OrthoDuad ES400 User manual

USER’S MANUAL MOBILITY SCOOTER - ES400 / ES500
WARNING
Read the User Manual carefully before operating the ES400/ES500.
If you do not fully understand any part of this manual, please contact your dealer or
any of our Service Centres.
Read this manual step by step, as injury or damage may occur from misuse!
WARNING
Electromagnetic Interference (“EMI”) can cause powered vehicles to behave
erratically, which could be dangerous to the user.
For your safety and protection, it is IMPERATIVE that you take time to read
Chapter V (“EMI WARNING”) before operating the ES400/ES500.

TABLE OF CONTENTS
I.
Introduction
3
II.
Specifications
4
III.
Features
5
IV.
Operating your scooter
6
V.
Safety Instructions
9
VI.
Battery Charging
14
VII.
Maintenance Schedule
15
VIII.
Warranty
16

I. INTRODUCTION
Thank you for choosing Orthoquad ES400/ES500
mobility scooter. This scooter is a mobility assistive device
designed for senior citizens who have walking difficulty or
are weak in physical strength and for also for the disabled
people.
We designed this scooter to restore your personal
freedom, to provide convenience and comfort to you.
This manual contains important information
concerning the safe operation and proper maintenance of
your scooters.
Your ES400 has many unique features not found on
other scooters. With proper care and maintenance, you
should enjoy many years of dependable service from your
unit.
Your scooter should receive regular maintenance
according to the schedule outlined in this manual, and the
recommendation from the authorized dealer. By following
the maintenance instructions, you will be able to take care
of most of your unit’s needs.
Above all, follow all service recommendation
outlined in this manual to achieve the most trouble free,
safe and enjoyable operation of your scooter.

II. SPECIFICATIONS
ES400/ES500
PERFORMANCE DATA
Maximum forward speed 12 km/h
Maximum Climbing Grade 6° -10.5%
Load Capacity 120kg - 265 pounds
Ground Clearance 6 cm
Range with Full Charge Up to 40km
Turning Radius 1.2m
DIMENSIONS
Length 51’’
Width 25’’
WEIGHT
Total (with battery) 98kg – 215lbs
BATTERY SPECIFICATIONS
12V/38 Ah Lead-acid battery
BATTERY CHARGER
Input AC /110V/60Hz Output DC24V/ 5amp
MOTOR POWER ES400: 400W / ES500: 450W

III. FEATURES
Swing away armrests
360 degrees swivel seat
Adjustable Forward/Reverse Seat
Adjustable tiller
Dynamic regenerative braking
Rear wheel direct drive with differential
Fully solid state controller
External Battery Charger
24-volt permanent magnet heavy duty DC motor
ON/OFF switch lock
Horn
LED Head light
Turning lights
Rear lights
Battery-charging indicator
Anti-tip-off safety wheels
Front and rear bumpers
Accessories adapter
Electronic High/Low speed switch

IV. OPERATING YOUR SCOOTER
The photo below shows the operating controls of your
mobility scooter.
Battery status
indicator
Throttle control lever
Throttle control lever
Horn
Horn
Turning lights
switch
Key Switch
Charger socket
High/Low speed mode
switch
Headlight switch
Speed limit dial

1, BEFORE OPERATION
1). Insert the power key into the switch lock and turn clockwise to the
ON position.
2). Check the battery charge indicator to make sure the batteries are
fully charged.
3). Make sure that clutch lever is at close position.
2, TURN POWER ON
Insert the key into the key switch on the upper tiller and rotate
clockwise to the “ON” position.
3, FORWARD MOTION
To move forward, pull the right thumb lever under the control
console forward. The further you pull, the faster the scooter will go.
The maximum speed may be selected by the speed selection switch
located on the top of the control console.
3. REVERSE MOTION
To reverse, pull the left side of the thumb lever under the control
console forward.
4. STOP
To stop the scooter, just release the thumb lever. The scooter will
quietly come to a smooth stop and electromechanical brake will
automatically engage to hold the scooter in position on horizontal
surface or an incline of up to 12 degrees, with a load of no more than
265 lb. (120 kg). Quick smooth stops are made possible by the
dynamic braking feature built in the controller.

