Drive Medical Royale Repair manual

ROYALE SCOOTER – SERVICE AND REPAIR MANUAL
Contents:
1.
2.
3.
4.
5.
6.
7.
Scooter Maintanence
Troubleshooting and Fault Repair
Circuit Digram
Service Record
Display Specifications
Parts Reference – Royale 3
Parts Reference – Royale 4
Royale By Drive Service Manual
Page 1
SCOOTER MAINTENANCE
Your power scooter is designed for minimal
maintenance. However, like any motorized vehicle it
requires routine maintenance. To keep your scooter
for years of trouble-free operation, we recommend
you follow the following maintenance checks as
scheduled.
Warning! Failure to maintain the brushes could
void the power scooter warranty.
To inspect or replace the motor brushes:
1.
Unscrew the motor brush caps (by using
a screwdriver on the caps shown by the
white arrow).
2.
Remove the brushes.
3.
Inspect the brushes for wear (replace if
less than 9mm)
4.
Replace the brushes if necessary.
DAILY CHECKS
1.
Visual check on the conditions of tyres.
2.
Inspect the battery gauge on the display to
determine if batteries need to be charged.
WEEKLY CHECKS
Your scooter comes with standard pneumatic tyres.
Make sure to maintain the pressure of the tires
between 30-35 psi.
Less than 9mm
MONTHLY CHECKS
Visually inspect the controller harnesses. Make sure
that they are not frayed, cut or have any exposed
wires.
SEMI-ANNUAL CHECKS
Check the motor brushes. We recommended
that your authorized dealer inspect the brushes
every six months or sooner if your power scooter
is not operating smoothly. If inspection
determines excessive wear on the brushes, they
must be replaced or motor damage will result.
The brushes should be inspected for wear and
colour of the braiding inside the spring. If the
braiding is dark brown, red, silver, purple or gold
then the brush needs replacing.
Royale By Drive Service Manual
Inspect the state of the battery terminals every
six months. Make sure that they are not
corroded and the connections are tight.
Periodically apply a thin film of petroleum jelly
on the surface of terminals to guard against
corrosion.
CHECKS:

Make sure you keep the controller clean
whilst protecting it from rain or water.
Never hose off your scooter or place it in
direct contact with water.
Page 2

Keep wheels free from lint, hair, sand and
carpet fibres.

Visually inspect the tyre tread. If less than
1mm (1/32”), please have your tyres
replaced by your local dealer.

All upholstery can be washed with warm
water and mild soap. Occasionally check
the seat and back for sagging, cuts and
tears. Replace if necessary. Do not store
your scooter in damp or humid conditions
as this will lead to mildew and rapid
deterioration of the upholstery parts.
Royale By Drive Service Manual

All moving mechanisms will benefit from
simple lubrication and inspection. Lubricate
using petroleum jelly or light oil. Do not use
too much oil, otherwise small drips could
stain and damage carpets and furnishings
etc. Always perform a general inspection of
the tightness of all nuts and bolts.
ANNUAL SERVICE
We recommend the scooter is servicing by
annually by your dealer or competent
technician. The service schedule is shown on
page 6
Page 3
TROUBLESHOOTING AND FAULT REPAIR
RHINO controller: If your scooter is fitted with a Rhino controller, which continuously monitors the
operating conditions of your scooter.
Error Number
Reference
Fault
Impact
Scooter
1
Battery needs
recharging
Will drive
Battery charge is running low. Recharge the batteries as
soon as possible.
2
Battery voltage
too low
Drive inhibited
Battery charge is empty. Recharge the batteries. If the
scooter is left off for a few minutes, battery charge may
recover sufficiently to allow driving for a short period of
time.
3
Battery voltage
too high
Drive inhibited
Battery charge is too high. If a charger is plugged in, unplug
it or turn the Charge/Run switch to Run.
Scooters powered by RHINO will charge the batteries when
traveling down slopes or decelerating. Excessive charging in
this manner may cause this fault. Turn the scooter power off
and then back on again.
