wiring drawings in 3.1 .
oReplace gray cover and seat.
Test Perform a general test of all Breeze functions : forward and
backward drive, change of speeds, manual operation of brakes,
automatic braking and lights.
1.6 - SHOCK ABSORBERS ADJUSTING TO THE USER WEIGHT
User Weight
lbsKg
Press Stage
176-22080-100Minimum Press - 0
220-253100-1151
253-286115-1302
286-340130-1453
340-352145-160Maximum Press - 5
Remark : To adjust the shock absorber use a standard S-Key or a simple Patent Key .

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CHAPTER 2 –TROUBLESHOOTING AND GENERAL FAULTS REPAIRING
The following table specifies troubleshooting and repairs of the possible faults in the Breeze. The table
suggests the recommended method to handle these faults. The table specifies:
a. Fault Description - a description of the manifest problem resulting from the fault.
b. Cause of the Fault - a list of all the possible causes of the fault, in decreasing order of
probability of occurrence.
c. Troubleshooting - actions to correct the fault. Each cause has a corresponding solution. If the
solution does not correct the problem, refer to a different cause and action.
Note: Additional details pertaining to the repairs appear after the table.
Please do not hesitate to contact the company for additional professional assistance.
Fault Description Possible Causes Troubleshooting
1 The hand brake is fully
squeezed yet the Breeze
does not stop
•Loose hand brake
mechanism
•Tighten the brake cable
2 Tire is flat and ride is
uneven and not smooth
•Low air pressure
•Flat tire
•Add air until correct
pressure is attained
•Fix the flat tire
3 Unusual noises when
driving
•Transaxle Fault
•Other mechanical
part fault
•Replace Transaxle .
•Replace part.
See assembling drawings in
Appendix B.
4 Broken Part •Accident •Replace part.
See assembling drawings in
Appendix B.