WARNING
The brake may not be effective when engaged on inclines greater
than 15 degrees or 21% if the occupant’s weight exceeds 265
pounds.
TEST DRIVE
Insert the ignition key into the main switch.
Check the battery charge indicator to ensure that
the batteries are fully charged.
Make sure the clutch lever is engaged.
Set the speed by turning the dial knob on top of the
console.
Go back and forth a short distance to make sure
your unit is in good working condition.
FREEWHEEL MODE
Your ES400/ES500 is equipped with a manual freewheel lever that,
when pushed forward, allows the ES400/ES500 to be pushed
manually.
Disengage the drive motors only on a level surface.
Stand beside the ES400/ES500 to engage or disengage freewheel mode.
Never do this while sitting on the ES400/ES500.
After you have finished pushing your ES400/ES500, always return it to the
drive mode to lock the brakes (pull the manual freewheel lever backward).
When using the freewheel lever, be careful not to touch the internal
surface of the motor, as it could be very hot and cause injury. See the
warning label at the rear of the scooter near the lever.
Freewheel Manual lever

V. SAFETY INSTRUCTIONS
Your scooter can move on grass , gravel, dirt, and sand surfaces, as
well as hard paved or carpeted surfaces. However, extra caution
should be taken when operating your unit on uneven surfaces other
than flat surfaces.
Slow the scooter when approaching an uneven or soft surface.
Avoid gravel and sand.
Avoid stop your scooter in the middle of a slope too steep. If you have to,
start up again slowly and then accelerate cautiously.
Inspect the following points before setting off:
• Check tire pressure (40-45 psi)
• Check electrical connections.
• Check the brakes
• Check the battery charge.

CAUTION:
IT IS VERY IMPORTANT THAT YOU READ THIS
INFORMATION REGARDING THE POSSIBLE EFFECTS OF
ELECTROMAGNETIC INTERFERENCE ON YOUR
POWERED SCOOTER.
Electromagnetic Interference (EMI) From Radio Wave Sources
Powered wheelchairs and motorized scooters (in this text, both
will be referred to as powered wheelchairs) may be susceptible to
electromagnetic interference (EMI), which is interfering
electromagnetic energy (EM) emitted from sources such as radio
stations, TV stations, amateur radio (HAM) transmitters, two-way
radios, and cellular phones. The interference (from radio wave
sources) can cause the powered wheelchair to release its brakes, move
by itself, or move in unintended directions. It can also permanently
damage the powered wheelchair’s control system. The intensity of
the interfering EM energy can be measured in volts per meter (v/m).
Each powered wheelchair can resist EMI up to certain intensity. This
is called its “immunity lever.” The higher the immunity level, the
greater the protection. At this time, current technology is capable of
achieving at least a 20-v/m immunity level, which would provide
useful protection from the more common sources of radiated EMI.
The immunity level of this powered scooter as shipped, with no
further modification, is not known.
There are ample sources of relatively intense electromagnetic
fields in the everyday environment. Some of these sources are
obvious and easy to avoid. Others are not apparent and exposure is
unavoidable. However, we believe that by following the warnings
listed below, your risk to EMI will be minimized.

The sources of radiated EMI can be broadly classified into three types:
1) Hand-held portable transceivers (transmitters-receivers) with the
antenna mounted directly on the transmitting unit. Examples include:
citizens band (CB) radios, “walkie talkie,” security, fire, and police
transceivers, cellular telephones, and other personal communication
devices. **Note: Some cellular telephones and similar devices
transmit signals while they are ON, even when not being used.
2) Medium-range mobile transceivers, such as those used in police
cars, fire trucks, ambulances, and taxis. These usually have the
antenna mounted on the outside of the vehicle; and
3) Long-range transmitters and transceivers, such as commercial
broadcast transmitters (radio and TV broadcast antenna towers) and
amateur (HAM) radios.
Note: Other types of hand-held devices, such as cordless phones,
laptop computers, AM/FM radios, TV sets, CD players, and cassette
players, and small appliances, such as electric shavers and hair dryers,
so far as we know, are not likely to cause EMI problems to your
powered wheelchair.
Powered Scooter Electromagnetic Interference (EMI)
Because EM energy rapidly becomes more intense as one
moves closer to the transmitting antenna (source), the EM fields from
Hand-held radio wave sources (transceivers) are of special concern. It
is possible to unintentionally bring high levels of EM energy very
close to the powered scooter’s control system while using these
devices. This can affect powered scooter movement and braking.
Therefore, the warnings listed below are recommended to prevent
possible interference with the control system of the powered scooter.
WARNINGS
Electromagnetic interference (EMI) from sources such as
radio and TV stations, amateur radio (HAM) transmitters, two-way
radios, and cellular phones can affect powered scooter and motorized
scooters. Following the warnings listed below should reduce the
chance of unintended brake release or powered scooter movement,
which could result in serious injury.
1) Do not operate hand-held transceivers (transmitters-receivers),
such as citizens band (CB) radios, or turn ON personal
communication devices, such as cellular phones, while the powered
scooter is turned ON.

