RiMO SiNUS Series User And Maintenance Manual
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RiMO SiNUS Series User And Maintenance Manual

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User and maintenance manual
RiMO SiNUS models
Version 1.0 • 24/05/2017

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Summary of Contents for RiMO SiNUS Series

  • Page 1 User and maintenance manual RiMO SiNUS models Version 1.0 • 24/05/2017...
  • Page 2 Proprietary notice RiMO GERMANY GmbH & Co. KG is the copyright holder of this document. Forwarding, duplicating and storing this document, using or revealing its contents are prohibited unless RiMO GERMANY GmbH & Co. KG has allowed it. Violations are subject to restitution for damages.

  • Page 3: Table Of Contents

    Text marks............................10 Revision log ............................11 Other applicable documents ......................11 Warranty and liability ......................... 11 Contacting RiMO GERMANY GmbH & Co. KG ................12 Product description ........................13 Kart identification ..........................13 General description ........................... 14 Driving kart ............................15 2.3.1...
  • Page 4 Table of contents 2.5.15 Control box ............................35 2.5.16 Bodywork ............................35 2.5.17 Side box ............................36 2.5.18 Surround protection ........................... 37 2.5.19 Rollbar ............................... 38 Safety devices ........................... 38 2.6.1 Overview ............................38 2.6.2 Safety devices ........................... 39 2.6.3 Signalling devices ..........................
  • Page 5 Table of contents Action in the event of an accident ..................... 59 Transport and installation ......................60 Required tools ........................... 60 Lashing points ........................... 60 Transport by forklift truck ........................61 Removing and disposing of packaging ..................... 61 Installation ............................62 4.5.1 Location of operation and local infrastructure ...................
  • Page 6 Repairs ............................132 Repair tasks to be performed by operator..................132 9.1.1 Exchanging/replacing battery cells ....................132 9.1.2 Replacing transmission ........................136 Repairs to be carried out by RiMO ....................136 Decommissioning, storage and disposal ..................137 10.1 Decommissioning ..........................137 10.2 Dismantling ............................138 10.3 Packaging kart ..........................138...

  • Page 7: About This Operating Manual

    This operating manual (hereafter referred to as "the manual") has been devised to ensure safe operation, maintenance and repair of the SiNUS models iON, MiNi and TWiN (hereafter referred to as "the kart"). It also includes detailed descriptions of the karts manufactured by RiMO GERMANY GmbH & Co. KG (hereafter re- ferred to as "RiMO").
  • Page 8 1 | About this operating manual WARNING Warning regarding a potential risk of injury This safety warning/instruction refers to a potential danger of serious or even fatal injury. CAUTION Warning regarding a potential risk of injury This safety warning/instruction refers to a potential danger of minor or medium injury. Attention Warning regarding damage to property These safety warnings highlight potential risks of damage to the kart.

  • Page 9: Prohibition Signs And Symbols

    About this operating manual | 1 1.3.2 Prohibition signs and symbols A prohibition sign consists of a red circle and a diagonal red line on a white background containing a symbol. Example: cigarette with red diagonal bar: Smoking prohibited! Symbol Description Do not drive kart without safety helmet.

  • Page 10: Other Symbols Used In This Manual

    1 | About this operating manual 1.3.4 Other symbols used in this manual Important or helpful alerts, information, and tips are structured as shown below: NOTICE Notice This symbol indicates operating tips and information that help you operate the kart in the most efficient manner.

  • Page 11: Revision Log

    Warranty and liability The General Business Terms and Conditions of RiMO GERMANY GmbH & Co. KG apply. A copy of these terms and conditions is handed over to the buyer of the kart at the time of signing of the contract.

  • Page 12: Contacting Rimo Germany Gmbh & Co. Kg

    1 | About this operating manual Contacting RiMO GERMANY GmbH & Co. KG If you have any queries regarding the kart, please contact us with the following details (by phone, fax, letter or online): – Your name and address – Contact at your company –...

  • Page 13: Product Description

    Product description | 2 Product description This chapter contains detailed descriptions of the kart and its main components. Kart identification Each kart is identified by a type plate attached to the kart frame. Type plate on kart frame Fig. 1: Type plate near pedals Data of type plate: –...

  • Page 14: General Description

    2 | Product description General description The kart is a sports vehicle designed for driving on a kart track. The kart must only be started: – for the intended purpose – when in proper working condition Defects or faults that might impair the safety of the kart must be eliminated without delay. Never start a kart, if it is defective or faulty.

  • Page 15: Driving Kart

    Product description | 2 Driving kart This chapter describes how the kart must be driven. 2.3.1 Intended use The kart is designed for forward travel on a suitable kart track. It must be driven by a properly instructed person who is physically able to control the kart safely at all times. Proper operation of the kart requires instruction of the driver in its handling and control.

  • Page 16: Reasonably Foreseeable Misuse

    2.3.3 Reasonably foreseeable misuse RiMO has identified the following reasonably foreseeable misuses of the kart. – Operation of the vehicle by a person who is not physically able to do so safely (due height, body size, age, consumption of alcohol, pacemaker, etc.).

  • Page 17: Work, Maintenance And Danger Areas

    Product description | 2 2.4.1 Work, maintenance and danger areas The diagram below shows the work, maintenance and danger areas of the kart. The work area of the kart must only be accessed to drive it. The maintenance area must only be accessed to service the kart.

