Related Manuals for Meyra 1.163
Summary of Contents for Meyra 1.163
- Page 1 SERVICE MANUAL SCOOTER Models: 1.163 3.264 1.363 / 1.364 2.363 / 2.364 2.663 / 2.664 2.563 / 2.564 W e m o v e p e o p l e .
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Page 3: Table Of Contents
Requirements..........................6 Term definitions........................7 Vehicle identification..................... 7 Electronic vehicles........................7 Overview ......................... 8 Cityliner 306, model 1.163 .....................8 Cityliner 408+, model 3.264 ....................8 Cityliner 406+, model 3.264 ....................8 Cityliner 310+, model 1.363 ....................9 Cityliner 410+, model 1.364 ....................9 Cityliner 312, model 2.363 ....................10 Cityliner 412, model 2.364 ....................10... - Page 4 Parking brake........................38 Renewing the bowden cable of the drum brake ..............38 Disassembly of the bowden cable:................38 Pre-assembly of the bowden cable: ................38 Steering column locking device ...................40 Lighting .........................42 Adjusting the headlights .....................42 Description of the rear lighting...................42 Electronic components ....................43 Control panel ........................43 Exchangeable electronic parts.....................44 Operating keypad PCB ......................45...
- Page 5 Drive batteries......................70 Battery replacement on model 1.163 .................70 Battery replacement on other models................70 Maintenance .........................71 Maintenance checklist......................72 Electrical system......................72 Mechanic ........................74 DIN norms and guidelines.....................75 Error code display ......................76 Notes..........................78...
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Page 6: Foreword
The required spare parts lists will be sent to you upon demand. All documents can also be downloaded from the following site in the internet: < www.meyra-ortopedia.de >. Requirements Special knowledge is required to carry out the maintenance work described in this service manual and may therefore only be carried out by educated qualified personnel. -
Page 7: Term Definitions
Additionally the plugged con- nections of the battery cables are to be pulled. VEHICLE IDENTIFICATION Electronic vehicles MEYRA-ORTOPEDIA Vertriebsgesellschaft mbH Meyra-Ring 2 · D-32689 Kalletal-Kalldorf For a definite vehicle identification in case you have K 9232200005308 Type 2.663 2009-52... -
Page 8: Overview
OVERVIEW Cityliner 306, model 1.163 Cityliner 408+, model 3.264 Cityliner 406+, model 3.264... -
Page 9: Cityliner 310+, Model 1.363
Cityliner 310+, model 1.363 Cityliner 410+, model 1.364... -
Page 10: Cityliner 312, Model 2.363
Cityliner 312, model 2.363 Cityliner 412, model 2.364... -
Page 11: Cityliner 315, Model 2.663
Cityliner 315, model 2.663 Cityliner 415, model 2.664... -
Page 12: Ortocar 315 Sp Ii, Model 2.563
Ortocar 315 SP II, model 2.563 Ortocar 415 SP II, model 2.564... -
Page 13: Drive
DRIVE The power drive is fitted with a permanent mag- net-Motor for 24 Volt DC current. The drive [1] consists of: – the motor (2), – Carbon brushes (5), – the magnetic brake (3), – Drive locking switch (6), – the differential gear (4). ☞... -
Page 14: Separating Electric Connections
Separating electric connections 1. If necessary remove the electronic cover [1]. 2. Unplug the cable connections of the motor and spring pressure brake (if required drive locking lever, only in respect to the S-Drive electronic) from the control electronic [2]. 3. - Page 15 Only on model 1.163 1. Unscrew the countersunk screws (1) and care- fully lift of the rear cover [2]. 2. Pull the cable shoes (3) of the battery cable. 3. Disconnect the plugged connection (4) of the motor cable. ☞ For this activate the release lever of the locking...
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Page 16: Disassembly Of The Drive
☞ Note: Before removal of the drive you should observe the position of the motor for the subsequent as- sembly. Model 1.163, Model 3.264, Model 1.363 / 1.364 and Model 2.363 / 2.364: 1. Disconnect the joint connection (1) of the hand ventilated pressure brake (magnetic brake). - Page 17 Model 3.264, Model 1.363 / 1.364 and, Model 2.363 / 2.364: 3. Dismantle the two screwed connections (5) of the attachment clamp on both sides of the drive [6]. 4. Lift the drive out of the frame [7].