2) Be aware of nearby transmitters, such as radio or TV stations, and try to
avoid coming close to them;
3) If unintended movement or brake release occurs, turn the powered scooter
OFF as soon as it is safe.
4) Be aware that adding accessories or components, or modifying the powered
scooter, may make it more susceptible to EMI (Note: There is no easy way to
evaluate their effect on the overall immunity of the powered scooter.
5) Report all incidents of unintended movement or brake release to the powered
scooter manufacturer, and note whether there is a source of EMI nearby.
If unintended motion or brake release occurs, turn the power
OFF as soon as it is safe.
FDA recommends that you report all incidents of unintended motion or
brake release to us or your dealer, and if possible, note whether there was a radio
wave source nearby at the time of the incident. You may also report to FDA’s
MedWatch problem reporting program. Call 1-800-FDA-1088 and ask for Form
3500.
The following warning label is included in order to make users always
aware that a possibility of electromagnetic interference exists.
WARNING: Radio wave sources may affect scooter control Radio waves
sources, such as radio stations, TV stations, amateur radio (HAM) transmitters,
cellular phones, and two-way radios, can affect motorized scooters. Following
the warnings listed below should reduce the chance of unintended brake release
or scooter movement, which could result in serious injury. 1). Do not turn ON or
use
hand-held personal communication devices, such as citizens band (CB) radios
and cellular phones, while your scooter is turned ON; 2). Be aware of nearby
transmitters, such as radio or TV stations and hand-held or mobile two-way
radios, and try to avoid coming close to them. 3). If unintended movement or
brake release occurs, turn the power OFF as soon as it is safe. 4). Be aware that
adding accessories or components, or modifying your scooter, may make it more
susceptible to interference from radio wave sources. (Note: There is no easy way
to evaluate their effect on the overall immunity of the scooter), and 5). Report
all incidents of unintended movement or brake release to the scooter
manufacturer, and note whether there is a radio wave source nearby. Important
Information: 1) 20 volts per meter (v/m) is a generally achievable and useful
immunity lever, against interference from radio wave sources (as of May 1994)
(the higher the lever, the greater the protection); 2) The immunity level of this
product is not known.

In summary,
- DO NOT try to climb sharp curbs.
- DO NOT drive off or over obstacles exceeding 5 cm in height.
- DO NOT make abrupt changes in direction at high speed or while
traveling on an incline.
-DO NOT climb inclines greater than 12 degrees or a rise of
- DO NOT move backward on uneven surfaces or inclines.
-DO NOT travel on highways and freeways; ALWAYS stay in the bike
lanes or sidewalks.
-DO NOT carry adult and child in any manner.
-DO NOT operate your unit when the red battery indicator light is
flashing.
-DO NOT operate your unit with the clutch lever in the
disengaging position.
-DO NOT mount or dismount your batteries with power switch in the
“ON” position.
-DO NOT turn ON or use hand-held personal communication devices,
such as citizens band (CB) radios and cellular phones, while your scooter
is turned ON.
-ALWAYS make sure that the steering tiller adjustment knobs are
tight.
-ALWAYS make sure that the seat is locked so that it will not swing
during operation.
-BE AWARE of nearby transmitters, such as radio or TV
stations and hand-held or mobile two-way radios, and try to
avoid coming close to them.
-BE AWARE that adding accessories or components, or modifying
your scooter, may make it more susceptible to interference from
radio wave sources.