  • Page 18: Steering System

    2 | Product description Fig. 6: Vehicle frame 1 Bumper 2 Kart frame Fig. 7: Footboards 1 Front left footboard 2 Front right footboard 3 Rear footboard 2.5.2 Steering system The steering system enables drivers to steer the vehicle along the track. Its main components are the steering wheel, the steering column with steering column struts to protect it, the tie rods and the steering knuckles.
  • Page 19 Product description | 2 The reverse button allows for the driving of the kart in reverse direction. This is done at reduced power and speed (approx. 10 km/h). This button can be pressed while the vehicle is still in forward motion. In this case, the kart first coasts to a halt before it accelerates in reverse direction.

  • Page 20: Pedals

    2 | Product description 2.5.3 Pedals The pedals include a gas pedal and a brake pedal. The vehicle is shipped with a pedal extension for each pe- dal. The folding extensions can be mounted to reduce the distance between the pedals and the driver seat. We also offer optional detachable pedal extension elements that make the above distance even shorter.

  • Page 21: Drive Unit

    Product description | 2 Fig. 11: Seat and seat frame 1 Seat frame 2 Seat adjustment cable 3 Seat adjustment lever 4 Seat 2.5.5 Drive unit The drive units transfer the output power of the motor through the transmission to the rear wheels of the kart. The kart is equipped with two drive units.

  • Page 22: Brake System

    2 | Product description 2.5.6 Brake system The two-circuit brake system is used to slow down the kart safely. The brake cylinder unit includes two separate cylinders, each acting on one rear wheel. The brake fluid level in the brake circuits can be monitored through the oil sight glass. The brake system must be operated with a DOT 5 silicone brake fluid.

  • Page 23: Batteries

    11 Drive switch (EMERGENCY-STOP switch) 2.5.8 Batteries The RiMO SiNUS karts must be run with LiFeMnPo4 batteries. Never use LiFeMnPo4 cells, as these produce discharge currents that are too high. The batteries are designed for a continuous load of 3.5 C and a peak load of 10 C.

  • Page 24: Battery Management System (Bms)

    Cable harness 2.5.9.2 Pin assignment Pin assignment of BMS CPU unit Fig. 16: BMS CPU (RiMO prod. no. 1382953) 1 BMS CPU plug 2 BMS CPU The colours in the diagram below correspond to the actual wire colours. 24 / 148...
  • Page 25 Product description | 2 Fig. 17: Colour coding No. Pin Colour code Signal No. Pin Colour code Signal 1A white Battery + 16 2F pink Video not assigned 17 2G not assigned 1C brown Shunt - 18 2H not assigned 1D white Shunt + 19 2I...
  • Page 26 2 | Product description Sense board pin assignment The colours in the diagram below correspond to the actual wire colours. Fig. 18: Sense board pin assignment 1 Sense board 2 Sense board plug Colour code Signal white Sense Data - black Ground Sense 12 V +...
  • Page 27 Product description | 2 Display plug assignment The colours in the diagram below correspond to the actual wire colours. Fig. 20: Display plug assignment 1 Display plug 2 Display Colour code Signal white +5 V black Ground green CAN High yellow CAN Low brown...
  • Page 28 2 | Product description 2.5.9.4 Warning and error signals SOC indicator The yellow LEDs on the display shows the SOC (state of charge) value. If all LEDs are lit, the kart battery is fully charged. Pit LED The pit LED on the steering wheel or on the front panel flashes when the SOC drops below 20%. In this case, the kart must be recharged without delay.
  • Page 29 Product description | 2 2.5.9.5 System conditions and safe operation Charging Charging is only enabled by the BMS if the following conditions are met: – Kart is switched on (main switch set to ON) – Drive switch is pushed in (OFF) –...
  • Page 30 2.5.9.6 BMS LCD display The monitor shipped with the kart (RiMO Shop prod. no. 1389227 LCD screen RiMO SiNUS) shows the actual values for a range of parameters monitored by the BMS. The monitor can be connected to the kart in the control box (see Electric system with battery cells [...
  • Page 31 Product description | 2 Item Description Current cell temperature Current cell voltage Measured current in ampere; negative value during charging - positive value during driving Highest measured cell temperature in battery Max. permissible percentage rate for charging as determined by BMS Example 1: The rated cell capacity is 100AH;...

  • Page 32: 2.5.10 Charger

    The charger is equipped with advanced high-frequency charging technology for extra high efficiency. Its energy consumption is up to 20% lower than that of a conventional single-phase charger. The charger is configured for operation with the RiMO BMS, ensuring fast yet careful charging without causing damage to the battery.

  • Page 33: 2.5.12 Motor

    Motor 1 Motor All RiMO SiNUS kart models are driven by brushless disc motors. This type of motor is extremely durable and maintenance-free as commutation is performed electrically and not mechanically. Other advantages are its compact and flat size, low weight and excellent efficiency within a broad speed range. In addition, disc motors can be flexibly configured as regards their speed / power ranges.

  • Page 34: 2.5.13 Transmission

    2 | Product description 2.5.13 Transmission Fig. 26: Transmission 1 Motor 2 Planetary gear 3 Clamping hub The power from the motor is transmitted to the wheel by means of a backlash-free planetary gear with a trans- mission ratio of 1:7. Other transmission ratios (e.g.

