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RiMO SiNUS Series User Manual

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

Table of Contents

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RiMO SiNUS Series Specifications

General IconGeneral
BrandRiMO
ModelSiNUS Series
CategoryUtility Vehicle
LanguageEnglish

Summary

About this operating manual

Purpose of this manual

Explains the manual's objective for skilled technical personnel.

Keep a copy near the karts

Instruction to keep the manual accessible near the karts.

About this manual

Section describes signs and symbols used in the manual.

Safety instructions

Details how safety warnings and instructions are highlighted in the manual.

Product description

Kart identification

Explains how each kart is identified by a type plate and other details.

General description

Provides an overview of the kart as a sports vehicle for kart tracks.

Driving kart

Describes how the kart must be driven.

Intended use

Specifies the kart's design for forward travel on a kart track.

Improper use

Details operations deemed improper and their associated risks.

Reasonably foreseeable misuse

Identifies common ways the kart might be misused.

Kart design

Illustrates and lists the main components of the kart.

Work, maintenance and danger areas

Diagram showing work, maintenance, and danger areas of the kart.

Kart components and functions

Describes the kart's components and their functions.

Vehicle frame with footboards

Describes the vehicle frame and footboards' construction and purpose.

Steering system

Explains the steering system components and functions, including boost and reverse.

Pedals

Details the gas and brake pedals, including extension options.

Seat and seat adjustment

Describes the driver's seat and its adjustment mechanism.

Drive unit

Explains how drive units transfer motor power to the rear wheels.

Brake system

Details the two-circuit brake system, including fluid level monitoring.

Electric system with battery cells

Describes the electric system powered by 16 battery cells in series.

Batteries

Specifies the use of LiFeMnPo4 batteries and their characteristics.

Battery management system (BMS)

Explains the function and parameters of the battery management system.

Cable harness

Diagram showing the BMS cable harness.

Pin assignment

Details the pin assignment of the BMS CPU unit.

Description of display unit

Describes the BMS display and its location.

Warning and error signals

Explains SOC indicators, pit LED, and various fault indicators.

System conditions and safe operation

Details conditions for charging and driving, and safety notices.

BMS LCD display

Shows the BMS LCD display and lists the parameters monitored.

Charger

Describes the charger's advanced high-frequency charging technology.

ACD controller

Explains the ACD motor controller's function and status LED.

Motor

Details the brushless disc motors used in RiMO SiNUS kart models.

Transmission

Describes the transmission system with its planetary gear and ratio.

Gas sensor

Explains how the gas sensor converts pedal movement into an electrical signal.

Control box

Details the control box containing main cables, fuses, and optional sound system.

Bodywork

Describes the bodywork's protective function and side boxes for weight compensation.

Side box

Details the side box construction, function, and capacity for cells and weights.

Surround protection

Explains the surround protection's role in protecting against impact and preventing kart diving.

Rollbar

Describes the rollbar's function in protecting the driver during collisions or rollovers.

Safety devices

Covers the kart's safety devices and their importance.

Overview

States that the kart is equipped with safety devices at all relevant danger points.

Safety devices

Details guards and other safety devices like seat, belt, rollbar, and surround protection.

Signalling devices

Explains indicators on switches and steering wheel.

EMERGENCY-STOP devices

Identifies the drive switch and main switch as EMERGENCY-STOP devices.

Warning signs

Explains the identification of hazard zones with warning signs.

Kart operation

Describes how the kart is operated and controlled.

Scope of delivery

Lists the items included in the kart's scope of delivery.

Technical data

Provides technical specifications for the kart.

General information

Provides general designation and year of manufacture for the kart.

Mechanical equipment

Details mechanical aspects like dimensions and weight.

Transmission

Details the transmission ratio and oil filling.

Electric charger

Provides specifications for large and small chargers.

Ambient conditions

Lists operating and storage temperatures, humidity, and pressure.

Noise emission

Specifies the continuous sound pressure level.

BMS default thresholds

Lists default thresholds for the Battery Management System.

Safety

General safety instructions

Provides general rules for safe operation and maintenance.

Avoiding dangerous situations

Offers instructions to prevent dangerous situations during kart operation.

Operating instructions

Outlines general rules for kart operation.

Troubleshooting instructions

Provides general rules for fault location and troubleshooting.

Maintenance and repair instructions

Outlines general rules for all maintenance and repair work.

General notes and instructions re. electrical equipment

Gives rules for working on the kart's electrical equipment.

Electromagnetic compatibility (EMC)

Discusses electromagnetic compatibility and potential interference.

Environmental protection

Emphasizes keeping the environment in mind during work on the kart.

Inadmissible operating conditions

Lists conditions under which operating the kart is unsafe.