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Page 19: Assembly Of The Drive Unit
Assembly of the drive unit Assembly of the drive is achieved in reverse order to the disassembly. 1. Slide the attachment clamp with the damping rubber (1) onto the square of the drive. 2. Insert the drive into the rear frame and align it. –... - Page 20 5. Insert the shock absorber and assemble the screwed connections (6). 6. Re-establish the electric connections. – Connect the corresponding plugs (7) to motor and spring pressure brake (respectively drive locking lever (12), only with respect to the S- Drive electronic). 7 .
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Page 21: Replacing The Drive - Ortocar Sp Ii
Replacing the drive - Ortocar SP II Preparations 1. To replace the drive the rear chassis has to be detached [1]. ☞ Therefore observe the corresponding chapter of the respective < user manual >. 2. Afterwards disassemble the drive wheels. 3. -
Page 22: Disassembly Of The Drive
Disassembly of the drive ☞ Note: Before removal of the drive you should observe the position of the motor for the subsequent as- sembly. with mounting jig: 1. First disassemble the upper screw (1) of the two shock absorbers (2). ☞... - Page 23 3. Dismantle the attachment screws (1)+(2) on both sides and remove the rocker [3]. 4. Now disconnect the following electric connec- tions of the drive: – Motor plug (4). – Brake plug (5). – Microswitch plug (6). 5. Lift the drive out of the frame.
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Page 24: Assembly Of The Drive
Assembly of the drive 1. Place the rockers (1) on both sides of the drive and mount then to the rear with attachment screws (2)+(3) [4]. ☞ The side parts must be dirt and grease free (6) near the gliding washers (5). 2. - Page 25 3. Insert the shock absorber and assemble the two screwed connections (1). ☞ For this you need to slightly compress the spring of each shock absorber. 4. Mount the wheel flange (2) on both sides (3).
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Page 26: Subsequent Operations
Subsequent operations Valid for all models: Fit the scooter components together again, respec- tively Connect the front and rear units [1], insert the batteries and mount the revetment with light- ing. ☞ Therefore observe the corresponding chapter of the respective < user manual >. Functional checks Check the mechanical elements –... - Page 29 Model 2.563 / 2.564: – Unscrew the attachment screws (2) and remove the cover cap brake. – Unscrew the attachment screws (3) and remove the spring pressure brake. Assembly The assembly is done analogue in reverse order. ☞ An adjustment of the brake is not necessary...
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Page 30: Carbon Brushes
– On intact carbon brush- es the contacts are anthracite coloured and shin- ing. Disassembly of the carbon brushes Model 1.163, Model 3.264, Model 1.363 / 1.364, Model 2.363 / 2.364 and Model 2.663 / 2.664: –... - Page 31 Model 2.563 / 2.564: – Pull off the rubber buffer (1) (2). – Slide the cap (2) of the carbon brush towards the cable and take it out [3]. ☞ Note: ☞ When reapplying the carbon brushes after in- spection, watch for their position and place- ment! –...
- Page 32 Collector The collector (5) is also to be checked for damag- ☞ Note: The slight grinding marks (6) caused by the car- bon brushes correspond to their normal wear and have no influence on the performance of the motor. In case deep grooves as well as single broken out parts or very burnt segments occur the motor is to be replaced.
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Page 33: Alignment
ALIGNMENT (only 4-wheel-models) Checking the alignment (all models) 1. Load the vehicle with about 50 kg on the foot floorboard. 2. Adjust the tiller to a straight forward course. 3. Hold the alignment measure (1) between the front rim horns (2) and adjust so that the ends barely tough the rim horns. -
Page 34: Adjusting The Straight Forward Course (Parallelity Of Front To Rear Wheels)
Adjusting the straight forward course (parallelity of front to rear wheels) (all models) 1. Fold the tiller down, align it to the center of the rear drive wheels and fasten it (e.g. with straps). Adjusting the alignment ☞ Note: During the adjustment watch for the thread symmetry, meaning the visible thread must be of the same length on both sides of the tie rod. -
Page 35: Revetment
REVETMENT Removing the steering column revet- ment Model 1.363 / 1.364: Removing the rear tiller revetment: 1. Unscrew the attachment screws (1) of the rear steering tiller revetment. 2. Remove the rear tiller revetment. Removing the front tiller revetment: 1. Unscrew the basket holder. 2. -
Page 37: Attaching The Steering Column Revetment
Removing the rear tiller revetment: 1. Disconnect the plug of the driving lock (1) and to the battery charging socket (2). 2. Unscrew (3) or pull off (4) the release lever. 3. Loosen the four clamping screws (5). Afterwards unhook the rear tiller revetment and pull it off. ☞... -
Page 38: Parking Brake
PARKING BRAKE Renewing the bowden cable of the drum brake Disassembly of the bowden cable: 1. Remove the front tiller revetment. 2. Unhook the bowden cable (1) on the hand brake lever (2). 3. Remove the cable binders (3) that hold the bow- den cable. - Page 39 Model 3.264 (4-wheel) Model 2.664 (4-wheel) and Model 2.564 (4-wheel): 2. Guide the upper bowden cable down in the cen- tre of the tiller. Afterwards align the two bowden cables under- neath the Y-plug (1) left and right and through the sleeve [2].
