Afikim Caddy User manual

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CADDY
Scooter
User’s Manual
Cat No. - PRCA001 Edition 01

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1. INTRODUCTION .................................................................................4
1.1 General information .......................................................................4
1.2 Technical specifications .................................................................6
1.2.1 Dimensions..............................................................................6
1.2.2 Weights....................................................................................6
1.2.3 Maximum loads .......................................................................6
1.2.4 Drive characteristics ................................................................7
1.2.5 Drive system and tires.............................................................7
1.2.6 Batteries and charger ..............................................................8
1.2.7 General specifications .............................................................8
1.2.8 Options and accessories.........................................................8
1.3 Safety instructions........................................................................10
1.3.1 Stability and slopes ...............................................................10
1.3.2 Electromagnetic compatibility (EMC) ....................................11
1.3.3 Batteries ................................................................................12
1.3.4 Hot areas...............................................................................13
1.3.5 Danger of pinching body parts ..............................................13
1.3.6 General warnings ..................................................................14
2. UNPACKING AND ASSEMBLY ........................................................17
2.1 Unpacking the box .......................................................................17
2.2 Mounting the rear wheels.............................................................19
2.3 Fixing the tiller to the frame..........................................................20
2.4 Placing the batteries ....................................................................22
2.5 Unfolding the Seat to driving position ..........................................23
2.6 Mounting the rear basket .............................................................25
2.7 Checking the assembly................................................................26
2.8 Mounting the seat belt option.......................................................27
3. OPERATION AND USE OF THE CADDY.........................................28
3.1 Seating into the Caddy.................................................................28
3.11 Tilting the handlebar forward and backward..............................28
3.2 Driving the Caddy ........................................................................29
3.3 Speed control of the Caddy .........................................................33
3.4 Emergency stopping ....................................................................33
3.5 The Caddy headlight....................................................................35
3.6 The Caddy horn ...........................................................................35
3.7 The battery discharge indication..................................................35
3.8 Pushing the Caddy: the freewheel function .................................37
4. DISASSEMBLING FOR TRANSPORT IN A CAR.............................40
4.1 Folding the Seat...........................................................................40
4.2 Removing the tiller from the frame...............................................42
4.3 Removing the basket ...................................................................43

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4.4 Removing the batteries ................................................................43
4.5 Removing the rear wheels ...........................................................45
5. TRANSPORTING THE CADDY IN A CAR AND STORING THE
CADDY AT HOME.................................................................................46
5.1 Transporting the Caddy in a car trunk..........................................46
5.2 Lifting heavy parts ........................................................................49
5.3 Storing the Caddy at home ..........................................................50
6. CHARGING THE BATTERIES ..........................................................51
6.1 Charging.......................................................................................51
6.2 Attention points when charging....................................................52
6.3 The external charger adapter (optional).......................................53
7. TROUBLESHOOTING.......................................................................55
7.1 Troubleshooting the Caddy..............................................................55
7.2 Troubleshooting the battery charger ............................................58
8. SMALL MAINTENANCE AND PERIODIC CHECKS.........................60
8.1 Cleaning .......................................................................................60
8.2 Checking the PU tires ..................................................................61
8.3 Checking the inflatable tires.........................................................61
8.4 Checking the throttle levers..........................................................62
8.5 Checking the assembly................................................................62
8.6 Checking the parking brake .........................................................63
8.7 Replacing the batteries ................................................................64
8.8 Discarding of old or damaged batteries .......................................65
8.8.1 Discarding of old batteries.....................................................65
8.8.2 Discarding of damaged batteries...........................................65
8.9 Programming the controller..........................................................66
9. SERVICE AND REPAIRS..................................................................69
9.1 Necessary annual maintenance...................................................69
9.2 Replacement parts .......................................................................69
9.3 Service manual ............................................................................70
10 LABELLING ......................................................................................71
10.1 The type plate ............................................................................71
10.2 Other labels................................................................................72
10.3 Labels and printing on the tiller ..................................................73
11. EC DECLARATION OF CONFORMITY..........................................75
12. WARRANTY STATEMENT .............................................................76
13. PHONE NUMBERS AND ADDRESSES .........................................78