  • Page 35: 2.5.15 Control Box

    Product description | 2 2.5.15 Control box Fig. 28: Control box 1 Control box The control box contains the main cables for electrical components and provides mechanics with a well- organised board for fault location and measurements. The control box also contains the main fuses. The terminals in the control box are numbered, and the individual cables are equally identified with numbers or colour-coded.

  • Page 36: 2.5.17 Side Box

    2 | Product description Fig. 29: Bodywork 1 Front panel 2 Front spoiler 3 Right side box (top and bottom part) 4 Brake light 5 Axle cover 6 Bodywork squeeze fastener 7 Extra weight (5 kg per unit) 8 Left side box 2.5.17 Side box Fig.

  • Page 37: 2.5.18 Surround Protection

    Product description | 2 Each side box is equipped with a fan that cools the battery cells, should this be necessary. Cool air is taken in at the outside of the cells and flows through channels between the cells. Heat dissipates from the cells to the air, which is then extracted by the fan and released at the rear of the side box.

  • Page 38: 2.5.19 Rollbar

    2 | Product description 2.5.19 Rollbar The rollbar protects the driver in the event of a collision or when the kart rolls over. Various types of safety belts can be attached to the rollbar. The head pad protects the driver from hitting his/her head on the rollbar tube. Fig.

  • Page 39: Safety Devices

    Product description | 2 2.6.2 Safety devices The safety devices protect the danger areas of the kart. They do not affect the movement of the vehicle. Guards Guards include: – Protective covers – Safety panelling Guards protect prevent or obstruct direct access to rotating/moving kart parts. They must only be removed, if this is required for maintenance or repair and must be re-mounted before the kart is restarted.

  • Page 40: Signalling Devices

    2 | Product description Fig. 34: Other safety devices 1 Safety belt (optional) 2 Seat 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, the respective switch is on. If the indicator is off, the switch is off. Fig.

  • Page 41: Emergency-Stop Devices

    Product description | 2 Indicators on steering wheel Depending on the model, the steering wheel might be equipped with various indicators and control buttons. Fig. 36: Indicators on steering wheel 1 Pit indicator 2 Boost ON indicator 2.6.4 EMERGENCY-STOP devices The drive switch acts as an EMERGENCY-STOP switch.

  • Page 42: Kart Operation

    2 | Product description Symbol Description Warning: Dangerous electric voltage Tab. 6: Warning signs Prohibition signs Symbol Description Do not drive kart without safety helmet. Do not drive kart with long open hair. Do not wear scarf or headscarf. Wear tight-fitting clothes. Do not clean the car with a high-pressure jet.

  • Page 43: Scope Of Delivery

    – Check the delivery upon receipt of the kart. – Any detected transport damage and/or missing parts must be reported immediately in writing. Technical data General information Designation Electric kart of the SiNUS series, model iON, MiNi or TWiN Year of manufacture from 2016 Tab. 8: Kart...

  • Page 44: Tab. 9: Kart Dimensions

    210 x 6 mm brake disc (prod. no. 1383067) [mm] 210 x 8 mm brake disc (prod. no. 1383015) [mm] RiMO 160 x 4 mm brake disc (prod. no. 1383424) [mm] Tab. 10: Brake disc wear limit SiNUS iON [kg]...

  • Page 45: Tab. 12: Transmission

    Product description | 2 Transmission ratio Oil filling For-life grease lubrication Tab. 12: Transmission Electric charger Supply power 400 VAC ± 10 % 50 Hz, 3-phase, N + PE Fuse [A] 16 A per phase Max. power consumption [kVA] Tab. 13: Large charger, 100 A Supply power 230 VAC ±...

  • Page 46: Bms Default Thresholds

    2 | Product description 2.9.1 BMS default thresholds Designation Value Description Final charging voltage 3.65 V The moment the first cell reaches this voltage, charging is temporar- ily suspended. Final discharge voltage 2.60 V The moment the first cell reaches this voltage, SOC is set to zero; the vehicle stops.

  • Page 47: Safety

    Safety | 3 Safety The kart has been designed according to the latest state of technology and in compliance with the relevant safe- ty regulations and rules. Improper use of the kart can however cause serious or even fatal injury to the driver or other persons, or serious damage to the kart or other equipment.

  • Page 48: Troubleshooting Instructions

    – The kart is powered electrically. If the electrical equipment is incorrectly installed or if its insulation fails, there is a risk of fatal injury. – The electrical equipment of the kart must only be accessed by electricians or personnel trained by RiMO. Keep all control cabinets locked at all times.

  • Page 49: Electromagnetic Compatibility (Emc)

    Safety | 3 – Unauthorised modifications to the kart are prohibited. All planned modifications must be approved in writing by the manufacturer of the kart. 3.1.6 Electromagnetic compatibility (EMC) If operated correctly and for the intended purpose, the electrical equipment of the kart conforms to the statutory regulations regarding electromagnetic compatibility.

  • Page 50: Duties Of The Kart Operator

    3 | Safety – A foreign object or a person is inside the kart's danger zone. – The kart has been modified without prior authorisation by the manufacturer. – The control system has been modified without authorisation. – Operating parameters have been changed without prior authorisation by the manufacturer. –...

  • Page 51: Assigning Tasks To Personnel

    Safety | 3 – During kart operation, qualified first aiders must be present on site so that first aid can be provided, if necessary. – There must be clarity as regards the procedures, processes and responsibilities regarding the kart and its operation.