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Page 40: Steering Column Locking Device
Steering column locking device Model 1.163 and Model 3.264: The steering column lock is released with the hand- wheel (1). – For correct steering column locking the teeth must grip tightly into each other. Model 1.363 / 1.364: Loosening the tiller lock is achieved through the lever (2) that turns the blocking spring with a bow- den cable. - Page 41 Model 2.363 / 2.364, Model 2.663 / 2.664 and Model 2.563 / 2.564: Loosening the steering column lock is achieved through the lever with the clamping grip (1) or re- tracting grip (2) that releases the blockage of the gas spring. ☞...
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Page 42: Lighting
LIGHTING The 12-Volt-lighting jig and the turn signal are synchronised by the processor and guided over a shortage proof line driver. With the help of the curve speed sensor an auto- matic reset of the turn signal is also achieved simul- taneously. -
Page 43: Electronic Components
ELECTRONIC COMPONENTS Control panel – The complete electronic is switched on and off with the driving key. Model 1.163, Model 3.264 and Model 1.363 / 1.364: – Malfunctions are displayed through the blinking status display (1). Model 2.363 / 2.364, Model 2.663 / 2.664 and... -
Page 44: Exchangeable Electronic Parts
Exchangeable electronic parts The steering column revetment as well as the oper- ating keypad must be removed before disassembly of the respective electronic device. Operating keypad PCB The control panel PCB is located directly behind the keypad. ☞ Therefore observe chapter < Operating panel PCB >. -
Page 45: Operating Keypad Pcb
Operating keypad PCB Model 1.163: Disassembly of the operating keypad PCB – Remove the six attachment screws of the operat- ing panel [1]. ☞ Note: Carefully lift the operating panel and swivel it to the side [2]! – Take out the operating panel PCB (3). - Page 46 Operating keypad PCB Model 2.364 and Model 1.363 / 1.364: Disassembly of the operating keypad PCB 1. On model 1.363 / 1.364 disassemble the front and rear tiller revetment first. ☞ Therefore observe chapter < Steering column re- vetment >. 2.
- Page 47 Operating keypad PCB Model 3.263 / 3.264, Model 2.663 / 2.664 and Model 2.563 / 2.564: Disassembly of the operating panel 1. Unscrew the operating panel. – Therefor remove the attachment screws (1). ☞ Note: Carefully lift the operating panel housing and swivel it to the side [2]! 2.