VI. BATTERY CHARGING
To ensure the best performance and maximum battery life, we recommend to
charge your scooter after use. Your scooter comes with an external battery
charger for your ease and convenience. The console battery display makes
charging simple and easy. Follow these steps for battery charging.
The console battery level display has two green lights (100% and
50%), one yellow light (25%), you’d better charge now), and one red light
(almost empty, you must charge them right now).
There is no possible way to overcharge the battery as the charging voltage is set
constant. In general, you may start charging before you go to bed at night and
disconnect it in the next morning.
CHARGING BATTERIES (see Figure C)
1. Insert the charger plug (8) in the charging socket (10) located on the right side of the
tiller column.
2. Plug the charger power cord (9) into a wall socket (11).
3. When charging is complete, remove the charger power cord (9) from the wall socket
(11) and then remove the charger plug (8) from the charging socket (10).
4. Under ideal storage conditions, batteries that were charged to full capacity and were not
used should be recharged every month.
5. If you expect not to use your ES400/ES500 for an extended period of time, we
recommend charging it for two days and then disconnecting the batteries.
6. If you have not used your ES400/ES500 for an extended period of time, charge the
batteries for at least 24 hours before driving.
Note: There is NO need to disconnect the charging plug immediately after the
charging is complete.
However, DO NOT leave the charger connected to the batteries FOR MORE THAN
TWO WEEKS.
As long as the charging plug is in the charging socket, the electronic control of
the ES400 automatically cuts all power to the electric system and it cannot be
driven.
The charger supplied is suitable for charging lead acid dry/gel batteries. Use
only the defined type of charger. Before using any other type of charger, check
with your dealer.
Figure C

VII. MAINTENENCE SCHEDULE
In order to obtain the best performance and lasting service life, please
maintain your unit according to the following schedule and instructions:
DAILY
Test brake effectiveness before you drive. Recharge
battery fully every night.
WEEKLY
1. Check tire pressure. Pressure should be 40 - 50 psi.
2. Clean seat upholstery, plastic body and covers. To avoid
the electrical failure, do not spray water directly to your unit. Use a damp
clean rag to clean all parts.
3. Check and tighten the throttle screw.
MONTHLY
1. Check battery condition. Clean terminals if necessary.
2. Check all electrical wire connectors to eliminate loose connections.
3. Tighten all exposed bolts and nuts.
4. Check wheel bearings by spinning tires and checking for free rotation.
YEARLY
IMPORTANT - Visit your Orthoquad dealer and let technician check your
scooter completely.
TROUBLE SHOOTING AND REPAIR
CASE : The scooter seems completely dead.
• Make sure the ignition key is ON.
• Check the battery charge.
• Check for loose battery connections and cables of the controller power supply.
CASE: The scooter does not move when I press the accelerator.
• When the manual clutch lever is raised the scooter is on freewheel mode and the current is cut.
Simply push the hand lever down and turn off the ignition with the key and turn the key in the
ignition to the ON position.
If you have problems you can not solve, contact your
ORTHOQUAD dealer.

VIII. WARRANTY
The Orthoquad ES400/ES500 are covered by a full warranty on all components of the product for 1 year.
The Orthoquad ES500 only have a 2 year warranty on the powertrain
ES400/ES500 Batteries guaranteed for 3 months.
FOR MORE INFORMATION CONTACT YOUR ORTHOQUAD
DEALER
STORAGE INSTRUCTIONS
Always store in a dry area protected from freezing to avoid damage to the scooter and
premature wear of the batteries.
Avoid exposure to rain, snow, ice, salt or stagnant water. Keep your scooter clean and dry.
Never expose the electronic components of the scooter to humidity (rain, snow, mist, or water
from washing), as it may damage electronic circuits.
Always store your scooter with batteries fully charged. When storing the scooter for more than
two weeks, charge the batteries and disconnect them.
During the storage, check the charge once a month and recharge the batteries as needed. You
must complete a full charge cycle every month or damage to batteries can occur.
Avoid extreme temperature of hot and cold during storage. Freezing can damage low charged
batteries and they may become unusable.