  • Page 52: Driver Instruction

    3 | Safety 3.3.4 Driver instruction Knowledge of the relevant general statutory health and safety regulations are an important requisite for the safe driving and operation of the kart. Best practice includes the wearing and use of personal protective equipment by all drivers.
  • Page 53 Safety | 3 – They must have read and fully understood this operating manual, in particular the safety instructions and the chapters that are relevant for their work. – They must be familiar with the relevant occupational and accident prevention regulations. As a rule, all personnel working on or with the kart must have the following minimum qualifications: –...

  • Page 54: Tab. 17: Qualification Of Operator's Personnel

    3 | Safety Kart life phase Examples of tasks Qualification criteria for operator's per- sonnel Lay- Trained/instructed Skilled person person worker Cleaning – Cleaning - trained/instructed person Maintenance – Topping up transmission oil - trained/instructed person – Disconnection from power supply - skilled worker –...

  • Page 55: Skills And Knowledge For Drive Operation

    Safety | 3 3.4.2 Skills and knowledge for drive operation Operator's personnel on the race track should have the following skills and knowledge: – Personal safety – Driver instruction, covering all relevant topics – Safety inspection of kart – Special safety precaution for children –...

  • Page 56: Specific Skills And Knowledge

    3 | Safety 3.4.4 Specific skills and knowledge The following tasks must only be performed by personnel who have specialist skills and knowledge: Task Qualification Work on electrical equipment Electrician Work on mechanical equipment Industrial mechanic other technician under the supervision of an industrial mechanic; all work must be performed according to best practice.

  • Page 57: Personal Protective Equipment

    Safety | 3 Personal protective equipment Personal protective equipment is designed to protect drivers and operator's personnel against hazards that might impair their safety or health when working on or driving the kart. When driving or carrying out work on the kart, the driver and the operator's personnel must wear personal pro- tective equipment.

  • Page 58: Residual Risks

    3 | Safety Personal protective equipment for operator's personnel Symbol Description Safety goggles Eye protection against propelled vehicle parts and other objects. Hearing protection To protect the hearing against excessive noise. Protective gloves To protect the hands against grazing, abrasion, punctures, cuts, etc. and against burns from hot surfaces.

  • Page 59: Action In The Event Of An Accident

    Safety | 3 Action in the event of an accident NOTICE General rules regarding accidents Remove casualties from danger area! Provide first aid and alert the emergency services by telephone! Notify supervisor! When calling the emergency servicesrelay the following information: –...

  • Page 60: Transport And Installation

    4 | Transport and installation Transport and installation Prior to delivery, the kart has been assembled, configured and tested at the factory. For transport, the kart might have been disassembled. In order to prevent serious or even fatal injury or damage to property during transport and installation, adhere to the following instructions: –...

  • Page 61: Transport By Forklift Truck

    Transport and installation | 4 Transport by forklift truck WARNING Risk of injury from lifted loads Lifted loads might suddenly drop or topple over, posing a risk to life and limb. a) Never stand under suspended loads! b) Ensure that, during transport, the kart is always fully placed on the fork arms of the forklift truck.

  • Page 62: Installation

    4 | Transport and installation Installation This chapter describes the conditions and procedures for proper installation of the kart. 4.5.1 Location of operation and local infrastructure The location of operation of the kart must meet the following conditions: – The surface on which the kart is to be placed must be level and strong enough to carry the weight of the kart. –...

  • Page 63: Installing Mechanical Components

    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. NOTICE Mounting wheels on front and rear axle The front wheels are secure with one hexagon nut each.
  • Page 64 Apply assembly paste to the front axle steering knuckles. NOTICE! The assembly paste is not included in the scope of delivery and can be purchased separately from RiMO. Contact RiMO service department for advice. Product no.: 1892036 - HSP 1400 lubrica- tion, disassembly and corrosion protection paste c) Slide the rear wheels onto the wheel centre.
  • Page 65 Transport and installation | 4 a) Position the kart safely at an ergonomically suitable height (e.g. with KHB 250 lifting platform). b) Remove the steering wheel cover from the steering wheel. c) Thread the signal cable through the hub of the steering wheel and place the steering wheel on the steering wheel mount.
  • Page 66 4 | Transport and installation b) Remove the cover on the rear bodywork (axle cover).  The bottom parts of the rollbar are now freely accessible. top part of the rollbar bottom part of the rollbar Allen head screws c) Insert the into the and secure it with the (see Tightening torques...
  • Page 67 Transport and installation | 4 4.5.3.3 Installing safety belt Various types of safety belts can be attached to the rollbar. Install the belts according to the instructions in the documentation of the manufacturer: – 3-point safety belt: manufacturer: Carpoint – 4-point safety belt: manufacturer: Schroth Safety Products GmbH Fig.

  • Page 68: Installing Electrical Components

    4 | Transport and installation 4-point safety belt For detailed instructions, see original operating manual of Schroth Safety Products GmbH.  The kart is switched off. a) Position the kart safely at an ergonomically suitable height (e.g. by placing it on an assembly trolley or a lift- ing platform (e.g.

  • Page 69: Installing Safety Devices And Guards

    Use only chargers that are suitable for the kart and have been approved by RiMO. b) For details, contact RiMO service department. The charger must be installed in a dry place. Protect the charging cable against mechanical damage (from chaffing, friction, kinking, pulling).

