RiMO SiNUS Series Operating instructions

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

RiMO GERMANY GmbH & Co. KG
Amerikastraße 4
58675 Hemer
Phone: [phone]
Fax: [phone]
[e-mail]
http://www.rimo-germany.com
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.
All rights reserved with regard to patent claims or submission of utility patent.
All product designations referred to in these operating instructions are trademarks of their respective compa-
nies.
Subject to modifications without prior notice.
These operating instructions were created by dokupartner, http://www.dokupartner.de.

Table of contents
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Table of contents
1 About this operating manual ............................................................................................................ 7
1.1 Purpose of this manual .......................................................................................................................7
1.2 Keep a copy near the karts .................................................................................................................7
1.3 About this manual ...............................................................................................................................7
1.3.1 Safety instructions...............................................................................................................................7
1.3.2 Prohibition signs and symbols ............................................................................................................9
1.3.3 Warning signs and symbols ................................................................................................................9
1.3.4 Other symbols used in this manual...................................................................................................10
1.3.5 Directions ..........................................................................................................................................10
1.3.6 Text marks.........................................................................................................................................10
1.4 Revision log.......................................................................................................................................11
1.5 Other applicable documents .............................................................................................................11
1.6 Warranty and liability.........................................................................................................................11
1.7 Contacting 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 misuse.......................................................................................................16
2.4 Kart design ........................................................................................................................................16
2.4.1 Work, maintenance and danger areas..............................................................................................17
2.5 Kart components and functions ........................................................................................................17
2.5.1 Vehicle frame with footboards...........................................................................................................17
2.5.2 Steering system ................................................................................................................................18
2.5.3 Pedals ...............................................................................................................................................20
2.5.4 Seat and seat adjustment .................................................................................................................20
2.5.5 Drive unit ...........................................................................................................................................21
2.5.6 Brake system ....................................................................................................................................22
2.5.7 Electric system with battery cells ......................................................................................................22
2.5.8 Batteries ............................................................................................................................................23
2.5.9 Battery management system (BMS) .................................................................................................24
2.5.10 Charger .............................................................................................................................................32
2.5.11 ACD controller...................................................................................................................................32
2.5.12 Motor .................................................................................................................................................33
2.5.13 Transmission.....................................................................................................................................34
2.5.14 Gas sensor........................................................................................................................................34

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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
2.6 Safety devices ...................................................................................................................................38
2.6.1 Overview ...........................................................................................................................................38
2.6.2 Safety devices ...................................................................................................................................39
2.6.3 Signalling devices..............................................................................................................................40
2.6.4 EMERGENCY-STOP devices...........................................................................................................41
2.6.5 Warning signs....................................................................................................................................41
2.7 Kart operation....................................................................................................................................42
2.8 Scope of delivery...............................................................................................................................43
2.9 Technical data ...................................................................................................................................43
2.9.1 BMS default thresholds .....................................................................................................................46
3 Safety ............................................................................................................................................ 47
3.1 General safety instructions................................................................................................................47
3.1.1 Avoiding dangerous situations ..........................................................................................................47
3.1.2 Operating instructions .......................................................................................................................47
3.1.3 Troubleshooting instructions .............................................................................................................48
3.1.4 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 Inadmissible operating conditions .....................................................................................................49
3.3 Duties of the kart operator.................................................................................................................50
3.3.1 Minimising risk of injury .....................................................................................................................50
3.3.2 Assigning tasks to personnel ............................................................................................................51
3.3.3 Personnel training .............................................................................................................................51
3.3.4 Driver instruction ...............................................................................................................................52
3.3.5 Personal protective equipment..........................................................................................................52
3.4 Requirements for operator's personnel.............................................................................................52
3.4.1 Qualification.......................................................................................................................................52
3.4.2 Skills and knowledge for drive operation ..........................................................................................55
3.4.3 Operator's personnel groups.............................................................................................................55
3.4.4 Specific skills and knowledge............................................................................................................56
3.5 Requirements to be met by drivers ...................................................................................................56
3.5.1 Clothing and physical fitness.............................................................................................................56
3.6 Personal protective equipment..........................................................................................................57
3.7 Residual risks ....................................................................................................................................58

