Afikim PRS4024a User manual

Assembly Instructions
PRS4024a
Roof Canopy for Breeze-S3 and Breeze-S4 Scooters
Afikim Electric Vehicles

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Table of contents
CANOPY PART LIST ................................................................................................................................. 3
TOOL TABLE............................................................................................................................................ 4
INTRODUCTION ...................................................................................................................................... 5
PART A: DISASSEMBLING THE FRONT AND BATTERY COVERS ................................................................. 6
PART B: MOUNTING THE INNER BRACKET .............................................................................................. 7
PART C: ASSEMBLING THE REAR FRAME................................................................................................. 9
PART D: RETURNING THE FRONT COVER TO SCOOTER.......................................................................... 10
PART 1: ASSEMBLING THE BOTTOM BEAM........................................................................................... 11
PART 2: ASSEMBLING THE TOP BEAM .................................................................................................. 12
PART 3: ASSEMBLING THE SIDE BEAMS ................................................................................................ 13
PART 4: ASSEMBLING THE PLASTIC SHEET ............................................................................................. 14
PART 5: ASSEMBLING THE SIDE PANELS ................................................................................................ 18
PART 6: TOP BEAM ASSEMBLY TO THE REAR FRAME ............................................................................. 20
PART 7: DISASSEMBLING THE CANOPY FROM THE JIG, PREPARING THE SCOOTER ................................. 21

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Canopy Part List

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Tool Table
1.
Screwdriver cross slot (phillips)
2.
Short neck screwdriver cross slot (phillips)
3.
Hexagon driver 4mm
4.
For power screwdriver!!!
Recommendation: a drive bit No. PH2.
Drill tool Ø6mm.
5.
Reversible Ratchet Spanner Size 10mm, (for M6 bolts)
6.
socket 13mm, (for M8 bolts)
7.
3M™ Safety-Walk™ Rubber Hand Roller
8.
9.
10.
DREMEL® 300 Series
Tool: Tungsten Carbide Cutter square tip 3,2 mm (9901)

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Introduction
This manual describes how to assemble the canopy roof for AfiKim Breeze-S3 and Breeze-S4
scooters.
The assembled canopy is possible on a chassis jig or a Breeze-S3/4
When assembling directly onto a Breeze-S3/4:
A. Part A: Disassembling the Front and Battery Covers.(Page 6)
B. Part B: Mounting the Inner Bracket. (Page 7)
C. Part C: Assembling the Rear Frame. (Page 9)
D. Part D: Returning the Front Cover to Scooter. (page 10)
Assembly steps:
1. Part 1: Assembling the Bottom Beam. (page 11)
2. Part 2: Assembling the Top Beam. (page 12)
3. Part 3: Assembling the Side Beams. (page 13)
4. Part 4: Assembling the Plastic Sheet. (page 14 17)
5. Part 5: Assembling the Side Panels. (page 18 19)
6. Part 6: Top Beam Assembly to the Rear Frame. (page 20)

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Part A: Disassembling the Front and Battery Covers
When mounting the canopy onto scooters, follow the instructions below.
1.
Dismantle the:
a. Front cover.
b. Seat.
c. Battery Cover.
From the scooter.
2.
Cut bores in the front
cover, for the inner
bracket.
Cut bores in the
designated locations,
as shown. A tool,
such as this DREMEL
tool, may be used to
cut bores.
Front cover
DREMEL tool
Bore holes
Front cover, Exterior and Interior Views, Showing Bore Holes
Battery cover
Seat
Battery cover

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Part B: Mounting the Inner Bracket
Mount the inner bracket as shown below.
Note: You may need to pre drill (Ø6mm) the holes upon the scooter frame.
M6X16
NYLOCK M6
M6X16
NYLOCK M6

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1.
2.
Slightly tighten bolts.
3.
place 320±2 mm
and Tighten bolts
securely.

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Part C: Assembling the Rear Frame
Assemble the rear frame as shown below.
1.
2.
Three bolts anchor
each frame base.
Tighten bolts
securely.
After assembling the
rear frame and the
inner brackets, the
scooters will appear
as shown.
After
assembling
the rear
frame and
the inner
brackets,
the chassis
will appear
as shown.
M6x16
NYLOCK M6

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Part D: Returning the Front Cover to Scooter
Reassemble the front cover onto the scooter.
Reassemble the:
a. Front cover.
b. Battery Cover.
c. Seat.
Inner Brackets

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Part 1: Assembling the Bottom Beam
1.
Assemble the
bottom beam, onto
the inner brackets,
as shown.
2.
If using a chassis as
a jig, fasten the
bolts, but do not
fasten them
strongly. (After
assembly, these
bolts will be
loosened to remove
the canopy.)
If assembling the
canopy directly onto
the scooter, fasten
these anchor bolts
securely. (This is a
permanent assembly
of the bracket to the
vehicle.)
M8x16
Spring washer
5/16

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Part 2: Assembling the Top Beam
1.
LOOSLY attach the
cover to the top-
beam back plate.
Do NOT tighten the
square neck bolts.
2.
Place the top-beam
assembly on the rear
frame, as shown.
LOOSLY Secure the
top-beam assembly
to the rear frame
with a hex socket
screw.
Top-Beam
Cover
Top-Beam
Top-Beam
Assembly
Rear Frame
washer
NYLOCK M6
SQ.NECK M6x20
Hex socket button
M6x20
Ensure that slots are placed
over flat pins.

