RiMO SiNUS iON, User And Maintenance Manual

Page 1: ...User and maintenance manual RiMO SiNUS models Version 1 0 24 05 2017...

Page 2: ...cument using or revealing its contents are prohibited unless RiMO GERMANY GmbH Co KG has allowed it Violations are subject to restitution for damages All rights reserved with regard to patent claims o...

Page 3: ...RiMO GERMANY GmbH Co KG 12 2 Product description 13 2 1 Kart identification 13 2 2 General description 14 2 3 Driving kart 15 2 3 1 Intended use 15 2 3 2 Improper use 15 2 3 3 Reasonably foreseeable m...

Page 4: ...1 4 Maintenance and repair instructions 48 3 1 5 General notes and instructions re electrical equipment 48 3 1 6 Electromagnetic compatibility EMC 49 3 1 7 Environmental protection 49 3 2 Inadmissibl...

Page 5: ...p 71 5 1 Checking kart and safety devices 71 5 2 Commissioning 73 5 3 Daily start up 76 5 3 1 Checking brake system 78 5 3 2 Checking steering system 79 5 3 3 Checking pedals 79 5 3 4 Checking wheels...

Page 6: ...d servicing mechanical parts 105 8 2 4 Checking and servicing electrical parts 124 8 2 5 Replacing wear parts 129 8 3 Tightening torques 129 8 4 Wear and spare parts 131 8 4 1 Storage of tyres 131 8 5...

Page 7: ...formation regarding settings maintenance work and electrical equipment has been compiled for specialist technicians who are authorised to perform the respective tasks Unauthorised personnel are prohib...

Page 8: ...ger of minor or medium injury Attention Warning regarding damage to property These safety warnings highlight potential risks of damage to the kart A safety instruction contains the following informati...

Page 9: ...met Do not drive kart with long open hair Do not wear scarf or headscarf Wear tight fitting clothes Do not drive kart under the influence of alcohol 0 alcohol limit Tab 1 Prohibition signs and symbols...

Page 10: ...Text marks Lists are identified by a bullet point Text highlighted like this 10 contains a reference or hyperlink to related chapters websites and additional information available in this document or...

Page 11: ...on Figures The figures in this manual are simplified images of the kart or schematic diagrams 1 4 Revision log Date Index Revision Designation page Tab 3 Revision log of this document 1 5 Other applic...

Page 12: ...us with the following details by phone fax letter or online Your name and address Contact at your company Data found on the type plate type serial no and year of manufacture Address RiMO GERMANY GmbH...

Page 13: ...pe plate attached to the kart frame Type plate on kart frame Fig 1 Type plate near pedals Data of type plate Type Kart type ID no year of manufacture digits 1 2 month digits 3 6 year Chassis no Other...

Page 14: ...it safely The driver is given personal protective equipment protective gloves integral helmet to be worn while driving the kart The driver takes place on the driver seat and adjusts the seat and peda...

Page 15: ...the manual The kart must be regularly inspected and serviced The kart is intended for commercial use only Any other use is deemed improper See also Technical data 43 2 3 2 Improper use Any operation o...

Page 16: ...o safely due height body size age consumption of alcohol pacemaker etc Actuation of drive switch when no driver is seated in the vehicle Other use of the vehicle in contravention of the above stated i...

Page 17: ...maintenance areas of kart 1 Kart 2 Maintenance area 3 Driver seat 4 Drive switch 5 Working area 2 5 Kart components and functions This chapters describes the components of the kart and its functions 2...

Page 18: ...ing knuckles Depending on the model the steering wheel might be equipped with various indicators and control buttons The pit indicator flashes if the battery charge has dropped below 20 In this case t...

Page 19: ...es in reverse direction During reverse motion the driver must keep the button pressed The moment the button is released the kart is switched to forward motion It first comes to a halt and then acceler...

Page 20: ...distance even shorter Fig 10 Pedals 1 Brake pedal 2 Brake pedal 3 Gas pedal 4 Folding pedal extension bracket 2 5 4 Seat and seat adjustment To drive the vehicle the driver must take place on the sea...

Page 21: ...r the output power of the motor through the transmission to the rear wheels of the kart The kart is equipped with two drive units The transmission is connected to the motor through an adapter plate Th...