  • Page 70: Final Inspection

    The following inspections and checks must be performed by specially trained techni- cians. RiMO provides detailed training for final inspections performed as part of the commis- sioning process. Before starting the kart for the first time, complete the following safety checks: –...

  • Page 71: Start-Up

    Start-up | 5 Start-up Before starting the kart for the first time, check the following in the prescribed sequence: – Have all components and assemblies been installed and has the final inspection been completed successfully? – Are all safety device installed? Safety notes and instructions for commissioning WARNING Risk of accident kart starting up...
  • Page 72 5 | Start-up Testing safety devices a) Test the safety devices to ensure that they are in proper working order: – Prior to commissioning – Prior to start-up after prolonged standstill – Every day prior to first start-up Testing EMERGENCY-STOP function Fig.

  • Page 73: Commissioning

    Start-up | 5 Commissioning NOTICE Before switching on the kart, carefully read the instructions in chapter Safety [ 47] in this manual. Ensure that all mechanical electrical work has been completed and that no persons are standing inside the danger area of the kart. All safety devices are installed, tested and ready for operation.
  • Page 74 Ensure that the plug is fully inserted to the stop into the socket. For more information, see Charger [ 32] or contact RiMO service department. NOTICE Charging time The charging time for the first few charging cycles is slightly longer than normal. After about five to ten charging cycles, the battery cells become balanced so that charging will take less time.
  • Page 75 (including full braking), the steering and the general vehicle behaviour and response.  If you encounter any problems and for more information, see Fault list [ 94] or contact RiMO service department.  The first test run has been successfully completed.

  • Page 76: Daily Start-Up

    5 | Start-up Daily start-up Before starting the kart, ensure that the batteries are fully charged. Normally, operators charge the karts after the track has been closed 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.
  • Page 77 For more information, see Charger [ 32] or contact RiMO service department.  The charging process is started automatically.  When the batteries are fully charged (100 %), LEDs 1 and 3 are lit in green, and message "END" is dis- played on the charger display.

  • Page 78: Checking Brake System

    – Defective or damaged screw fittings and lines must be replaced without delay. – Defective or worn parts must be replaced with RiMO original parts. – Karts with defective brake components or showing loss of brake fluid must be removed from the track and switched off.

  • Page 79: Checking Steering System

    – Ensure that all components of the steering system are in proper working order. – Deformed or damaged parts (e.g. tie rods, steering knuckles) must be replaced with RiMO original parts without delay. – After an impact on the front axle/steering system, check all parts of the steering and tracking system for damage.

  • Page 80: Checking Wheels

    WARNING Risk of accident non-conforming tyre dimensions Only use tyres and wheel rims of the size specified by RiMO. Wheels or tyres with other dimensions can cause damage to the vehicle and lead to unexpected drive behaviour, resulting in accidents.

  • Page 81: Checking Safety Elements

    [ 115]). – When the kart is switched off, the rear wheels must rotate freely. If this is not the case, contact RiMO service. 5.3.5 Checking safety elements The panelling/bodywork and the surround protection are crucial safety devices, protecting both the kart and the driver.

  • Page 82: Start-Up After Prolonged Storage

    5 | Start-up Fig. 52: Panelling/bodywork 1 Bodywork 2 Surround protection – Inspect the bodywork for cracks, deformation and loose fixtures. Eliminate all damage without delay. surround protection front mount – Inspect all mounts and the for damage and proper fixture. Eliminate all damage without delay.

  • Page 83: Kart Operation And Control

    Kart operation and control | 6 Kart operation and control The following general rules apply to the operation of the kart: – The operator's personnel 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.

  • Page 84: Description Of Kart Controls For Drivers

    6 | Kart operation and control Description of kart controls for drivers The kart controls for drivers are located on the driver seat, the steering wheel, around the drive switch and the pedals. See also  Work, maintenance and danger areas [...

  • Page 85: Adjusting Seat Position

    Kart operation and control | 6 During driving on track – The kart operator must enforce compliance with the safety rules, signs and posts along the track, flags and/or signal lights. – Drivers who show aggressive or dangerous driving behaviour must be reminded of the rules or even ex- cluded from driving the kart.
  • Page 86 Seat adjustment range insufficient for driver If the seat adjustment range is not sufficient for the driver, as the driver is small (140-150 cm), adjust the pedal position and/or install a booster seat (SRS) (RiMO prod. no. 1387042, available from RiMO online shop at www.rimo.de/shop).

  • Page 87: Switching On/Off Sequence

    Kart operation and control | 6 WARNING Risk of injury from unlocked safety belt buckle If the safety belt buckle is not properly locked, or if the belt is incorrectly posi- tioned/fitted, it might not protect the driver in the event of a collision. This can result in serious injury.

  • Page 88: Switching Kart Off

    6 | Kart operation and control b) Check the ground around and under the kart for escaped liquids.  If you detect any damage or liquid, identify the problem and eliminate it.  The kart can now be switched on. Switching on kart Fig.
  • Page 89 Kart operation and control | 6  The kart is in a suitable position for temporary switch-off (box lane, etc.)  The driver is sitting on the driver seat. drive switch a) Push in the to switch off the kart. drive switch indicator ...