4
Current limit
time out
Drive inhibited
The scooter has drawn too much current for too long,
possibly because the motor has been over worked, jammed
or stalled. Turn the scooter power off, leave for a few
minutes, and then turn 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
Drive inhibited
Check that the park brake release lever is in the engaged
position.
The park brake coil or wiring is faulty. Check the park brake
and wiring for open or short circuits. Contact your service
agent.
6
Out of Neutral
at Power Up
Drive inhibited
Throttle is not in neutral position when tuning switch key on.
Return throttle to neutral, turn power off and back on again.
Throttle may need to be re-calibrated Check throttle wiring.
7
Speed Pot Error
Drive inhibited
The throttle or its wiring is faulty. Check for open or short
circuits.
Throttle may not be correctly set up. Contact your service
agent.
8
Motor Volts
Error
Drive inhibited
The motor or its wiring is faulty. Check for open or short
circuits.
Contact your service agent.
9
Other Internal
Errors
Drive inhibited
Contact your service agent.
10
Push Too Fast
fault
Drive inhibited
The scooter has been pushed faster than the 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. Turn
the scooter off and then back on again.
Royale By Drive Service Manual
on
Notes
Page 4
S-DRIVE controller: If your scooter is fitted with a S-Drive controller, which continuously monitors the operating
conditions of your scooter.
Error Number
Reference
Fault
Impact
Scooter
on
Notes
1
Low Voltage
Error flashing
The battery requires charging or there is a bad connection
to the battery.
2
Motor
Connection
Scooter will not
drive
There is a bad connection to the motor. Check all
connections between the motor and controller.
3
Short Circuit
Scooter will not
drive
The motor has experienced a short circuit to a battery
connection. Check all motor and battery connections.
4
Not Used
Not Applicable
Not Applicable
5
Not Used
Not Applicable
Not Applicable
6
Inhibit
Scooter will not
drive
Inhibit circuit has become active not permitting drive. Likely
to be caused by a charger being connected or a fault within
the controller or wiring.
7
Throttle Fault
Scooter will not
drive
A throttle fault has been indicated. Ensure the throttle is in
neutral before switching the scooter on. Throttle may require
calibration.
8
Controller Fault
Scooter will not
drive
A controller fault has been indicated. Make sure all
connections are secure. Also cycle keyswitch as this fault can
be initiated by a break in the circuit during keyswitch
initiation.
9
Brake Fault
Scooter will not
drive
There is a fault within the electromagnetic brake circuit,
Check all brake and motor connections. Make sure
controller connections are secure and that the scooter is not
in freewheel mode.
10
Excessive
Voltage
Scooter will not
drive
An excessive voltage has been applied to the controller. This
is very often caused by a poor battery connection. Check all
connections from the batteries to the controller.
Note:
If you experience any technical problems, it is recommended that you check with your local dealer
before attempting to troubleshoot on your own.
The following symptoms could indicate a serious problem with your scooter. Contact your local dealer if
any of the following arises:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Motor noise
Frayed harnesses
Cracked or broken connectors
Uneven wear on any of tires
Jerky motion
Pulling to one side
Bent or broken wheel assemblies
Does not power up
Powers up, but does not move
Royale By Drive Service Manual
Page 5
CIRCUIT DIAGRAM
Royale 3 and 4 (Rhino)
Royale By Drive Service Manual
Page 6
SERVICE RECORD
YEAR
1
2
3
4
(SHOWN IN USER MANUAL)
5
YEAR
Service Dates
Service Dates
Controller
Upholstery
On/off switch
Seat
Control Lever
Back
Braking
Armrests
Recharge point
Electrics
Batteries
Connections
condition
Levels
Lights
Connections
Test run
Discharge test
Forwards
Wheels and
Tyres
Reverse
Wear
Emergency stop
Pressure
Left turn
Bearings
Right turn
Wheel nuts
Slope test
Motors
Over obstacles
Wiring
List Items repaired
1
2
3
4
5
Noise
Connections
Brake
Brushes
Chassis
Condition
Steering
Royale By Drive Service Manual
Page 7
DISPLAY SPECIFICATIONS
Below is a comprehensive specification and functional manual for the digital display. It is a technical
reference guide for dealers and engineers.