Page 22: ...ery cells can be recharged and are controlled by the battery management system BMS The BMS prevents overcharging or exhaustive discharging of the battery cells At the end of a drive run the battery ce...

Page 23: ...ands for what is known as the C rating The current in ampere corresponds to the C rating multiplied with the capacity of the battery in ampere hours Example A battery with a capacity of 4 Ah and a loa...

Page 24: ...ctions and parameters of the battery management system BMS See also BMS default thresholds 46 2 5 9 1 Cable harness Fig 15 Cable harness 2 5 9 2 Pin assignment Pin assignment of BMS CPU unit Fig 16 BM...

Page 25: ...ot assigned 5 1E not assigned 20 2J not assigned 6 1F green CAN High 21 3A blue Sense Enable Out 7 1G yellow CAN Low 22 3B not assigned 8 1H not assigned 23 3C brown Sense 12 V 9 1I red 12 V 24 3D bla...

Page 26: ...wire colours Fig 18 Sense board pin assignment 1 Sense board 2 Sense board plug Colour code Signal white Sense Data black Ground red Sense 12 V green Sense Enable Out Shunt plug assignment The colour...

Page 27: ...Display plug 2 Display Colour code Signal white 5 V black Ground green CAN High yellow CAN Low brown Pit LED leer Not assigned 2 5 9 3 Description of display unit The BMS display is located in the lef...

Page 28: ...replace sense boards BMS CPU unit defective replace The Undertemperature LED is lit if the temperature measured at one or more cells is below 10 C Possible causes Low ambient air temperature do not d...

Page 29: ...ll has a voltage of below 2 6 V Attention Damage of cells by undertemperature If a cell is charged while its temperature is below 5 C it might become damaged Before charging the battery ensure that th...

Page 30: ...markedly reduced This means that the capacity and driving time are also significantly reduced We recommend completing a few slow rounds on the track to heat up the cells 2 5 9 6 BMS LCD display The m...

Page 31: ...determined by the BMS is 50 the charger can load with 30 A I Min max cell voltage measured in battery J SOC value chart the respective percentage value is shown below the chart K Total battery voltag...

Page 32: ...ing fast yet careful charging without causing damage to the battery Fig 23 Charger 4 Charger 2 5 11 ACD controller The ACD motor controller controls and monitors the motor Fig 24 ACD motor controller...

Page 33: ...tor to optimise the motor for the actual driving track NOTICE Parameterisation with WFM If the operator has opted for WFM he can adjust certain parameters within a preset range 2 5 12 Motor Fig 25 Mot...

Page 34: ...ratios e g 1 5 are available on request The gear system is lubricated for life and requires no maintenance During normal operation gear system temperature 80 C there is no need to ever change the oil...

Page 35: ...coded Based on the wiring and connection diagrams the connections to the various components can be easily identified In vehicles with an optional sound system this system is also installed in the cont...

Page 36: ...e box 1 Screw fittings 2 Side box 3 Cooling air flow channel 4 Cells 5 Fan The side box is made from HDPE Thanks to its sturdy design it provides excellent protection for the battery cells and the ele...

Page 37: ...ection also prevents the kart from diving into the track barriers The surround protection is float mounted with silent blocks to the vehicle frame The surround protection front mount absorbs the energ...

Page 38: ...Safety belt 5 Head pad 2 6 Safety devices 2 6 1 Overview The kart is equipped with safety devices at all relevant danger points If these safety devices are not correctly installed and adjusted there i...

Page 39: ...re mounted before the kart is restarted Fig 33 Guards 1 Safety panelling of side box 2 Rear safety panelling 3 Front safety panelling Other safety devices Other safety devices include Seat Safety belt...

Page 40: ...at 3 Rollbar 4 Surround protection 2 6 3 Signalling devices Indicators of switches Both the drive switch and the main switch are equipped with an indicator If the green indicator is lit continuously t...

Page 41: ...off the kart is safety switched off Fig 37 Drive switch and main switch 1 Main switch 2 Drive switch The kart is equipped with the following EMERGENCY STOP devices Drive switch located on top of the l...