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1. INTRODUCTION
Thank you for choosing the Caddy transportable / foldable scooter by
Afikim Electric Vehicles. The Caddy Scooter has been developed
especially for those people with mobility problems. Mobility problems are
generally problems with walking or with the stamina.
Afikim Electric Vehicles has many years experience with the
development of these kinds of vehicles and also markets different types
of electric vehicles for a wide range of applications and needs.
The Caddy scooter was developed especially for use in and around the
house and to be taken along for trips. For this purpose the scooter can
be folded and disassembled easily and the separate parts can be
handled with ease.
Please read this manual carefully before you start using the product,
you will find there are many useful hints and instructions.
Please give extra attention to reading the safety warnings. This manual
will help you enjoy using your purchase safely and for a long time.
ATTENTION:
Give special attention to the SAFETY INSTRUCTIONS (§1.3), read
them carefully and please study them again from time to time. No
vehicle can be used without risk, risk both to yourself as the user as well
as to others. This electric vehicle comes with some quite specific risk
that you should be aware of before using the product.
1.1 General information
•The Caddy complies with the current European Union
standards for this type of vehicle. They are formulated in the
standard EN12184 (April 1999).
•The status of the scooter in the traffic laws and regulations will
differ from one country to the next. Make sure you know the
laws and regulations in the country you live in and act
accordingly.

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•The maximum speed of the Caddy is 7,5 kilometres per hour
(km/h). It possible to have your dealer adjust the drive
electronics of the scooter to a lower speed.
•The Caddy has been developed for use in and around the
house. According to the EU standard EN12184 this means the
Caddy is a class A electric vehicle.
•The Caddy should not be used during rainfall, snowfall or in
temperatures below 0°C or above 40°C.
•Despite harmonisation efforts in the EU, depending on the
country you are in, you may have to buy insurance for the
Caddy vehicle before you can use it outside. It is also possible
that you have to pay a road tax or pass some sort of drive test.
Please follow local rules and legislation.
•The Caddy was developed and tested for a maximum user
weight of 100 Kg. including luggage.
•The user of the Caddy scooter should have sufficient physical
abilities (hearing, sight, strength and mental abilities) to be able
to use the scooter safely. If in doubt please consult your doctor.
Please give special attention to §1.2 TECHNICAL SPECIFICATIONS
and §1.3 SAFETY INSTRUCTIONS.

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1.2 Technical specifications
1.2.1 Dimensions
Length 1100 mm.
Folded Length 900 mm.
Width 610 mm.
Height 900 mm.
Height Folded 470 mm.
Dimensions of the largest part
Length 900 mm.
Width 610 mm.
Height 340 mm.
1.2.2 Weights
Total weight including batteries 12 Ah 31 kg.
Total weight including batteries 17 Ah 36 kg.
Total weight excluding batteries 22 kg.
Weight of the frame with seat 13 kg.
Weight of the tiller 9 kg.
Weight of one battery 12Ah 4.5 kg.
Weight of one battery 17Ah 7 kg.
Weight of one wheel 0,9 kg.
1.2.3 Maximum loads
Maximum user weight 100 kg.
Maximum load in the rear basket 10 kg.
Maximum number of persons 1

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1.2.4 Drive characteristics
Speeds
Maximum speed forward (hare symbol) 7,5 km/h.
Slow speed forward (tortoise symbol) 4,5 km/h.
Reverse speed 4,5 km/h.
Turning radius 75.0 cm.
Ground clearance 8 cm.
Maximum obstacle height 3 cm.
Maximum safe slope 3°
Range according ISO 7176-4 20 km.
(Range is dependant on the circumstances during use, it can be
less i.e when hills, wind or loose surface such as gravel or sand.
Range can also vary with the user weight)
1.2.5 Drive system and tires
Drive system front wheel, worm wheel reduction direct drive
Motor 24 Volt / 200 Watt.
Motor controller (complies with ISO7176-14) 24 Volt / 60 Amp.
programmable
Brake systems - Regenerative motor brake
- electro-magnetic parking brake
Tires
PU tire size Ø 250x50
Tire size (inflatable) Ø 250x50 (10”x2”)
ETRTO: 54-152
Tube size (with right angle valve) 10”x2”
ETRTO: 54-152
Tire pressure (when using inflatable tires) 2,4 bar.