Speed Sensor and Display
ITEM
SPECIFICATION
Operation Features
Speed detection by speed sensor from transaxle with conversion at 1400rpm
equal to 60km/h.
Tolerance
15~20%
≤ 19.9: 0~19.9
Digits range
> 19.9: displayed by integer “20~199” (199 max)
Display Switch Button
Royale By Drive Service Manual
Initial setting at km/h, switch to MPH by MODE and SET buttons
Page 8
High / Low / Turn Speed
ITEM
SPECIFICATION
(1) Switch High / Low speed by pressing button
once.
(TRN as control signals)
Press one time: High-speed <<--->> Low-speed
Operation Features
(with memory storage).
(2) Take exterior turn-switch as determinant signal
(TRN as control signals).
SPEED
"H"symbol means “High Speed”:
SPEED
Symbols on LCD
"L"symbol means “Low Speed”:
SPEED
SPEED
"L"symbol flashing means “Turn Speed”:
Flicker Frequency
Royale By Drive Service Manual
1 sec.
Page 9
Power Indication / Battery Gauge
ITEM
SPECIFICATION
Remaining
Capacity (%)
Voltage (V)
Scale Bar
100
> 25.42
(6)
85
≦ 25.42
(5)
70
≦ 25.12
(4)
Battery Remaining
Capacity
55
≦ 24.78
(3)
40
≦ 24.42
(2)
30
≦ 23.88
(1)
and
20
Flicker
Frequency
Operation
Characters
Low-power
Warning
Flashing
Warning LED Flashing
2 sec.
(1) Scale status only decrease, won’t increase.
(2) When the remaining capacity was less than 30%, warning sound (“Be-Be” two short
sounds) act at 5 seconds intervals.
While (a) Key Off (b) Charging Mode (c) Sleep Mode, warning sound released.
Royale By Drive Service Manual
Page 10
ITEM
SPECIFICATION
Remaining
Capacity (%)
Voltage
(V)
40
< 25.44
Scale Bar
(2)
55
> 25.44
(3)
70
> 26.18
Charge Indication (4)
80
> 26.92
(5)
90
> 28.5
(6)
100
(7)
Increase
Frequency
0.5 sec.
(1) Scale status only decrease, won’t increase.
Operation
Character
(2) Take the PIN3(CH3) of charger as determinant signal, enter「Charging
Mode」when CH3 grounding (L), not only “KEY ON” or “KEY OFF”.
Remarks
Above scale bar status only for reference, must take the indicator of charger as
the precise diagnosis.
Royale By Drive Service Manual
Page 11
Clock
ITEM
SPECIFICATION
Tolerance (per day)
±2 sec.
Initial Setting Value
『Hour:Min』mode :『AM 12:00』
Display range : AM12:00 ~ PM11:59
『Hour : Min』Setting
(12-Hour format)
:
A
M
P
M
m
i
l
e
k
m
When『Hour』is between 1 and 9 o’clock, displayed at 1~9.
Royale By Drive Service Manual
Page 12
Odometer
ITEM
SPECIFICATION
Operation Features
Odometer detected by the signal of Opto Coupler then converts into distance.
「km/h」 means the odometer displayed as kilometer.
Display Switch Button
「mph」 means the odometer displayed as mile.
(1) Display Range:00000~99999
:
m
i
l
e
k
m
A
M
P
M
Accumulative Display
[ODO]
(2) Once the total mileage up to 99999km or 62149mile (99999÷1.609mile), the
counter will restart from “00000”.
(1) Display Range:00.0~99.9
:
A
M
P
M
TRIP Counter
m
i
l
e
k
m
(2) When over 99.9km, display stop counting
(won’t restart from “00.0”).