Page 42: ...Do not wear scarf or headscarf Wear tight fitting clothes Do not clean the car with a high pressure jet Do not drive kart under the influence of alcohol 0 alcohol limit Tab 7 Prohibition signs 2 7 Kar...

Page 43: ...te for wheels DOT 5 silicone brake fluid Brake bleeder kit Wheel alignment device Tools lubricants cleaners and other chemicals required for maintenance and repair work Please note The kart is deliver...

Page 44: ...iON 2035 1455 600 1100 Sinus Mini 1760 1280 860 Sinus Twin 1900 1530 600 1100 Tab 9 Kart dimensions 210 x 6 mm brake disc prod no 1383067 mm 4 210 x 8 mm brake disc prod no 1383015 mm 5 RiMO 160 x 4...

Page 45: ...Tab 13 Large charger 100 A Supply power 230 VAC 10 50 Hz 1 phase Fuse A 16 A Max power consumption kVA 3 7 Tab 14 Small charger 50 A Ambient conditions Operating temperature C 5 to 45 Storage tempera...

Page 46: ...anced start voltage 3 54 V As soon as one cell exceeds this limit the electrical energy fed to that cell during charging is converted into heat Minimum temperature 10 C As soon as the temperature at o...

Page 47: ...h or on the kart operator s personnel Keep a complete copy of this manual near the kart track where it is at all times accessible to personnel Only use the kart for its intended use Before starting th...

Page 48: ...f the problem and eliminating it 3 1 4 Maintenance and repair instructions The following general rules apply to all maintenance and repair work All maintenance and repair work must be performed by sui...

Page 49: ...nsure that there are no electromagnetic fields near the kart 3 1 7 Environmental protection Personnel must keep the environment in mind when working with or on with the kart to prevent any negative im...

Page 50: ...ting manual This must be confirmed in writing with signature These signatures must be collected in a list by the kart operator This list thus serves as a list of authorised kart operators and maintena...

Page 51: ...onnel 52 3 3 3 Personnel training Knowledge of the relevant general statutory health and safety regulations and best practice are an important requisite for the safe driving operation and maintenance...

Page 52: ...proper operating procedures potential hazards and safety measures This ensures that all authorised drivers have the necessary knowledge to prevent incidents and to ensure the safe operation of the ka...

Page 53: ...t work on the kart without supervision Kart life phase Examples of tasks Qualification criteria for operator s per sonnel1 Lay person Trained instructed person2 Skilled worker3 Transport Lifting Loadi...

Page 54: ...s to persons responsible for the installation setup operation maintenance clean ing repair and transport of machines 2 Trained or instructed personnel refers to persons who have been instructed in the...

Page 55: ...manual 3 4 3 Operator s personnel groups In this manual a clear distinction is made between two groups of persons working on the kart namely opera tor s personnel and maintenance personnel Personnel...

Page 56: ...ator must instruct the driver in the safe operation of the kart 3 5 1 Clothing and physical fitness Operator s personnel must ensure that a driver is physically fit to drive the vehicle and wears appr...

Page 57: ...ed to Personal protective equipment for drivers Integral helmet CE approved of suitable size with chin strap and closed visor Fully covering tight fitting clothes The clothing must be suitable to prot...

Page 58: ...rts and tools and point ed objects on the ground Tab 22 Personal protective equipment Operator s personnel 3 7 Residual risks The following residual risks cannot be eliminated by design measures Risk...

Page 59: ...services by telephone Notify supervisor When calling the emergency servicesrelay the following information What happened Where did it happen Who is making the emergency call Number of casualties List...

Page 60: ...rge for safe manoeuvring Door and gate openings must be at least 5 cm wider and higher than the transport unit including the transport vehicle Have the transport path secured by a third person For saf...

Page 61: ...a forklift truck observe the following instructions a Use a forklift truck with suitably long forks b Pick up the transport pallet at the side marked for this purpose c If required place timber beams...

Page 62: ...t weight The kart is not approved for operation in potentially explosive atmospheres Before installing the kart observe any additional conditions regarding the location of operation and the infra stru...

Page 63: ...port requirements the wheels might have been removed from the kart prior to shipping After unloading the kart mount the wheels WARNING Risk of accident from non approved wheel rims or tyres Non approv...