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Page 48: Voltage Transformer
Voltage transformer Model 3.264 and Model 1.363 / 1.364: Disassembly of the voltage transformer – Disassemble the four screws (1) of the voltage transformer (2). ☞ Note: Carefully lift the voltage transformer and swivel it to the side! – Pull the plug (3) from the PCB of the voltage transformer. -
Page 49: Director
(1) for the speed (Level: 2.5 V +/- 2 V) are directed to the power electronics in the rear. Model dependent version (A) Model 1.163, ☞ up to October 2008 also: Model 3.264 and Model 1.363 / 1.364 Model dependent version (A)+(B) Model 2.363 / 2.364,... -
Page 50: Exchanging The Director Foot Pedal Complete
2. Foot accelerator The signals that are created with the director - foot pedal gas (1) for the speed (Level: 0.0 V to +/- 0.5 V) are directed to the power electronics in the rear. Model dependent version (A)+(B) Model 2.363 / 2.364, Model 2.663 / 2.664 and Model 2.563 / 2.564 Exchanging the director foot pedal complete... -
Page 51: Exchanging The Director Hand Gas Complete
3. Hand gas The signals that are created with the director - hand gas (1) for the speed (Level: 2.5 V +/- 2 V) are directed to the power electronics in the rear. Model dependent version (B) Model 2.363 / 2.364, Model 2.663 / 2.664 and Model 2.563 / 2.564 Exchanging the director hand gas complete... -
Page 52: Power Electronic
POWER ELECTRONIC The power electronic < SOLO > (1) as well as < S- Drive > (2) is located in the rear unit (depending on model) underneath a separate cover (3). Working method The power electronic is a one-channel-controller for vehicles with a drive motor. It is addressed from the operating panel. -
Page 53: Parametrics
Parametrics The parametrics of the power electronic can be ad- justed though the hand programming unit SP1 or through a PC. For this you need the following parts, depending on the power electronic: SOLO - electronic – Hand programming unit SP1 (1) –... -
Page 54: Programming Sequence
On all models with LCD-display in the operating panel some parameters can already be changed by "ON-Board-Programming". ☞ For this observe chapter < Operating panel in the LCD-display >. Model 1.163: ☞ A programming of model 1.163 is not planned. -
Page 55: Programming Unit Sp1
PROGRAMMING UNIT SP1 Purpose Before first use the specialist dealer might need to make some adjustments of the driving behaviour according to the disease pattern. For notes hereto view < Tips for the adjustment >. Overview LCD-Display ➀ Shows the parameter menu, indicating param- eter values or help-texts. -
Page 56: Driving Parameter
Driving parameter The driving features of the vehicle are defined by adjusting the single parameters. The following pa- rameters can be changed with the programmer SP 1. Forward Acceleration: Starting acceleration in forward motion, adjustable from 0 % (or ma- nufacturer minimum) to 100 % (manufacturer maximum). -
Page 57: Programming Sequence
Programming sequence After the plug of the programming unit is inserted into the programming socket of the vehicle and the vehicle has been switched on, the display indi- cates the description of the programming unit and the software version (e. g. SP1 2.0). Afterwards the display switches to the first driving parameter <... - Page 58 Adjustment example The maximum < Forward Speed > is set to the value 30 and is to be increased to the value 50. The fol- lowing steps are needed for the adjustment: – Switch the vehicle off. – Connect the programming unit. –...
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Page 59: Standard Settings
☞ Note: ☞ If there are deficiencies in the physical The new values can already be pro- ability of the driver, the reactive behav- grammed while driving and transferred iour of the vehicle should be dampened from the programming unit to the vehicle against abrupt joystick motions. -
Page 60: Pc-Programming
PC-PROGRAMMING Purpose Before first use the specialist dealer might need to make some adjustments of the driving behaviour according to the disease pattern. For notes hereto view < Tips for the adjustment >. Programming sequence ☞ First view chapter < Programming sequence >. –... -
Page 61: Operating Panel With Lcd Display
OPERATING PANEL WITH LCD DISPLAY from software version 1.22 Service-menu The following menus can be selected through the service menu (1): V1.41 Time Vehicle type Wheel diameter Warning tone Director (accelerator lever) Backlight Current software version Selecting the service menu V1.41 1. - Page 62 V1.41 Menu selection Enter / Confirm With the < lighting > key the submenu is selected. After confirming the corresponding parameters by pressing the < lighting > key the selection is stored. At the same time you switch back into the previous menu.
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Page 63: Clock Adjust
Clock adjust V1.41 The time can be readjusted through the menu, e.g. to switch from summer to winter time. ☞ The LCD-display shows the adjusted time. Hours With each pressing of the < speed control > key the clock in the < Time > menu is advanced by one hour. -
Page 64: Scooter Type (Model)
Scooter type (model) V1.41 By selecting the type of vehicle all required param- eters for the corresponding vehicle are set. ☞ The director < Foot pedal and hand gas > must be selected manually. After selection of the vehicle type switch through the menu <... -
Page 65: Wheel Diameter
Wheel diameter V1.41 The wheel diameter is automatically designated upon the selection of the scooter and shown in ☞ If this value is selected incorrectly the display for the speed of the vehicle will be either too high or too low. V1.41 Audible warning ☞... -
Page 66: Tiller Menu
Tiller menu The following sub-menu can be selected through the tiller menu: Director zero zone Director position Director movement Selection of different directors Speed reduction Cruise control Curve speed Curve sensor Right / left operation Tiller zero zone (director zero zone) V1.41 In the idle condition the acceleration lever must be within the <... -
Page 67: Speed Adjust
Tiller gain With this value the movement sector of the direc- tor should be adjusted to the mechanical way. ☞ When moving the director by 50 % a driving speed of 100 % can be reached, if the manufac- turer set value of 100 is reduced to 50. back / forward (director) The type of director is set and at the same time the forward / backward key activated. - Page 68 Economical speed Here you can activate or deactivate the cruise con- trol. Curve reduction Here you can activate or deactivate the speed re- duction in curves. ☞ While driving in curves the speed is reduced to about 7.5 km/h. ☞ When the final speed is set to 6 km/h a curve speed setting is not possible.