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1.2.6 Batteries and charger
Batteries; use only:
2x FIAMM-GS FGCS21803 12V 18,0 Ah.(20h.) / 15,8 Ah.(5h.)
Size LxWxH (mm.) 181x76x167
Weight 6,7 Kg. each
2x Ztong Yee Industrial Co / GS 12V 17,0 Ah.(20h.) / 14,4 Ah. (5h.)
Size LxWxH 181x76x167
Weight 6,7 Kg. each
Battery charger (220/230V) 24 Volt
Maximum charger current (RMS) 2 Amp.
Charging time to 80% charge 8 hours
Charging time to full charge 12 hours
(Data depending on charger used.)
1.2.7 General specifications
Seat width 460 mm.
Backrest height 390 mm.
Seat depth 440 mm.
Armrest height from seat 168 ??? mm.
Seat height from scooter platform 440 mm.
1.2.8 Options and accessories
•Seat belt for additional stability
•Bag for front
•External charger adapter for charging batteries not mounted to
the scooter.
•Car-charger: battery charger for connecting to the cigarette
lighter contact in the car.
Afikim Electric Vehicles has a policy of constant product improvement,
as a consequence of this specifications may change without prior notice.
The documentation may not represent the actual product in some
details.

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1.3 Safety instructions
1.3.1 Stability and slopes
•The maximum safe slope for the Caddy scooter is 3°. This is
the maximum slope where you can turn and manoeuvre safely
with the scooter without compromising the stability of the
vehicle.
•If you have any doubts about safety of the angle of the slope,
try to find another route. If this is not possible for any reason,
try to avoid making sudden movements (accelerating or
braking) and always drive straight up. Never attempt to turn on
a slope! Lean forward when driving up, lean back when driving
downhill. Don’t hesitate to call on help for someone to walk
behind you or beside you for support when you need it.
•It is possible your scooter will climb an incline steeper than the
maximum safe slope, this does not mean it is safe to do so.
Keep in mind the instructions in the last point.
•Your Caddy can take obstacles up to 3 cm. don´t try to climb
kerbs or obstacles higher than 3 cm. this can destabilize your
scooter. If you encounter an obstacle higher than 3 cm. call on
the help of another person to support you for safety while you
drive.
•Also when you are driving down a kerb or obstacle higher than
3 cm. the stability of your scooter can be compromised. In such
a situation always call upon the help of another person to
support you while driving down this obstacle.
•Especially the sideways stability of the scooter can be easily
compromised, for example when one of the rear wheels is on
an obstacle higher than 3 cm. Try to avoid such situations,
always lean towards the obstacle.

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•It is dangerous to use the Caddy on loose gravel or sand or on
a very bumpy surface. Because of the sudden weight shifts the
stability of the scooter can be easily compromised.
•In order to be able to push the scooter in case of a malfunction
or low batteries the automatic parking brake can be dislodged.
Dislodging the parking brake will put the vehicle in potentially
unsafe state, for instance when you are at the top of a slope.
When you are on the scooter at the top of an incline or slope
always make sure the parking brake is active. Dislodging the
parking brake may cause the vehicle to roll down a slope or
incline uncontrolled.
•Always reduce speed in turns and going around curves.
Making a sharp turn at full speed may cause the vehicle to turn
over.
1.3.2 Electromagnetic compatibility (EMC)
•Most electric devices and machines create electromagnetic
fields. These electromagnetic fields can influence the operation
of other devices or machines causing them to malfunction or
behave in an abnormal way. Machines and devices producing
very strong electromagnetic fields are mobile phones and other
radio transmitters such as 27MC transceivers and portable
transceivers (walkie talkies). All scooters are to a certain
degree sensitive to EM fields. Because they are vehicles there
are rules and standards these scooters have to comply to in
order to be admitted for use. The vehicles have to be submitted
to a series of tests to establish the sensitivity (immunity) to and
emission of EM fields. The Caddy complies with all European
standards for EMC.
•It is possible that a certain device or machine produces an
electromagnetic field stronger than the immunity level
(sensitivity) of the scooter, in such a case the scooter may
malfunction or may not respond to the control input in a normal
way. Examples are: taking off suddenly, operation of the
parking brake without you touching the throttle lever or
intermittent driving (shocks). When this happens, immediately