Page 64: ...agon nut and tighten it a little Turn the wheel to check whether it rotates freely If the wheel rotates freely tighten the hexagon nuts further and check again for free rotation If the wheel does not...

Page 65: ...teering wheel mount see Tightening torques 129 The steering wheel is now properly secured to the steering column f Secure the steering wheel cover with the screws to the steering wheel The steering wh...

Page 66: ...ads 1 Surround protection 2 Rear plastic pad 3 Side front plastic pad 4 Centre front plastic pad Switch off the kart and secure it against inadvertent start up a Position the kart safely at an ergonom...

Page 67: ...t safety belt For detailed instructions see original operating manual of Carpoint The kart is switched off a Position the kart safely at an ergonomically suitable height e g by placing it on an assemb...

Page 68: ...c Attach the fittings of the two safety belts in the eye bolts on the vehicle frame see also Tightening torques 129 d Test the safety belt mechanism the tabs and the buckle To do this engage the tabs...

Page 69: ...4 5 4 1 Positioning charger Attention Damage due to wrong charger Charging with an unsuitable charger can cause damage to kart components and or the charger a Use only chargers that are suitable for...

Page 70: ...The torque and power settings of the drive must be adjusted to suit the kart track limiting the kart s maximum speed RiMO will assist you in adjusting the kart setup During the kart run in first 10 o...

Page 71: ...ure it against inadvertent switching on WARNING Risk of accident missing safety devices Missing guards can cause serious injury a Mount all guards before starting the kart b Before starting the kart c...

Page 72: ...n switch The kart is fully assembled and set up The kart is properly propped up so that its wheels turn freely a Switch on the main switch The LEDs of the BMS display are lit b Turn the drive switch b...

Page 73: ...d ready for operation Checking battery charge and charging batteries Fig 46 Drive switch and main switch 1 Main switch 2 Drive switch 3 Drive switch indicator Fig 47 BMS LCD display and charger 1 Char...

Page 74: ...e END is dis played on the charger display e Disconnect the charging plug from the kart CAUTION Do not disconnect the charging plug while the kart is being charged The batteries are fully charged Test...

Page 75: ...ce life of the brake pads and discs Performing first test run The accelerator and brake function tests have been successfully completed a Place the kart on a suitable approved kart track b Take place...

Page 76: ...ed or prior to opening the track Attention Faults during charging When the kart is being charged keep an eye on it In the event of a fault immediately terminate the charging process a Do not charge th...

Page 77: ...charging plug from the kart CAUTION Do not disconnect the charging plug while the kart is being charged Do not disconnect the charging plug by pulling the cable The batteries are fully charged NOTICE...

Page 78: ...t must be run in carefully After a high impact on the kart immediately inspect the brake system of the kart and perform a brake test The brake system of the kart must always generate the necessary bra...

Page 79: ...the front axle steering system check all parts of the steering and tracking system for damage Also check the steering alignment tracking Check and tighten all screw connections Steering play often in...

Page 80: ...level Check the screw connections of the pedals 5 3 4 Checking wheels WARNING Risk of accident from defective pedals Defective or worn wheels can lead to accidents and serious injury a Check the whee...

Page 81: ...ows on the tyres Check the wheels for axial play see Maintenance change of wheels 115 When the kart is switched off the rear wheels must rotate freely If this is not the case contact RiMO service 5 3...

Page 82: ...after prolonged storage To recommission the kart after prolonged storage proceed as described for commissioning with initial battery charging discharging as follows a Check all components for stiffne...

Page 83: ...y notify your supervisor Before switching on the kart make sure that no persons are standing in its danger area To drive the kart the driver must wear the prescribed personal protective equipment see...

Page 84: ...must assess whether a person is fit to drive the kart taking into account the age height and weight of the person as well any medical concerns The kart operator must instruct personnel in how to make...

Page 85: ...4 Adjusting seat position If required the seat position and the pedals must be adjusted to suit the driver Seat Position the seat so that the driver can reach the steering wheel with bent arms The ar...

Page 86: ...available from RiMO online shop at www rimo de shop Pedals The driver must be able to reach the pedals easily while keeping the legs slightly bent To shorten the distance to the pedals fold down the e...