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Page 69: Backlight Menu
Change acceleration direction Here you can switch the forward / backward alloca- tion of the acceleration lever. Backlight menu The keys and display of the operating panel are backlit in correspondence with the parameters when the lights are switched on. ☞... -
Page 70: Drive Batteries
DRIVE BATTERIES Battery replacement on model 1.163 Removal 1. Remove the battery pack (1) and open it (2). – Therefor remove the attachment screws (3). ☞ Note: Due to the cables carefully lift and swivel the battery pack cover to the side (2)! 2. -
Page 71: Maintenance
W e m o v e p e o p l e . MAINTENANCE Scooter are medical devices of the class I- With the signature the undersigned de- MDD. As a medical device they underlie the clares to have duly performed the measured operator provision and are to be maintained declared in the maintenance checklist. -
Page 72: Maintenance Checklist
Maintenance checklist Electrical system Batteries ❑ No external damage or stains on the batteries? ❑ Tight fit of the screwed connections of the battery poles? ❑ Poles and attachment clamps cleaned and greased with Vaseline or Acid protector grease? ❑ Are the protective caps on the battery poles? ❑... - Page 73 Maintenance checklist Driving ❑ Test drive done? ❑ Personal barriers of the user regarded during the adjustment of the driving features? ❑ Variation from the adjusted maximum speed not more than + 10 % on level surface? ❑ Vehicle drives straight forward with straight steering and even motion? ❑...
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Page 74: Mechanic
Maintenance checklist Mechanic Chassis ❑ Covers and revetments are free of dents and tears? ❑ Revetments are firmly screwed on or strapped tight with velcro at all designated attach- ment points? ❑ Chassis complete and undamaged? ❑ Foot mats undamaged and laid out correctly? Seat ❑... -
Page 75: Din Norms And Guidelines
Items with order number 50 Nm Loctite 243 (medium hard) ....205 638 800 85 Nm MEYRA-ORTOPEDIA Vertriebsgesellschaft mbH Meyra-Ring 2 · D-32689 Kalletal-Kalldorf P.O. Box 1 703 • D-32591 Vlotho Fon +49 (0)5733 922-355 Fax +49 (0)5733 922-9355 info@meyra-ortopedia.de www.meyra-ortopedia.de... -
Page 76: Error Code Display
ERROR CODE DISPLAY The following error code list is valid for all Scooter models with LCD-operating panel (item- no. 1062101) Error display Cause of error Measure not used Motor (interruption) Check motor cables, check motor Motor (short circuit) Check motor cables, check motor valid from Micro switch magnet- Scooter in push mode, engage magnetic... - Page 77 Error display Cause of error Measure Director error Check per „On-Board-programming“: Selection of the correct director (lever, hand gas, foot pedal gas), zero zone and adjustment range. Interruption of the director; check cables. Director error Check per „On-Board-programming“: Selection of the correct director (lever, hand gas, foot pedal gas), zero zone and adjustment range.
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Page 78: Notes
NOTES... - Page 79 NOTES...
- Page 80 Your specialist dealer: MEYRA-ORTOPEDIA Vertriebsgesellschaft mbH Meyra-Ring 2 · D-32689 Kalletal-Kalldorf P.O. Box 1 703 • D-32591 Vlotho Fon +49 (0)5733 922-366 Fax +49 (0)5733 922-9366 info@meyra-ortopedia.de www.meyra-ortopedia.de W e m o v e p e o p l e .
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Hello wath is error E04 and E12 on scooter Meyra cytyliner i change baterri and dont whirk