Postable Electric Scooter SERVICE MANUAL (Version 2014-2) · SCOOTER’s CARE – a proper...

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Postable Electric Scooter

SERVICE MANUAL

(Version 2014-2)

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TABLE OF CONTENTS

TABLE OF CONTENTS

WARNINGS 3 I. SPECIFICATION 4 II. STRUCTURE 5 III. BLOCK DIAGRAM 18 IV. OPERATION 19 V. SOLUTIONS 23

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WARNINGS

CHARGE THE BATTERY FULLY BEFORE THE FIRST USE - The battery must be fully charged once the product is received and recommended after each use. It is recommended to charge the battery about 4-6 hours.

Properly maintained and cared, E-Twow will ensure ease of use and a pleasant ride. Below are

points that will help you to maximize the pleasure of using this electric scooter.

FACTORS THAT MAXIMIZE THE DISTANCE TRAVELLED WITH THE ELECTRIC SCOOTER

SLOPE – more horizontal the road, longer distance you will ride

WEATHER - cold weather can negatively affect battery’s capacity

WIND - traveling with the wind from behind will increase the distance travelled, traveling

with the wind in front will decrease the distance travelled

SURFACE - more smoother the road surface, greater distance you will ride

USER WEIGHT - the more user weighs less, even greater is the distance travelled

SCOOTER’s CARE – a proper maintenance of the scooter will increase its life

BATTERY - maintained properly charged, it will increase the duration of use. Batteries

stored in cool areas (below 10 Celsius degrees) will deteriorate over time. Never allow

the batteries to freeze (below 0 Celsius degrees) because they will deteriorate.

WET WEATHER

IT IS NOT RECOMMENDED TO USE THE SCOOTER IN WET WEATHER. This type of scooter is not designed to be used in wet weather (wet roads, puddles, rain, etc.). Never immerse this product into the water because the electrical system may be damaged.

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I. SPECIFICATION

ECO MASTER BOOSTER

Range: 30 km 40 km 35 km

(speed: 20km/h, load: 75kg, wind: about 10km/h)

Maximum speed: 27 km/h 28 km/h 30 km/h

Folding function: Completely foldable electric scooter (patented) – Adjustable height,

Foldable handlebar + Automatic folding

Front wheel energy recovery brake + Emergency Braking function: rear wheel brake (During the emergency braking also the front wheel with

energy recovery brakes)

Buffer: Front buffer + Rear buffer

Lights: LED headlight (Includes 6 LEDs, the light intensity is kept constant regardless of battery voltage); Light sensor

Cruise control function: optional

Zero Start function: optional

Horn: piezo-ceramic horn

UBHI: Control and display console (patent)

UBHI functions: acceleration control, braking control, display, lights, horn

Acceleration control: Acceleration is controlled by the lever in the right of the UBHI console

Braking control: Brake is controlled by the lever in the let of the UBHI console

Maximum slope: 15 degrees 20 degrees 25 degrees

Tires: Raw rubber (patent)

Motor power: 350W 450 W 500 W

Motor type: Brushless DC motor

Power consumption: 6.15 Wh/km 7.5 Wh/km

Maximum torque: 13,3 Nm 14,1 Nm 15 Nm

Charging time: 1.5 h-2 h (Charger 4A) or 3h-3.5h (Charger 2A)

Charger input 220V/110V voltage:

Display dimensions: 80 x 60 x 60 mm

Display information: ODO / Km done / Temperature / Speed / Battery level / Battery percentage / Light indicatorOn/Off

Material: Aluminium alloy + Metallic paint

Battery: 190 W; Li-Po 250 W; Li-Po 280 W; Li-Po

Weight: 10.7 kg 10.9 kg 10.8 kg

Maximum load: 110kg

Charger: 2A (optional - 4A)

Dimensions: Unfolded: 940 x 135 x 1160 mm;