Page 87: ...tting on the driver seat a Adjust the 4 point safety belt to the driver s torso This can be down with the adjusting elements positioned at the height of the driver s shoulder chest and pelvis WARNING...

Page 88: ...ch indicator 2 Drive switch 3 Main switch indicator a Take place on the driver seat b Switch on the main switch c Turn the drive switch by approx 1 8 revolution clockwise to switch on the kart d The g...

Page 89: ...ched off Switching off kart for prolonged shutdown At the end of the shift or to carry out maintenance work the kart must be fully shut down Fig 56 Drive switch and main switch 1 Main switch 2 Drive s...

Page 90: ...and serious injury a Reversing during normal track driving is prohibited b Reversing is only permitted in the event of an emergency See also Steering system 18 6 7 Safe driving For safe driving the fo...

Page 91: ...s before it can resume driv ing on the track a Inspect the surround protection and the bodywork for damage b Inspect and test the brake and the steering system c For vehicles with safety belt After an...

Page 92: ...nd instructions regarding malfunctions and errors WARNING Risk of injury from disabled safety devices during troubleshooting When troubleshooting the kart it might be necessary to temporarily switch o...

Page 93: ...b Before starting the kart check all safety devices 7 1 Restart after unplanned stop Prior to switching on a Identify and eliminate the cause of the unplanned stop b Inspect the kart and all component...

Page 94: ...vice 7 2 Faults and malfunction during operation 7 2 1 Fault list NOTICE Troubleshooting All tasks described below must be performed by authorised technicians or skilled workers If you are unsure how...

Page 95: ...heck BMS OS No control connection to main switch solenoid Check cable from BMS to main switch solenoid OS Fuse defective Check fuses F4 F5 F6 in control cabinet OS Main switch defective Check main swi...

Page 96: ...ectly set Check pedal replace if necessary OS OP operator s personnel OS operator s skilled worker M manufacturer Tab 23 Fault list 7 2 2 Eliminating faults NOTICE Troubleshooting If you have any quer...

Page 97: ...eter To identify the terminal for the measurement refer to the pin assignment schedule and the wiring diagram The terminal can then be identified from the terminal assignment schedule In our case it i...

Page 98: ...vice technician In order to deal with your problem quickly and efficiently the RiMO service department needs the following information Serial number of charger LED display signal Description of proble...

Page 99: ...ergonomically suitable height e g with KHB 250 lifting platform f Some of the kart components are very heavy Use suitable lifting gear and attachments g Before restarting the kart re install all safe...

Page 100: ...kart parts that remain powered NOTICE Service the kart regularly Regular servicing is an integral part of proper use and crucial for the safe and efficient operation of the kart 8 1 Maintenance sched...

Page 101: ...ion for damage function test OP Tyres T Check tyre pressure OP Wheels I T Visual inspection for wear and damage 115 function test OP Screw connections I T Visual inspection for wear and damage 115 che...

Page 102: ...tion T test check R replace C clean OP operator s personnel OS operator s skilled worker M manufacturer Tab 25 Weekly maintenance schedule See also Maintenance of steering alignment system 113 Checkin...

Page 103: ...completed once after first 10 operating hours Component Task Description of task To be carried out by Drive components T Check setup adjust reduce if necessary OS I visual inspection T test check R re...

Page 104: ...ng agents can cause damage to the kart or its components a Wear protective gloves and safety goggles b Wherever possible use only mild cleaning agents c Do not use high pressure devices or aggressive...

Page 105: ...e system component has been replaced the kart must be run in carefully For the assembly of the components strictly adhere to the specified tightening torques seeTightening tor ques 129 Use only DOT 5...

Page 106: ...ase change it Do not forget to bleed the system The brake fluid can be inspected through the sight glasses Clean brake fluid is clear and purple in colour Dirty brake fluid shows dark discolouration 8...

Page 107: ...ight glass 1 Max filling level 2 Filling level upon delivery and after brake pad change 3 Recommended filling level 4 Min filling level CAUTION Risk of injury from contact with DOT 5 Silicone The maxi...

Page 108: ...fluid is free of bubbles ensure that there is a sufficient brake fluid supply g Complete the same procedure with the other three bleeder screws h The brake circuits must be bleed twice After the seco...