  • Page 90: Drive Functions

    6 | Kart operation and control Drive functions Pedals To accelerate the kart, push down the gas pedal. To decelerate the kart, push down the brake pedal. If the two pedals are pushed down simultaneously, the kart is decelerated. Steering wheel To steer the kart in a different direction, turn the steering wheel.

  • Page 91: Collisions/Accidents

    Kart operation and control | 6 Collisions/accidents After a collision or accident during driving, the kart must undergo a number of checks 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.

  • Page 92: Malfunctions And Faults

    7 | Malfunctions and faults Malfunctions and faults For troubleshooting, adhere to the following rules: All tasks described below must be performed by specially trained and authorised skilled workers. a) Before starting work, allow hot parts to cool down. b) Wear suitable protective clothing. c) Before restarting the kart, re-install all safety devices.

  • Page 93: Restart After Unplanned Stop

    Malfunctions and faults | 7 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, check all safety devices. Restart after unplanned stop Prior to switching on a) Identify and eliminate the cause of the unplanned stop.

  • Page 94: Faults And Malfunction During Operation

     The kart is switched on and ready for operation. NOTICE If you are unable to reset the emergency-stop function, leave the kart switched off. Do not carry out any work on the kart. Contact RiMO service department for advice. Faults and malfunction during operation 7.2.1...
  • Page 95 Malfunctions and faults | 7 Fault Possible cause Remedy Person responsible* Charge release cable Check cable from BMS to charg- disconnected/wire break ing socket Wire break Check load cable Charger defective Check charger No mains power Check power mains Kart fails to drive SOC value 0 Check charge status Drive sensor defective or...

  • Page 96: Eliminating Faults

    Fault list 7.2.2 Eliminating faults NOTICE Troubleshooting If you have any queries, contact RiMO service department. Faults must only be rectified by authorised skilled workers and other qualified person- nel. 7.2.2.1 Control box The control box contains the main cables for electrical components and provides mechanics with a well- organised board for fault location and measurements.

  • Page 97: Warning And Fault Signals At Charger

    WARNING! High voltage! This check must be performed by a qualified electrician!  The charger fails to work properly, but none of the above checks revealed any problem. a) If you need assistance or if the charger is still not working properly, contact RiMO service department. User and maintenance manual...

  • Page 98: Troubleshooting Assistance

    7 | Malfunctions and faults All additional troubleshooting steps must be performed by a RiMO service technician. In order to deal with your problem quickly and efficiently, the RiMO service department needs the following information: – Serial number of charger –...

  • Page 99: Checks And Servicing During Operation

    Checks and servicing during operation | 8 Checks and servicing during operation The following general rules apply to the checking and servicing of the kart: All tasks described below must be performed by specially trained and authorised skilled workers. a) Switch off the kart by pressing the drive switch and secure it against inadvertent switching on. b) Before starting work, allow hot parts to cool down.

  • Page 100: Maintenance Schedule

    8 | Checks and servicing during operation 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 system of the kart must be carried out by qualified elec- tricians.

  • Page 101: Weekly Tasks

    Checks and servicing during operation | 8 Component Task* Description of task To be carried out by** Steering system I, T Visual inspection of all steering components for wear and damage; function test Visual inspection for wear and damage [ 115];...

  • Page 102: Monthly Tasks

    8 | Checks and servicing during operation Component Task* Description of task To be carried out by** Vehicle frame Visual inspection for damage Front bumper Visual inspection for damage Tracking Check tracking Check bearing play [ 119] Steering knuckles Visual inspection for wear [...

  • Page 103: Tasks To Be Completed Every 6 Months / 200 Operating Hours

    Checks and servicing during operation | 8 8.1.4 Tasks to be completed every 6 months / 200 operating hours Component Task* Description of task To be carried out by** Electrical connec- I, T Visual inspection for damage; check electrical tions, switchgear and connections for proper contact connecting cables * I = visual inspection;...

  • Page 104: Cleaning

    8 | Checks and servicing during operation 8.2.2 Cleaning To clean the drive systems and its components (with the exception of the brake system), use a product that cleans, degreases and protects. Always use a cleaning product that is moisture-repellent. WARNING Loss of brake power If oily or greasy substances enter the brake system, the brakes might not be as effec-...