Folded: 945 x 135 x 300 mm

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II. STRUCTURE

Fig. II.1

Description

001 Control and display console

002 Folding handlebar

003 Median tube

004 Steering assembly

005 Front fork and suspension

006 Front wheel (Motor)

007 Controller

008 Controller support and folding system

009 Chassis

010 Rear suspension forkand mechanical braking system

011 Rear wheel

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II. STRUCTURE

001 - Control and display console

Fig. II.2

Pos. Reference No. Qty. Description

1 2 Self-tapping screw 2.5 x 16mm

2 1 Display protective cover

3 1 Buttons protection


5 1 Display protective glass


7 1 Electronic board

8 2 Bulkhead holtzsurub

9 1 Acceleration lever

10 1 Headlight protective glass

11 1 Magnetic brake lever

12 2 Self-tapping screw 3 x 16mm

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II. STRUCTURE

002 – Folding handlebar

Fig. II.3


1 2 Secondary bar

2 4 Bolt 04 x 25mm

3 1 Primary bar

4 2 Rivet 04 x 12mm

5 1 T pipe

6 1 Handlebar height adjustment button

7 1 Plastic ring

8 1 Spring clip

9 2 Rubber lever

10 2 Pipe lever

11 2 Spring button handlebar folding

12 2 Handlebar folding button

13 2 Traction spring

14 2 Hexagonal screw M3 x 10mm

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II. STRUCTURE

003 – Median tube


1 Pipe

2 Lower collar

3 Allen head screw M6 x 20mm

4 Upper collar

5 Threaded rod M6 x 55mm

6 Special nut M6

7 Plastic tube

8 Allen head screw M5 x 14mm

9 Folding hook

10 Locking lever

11 Special nut M6

12 Plastic bracket

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II. STRUCTURE

004 – Steering assembly

Fig. II.5


1 1 Locking nut

2 1 Special washer

3 1 Threaded cuvette

4 2 Bearing

5 2 Pressed cuvette

6 1 Pipe with holes

7 1 Nut M6

8 1 Plastic washer

9 1 Threaded pipe

10 1 Lower cuvette

11 1 Octagonal plastic muff

12 1 Aluminium nut

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II. STRUCTURE

005 – Front fork and suspension

Fig. II.6

Pos. Reference no. Qty. Description

1 1 Rubber pleated tub

2 1 Front suspension spring

3 1 Octagonal pipe

4 4 Allen screw M6 x 20mm

5 1 Rubber washer

6 1 Front fork

7 1 Protection cover formotor cable




11 1 Front wing

12 4 Nut M6

13 2 Nut M4

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II. STRUCTURE

006 – Front wheel (Motor)