(1) Odometer indication display on ODO mode when Power On, then switch to
TRIP mode after 5 seconds.
Operation status
(2) TRIP can be reset to “00.0”.
Royale By Drive Service Manual
Page 13
Headlight Control
ITEM
SPECIFICATION
Take exterior headlight switch as determinant signal.
Operation Feature
(1) Switch on/off the head light by pressing button
turn on/off simultaneously.
once, then LED
will
(2) LCD backlights turn on / turn off with head light.
When motor stop, the modulation down to 30% (Headlight)
Power Saving Mode
When motor act, 100% output power (Headlight)
Usage Condition
While (a) KEY OFF (b) Power-Saving mode (c) Sleep mode , all functions closed.
(1) 2.2V>WIP>2.8V ( 100% Full-power )
Determinant
(2) 2.2V<WIP>2.8V ( 100% Full-power )
Condition
(3) Full / Half power switch at real time.
(4) The determination of “Reversing Mode” need to consider the motor direction and panel
setting.
(1) Loop Load: 24V/50W max
Remarks
(2) With “short circuit” and “overload” protection
Royale By Drive Service Manual
Page 14
Back-up Lamp Control
ITEM
SPECIFICATION
Take exterior back-up lamp switch as determinant signal.
(1) Switch on/off the head light by pressing button
once, then LED
Operation Feature
will turn on/off simultaneously.
(2) LCD backlights turn on / turn off with head light.
(Control Mode)
Brake-lamp Mode
Reversing-lamp Mode
When motor changes from act (go forward) to stop, the lamp reinstated after
flashing for 3 sec.
Determine as “Reversing Mode”, back-up lamp keep flashing.
Reverse warning sound can be set by panel ( Turn on / Turn off)
While (a) KEY OFF (b) Charging Mode (c) Sleep Mode, all functions closed.
Usage Condition
* Brake-lamp & Reversing-lamp Mode won’t be limited by Back-up lamp
switch on or off.
Flicker Frequency
1 sec.
(1) 2.2V>WIP>2.8V ( 50% Half-power )
(2) 2.2V<WIP>2.8V ( 100% Full-power )
Determinant Condition
(3) Full / Half power switch at real time.
(4) The determination of “Reversing Mode” need to consider the motor
direction and panel setting.
(1) Loop Load : 24V/50W max
Remarks
(2) With “short circuit” and “overload” protection
Royale By Drive Service Manual
Page 15
Indicators and Parking-Lamp Control
ITEM
Operation Feature
SPECIFICATION
Take exterior left-right indicators and parking-lamps switch as the
determinant signal.
Press button
Control Mode
once, the right-indicator and
and
flashing, warning sound act. Press
indicator.
turn off, left-indicator
again to turn off left-
(Left-direction lamp)
(Right-direction lamp)
Press button
once, the right-indicator and
and
flashing, warning sound act. Press
indicator.
(Parking lamp)
Press button
once,
turn off, left-indicator
again to turn off left-
turn on, right-left indicators and
flashing , warning sound act . Press
function.
again to turn off the Parking lamp
Usage Condition
While (a) KEY OFF (b) Charging Mode (c) Sleep Mode, all functions closed.
Flicker Frequency
1 sec.
Warning Sound Frequency One short “Bi” sound per second
Left-Right indicators have priority to Parking lamp.
<Ex.>
Determinant Condition
If “Parking lamp” turned on already, now you start “Right indicator” function,
the flashing indicator lamps will change from both side (left & right) to right
side, and the “Parking lamp” function will be closed.
(1) Load circuit for left-direction light: 24V/50W max
Remarks
(2) Load circuit for right-direction light: 24V/50W max
(3) With “short circuit” and “overload” protection
Royale By Drive Service Manual
Page 16
Malfunction Message / Fault code
ITEM
SPECIFICATION
Take the connector pin (KEY) of controller as determinant signal, then converts it
into digital code.