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Part 3: Assembling the Side Beams
Assemble side beams to the bottom beam, and Top-Beam, as shown below.
1.
At first, LOOSLEY
attach the side
beams to the
bottom beam and
top-beam.
Do NOT tighten the
bolts.
2.
Secure the center
beam between the
two side beams.
Tighten the bolts
securely on both
sides.
3.
After securing the
center beam, tighten
all remaining bolts
on both sides.
AC00198
Foam Tape

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Part 4: Assembling the Plastic Sheet
Assemble the plastic sheet onto: Top, Side and Bottom Beams, side rails as shown below.
1.
Assembly the sun shield to the
wind shield with a
connection HP2 profile, upon
a flat table or box.
Make sure that the HP2
profile SUN direction is UP.
Slip in the sheet in to the HP2
lips by pressing down and
shoving it in.
Note: pre peel off a 100mm
(4`) of the protection film
around the edge contours to
avoid catching.
2.
Secure the sheets together
by cello taping it on the
upper side.
Insert a leftover plastic
between the tape and the
HP2 profile.
Stick the rubber strip
ACS4005 as shown, on the
rear edge apply it on both
upper and bottom side.
Make sure that ACS4005
sticks upon the plastic sheet
without protection film.
Note: avoid contact between
adhesive cello tape and
unprotected plastics.

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3.
Carefully lay the assembly
sheet over the side beams.
The top side of the sheet is the
HP2 profile SUN direction is
UP.
4.
Peel back the protection film
from the edges.
Insert the back end of the
sheet into the top-beam
assembly, between the Top-
Beam Cover and the top-
beam.
5.
Tighten screws in their
designated locations, along
the side beams. Work from
the back towards the front.
Note: Don`t over tighten,
leave sheet free.
6.
After tightening all the screws,
remove the Hex socket
button screw.
Tighten the cover to the top-
beam from the inside with
tool #5 (Tool Table).
The plastic sheet is
sandwiched in between the
cover and the top-beam
UP
M4x12
Washer M4x2

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7.
Place the top-beam assembly
into its proper position on
the rear frame and reinstall
the hex socket screw.
Hold the end of the railings
firmly with both hands.
Lift the assembly on top of
the rear frame, the slot and
the flat pins fits each over.
Note: If using a chassis as a
jig, ensure that the chassis is
secure, so that the complete
chassis will not be lifted up.
8.
Apply the rubber strip upon
the assembly plastic sheets,
from edge to edge
(top to bottom).
Make sure to cover the
screws and washers to avoid
water drips inside the
canopy.
9.
Press the rubber strip over
all upon the plastic sheets
and HP2 profile.
Make sure that the gap on
the screw area is closed.
Ensure that slots are placed
over flat pins.
Hex socket button
M6x20 place
Gap

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10.
Secure HP2 profile upon
center beam.
Push up the assembly plastic
sheet and remove the foam
tape AC00198 adhesive
protection layear.
(come upon the center
beam).
Press the HP2 profile agenst
the center beam firmly and
evenly.
Make sure that the HP2
profile is in good contact.
Note: Foam tape AC00198
will have the max adhesive
strength after 72 hours.
TOP-VIEW
HP2 profile
Center beam
+ foam Tape
In black
Peel off
protection layer
Push down

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Part 5: Assembling the Side Panels
Assemble side Panels as shown below.
1.
Assemble four side panels
onto the sides of the canopy.
Start from the back, and
work towards the front.
Caution: Don`t over tighten
the M4 screws.
Tmax=2.2 Nm (18.5 lbf·in).
2.
Fasten screws.
Ensure that each screw is
properly centered in its
housing.
Note: use tool #2 on the tool
table for the 4 corner screws.
3.
At the connection point
between the upper and
lower plastic beam, fasten a
black screw M4x16.
Black M4x12
Black washer
Black M4x16
Black washer

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4.
Mount the front plate onto
the front bracket.
5.
Fasten the screws of the
front plate.
6.
Windshield clean
instructions sticker.
Place the sticker on the
inside of the windshild.
Hex socket button
M6x20

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Part 6: Top Beam Assembly to the Rear Frame
Secure the top-beam assembly to the rear frame with three screws (by Tool Table #3 ), from the
interior of the canopy, as shown.
Assembly of the canopy is completed.
Hex socket button
M6x20