1 Stator

2 Stator aluminium support

3 Motor shaft

4 Rotor

5 Tire

6 2 Bearing

7 1 Seeger fuse

8 2 Nut M12

9 2 Special washer

10 2 Side cover

11 12 Screw M4 x 12mm

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II. STRUCTURE

007 – Controller

Fig. II.8


1 4 Screw M4 x 8mm

2 1 Controller

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II. STRUCTURE

008 – Controller support and folding system

Fig. II.9


1 3 Coupling nut with Allen hole and bulkhead M6 x 39mm

2 1 Left cover



5 Folding lever shaft

6 Locking bolt

7 Folding lever

8 Spring

9 Folding joint shaft

10 2 Wearing muff

11 3 Screw with Allen hole and bulkhead M6 x 16mm

12 1 Right cover

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II. STRUCTURE

009 – Chassis

Fig. II.10


1 1 Frame

2 4 Screw M3 x 10mm

3 2 Wearing muff

4 1 Battery protection front cover

5 6 Screw M6x 16

6 4 Nylon wearing muff

7 1 Right front ear

8 1 Left front ear



11 8 Nut M6

12 2 Screw M6 x 8mm

13 1 Right rear ear

14 1 Left rear ear

15 1 Battery protection rear cover

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II. STRUCTURE

010 - Rear suspension fork and mechanical braking system

Fig. II.11

Pos. Reference no. Qty. Description

1 1 Rear wing

2 1 Mechanical brake

3 1 Brake spring

4 1 Rear fork


6 1 Limitation muff


8 1 Fixing ear

9 2 Wearing muff

10 1 Threaded bar M8 x 85mm

11 1 Washer


13 1 Rear fork joint shaft


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15 1 Rear suspension body

16 1 Special spring supporting washer

17 1 Rear suspension spring

18 1 Special spring supporting washer

19 1 M8 ornamental nut

II. STRUCTURE

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011 – Rear wheel

Fig. II.12


1 1 Rear wheel rim

2 1 Tire

3 1 Rear wheel shaft

4 2 Bearing

5 2 Grower washer 06


III. BLOCK DIAGRAM

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IV. OPERATION

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Necessary tools

Position Description

1 Allen key 2mm

2 Allen key 2.5mm

3 Allen key 3mm

4 Allen key 4mm

5 Allen key 5mm

6 Wrench 19 mm

7 Cross-head screwdriver

8 Plastic flange

9 Rubber hammer

10 Pipe key 10mm

11 Pliers Spitz

12 Sfic

IV. OPERATION

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Dismantling control and display console (Figure II.2)

Loosenfastening screws pos. 1 and 4 of the protective cover pos. 2 in Figure II.2;

Remove the protection cover of the display together with the protection glass of the

display pos. 5 of Figure II.2;

Remove the protective glass of the LED headlight pos. 9 of Figure II.2;

Loosenfastening screws pos. 6 in Figure II.2 of the electronic board;

Extract the electronic board display pos. 7 in Figure II.2;

Disconnect cable connectors on the electronic board;

Loosen the fixing screws pos. 8 of the control levers pos. 9 and 11 of Figure II.2;

Loosen fastening screws pos. 12 of Figure II.2 of control levers;

Remove control levers outward.

Dismantling foldable handlebars (Figure II.3)

Weaken the upper fastening screws system on the median pipe;

Loosen the screw pos. 8 Figure II.4;

Remove the foldable handlebars together with plastic tube pos. 7 in Figure II.4.

Dismantling rubber handle (position 9 in Figure II.3)

Weaken the fastening screws screw of the handle pos. 14 Figure II.3;

Remove the retaining bolt of the handle pos. 2 in Figure II.3;

Push the handlebars button folding pos. 12 of Figure II.3;

While pushing the folding button pull the handle outward.

Dismantling median tube (Figure II.4)

Weaken the lower fastening screws system by loosening screws pos. 3 in Figure II.4;

Remove the median pipe.

Dismantling the front wheel (motor) (position 006 in Figure II.1)

Loosen the fastening screws pos. 7 in Figure II.6 of the protective cover pos. 8 Figure II.6

of the motor power cable;

Remove the protection cover of the motor power cable;

Decouple the motor cable;

Loosen the motor clamp nuts pos. 8 Figure II.7;

Remove the motor.

Dismantling the steering assembly (Figure II.5)

Remove the median tube (see "Dismantling the median pipe");

Remove the front wheel (see "Dismantling the front wheel (motor)");

Loosen the coupling screws and nuts pos. 1 and 11 of Figure II. 9;

Unscrew the fastening screws nut pos. 7 in Figure II.5;

Remove all the assembly.

IV. OPERATION

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Dismantling the front wing (position 11 of Figure II6)

Remove the front wheel (see "Dismantling the front wheel (motor)");

Loosen the clamp nuts pos. 13 Figure II.6;

Remove the wing.

Dismantling the controller (Figure II.8)

Loosen the fastening screws pos. 1 in Figure II.8;

Remove the controller pos. 2 in Figure II.8;

Disconnect the connectors between the controller and battery, rear brake sensor, display

and motor.