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switch off the scooter using the key switch. Try to find and
eliminate the cause of the strange behaviour before you
resume driving.
•I f you intend to use a mobile phone, portable transceiver or
any other kind of radio transmitter while you are using the
Caddy, we advise you to always switch off the scooter using
the keyswitch before doing so.
•It is possible that some devices or machines are influenced by
the electromagnetic field your scooter generates. Examples are
automatic doors or anti-theft systems in shops. Try to be aware
of problems like this and be extra careful in situations where
there is a danger of injury to yourself or others like with
automatic doors.
1.3.3 Batteries
•The Caddy scooter is delivered standard with two sealed
maintenance-free lead-gel type batteries placed in a removable
bracket. The battery housings are fully sealed and during
normal use no gasses or liquids can escape from them.
However the plastic housing of the batteries may be damaged!
If the plastic housing of the batteries is damaged, for instance
when you accidentally dropped it during dismantling the
scooter or during an accident, be aware an ACID GEL may
leak from the batteries. Do not touch the gel! If the gel contacts
your skin or eyes strong irritation and acid burning can the
result. If this happens rinse with water and contact a doctor or
first aid centre immediately.
•Batteries contain substances that are harmful to the
environment and they contain materials that can be recycled
such as lead and plastics. If you replace the batteries, do not
dispose of them in the environment, but hand them in at a
government appointed collection point. Information about these
collection points can usually be gotten from officials at your city
council.

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1.3.4 Hot areas
•Some areas on your scooter may get hot during use. The
motor can get hot after using for a certain period of time. This
is in itself normal, but be aware never to touch the motor after
you have used the scooter. There is a real danger of burning
the skin of your fingers.
•If you decide to use your Caddy outside in sunny weather, it is
possible that some surfaces such as the armrests, the plastic
parts and the upholstery heat up from the direct sunlight
possibly causing burning injuries to the bare skin. If you park
the scooter outside, try to avoid parking it in the direct sunlight.
1.3.5 Danger of pinching body parts
•Some places on the Caddy are marked with this sticker: This
sticker marks the places where there is a
danger of pinching for the fingers or other
body parts. The front frame at the location
of the tiller pivot is such a place. Be aware
especially when you are assembling and
disassembling the scooter of the danger of
pinching your fingers.
•When the seat is folded forward and down to the frame there is
risk of pinching your fingers between the base of the seat base
and the backrest and as well between the seat base and the
frame .
•When folding down the tiller there is risk of pinching your
fingers between the tiller and the motor cover .
•Please be aware of these problems .

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1.3.6 General warnings
•DANGER OF SUFFOCATION!: Never allow children to play
with the plastic bags the scooter is packaged in. The bags are
big enough for a child to crawl into: children are in real danger
of suffocating from lack of oxygen when this happens.
•DANGER OF INJURY!: Never allow children to play with the
carton board boxes without adult supervision. The large boxes
are very inviting for children to play with, but can easily fall over
with a child inside causing head injuries or other. There is also
a danger of suffocation from lack of oxygen when a child gets
inside the box.
•Read, before you operate the scooter, these instructions for
use carefully. Please also follow the instructions.
•Be aware that by using the scooter you may cause injury to
others, for this reason always use the slow-driving position
(tortoise position) when there are many people around an drive
carefully.
•Do not put yourself in dangerous situations, make sure you can
call for help when you need it.
•Try to estimate the distance you intend to go and make sure
your batteries are charged sufficiently for this distance. Take
into account that headwind, hills or inclines and a loose surface
can influence the range in a negative way.
•Do not use the Caddy on the open road, the scooter was not
designed for this: it does not have a standard rear light units or
indicators for open roads , but only to mark you if you pass by .
•Overloading the Caddy will shorten the life of the product by
accelerating the wear and tear of parts and components. Take
the maximum loads into consideration from this manual and do
not exceed them, use the product safely and with care.

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•The Caddy was not designed to be used in rain, snow or
extreme temperatures. The use of the Caddy in these
conditions may cause serious malfunctions and permanently
damage the product. Using the scooter in low temperatures will
cause the range of the product to be considerably smaller than
normal. Using in extreme high temperatures may lead to
overheating of the motor or controller, causing the controller to
shut down temporarily until the system has cooled down.
•Using the Caddy outside or on the road after dark is strongly
discouraged because the risk of accidents is much higher than
in daylight because there is insufficient lighting on the vehicle.
•It is strictly forbidden for a person under the influence of
alcohol, drugs or other substances influencing the ability to
drive a vehicle to use the scooter. When you are on
prescription drugs that may influence your ability to use the
Caddy, please consult your doctor for advice.
•A person using the Caddy scooter should have sufficient
eyesight to master the vehicle. The assessment of your ability
to use the vehicle is subject to the judgement of your doctor.
•A person with a seating stability problem may find that the
movement of the Caddy scooter during driving causes them to
slide from the seat. In order to avoid this problem a seat belt
can be mounted to the seat helping the driver to maintain a
good seating posture.
•Be careful with loose clothing that can be caught in or under
the wheel.
•If you suspect something wrong with your Caddy, always
contact your dealer and explain the problem, better safe than
sorry.
•Never turn the key switch to the OFF position while driving, this
will cause an very sudden stopping of the scooter. This may
cause you to loose balance and injury can be the result. On top