  • Page 105: Checking And Servicing Mechanical Parts

    [ 129]). – Use only DOT 5 Silicone brake fluid (prescribed by RiMO). Otherwise, the brake system might be damaged, resulting in brake failure. – The brake discs and pads must never come into contact with substances containing oil or grease, as this would lead to a significant reduction of the brake power.
  • Page 106  If the brake pad surface and the wear mark groove are at the same level, replace the brake pad.  The brake pad has been checked. See also  Changing brake pads of RiMO hydraulic brake [ 108] 106 / 148...
  • Page 107 Checks and servicing during operation | 8 8.2.3.1.2 Bleeding RiMO hydraulic brake system DOT 5 silicone only Fig. 60: Hydraulic brake system 1 Bleeder screw 2 Collecting vessel 3 Main brake cylinder 4 Screw plug 5 Shut-off valve 6 Brake pedal 7 Brake bleeder kit Fig.
  • Page 108 8 | Checks and servicing during operation Proceed as follows: a) Secure the kart in a horizontal position. b) Remove the screw plugs of the brake circuits at the main brake cylinder. c) Screw the brake bleeder kit (prod. no.1086) into the filling nozzle and fill the system with DOT 5 Silicone brake fluid.
  • Page 109 Checks and servicing during operation | 8 8.2.3.1.3 Changing brake pads of RiMO hydraulic brake If the brake pads have reached the wear limit or are defective, they must be replaced without delay. Fig. 62: Changing brake pads 1 Brake pedal...
  • Page 110 8 | Checks and servicing during operation NOTICE Running in brakes Running in or bedding in the brakes describes the process by which the brake pads and brake discs are carefully bedded in so that they fit properly for maximum brake effect.
  • Page 111 The pedals and screws must not show any sign of wear or damage. The pedals must move easily and return 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 Remove the screws of the steering column bearing, bottom steering column j) Remove the nut and the brass washer of the from the k) Replace all parts that need to be changed with original RiMO spare parts. 112 / 148 User and maintenance manual...
  • Page 113 Checks and servicing during operation | 8 l) Assemble and mount the dismantled components following the above instructions in reverse order. Observe the prescribed tightening torques for the screws: Screws of steering wheel = 10 Nm Screw of steering wheel mount = 30 Nm Screws of steering bearing holder, top = 25 Nm Screws of tie rods = 30 Nm Steering column, bottom = 20 Nm...
  • Page 114 8 | Checks and servicing during operation 8.2.3.5.3 Tracking realignment If a component of the steering system has been replaced, or if the steering alignment of the kart is poor, it must be adjusted. Fig. 66: Aligning steering 1 Wheel alignment tool 2 Locknuts at tie rods Proceed as follows: ...
  • Page 115 – Observe the direction mark on the tyres (if any). – Only use tyres and wheel rims of the size specified by RiMO. Wheels or tyres with other dimensions can cause damage to the vehicle and lead to unexpected drive behaviour, resulting in accidents.
  • Page 116 8 | Checks and servicing during operation Fig. 67: Checking wheels 1 Wear mark 2 Arrow: direction of rotation of wheel Removing wheels NOTICE Mounting wheels on front and rear axle The front wheels are secured with one hexagon nut each. The rear wheels are se- cured with three hexagon nuts each.
  • 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 the wheel.
  • Page 118 Apply assembly paste to the front axle steering knuckles. NOTICE! The assembly paste is not included in the scope of delivery and can be purchased separately from RiMO. Contact RiMO service department for advice. Product no.: 1892036 - HSP 1400 lubrica- tion, disassembly and corrosion protection paste c) Slide the rear wheels onto the wheel centres.
  • Page 119 Checks and servicing during operation | 8 d) Rear axle: Mount the three hexagon nuts and tighten them with the prescribed torque (see Tightening tor- ques [ 129]). e) Front axle: Mount the hexagon nut and tighten it a little. Turn the wheel to check whether it rotates freely. If the wheel rotates freely, tighten the hexagon nut further and check again for free rotation.
  • Page 120 8 | Checks and servicing during operation Fig. 70: Safety elements/bodywork 1 Bodywork 2 Surround protection and rubber silent blocks Replacing bodywork  The kart is switched off. a) Position the kart safely at an ergonomically suitable height, for instance by placing it on an assembly trolley or a lifting platform (e.g.
  • Page 121 – Screw connections of wheel centres and wheel fixtures – Screw connections of brake system Screws and bolts that show damage or defects must be replaced without delay with original RiMO parts or DIN ISO EN standard parts with identical strength properties.
  • Page 122 8 | Checks and servicing during operation 8.2.3.9 Maintenance of safety belts For best operational safety of the vehicle, it should be equipped with a rollbar and a three-point or four-point safety belt. These safety devices must be inspected for damage and tested on a daily basis. Fig.
  • Page 123 Checks and servicing during operation | 8 Cleaning safety belts Attention Damage to belt from cleaning agent Chemicals in cleaning products can cause damage to the safety belts. As a result, the belts might not work properly, which can cause serious injury. a) Clean the belts only with cleaning products approved by the belt manufacturer.

  • Page 124: Checking And Servicing Electrical Parts

    8 | Checks and servicing during operation 8.2.3.11 Maintenance of gas sensor When the gas pedal is in its zero position, the gas sensor must not be actuated. Fig. 73: Gas sensor 1 Gas sensor 2 Gas pedal 3 Securing screws Adjusting gas sensor ...
  • Page 125 In certain cases, additional components might need to be replaced. Contact RiMO service department for advice. See also  Contacting RiMO GERMANY GmbH & Co. KG [ 8.2.4.3 Maintenance of battery cells/side box Closing side box Fig.
  • Page 126 8 | Checks and servicing during operation 8.2.4.4 Maintenance of drive switch The drive switch is an EMERGENCY-STOP switch designed for the switching of high direct currents. Fig. 75: Drive switch 1 Drive switch 2 M5 securing screws 3 Screws at bracket 4 Screws at load cable When mounting the drive switch, ensure that the M5 securing screws are tightened with max.
  • Page 127 Checks and servicing during operation | 8 As soon as only LED 1 and LED 3 on the charger are lit in green and message END is displayed, the cells of the kart are fully charged. We recommend connecting the charger to the kart at least once a day until the cells are fully charged.
  • Page 128 For more information, refer to Charger [ 32] or contact RiMO service department.  The charging process starts automatically.  When the batteries are fully charged (100 %), LED 1 and LED 3 are lit in green and message "END" is displayed on the charger display.