Operation Feature
When the controller send out an error message, red LED flashing with controller
signal at same time, the “Error message code” will show on LCD.
Usage Condition
mphkm/h
Flicker Frequency
1 sec.
Controller
Message
LED
message
code
(Flicker)
symbol
Status
(Flicker)
1
--
--
Battery needs charge soon.
2
2
On
Low-voltage, needs charge now
3
3
On
Over-voltage
4
4
On
5
5
On
6
6
On
7
7
On
Accelerator broken or faulted
8
8
On
Motor broken or faulted
9
9
On
Others
Flashing,
opposite
controller
message.
Over-current
to
Park Brake lost or faulted
Accelerator not align center
5-12. Power On Self Test
ITEM
Initial Status
SPECIFICATION
When scooter power on, the control panel will go through a self-test routine; the
backlight and all LCD segments will be tuned on for 3 seconds, then switch
automatically to the general operation mode (ODO).
Royale By Drive Service Manual
Page 17
Temperature meter (TEMP)
ITEM
SPECIFICATION
Temperature detected by temperature sensor (NTC) from transformation with
signal.
Operation Feature
Tolerance
2C
Display Range
-20 C ~50 C
:
A
M
P
M
m
i
l
e
k
m
-4 F ~122 F
When display C, degree stand for Celsius thermometer
Display Switch Button
When display F, degree stand for Fahrenheit thermometer
Reverse Indicator
ITEM
SPECIFICATION
Operation Feature
Take exterior forward / backward switch as determinant signal.
When switch direct to “forward”, no symbol on LCD.
Power Saving Mode
When switch direct to “backward”,
Flicker Frequency
Royale By Drive Service Manual
symbol flashing on LCD.
1 sec.
Page 18
Adjust Buttons
ITEM
SPECIFICATION
Button
“MODE” switch
Function set
MOD
SET
General Display Mode E
Press SET for 3 seconds to reset TRIP at “00.0”.
(TRIP)
Press MODE and SET simultaneously for more than 2 seconds. to enter “Setting
Mode”, then 『Hour:MIN』start flashing.
(1) When『Hour』flashing:
Press SET to increase of number, then press MODE to enter “Setting Mode”
of 『MIN』.
(2) When『MIN』flashing:
Setting Mode
Press SET to increase of number, then press MODE to enter “Setting Mode”
of 『km/h & mph』.
(3) When 『km/h』 or 『mph』flashing
Press SET to choose “km/h” or “mph” type, then press .MODE to enter
“Setting Mode” of 『 C / F』
(4) When『 C』or『 F』flashing
Press SET to choose C or F .
Under setting mode, if below situations happened, will auto save the last setting
value then escape to general operation mode.
Escape from Setting
(1) No any operation of ADJ button for 20 sec.
Mode
(2) Press MODE and SET at same time for more than 2 sec.
Royale By Drive Service Manual
Page 19
ITEM
SPECIFICATION
(1) 『Hour:Min』,『km/h』or『mph』,『 C』or『 F』offer Cyclical Switch
function.
(2) When adjusting 『Hour:Min』, press SET to increase number, if press SET
Operation Status
for more than 2 seconds, the number will increase continuously until button
released, setting value with Cyclical Switch function (only 2 seconds from 0 to
9).
* If『Hour』less than 10, the denary “0” doesn’t display.。
Remarks
Button tones: one short “Bi” sound
LCD Backlight
ITEM
SPECIFICATION
LCD Backlight
Royale By Drive Service Manual
When pressing MODE and SET buttons, the backlight will be turned on
voluntarily and turned off No any operation of ADJ button more than 5 sec.