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of this it may cause damage to the motor and drive system of
the Caddy.
•When mounting or dismounting the Caddy always make sure
the key switch is in the OFF position to prevent the scooter
from moving or taking off by accident when you accidentally
depress the throttle lever.
•When you do not use the Caddy scooter and it is parked
somewhere, ALWAYS REMOVE THE KEYS FROM THE KEY
SWITCH !. Leaving the keys in the switch is an invitation for
children and others for joyriding and abuse of the product,
possibly causing injury to themselves and to others.
•In an isolated case it is possible that the grease from the
gearbox of the motor may leak or sweat through the seal.
Avoid contact with the mouth or the eyes, the grease can be
cleaned off with a paper tissue. If the leakage persists, contact
your dealer for service and repair.

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2. UNPACKING AND ASSEMBLY
The Caddy can be delivered by your dealer fully pre-assembled, but it is
also possible that the product comes to you in parts in the box it was
packed in at the factory.
The Caddy was designed to be assembled and disassembled by the
user. Assembling the scooter is very easy and it is good to know the
procedure in case you want to disassemble the scooter for instance if
you want to take it with you in the back of a car.
2.1 Unpacking the box
The Caddy will normally be delivered to you in a large carton box,
please check if the box is not badly damaged. If this is the case you may
want to refuse the delivery. If there is damage to the box always report it
to the person delivering it and make sure the damage is noted on the
shipping documents you sign before accepting the delivery.
•Place the box on the floor the right way up (the top is marked
UP).
•Carefully cut the tape closing the box, make sure you don´t cut
the contents of the box.
•Open lid lid and remove all the parts from the box, mind your
back lifting some of the heavier parts out of the box.
•Put all parts on the floor and put the empty box away, you
should find the following parts (see figure 1):
•
a. The frame
b. The tiller
c. The rear basket
d. Two batteries
e. Two rear wheels
f. A battery charger
g. This manual

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Figure 1

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2.2 Mounting the rear wheels
The rear wheels (e - in figure 1) are to be assembled onto the frame (a
-in figure 1).
(See figure 2) The rear wheel (1) is assembled by means of a so called
quick release axle (2) into the wheel mount (3) of the frame (4).
In order to be able to assemble and disassemble the quick release axle
you need to press the button underneath the rubber cover (5) in the
centre of the wheel.
Take the rear wheel in your hand as shown in figure 2. Grip the wheel
(1) with your fingers through the spokes and depress the button under
the rubber cover (5) at the centre of the wheel with your thumb.
Lift the frame (4) using your other hand and fully insert the quick release
axle (2) into the Wheel mount (3) of the frame, release the button.
Check if the quick release axle is locked by pulling on the wheel.
Mount the other wheel the same way.
Figure 2

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2.3 Fixing the tiller to the frame
The tiller (b - in figure 1) must be fixed to the frame (a - in figure 1).
Refer to figure 3: The frame bushing (1) is inserted onto the tiller
tapered block (2) . It is also the fixation of the tiller to the frame by
means of a locking lever (3).
We advise you to approach the frame from the left hand side (when you
are right-handed. Take the tiller in your left hand, holding it at the frame
tube just above the control panel. Make sure you hold it up straight and
tilt it backwards slightly as indicated in figure 3.
Lift the frame bushing (1) by mean of the lever (3) using your right hand
as shown in figure 3 . Now place the frame bushing over the tapered
block (2) of the tiller. Than after they attached together push the lever
(3) forward and downward until it lock them together . Make sure that
you hear a clicks that will ensure you completely secured connection.
Please refer to figure 3 to the differences between the two positions :
Released and Secured . Also make sure that the connection is done
properly by means of tilting the tiller forward and backward .
The electrical connections between the tiller and the frame is done at
the same stage .