Page 109: ...are retracted Attention Damage to brake piston caused by tool Hard sharp edged objects can cause damage to the brake piston splintering frac ture a Before replacing the old brake pads push them back...

Page 110: ...nical brake parts Fig 63 Lubricating mechanical brake parts 1 Gas pedal 2 Brake pedal 3 Lubrication nipple 4 Knuckle joint 5 Brake pedal Proceed as follows The kart is switched off a Lubricate the bra...

Page 111: ...eturn automatically to their initial position when released Deformed or damaged pedals must be replaced with RiMO original parts The pedals must be regularly lubricated through the lubrication nipples...

Page 112: ...e g KHB 250 EH prod no 1397002 b Remove the screws at the steering wheel c If necessary disconnect all electronic connections from the steering wheel d Loosen the screw of the steering wheel mount an...

Page 113: ...For all other tightening torques refer to chapter Tightening torques 129 8 2 3 5 Maintenance of steering alignment system See also Maintenance change of wheels 115 Tightening torques 129 8 2 3 5 1 Che...

Page 114: ...g knuckles using the centring screws figure left d Loosen the locknuts of the tie rods e Position the steering column so that the tie rod mount figure to the left is aligned to the longitudinal axis o...

Page 115: ...following Replace tyres if the wear mark is no longer visible or if the tread carcase is damaged Always replace tyres in pairs i e replace both tyres of the front or of the rear axle or replace all f...

Page 116: ...ed with three hexagon nuts each Fig 68 Mounting wheel 1 Wheel 2 Hexagon nuts 3 Arrow direction of rotation of wheel The kart is switched off a Position the kart safely at an ergonomically suitable hei...

Page 117: ...The road adhesion of the tyres might not be suitable for the kart This can result in serious injury a Use only wheel rims and tyres that have been approved by RiMO The old tyre has been removed from...

Page 118: ...axle wheel bearing Fig 69 Mounting wheel 1 Wheel 2 Hexagon nuts 3 Arrow direction of rotation of wheel The new tyres are mounted a Position the kart safely at an ergonomically suitable height e g wit...

Page 119: ...p the kart and check whether the front wheels rotated freely b Turn the wheels to check whether they rotate freely c Front axle Mount the hexagon nut and tighten it a little Turn the wheel to check wh...

Page 120: ...efective bodywork c Mount the new bodywork Tighten the screws with the prescribed tightening torque see Tightening torques 129 The bodywork has been replaced Replacing surround protection The kart is...

Page 121: ...ons Screw connections of steering knuckles Screw connections of wheel bearings Screw connections of tie rods Screw connections of steering bearing top Screw connections of seat fixture Screw connectio...

Page 122: ...in working order Test the belt tensioner Pull out the belt to the stop and release it to check whether it fully retracts Pull the belt firmly to check whether the belt tensioning mechanism engages Che...

Page 123: ...status of the ACD motor controller Fig 72 ACD motor controller 1 Status LED of ACD motor controller Signal Description LED off Controller not in operation LED continuously on Controller activated and...

Page 124: ...nsor is not actuated when the gas pedal is in its zero position but the kart is accelerated at the maximum rate when the gas pedal is pushed to the stop c Tighten the screws with a tightening torque o...

Page 125: ...replaced when they reach the end of their service life To prevent damage to or failure of the safety system replace these components without delay and perform a function test of the respective safety...

Page 126: ...nection to the side box top section must be made WITHOUT screw locking compound Tighten the load cable screws with 7 8 Nm NOTICE Mounting spring washers Spring washers prevent nuts and screws from bec...

Page 127: ...charged This ensures that the cells are better balanced and that their maximum capacity can be uti lised The cells cannot be overcharged Charging batteries Attention Faults during charging When the ka...

Page 128: ...reached d Disconnect the charging plug from the kart CAUTION Do not disconnect the charging plug while the kart is being charged Do not disconnect the charging plug by pulling the cable The batteries...

Page 129: ...45 Nm Adapter plate transmission motor motor 25 Nm Adapter plate transmission motor transmission 25 Nm Adapter plate transmission motor frame 20 Nm Adapter plate frame 20 Nm Safety belt securing poin...