Duties of the kart operator

Defines the operator's responsibility for safety measures and preventive actions.

Minimising risk of injury

Provides general rules to minimize the risk of injury.

Assigning tasks to personnel

Defines the operator's responsibility for assigning tasks to qualified personnel.

Personnel training

Highlights the importance of training for safe operation and maintenance.

Driver instruction

Stresses the importance of driver instruction in safe handling and operation.

Personal protective equipment

Ensures drivers and personnel are given and wear prescribed PPE.

Requirements for operator's personnel

Details skills and knowledge for operating and maintenance personnel.

Qualification

Lists requirements for personnel working with or on the kart.

Skills and knowledge for drive operation

Outlines essential skills and knowledge for personnel on the race track.

Operator's personnel groups

Distinguishes between operator's and maintenance personnel.

Specific skills and knowledge

Lists tasks requiring specialist skills and the required qualification.

Requirements to be met by drivers

Details driver requirements regarding fitness and clothing.

Clothing and physical fitness

Specifies clothing restrictions and physical fitness requirements for drivers.

Personal protective equipment

Details required personal protective equipment for drivers.

Residual risks

Lists residual risks that cannot be eliminated by design measures.

Action in the event of an accident

Provides guidance on actions to take in the event of an accident.

Transport and installation

Required tools

Lists the tools required for the installation of the kart.

Lashing points

Describes the clearly labelled lashing points for shipping.

Transport by forklift truck

Provides instructions and warnings for transporting the kart using a forklift.

Removing and disposing of packaging

Instructions for removing and disposing of transport packaging.

Installation

Details conditions and procedures for proper kart installation.

Location of operation and local infrastructure

Specifies conditions for the kart's location and local infrastructure.

Installation and connection

Provides steps for kart installation and connection, with CAUTION about tripping hazards.

Installing mechanical components

Details mounting wheels and steering wheel, with warnings.

Mounting rollbar

Instructions for mounting the rollbar.

Mounting plastic pads

Details mounting optional plastic pads for surround protection.

Installing safety belt

Instructions for installing 3-point and 4-point safety belts.

Installing electrical components

CAUTION regarding electrical components and instructions for electricians.

Positioning charger

Instructions for positioning the charger and warnings about wrong chargers.

Installing safety devices and guards

Instructions for installing safety devices and guards.

Final inspection

Details final inspections and checks performed by trained technicians.

Adjusting kart setup

Explains adjusting torque and power settings for the kart track.

Start-up

Checking kart and safety devices

Guides on checking the kart and its safety devices for damage and function.

Testing safety devices

Details testing procedures for safety devices.

Testing EMERGENCY-STOP function

Describes how to test the EMERGENCY-STOP function of the drive switch.

Commissioning

Provides notices and steps for commissioning the kart, including battery charging.

Testing accelerator and brake functions

Details testing procedures for accelerator and brake functions.

Performing first test run

Guides on performing the first test run of the kart.

Daily start-up

Provides instructions for daily start-up, including charging batteries.

Disconnecting charge from mains power

Instructions for disconnecting the charger from the mains power supply.

Checking brake system

Details how to check the brake system, including running-in procedures.

Checking steering system

Guides on checking the steering system for proper function and alignment.

Checking pedals

Instructs on checking the pedals for damage and proper function.

Checking wheels

Details checks for wheels, including wear, tyre pressure, and non-conforming dimensions.

Checking safety elements

Ensures panelling/bodywork and surround protection are undamaged.

Start-up after prolonged storage

Provides steps for recommissioning a kart after prolonged storage.

Kart operation and control

Description of kart controls for drivers

Locates kart controls on the driver seat, steering wheel, and pedals.

Operating modes

States that the kart can only be operated in manual mode.

Driver instruction by operator's personnel

Guides on assessing driver fitness and providing instruction.

Adjusting seat position

Details how to adjust the seat position for the driver's comfort and reach.

Pedals

Describes how drivers must reach pedals and optional extensions.

Safety belt (optional)

Ensures safety belts are properly worn and locked before starting.

Switching on/off sequence

Outlines the sequence for switching the kart on and off.

Switching kart on

Provides tasks and checks before switching the kart on.

Switching kart off

Details procedures for switching the kart off for short periods or prolonged shutdown.

Drive functions

Explains basic pedal and steering functions, and warnings about reversing.

Safe driving

Lists rules for safe driving, including starting, stopping, and exiting the kart.

Collisions/accidents

Details checks required after a collision or accident before resuming driving.

Malfunctions and faults

Restart after unplanned stop

Guides on how to restart the kart after an unplanned stop.

Resetting EMERGENCY-STOP

Explains how to reset the EMERGENCY-STOP function.

Faults and malfunction during operation

Provides a fault list for troubleshooting.