Page 20
BILL OF MATERIALS / PARTS REFERENCE – ROYALE 3
These diagrams are for parts reference only. To order parts, please consult the full parts lists:
1 FRONT TILLER COVER
21 LOCATOR
35 SIDE COVER R
2 TILLER FRAME
22 SPEED METER
36 REAR COVER
3 BUZZER
23 FRONT HUB
37 PLUG(R,L)
4 RUBBER DUST COVER
24 FRONT TYRE
38 DISK BRAKE SET
5 TILLER RAM MECHANISM
25 BEARING
39 TRANSAXLE
6 HANDEL CAP
26 FRONT AXLE
40 SUSPENSION BRACKET
7 HANDEL GRIP
27 CHARGER
41 REAR HUB
8 BRAKE LEVER
28 FR COVER
42 REAR TYRE
9 REAR VIEW MIRROR
29 FORK
43 BATTERY CAP
10 REAR TILLER COVER
30 SPEED SENSOR
44 SIDE COVER L
11 CONTROL PANEL
31 MAIN FRAME
45 FLOOR
12 FR SWITCH
32 REAR FENDER
46 REAR SUSPENSION
13 POTENTIOMETER COMBINATION 33 REAR BASKET
47 RELEASE LEVER
34 BATTERY
14 WIGWAG
48 REAR BUMPER
15 WIGWAG PAD
49 LAMP BASE
16 FRONT BASKET
50 REAR INDICATOR
51 LAMP CAP
17 FF COVER
55
18 FRONT BASKET CAP
52 SEAT SLIDING POST
53 SEAT BASE
19 HEADLIGHT
54
54 SEAT SLIDING RAIL
20 HEADLIGHT BRACKET
55 CAPTAIN SEAT ASM
12
13
15
50
53
11
51
49
14
1
10
52
3
48
27
9
2
47
8
32
7
5
4
6
46
31
39
17
38
16
34
36 37
35
30
18
40
41
33
42
29
20
21
45
22
23
26
19
Royale By Drive Service Manual
24
25
28
43
44
PT7
Page 21
BILL OF MATERIALS / PARTS REFERENCE – ROYALE 4
These diagrams are for parts reference only. To order parts, please consult the full parts lists:
1 FRONT TILLER COVER
21 TURNING COUPLING
35 SIDE COVER R
2 TILLER FRAME
22 SPEED METER
36 REAR COVER
3 BUZZER
23 FRONT HUB
37 PLUG(R,L)
4 RUBBER DUST COVER
24 FRONT TYRE
38 DISK BRAKE SET
5 TILLER RAM MECHANISM
25 BEARING
39 TRANSAXLE
6 HANDEL CAP
26 FRONT AXLE(R,L)
40 SUSPENSION BRACKET
7 HANDEL GRIP
27 CHARGER
41 REAR HUB
8 BRAKE LEVER
28 FR COVER
42 REAR TYRE
9 REAR VIEW MIRROR
29 SUSPENSION SPRING
43 BATTERY CAP
10 REAR TILLER COVER
30 SUSPENSION ARM(R,L)
44 SIDE COVER L
11 CONTROL PANEL
31 MAIN FRAME
45 FLOOR
12 FR SWITCH
32 REAR FENDER
46 REAR SUSPENSION
13 POTENTIOMETER COMBINATION 33 REAR BASKET
47 RELEASE LEVER
34 BATTERY
14 WIGWAG
48 REAR BUMPER
15 WIGWAG PAD
49 LAMP BASE
16 FF CAP
50 REAR INDICATOR
51 LAMP CAP
17 FF COVER
55
18 FRONT BUMPER
52 SEAT SLIDING POST
53 SEAT BASE
19 HEADLIGHT
54
54 SEAT SLIDING RAIL
20 HEADLIGHT BRACKET
55 CAPTAIN SEAT ASM
12
13
15
50
53
11
56 STEM
51
49
14
1
57 FRONT BUMPER
BRACKET
10
48
52
3
9
2
47
8
32
5
16
4
27
7
6
46
31
56
39
38
34
36 37
20
40
41
35
29
30
21
42
26
19
25
17
22
18
57
33
23
28
43
24
Royale By Drive Service Manual
45
44
PF7
Page 22