Page 130: ...mounting plate 6 7 Nm Pad surround protection 10 Nm Wheel centres drive shaft 30 Nm Surround protection silent rubber elements 35 Nm Side box top part drive switch EMERGENCY STOP button 2 Nm Side box...

Page 131: ...ts please contact RiMO providing the following information Type Product number Year of manufacture Part designation Quantity Shipping method Wear and spare parts list For more information contact RiMO...

Page 132: ...cessary technical knowledge and skills Repairs are excluded from the RiMO warranty If you have any questions regarding repairs contact RiMO service department 9 1 1 Exchanging replacing battery cells...

Page 133: ...main switch 1 Main switch 2 Drive switch 3 Drive switch indicator Fig 79 Cells in side box 1 Sense boards 2 Side box screws 3 Side box Fig 80 Disconnecting cells 1 Cell connector 2 Sense board 3 Load...

Page 134: ...e is a risk of a short circuit This can result in serious injury a When disconnecting the load and main power cables from the cells insulate them g Disconnect and insulate the load and main power cabl...

Page 135: ...ous damage to the kart battery a Therefore only install cells approved by RiMO Fig 81 Installing new cell 1 Cell connector 2 Sense board 3 Cell pack 4 Brace screws 5 Brace Fig 82 Installing cell pack...

Page 136: ...the new cell not be automatically detected by the BMS connect the charger and fully charge the kart 100 This charging process might take a bit longer than usual as the new cell is balanced by the BMS...

Page 137: ...missioning storage and disposal CAUTION Risk of injury when coming into contact with powered electrical components of the kart Electric shock can cause serious injury a All work on the electrical syst...

Page 138: ...ing cycles after 100 AH 12 months 60 AH 8 months 40 AH 6 months a Fully charge the kart batteries 100 until message END is displayed on the charger b Then discharge the batteries to approx 70 5 for in...

Page 139: ...mful to the environment and that must therefore be disposed of according to the ap plicable regulations The safety data sheets of factory applied substances are available from RiMO Dismantle the kart...

Page 140: ...ems including the plastic box to RiMO RiMO places new cells in the box and sends the cell system back to the operator Spent cells can be returned to RiMO for disposal free of charge 3 The operator rep...

Page 141: ...Technical documents appendices 11 User and maintenance manual 141 148 11 Technical documents appendices...

Page 142: ...Seat and seat frame 21 Fig 12 Drive components 21 Fig 13 Brake system 22 Fig 14 Electrical equipment 23 Fig 15 Cable harness 24 Fig 16 BMS CPU RiMO prod no 1382953 24 Fig 17 Colour coding 25 Fig 18 S...

Page 143: ...hing on drive switch and main switch 72 Fig 46 Drive switch and main switch 73 Fig 47 BMS LCD display and charger 73 Fig 48 Drive switch and main switch 76 Fig 49 Charge indicator 76 Fig 50 Checking p...

Page 144: ...el 118 Fig 70 Safety elements bodywork 120 Fig 71 Safety belts 122 Fig 72 ACD motor controller 123 Fig 73 Gas sensor 124 Fig 74 Side box 125 Fig 75 Drive switch 126 Fig 76 Drive switch and main switch...

Page 145: ...13 Large charger 100 A 45 Tab 14 Small charger 50 A 45 Tab 15 Ambient conditions 45 Tab 16 Noise emission 45 Tab 17 Qualification of operator s personnel 54 Tab 18 Operator s personnel groups 55 Tab 1...

Page 146: ...management system C Coulomb unit for electric charge C rating C rating indicates the maximum safe continuous discharge rate of a battery under certain ambient conditions EMC Electromagnetic compatibi...

Page 147: ...9 Forklift truck Instructions 61 Transport 61 I Infrastructure Location of operation 62 K Kart Check 71 Decommissioning 138 Description 14 Disposal 139 First start up 70 Improper use 15 Intended use 1...

Page 148: ...ualification of operator s personnel 54 Qualified technical personnel Qualification 56 R Resetting EMERGENCY STOP 93 S Safety Electrical equipment 48 Inadmissible operating conditions 49 Kart operatio...