Dismantling the controller support and folding system (Figure II.9)

Dismantle the steering assembly (see "Dismantling the steering assembly”, point 3);

Loosen the screws fastening the protective cover pos. 12 of Figure II.10

Remove the battery protection cover of pos. 4 of Figure II 10;

Remove the right front ear pos. 7 in Figure II.10:

■ Loosen the three screws fastening in frame pos. 5 of Figure II 10;

■ Disconnect the coupling screw and nut pos. 9 and 10 of Figure II 10;

■ Loosen the fastening screws in pos. 4 of the foldingshaft pos. 9 Figure II.9.

Loosen the fastening screw in pos. 4 on the left side of the folding shaft pos. 9 Figure

II.9.

Remove the controller support.

Battery removal

Loosen the screws fastening the protective cover pos. 12 of Figure II.10

Remove the battery protection cover of pos. 4 of Figure II 10;

Loosen the connector from the battery;

Remove the battery.

Dismantling the rear suspension fork and mechanical braking system (Figure II.11)

Loosen the fixing screws pos. 14 Figure II.11 of the suspension;

Loosen the fastening screws pos. 9 of the rear ears pos. 13 and 14 in Figure II.10;

Carefully detach the rear brake sensor;

Remove the whole assembly together with rear ears;

Loosen the fastening screw in pos. 5 of Figure II.11;

Remove the rear right ear pos. 13 Figure II.10;

Remove also the rear left ear pos. 14 Figure II.10 together with the joint shaft of the rear

fork pos. 13 Figure II.11;

Remove the front assembly from the ears fastening in frame.

IV. OPERATION

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Dismantling the rear suspension

Loosen the fixing screws pos. 14 Figure II.11 of the suspension;

Rotate up as much as possible the rear fork pos. 4 of Figure II.11;

Disconnect the coupling screw and nut pos. 7 and 12 in Figure II.11;

Remove the rear suspension.

Dismantling the rear wheel (Figure II.12)

Loosen the fastening screws pos. 6 of Figure II.12;

Remove the rear wheel.

V. SOLUTIONS

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PROBLEM POSSIBLE CAUSE SOLUTION

The scooter is not running at normal speed and the distance travelled decreased over time

Low Battery Faulty battery Mechanical brake is actuated or faulty sensor You are driving on rough terrain, wind in the face, etc.

Charge the battery Replace the battery Actuate the mechanical brake, change the sensor and try again Travel distance may increase when traveling on off-road and / or such weather conditions

Does not start when "ON" is pressed

Connectors weak Cables interrupted Faulty button The display board is damaged Faulty controller

Check all connectors Check all cables Replace the button and try again Replace the display board and try again Replace the controller and try again

The display is lit, but the scooter does not start

Weakened motor cable

connection

The rear brake sensor is faulty

Faulty acceleration

Zero Start is active

Check the connection controller-motor Replace the rear brake sensor and try again Replace the acceleration lever While holding down the acceleration lever push a little the scooter in front

Brakes do not cut the power of the motor when actuated

Connectors weak The rear brake sensor cable is damaged Brake lever is faulty Faulty controller

Check the sensor connectors on the rear brake Check the sensor cable from the rear brake Replace the brake lever and try again Replace the controller and try again

The charger indicates that the battery is fully charged, but the scooter does not start.

Connectors weak Contacts oxidized at the charging or battery connector

Check all connections

Check and clean the connectors

and try again.

The acceleration or brake do not return to the starting position

Faulty lever Replace the lever

Scooter’s power supply is randomly interrupted

Connectors weak

Oxidized fuse terminal

Interrupted cables

Check connections

Check terminals of the fuse

Check all cables

The charger indicates that the battery is fully charged in a very short time

Faulty charger

Faulty battery

Replace charger

Replace battery

The charger’s LED indicator lights up when the charger is not plugged in

No voltage socket

Faulty charger

Check socket

Replace charger

Charger’s LED indicator Faulty cable between the Check and clean the connectors

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does not change its status

charging connector and battery connector

Charger’s cable is

interruptedFaulty charger

Faulty battery

and try again.

Check cables of the charger

Replace charger

Replace battery

Postable Electric Scooter SERVICE MANUAL (Version 2014-2) · SCOOTER’s CARE – a proper...

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