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3.8 Action in the event of an accident.....................................................................................................59
4 Transport and installation .............................................................................................................. 60
4.1 Required tools ...................................................................................................................................60
4.2 Lashing points ...................................................................................................................................60
4.3 Transport by forklift truck...................................................................................................................61
4.4 Removing and disposing of packaging .............................................................................................61
4.5 Installation .........................................................................................................................................62
4.5.1 Location of operation and local infrastructure...................................................................................62
4.5.2 Installation and connection................................................................................................................62
4.5.3 Installing mechanical components ....................................................................................................63
4.5.4 Installing electrical components ........................................................................................................68
4.5.5 Installing safety devices and guards .................................................................................................69
4.5.6 Final inspection .................................................................................................................................70
4.5.7 Adjusting kart setup...........................................................................................................................70
5 Start-up.......................................................................................................................................... 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 ...............................................................................................................................80
5.3.5 Checking safety elements.................................................................................................................81
5.4 Start-up after prolonged storage .......................................................................................................82
6 Kart operation and control ............................................................................................................. 83
6.1 Description of kart controls for drivers ..............................................................................................84
6.2 Operating modes...............................................................................................................................84
6.3 Driver instruction by operator's personnel ........................................................................................84
6.4 Adjusting seat position ......................................................................................................................85
6.5 Switching on/off sequence ................................................................................................................87
6.5.1 Switching kart on...............................................................................................................................87
6.5.2 Switching kart off...............................................................................................................................88
6.6 Drive functions ..................................................................................................................................90
6.7 Safe driving .......................................................................................................................................90
6.8 Collisions/accidents...........................................................................................................................91
7 Malfunctions and faults .................................................................................................................. 92
7.1 Restart after unplanned stop.............................................................................................................93
7.2 Faults and malfunction during operation...........................................................................................94
7.2.1 Fault list .............................................................................................................................................94

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7.2.2 Eliminating faults ...............................................................................................................................96
7.2.3 Warning and fault signals at charger.................................................................................................97
7.3 Troubleshooting assistance ..............................................................................................................98
8 Checks and servicing during operation.......................................................................................... 99
8.1 Maintenance schedule ....................................................................................................................100
8.1.1 Daily tasks .......................................................................................................................................100
8.1.2 Weekly tasks ...................................................................................................................................101
8.1.3 Monthly tasks ..................................................................................................................................102
8.1.4 Tasks to be completed every 6 months / 200 operating hours .......................................................103
8.1.5 Tasks to be completed once, after first 10 operating hours............................................................103
8.2 Maintenance tasks ..........................................................................................................................103
8.2.1 Visual inspection .............................................................................................................................103
8.2.2 Cleaning ..........................................................................................................................................104
8.2.3 Checking and 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 RiMO customer service...................................................................................................................131
9 Repairs ........................................................................................................................................ 132
9.1 Repair tasks to be performed by operator.......................................................................................132
9.1.1 Exchanging/replacing battery cells..................................................................................................132
9.1.2 Replacing transmission ...................................................................................................................136
9.2 Repairs to be carried out by RiMO..................................................................................................136
10 Decommissioning, storage and disposal...................................................................................... 137
10.1 Decommissioning ............................................................................................................................137
10.2 Dismantling......................................................................................................................................138
10.3 Packaging kart.................................................................................................................................138
10.4 Storing the kart ................................................................................................................................139
10.5 Disposal...........................................................................................................................................139
10.5.1 Changing batteries and disposal.....................................................................................................140
11 Technical documents/appendices................................................................................................ 141
12 List of figures ............................................................................................................................... 142
13 List of tables ................................................................................................................................ 145
14 Glossary ...................................................................................................................................... 146
15 Index............................................................................................................................................ 147

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1About 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").
–Please read this manual carefully.
–Observe all safety instructions!
1.1 Purpose of this manual
This manual has been devised for skilled technical personnel as a reference manual and guide regarding the
technical aspects and features of the karts.
The technical information regarding settings, maintenance work and electrical equipment has been compiled for
specialist technicians who are authorised to perform the respective tasks. Unauthorised personnel are prohibit-
ed from carrying out any of the work described in the relevant chapters (see Requirements for operator's per-
sonnel [52]).
1.2 Keep a copy near the karts
A copy of this manual must be keep near the karts. A copy of this document must be available at all times near
the kart where it is accessible to technical personnel and drivers (operators).
1.3 About this manual
This section describes the signs and symbols used in this manual.
1.3.1 Safety instructions
The safety warnings and instructions in this manual are highlighted as follows:
DANGER
Warning regarding imminent risk of injury
This safety/warning instruction refers to an
imminent
danger of serious or even fatal
injury.

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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.
A safety instruction contains the following information:
–Signal word
–Nature and source of danger
–Potential consequences
–Measures to avert the danger
Example
DANGER
Risk of injury from high voltage (nature and source of danger)
Risk of electrocution! (potential consequences)
a) Wait at least 4 minutes before carrying out any work on the motor connections!
(actions to avert danger)

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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.
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
1.3.3 Warning signs and symbols
The following warning are used in this manual: These symbols are designed to make the reader aware that the
text to the left of the symbol contains important safety warnings and instructions.
Symbol
Description
Warning! Danger!
Warning: Dangerous electric voltage
Tab. 2: Warning signs and symbols

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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.
1.3.5 Directions
Directions are indicated as seen in driving direction from the driver seat.
1.3.6 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 online.
–Text highlighted in bold print indicates important information. Bold print is also used for subheadings.
–Menu items, tabs, buttons and switches are enclosed in brackets <...>, e.g. <Machine>.
–Sequences of such elements are also shown in brackets <...>, e.g. <Login/Semi-automatic mode/Start>.
–Keys on a keyboard are printed in square brackets, e.g. [Return].
–Text highlighted like this contains references to the enclosed glossary.