  • Page 129: Replacing Wear Parts

    Replace all wear parts such as brake pads when they have reached the end of their service life. For more information, contact RiMO service department. See also  Contacting RiMO GERMANY GmbH & Co. KG [  Technical documents/appendices [...
  • Page 130 5 Nm Brake calliper screw plugs 12 Nm Main brake cylinder screw plugs 5 Nm If you have any questions, contact RiMO service department. See also  Contacting RiMO GERMANY GmbH & Co. KG [ 130 / 148 User and maintenance manual...

  • Page 131: Wear And Spare Parts

    Checks and servicing during operation | 8 Wear and spare parts All spare parts must meet the technical specifications laid down by RiMO. Original RiMO spare parts meet this requirement and undergo stringent inspections. RiMO shall not be liable for damage caused by the use of third-party spare parts.

  • Page 132: Repairs

    Repairs can be carried out by the operator, provided that he/she has the necessary 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 When a LiFeMnPo4 cell has come to the end of its service life, it must be replaced.
  • Page 133 Repairs | 9 Removing defective cell Fig. 78: Drive switch and 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...
  • Page 134 9 | Repairs  The kart is in a suitable position for charging (box lane, etc.) and is switched off. a) Fully charge the kart (100 %) (seeCharging batteries [ 126]). b) Disconnect the charging plug. drive switch c) Push in the to switch off the kart.
  • Page 135 Installing new cell Attention Risk of damage to battery from unsuitable cells The installation of cells that have not been approved by RiMO can cause serious damage to the kart battery. a) Therefore only install cells approved by RiMO. Fig. 81:...

  • Page 136: Replacing Transmission

    Repairs to be carried out by RiMO All welding and alignment work on the frame and attached components must be carried out by RiMO. Repairs on defective or faulty components are not admissible. These components must be replaced with new ones.

  • Page 137: Decommissioning, Storage And Disposal

    Decommissioning, storage and disposal | 10 Decommissioning, storage and disposal The following general rules apply to the decommissioning, storage and disposal of the kart: All tasks described below must be performed by specially trained and authorised skilled workers. a) Switch off the kart by pressing the drive switch and secure it against inadvertent switching on. b) Before starting work, allow hot parts to cool down.

  • Page 138: Dismantling

    10 | Decommissioning, storage and disposal main switch e) Switch off the f) Place the kart in a suitable location and cover it, if required. NOTICE! Do not disconnect any cables and do not remove any kart components.  The kart has been decommissioned. Performing recharging cycles When not in use, the kart must be regularly serviced by performing two recharging cycles.

  • Page 139: Storing The Kart

    To dispose of karts without dismantling it, contract a special- ist waste disposal company. Always observe the statutory waste disposal regulations. NOTICE If you have any queries regarding the disposal of your kart, contact RiMO service department. See also  Technical documents/appendices [...

  • Page 140: 10.5.1 Changing Batteries And Disposal

    10.5.1 Changing batteries and disposal Should you need to replace the batteries, RiMO offers you the following options: 1. Spent batteries are replaced on site by a RiMO technician. Spent cells can be returned to RiMO for disposal free of charge.

  • Page 141: Technical Documents/Appendices

    Technical documents/appendices | 11 Technical documents/appendices User and maintenance manual 141 / 148...

  • Page 142: List Of Figures

    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: Sense board pin assignment ........................26 Fig. 19: Shunt plug assignment ..........................
  • Page 143 List of figures Fig. 32: Rollbar ..............................38 Fig. 33: Guards ..............................39 Fig. 34: Other safety devices ..........................40 Fig. 35: Indicators ..............................40 Fig. 36: Indicators on steering wheel ........................41 Fig. 37: Drive switch and main switch ........................41 Fig.
  • Page 144 List of figures Fig. 65: Maintenance of steering system ......................112 Fig. 66: Aligning steering ............................ 114 Fig. 67: Checking wheels ............................ 116 Fig. 68: Mounting wheel ............................116 Fig. 69: Mounting wheel ............................118 Fig. 70: Safety elements/bodywork........................120 Fig.

  • Page 145: List Of Tables

    List of tables List of tables Tab. 1: Prohibition signs and symbols ........................9 Tab. 2: Warning signs and symbols ........................9 Tab. 3: Revision log of this document ........................11 Tab. 4: Table of other applicable documents: ....................... 11 Tab.

  • Page 146: Glossary

    Glossary Glossary Battery management system Coulomb, unit for electric charge. C rating C rating indicates the maximum safe continuous discharge rate of a battery under certain ambient conditions. Electromagnetic compatibility Permanent magnet synchronous Wireless fleet management 146 / 148 User and maintenance manual...

  • Page 147: Index

    Charging batteries 76, 127 Description Cleaning Disposal Cleaning agent First start-up Contact Improper use About RiMO GERMANY GmbH & Co. KG Intended use Mounting steering wheel Mounting wheels Danger area Packaging Driver Reasonably foreseeable misuse Personal protective equipment Removing wheels...
  • Page 148 Index Operator's personnel Visual inspection Qualification 54, 55 Skilled worker Trained and instructed personnel Personal protective equipment Personnel Training Qualification of operator's personnel Qualified technical personnel Qualification Resetting EMERGENCY-STOP Safety Electrical equipment Inadmissible operating conditions Kart operation Preventing hazards Safety devices Test Safety note Safety system...

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