This guide covers replacement of the battery endcaps and controller compartments for the IZIP E3 Path.

Transcription

1 Path Plastics Replacement Guide This guide covers replacement of the battery endcaps and controller compartments for the IZIP E3 Path. Required tools: Allen wrenches: 2.5, 3, 4mm Phillips-head screwdrivers: PH1, 2 X-ACTO knife or similar Heat gun (optional but useful) Contents: Battery endcap replacement Controller compartment replacement Battery endcap replacement E3 Path (RTMB 24V) Quick reference: Reflector-side 1. Remove the four screws (3mm Allen wrench) holding the endcap onto the metal battery case. 2. Remove the charger port from the endcap. (Phillips-head screwdriver) 3. Remove the rear reflector from the endcap. (Phillips-head screwdriver) 4. Remove the lock mechanism from the endcap. (Phillips-head screwdriver) 5. Transfer the Use only 24V Li-Ion charger decal and the battery serial number decal. (X-ACTO knife) Output-side 6. Remove the four screws holding the endcap onto the metal battery case. (3mm Allen wrench) 7. Remove the output port. (3mm Allen-wrench) Re-assembly 8. Transfer the hardware to the new endcaps, replacing the output port screws and output port strap with the pieces included in your parts bag, then re-install. Step 1 Remove the four screws (3mm Allen wrench) holding the endcap onto the metal battery case. To completely remove the endcap, you will need to unplug the charger port from the battery. You can release it by pushing down on the locking tab as shown in the photo below. Push down 1

2 Step 2 Remove the charger port from the endcap (Phillips-head screwdriver). Step 3 Remove the rear reflector from the endcap. (Phillips-head screwdriver) Step 4 Remove the lock mechanism from the endcap. (Phillips-head screwdriver) 2

3 Step 5 Transfer the Use only 24V Li-Ion charger decal and the battery serial number decal to the new endcap. You may need to briefly use a heat gun to remove the decals cleanly. The serial number decal must be transferred to avoid Warranty issues. Step 6 Remove the four screws holding the output-side endcap onto the metal battery case. (3mm Allen wrench) 3mm 3

4 Step 7 Remove the output port (3mm Allen-wrench). The two screws will be replaced with the ones included in your parts bag to allow more clearance and easier re-assembly. If the strap piece inside your battery is made of plastic, it will need to be replaced with the included stronger metal strap. Strap Replace these two screws +/red /black Step 8 Transfer the hardware from the previous steps to the new endcaps. As noted earlier, you should replace the output port screws and the output port strap with the pieces included in your parts bag. Screw the completed endcap assemblies to the battery case. If using an electric drill, be sure to use it at a low torque setting to avoid over-stressing the plastics. Be very careful to note the rotation of the output port. See the pictures above for the proper polarity (the + always goes closer to the middle of the battery). 4

5 Controller compartment replacement E3 Path (RTMB 24V) Quick reference: Remove the old compartment 1. Remove the four screws holding the controller compartment to the rack. (3mm Allen wrench) 2. Slide the controller compartment forward, out of the bike. 3. Open the controller compartment access door, pull out the wiring, then disconnect the controller from the bike. 4. Open the controller compartment by removing the two center screws. (Phillips-head screwdriver) 5. Transfer the controller, the input terminal ( prongs ), and the rear cover plate from the old compartment to the new. Be sure you note the orientation of the terminal! Please read the full instructions for this step later in this guide. Install the new compartment 6. Screw the top cover onto the new controller compartment, pull the controller plugs out of the access door, and re-connect them to the bike. IMPORTANT: Be sure to read the full instructions for this step later in this guide before connecting the battery! 7. Slide the controller compartment into the rack. Replace the four screws that hold the compartment to the rack, but leave them loose for now. 8. Slide the battery into the rack, making sure it s pushed all the way into the input prongs. Lock the battery to the rack. 9. Tighten the four screws you replaced in step Push the plugs and excess wiring up into the compartment, then replace the access door. Step 1 Remove the four screws holding the controller compartment to the rack. (3mm Allen wrench) Step 2 Slide the controller compartment forward, out of the bike. 5

6 Step 3 Open the controller compartment access door and pull out the wiring. Find the two 5-pin connector pairs (labeled Throttle and Motor Hall). Each of these pairs is labeled, but only on one side of the connector. Use the included stickers to mark the unlabeled side of each pair. This will help distinguish the plugs during re-assembly. See step 6 for more info. Disconnect each plug from the controller. Step 4 Open the controller compartment by removing the two center screws. (Phillips-head screwdriver) 6

7 Step 5 Transfer the controller, the input terminal ( prongs ), and the rear cover plate from the old compartment to the new. Be sure you note the orientation of the terminal! See the photo below for help. If the input terminal is installed backwards, the controller or battery could be ruined! The small tab should point upward when the prongs are installed in the bike, and the red wires should be closer to the middle of the compartment. Connect the input prongs to the controller (large white plug). / black Tab faces upward + / red Rear cover plate 7

8 Step 6 Screw the top cover onto the new controller compartment (image 1), pull the controller plugs out of the access door, and re-connect them to the bike. IMPORTANT! When re-connecting the controller, you must be certain you do not cross-connect the Motor Hall and Throttle connectors. Both connectors are 5-pin, and can easily be confused. If they are connected incorrectly, the motor and controller could both be ruined. We recommend connecting the large white connector, labeled Motor, first. This helps avoid misconnection; the 5-pin Motor Hall connectors branch from the large Motor cable, so this step brings them together immediately for easy connection. Please look closely at the pictures and wiring diagram below (images 2 & 3) and double-check your work before plugging in the battery for the first time Battery BA-PK Brake lever, Left BL-H471D-L08 Brake lever, Right BL-H471D-R09 Throttle TH-LT29X-DX03 (IZ-PATH-GY) TH-LT29X-DX04 (IZ-PATH-BL-W) With on/off switch Hub motor WH-700R-023 (blue rim) WH-700R-022 (green rim) With quick-disconnect plug + - WR-JC08DL04 Motor Wire Extension Harness WR-MTR-005 Handlebar PAS/TAG Switch WR-YKG-003 (IZ-PATH-GY) WR-YKG-004 (IZ-PATH-BL-W) Conect this plug first Controller CT Throttle signal and lights PAS/TAG Sensor WR-JC09SEN-005 On bottom bracket, including magnet ring 8 Be careful not to confuse these plugs! ON/OFF button

9 Step 7 Slide the controller compartment into the rack. Replace the four screws that hold the compartment to the rack, but leave them loose for now. Step 8 Slide the battery into the rack, making sure it s pushed all the way into the input prongs (photo 1). Lock the battery to the rack to set the position of the controller compartment (photo 2)

10 Step 9 Now that the controller compartment is aligned by the battery, you can tighten the four screws you replaced in step 7. Step 10 Push the plugs and excess wiring up into the compartment, then replace the access door. 10