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Work instructions
Work instructions are structured as follows:
Heading
In this part, you might find preconditions that must be met before the individual steps can be performed.
a) Operating step
b) Another operating step
(Partial) result of an operating step
c) Another operating step
Final result of a work instruction
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 applicable documents
Document
Version
Author
Tab. 4: Table of other applicable documents:
1.6 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.
Warranty cover shall not apply to damage caused by improper use of the kart.

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1.7 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
–Data found on the type plate: type, serial no. and year of manufacture.
Address: RiMO GERMANY GmbH & Co. KG
Amerikastraße 4
58675 Hemer
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: http://www.rimo-germany.com
Tab. 5: Main office

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2Product description
This chapter contains detailed descriptions of the kart and its main components.
2.1 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:
–Type
–Kart type
–ID no. (year of manufacture: digits 1-2 = month, digits 3-6 = year)
–Chassis no.
Other identification details on the vehicle
Fig. 2: Serial no. near charging plug
Quality seal
Fig. 3: Quality seal near pedals
Qualitätsendkontrolle bestanden
Final quality check passed
verantwortlich / responsible
Mustermann

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2.2 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.
Functional principle
The kart is designed as a vehicle to be driven by a person (adult or child) after a brief instruction session by kart
operator's personnel. The karts are available in different models (iON/MiNi or TWiN) to suit different body sizes.
The person driving the kart must be able to control 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 pedals, if required. The final seat and pedal
positions are examined by operator's personnel to ensure that they are suitable for the safe driving of the vehi-
cle. The driver pulls out the drive switch of the kart. After the start signal is given, the driver puts the vehicle in
motion to start driving on the track.
The track and all vehicles on it are continuously monitored by operator's personnel. If required, drivers might be
requested by a signal to stop their vehicle.
After the agreed driving time has elapsed, the kart is driven by the driver to the dedicated stop zone. The driver
pushes in the drive switch to switch off the kart and exists the vehicle.
See also
Intended use [15]

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2.3 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. All track personnel must
have read and fully understood the content of this manual. Proper use of the kart also includes adherence to all
instructions contained in 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 other than the forward driving on a suitable kart track is deemed improper. Improper use can
pose risks to persons and property.
–Improper use includes unauthorised interference with kart components that are relevant for its safety.
–Improper use is also given, if the specific limit parameters (e.g. temperature) are not adhered to, or if the
kart is run with insufficient cooling.
–Never place or drive the car in an area where there is a potentially explosive atmosphere (Ex zone).
–Keep the kart away from flammable liquids and other substances.
See also
Technical data [43]
Safety devices [38]

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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.).
–Actuation of drive switch when no driver is seated in the vehicle.
–Other use of the vehicle in contravention of the above stated intended use.
2.4 Kart design
Diagram of kart
Fig. 4: Kart
1 Steering wheel 2 Panelling
3 Seat 4 Drive with powertrain
5 Rollbar 6 Surround protection
7 Rear wheel 8 Batteries (in special boxes)
9 Front wheel 10 Steering axle
10
6
5
7
4
1
9
2
8
3

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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.
Fig. 5: Work and 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.
2.5.1 Vehicle frame with footboards
The footboards are attached together with the other components of the kart to the vehicle frame.
The frame is made from strong, welded steel tubes.
The footboards allow drivers to get in and out of the vehicle safely and also protect them during driving on the
track.
5
2
3
4
1

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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.
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, the driver should go to the
charging station before starting the next round, as the kart needs to be recharged.
By pressing the boost button, the output power of the drive can be briefly increased, for example to overtake
another vehicle. This function is only available for a short time and can only be reactivated after a preset interval
has elapsed. The boost button is only ready for operation when it is lit.

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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.
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 accelerates.
The reversing function and the reverse button can be activated/deactivated by means of the optional WLAN
connection.
Fig. 8: Steering system
1 Steering wheel 2 Steering wheel mount
3 Steering column 4 Steering wheel struts
5 Tie rod 6 Steering knuckles
Fig. 9: Steering wheel
1 Pit indicator 2 Boost button
3 Reverse button

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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.
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 seat. The seat is available in various sizes (L, XL, XXL)
and designs (with/without padding). We also offer seat pads that can be customised to suit the driver and re-
duce the risk of injury in the event of side impact.
The seat adjustment mechanism allows for the repositioning of the seat in the seat frame to adjust the distance
between the seat and the steering wheel.