Fault list

Lists common faults, their possible causes, remedies, and responsible persons.

Eliminating faults

Guides on fault elimination, focusing on the control box.

Control box

Details the control box for fault location and measurements.

Warning and fault signals at charger

Details warning and fault signals related to the charger.

Troubleshooting assistance

Provides contact information for troubleshooting assistance.

Checks and servicing during operation

Maintenance schedule

Outlines the maintenance schedule, including daily tasks.

Daily tasks

Lists daily maintenance tasks for various kart components.

Weekly tasks

Lists weekly maintenance tasks for the kart.

Monthly tasks

Lists monthly maintenance tasks for the kart.

Tasks to be completed every 6 months / 200 operating hours

Details tasks for semi-annual maintenance.

Tasks to be completed once, after first 10 operating hours

Specifies initial maintenance tasks after 10 operating hours.

Maintenance tasks

Introduces detailed maintenance tasks.

Visual inspection

Guides on performing visual inspections of the kart.

Cleaning

Provides instructions for cleaning the kart, with warnings.

Checking and servicing mechanical parts

Guides on checking and servicing mechanical parts, focusing on the brake system.

Testing brake pads

Details how to test brake pads for wear.

Bleeding RiMO hydraulic brake system

Step-by-step guide to bleeding the hydraulic brake system.

Changing brake pads of RiMO hydraulic brake

Instructions for changing brake pads, with attention to brake piston.

Lubricating mechanical brake parts

Guides on lubricating mechanical brake parts.

Maintenance of pedals

Details pedal maintenance, including lubrication.

Maintenance of seat

Guides on checking seat adjustment, bearings, and levers.

Maintenance of steering system

Details maintenance and replacement of steering system components.

Maintenance of steering alignment system

Covers checking and adjusting steering alignment and knuckles.

Checking tracking alignment

Instructions for checking tracking alignment with a tool.

Checking steering knuckles

Details weekly inspection of steering knuckles for damage and play.

Tracking realignment

Guides on adjusting steering alignment if components were replaced.

Maintenance/change of wheels

Details maintenance and replacement of tyres and wheels.

Removing wheels

Instructions for removing wheels from the kart.

Removing tyre

Guides on removing tyres from wheels.

Mounting tyre

Details tyre mounting procedures, including inflation and pressure.

Mounting wheels and adjusting wheel bearings

Instructions for mounting wheels and adjusting front axle wheel bearings.

Checking and adjusting wheel bearings

Guides on checking and adjusting wheel bearing play.

Replacing safety elements

Emphasizes replacing damaged bodywork and safety elements without delay.

Replacing bodywork

Instructions for replacing defective bodywork.

Replacing surround protection

Details how to replace the surround protection.

Maintenance of screw connections

Guides on checking screw connections for proper fixture and potential risks.

Maintenance of safety belts

Details inspection and testing of 3-point and 4-point safety belts.

Maintenance of ACD controller

Explains operating status and cable connections for the ACD controller.

Maintenance of gas sensor

Guides on adjusting the gas sensor for correct operation.

Checking and servicing electrical parts

Details regular inspection of electrical components for damage.

Testing EMERGENCY-STOP function

Tests the function of all installed EMERGENCY-STOP devices.

Maintenance of safety devices

Ensures safety-relevant components are replaced and tested.

Maintenance of battery cells/side box

Instructions for closing the side box and maintaining battery cells.

Maintenance of drive switch

Details maintenance of the drive switch, including mounting instructions.

Charging batteries

Specifies conditions for charging batteries and monitoring the process.

Replacing wear parts

Guides on replacing wear parts like brake pads.

Tightening torques

Lists tightening torques for various screw connections.

Wear and spare parts

Specifies requirements for spare parts and ordering information.

Storage of tyres

Recommends storing minimal numbers of tyres near the track.

RiMO customer service

Provides contact information for RiMO customer service.

Repairs

Repair tasks to be performed by operator

Details repairs the operator can perform, excluding warranty issues.

Exchanging/replacing battery cells

Guides on identifying and replacing defective LiFeMnPo4 battery cells.

Replacing transmission

Details transmission replacement, including tightening torque and shaft alignment.

Repairs to be carried out by RiMO

Specifies repairs that must be performed by RiMO, such as welding.

Decommissioning, storage and disposal

Decommissioning

Guides on decommissioning the kart for prolonged standstill.

Dismantling

Instructions for dismantling the kart after decommissioning.

Packaging kart

Guides on packaging the kart for storage or transport.

Storing the kart

Recommends storing the kart under specified technical data conditions.

Disposal

Provides guidelines for disposing of kart components and the kart itself.

Changing batteries and disposal

Outlines options for changing batteries and their disposal.

Technical documents/appendices

List of figures

List of tables

Glossary

Index