EZ Lite Cruiser STANDARD MODEL User manual

EZ LITE CRUISER
Service & Maintenance Manual

Table Of Contents
Introduction to the EZ Lite Cruiser______________________________________________ 3
Identification of Components __________________________________________________ 4
Controller System Component Diagram _________________________________________ 6
Controller System I/O Ports Detail ______________________________________________ 7
Joystick Control Panel Detail __________________________________________________ 8
Fault Indicator Panel Guide ___________________________________________________ 9
Maintenance & Replacement of Parts ___________________________________________ 10
Arm Rest Pads Replacement ____________________________________________10
Arm Rest Raising Hinge Test, Tightening & Replacement ______________________11
Back Support Cushion and Support Straps Maintenance & Replacement __________12
Seat Cushion and Support Straps Tightening & Replacement ___________________13
CPU Replacement ____________________________________________________ 14
Joystick and Fork Replacement __________________________________________ 15
Front Wheel Maintenance & Replacement _________________________________ 16
Front Wheel Fork Replacement __________________________________________ 17
Foot Rest Maintenance & Replacement ____________________________________ 18
Mud Guard Replacement _______________________________________________ 19
Rear Wheel Replacement _______________________________________________20
Rear Motor Replacement _______________________________________________ 21
Folding Wire Replacement ______________________________________________ 22
Electrical Component Testing _________________________________________________ 24
Connecting the Battery & Testing Battery Voltage Output ______________________ 24
Joystick Charging Port Voltage Testing ____________________________________ 25
Testing for Short Circuits & Open Circuits __________________________________ 26
Helpful Tips ________________________________________________________________ 27
Watch for Wires Getting Caught When Folding_______________________________ 27
Troubleshooting Guide for Common Problems_______________________________ 28

Introduction to the EZ Lite Cruiser
The EZ Lite Cruiser is a Light Weight Power Wheelchair with Brushless Hub Motors. It uses a lithium ion
battery as a source of power. The battery connects underneath the seat, from the CPU controller compo-
nent.
The EZ Lite Cruiser comes with one lithium ion battery as the power source. It operates by using the con-
trol module to deliver all programmed commands to the brushless motors located on the rear wheels.
The joystick component of the control system carries out directional commands, as well as maintaining
the speed and power of the EZ Lite Cruiser.
The charging port for the EZ Lite Cruiser is located on the front (facing head on) of the joystick compo-
nent. The standard wall charger included with the EZ Lite Cruiser will have a matching connector which
can only be inserted one way. Please ensure proper alignment of the connector when plugging it in, and
power off the device when charging.
The main feature of the EZ Lite Cruiser is its ability to fold to a compact space. Using the wire located at
the back of the chair, near the base of the seat, you can fold the chair down. When standing behind the
EZ Lite Cruiser, pull on the wire outward straight on to release the locking mechanisms (spring loaded
pins) from each side of the main frame section.
By pushing downward on the top of the unfolded back support and the EZ Lite Cruiser will collapse on
itself. Notice the top half of the back support can be folded inward. When folding, first keep the top half
of the back support unfolded while pushing down, to expedite the folding overall. When the EZ Lite Cruis-
er is folded, then fold the top half of the back support inward toward the seat cushion.
When folded, the EZ Lite Cruiser can maintain a balanced position and be stood upright on the rear
wheels. It is kept balanced by the metal rods that act primarily to keep the top half of the back support
unfolded. Notice when you fold down the top half of the back support, on each side there are metal rods
protruding out. When the EZ Lite Cruiser is folded, it can stand up on the rear wheels and use those rods
to keep it balanced.
The front wheels of the EZ Lite Cruiser act in the same manner as caster wheels commonly found on
wheelchairs. They rotate completely depending on the direction being driven—forward or reverse. Allow
for adequate space for these to turn when changing direction.
The motors on the rear wheels have electromagnetic locks, by way of levers) to allow or prevent the rear
wheels from moving in free-wheel motion. When these levers are flipped forward towards the chair, the
electromagnetic locks will be disengaged and the wheels can roll freely. When the levers are flipped
backward towards the person standing behind the chair, the locks will be engaged and the rear wheels
will only move in the powered mode.
While the device is powered on, the wheels will always be locked. If the device is used in the powered
mode while the electromagnetic lock is disengaged, a fault indicator on the joystick component of the con-
troller system will indicate that the electromagnetic lock is disengaged.

Identification of Components
1 Back Support Bar 2 Back Support Cushion
3 Arm Rest Pad 4 Arm Rest Hinge
5 Joystick 6 Seat Cushion
7 Storage Compartment 8 Rear Wheel
9 Mud/Splash Guard 10 Front Wheel
11 Foot Rest

Identification of Components
12 Joystick Mounting Knob 13 Wire Clip
14 Folding Release Wire 15 CPU/Controller
16 Electromagnetic Brake Lever 17 Motor
18 Anti-Tilt Wheel

Controller System Component Diagram
Figure C
Figure C shows a sketched diagram of the full Controller System which powers & drives the EZ Lite
Cruiser.
The Battery and Joystick are connected together into the CPU controller component Input/Power I/O port
to provide power and control commands performed by the user.
The CPU controller component uses these commands to generate a signal that drives the motors in the
direction that the user indicates with the Joystick directional throttle.

Controller System I/O Ports Detail
Figure D

Joystick Control Panel Detail
Number Function Description of Functionality
1 Power On Button Pressing this button will power on the EZ Lite Cruiser
2 Power Off Button Pressing this button will power off the EZ Lite Cruiser
3 Speed Increase Button Pressing this button will increase the speed of the chair,
and illuminate the Speed Indicator LEDs until all 5 lights
are illuminated (top speed.)
4 Speed Decrease Button Pressing this button will decrease the speed of the chair,
and turn off each light of the Speed Indicator LEDs until
only one light is illuminated (lowest speed.)
5 Horn Pressing this button will sound the horn.
6 Battery Life Indicator LEDs This indicates the battery level. 3 Green, 3 Yellow and 1
Red LED light will be on with full power. As power is di-
minished, each light from top to bottom will turn off.
7 Control Joystick Knob Controls the direction and speed of the EZ Lite Cruiser.
Push the joystick towards the desired direction.
8 Speed Indicator LEDs With 5 LED lights on, the EZ Lite Cruiser is set at its max
speed. With 1 LED light on, the EZ Lite Cruiser is at its
lowest speed. This panel also doubles as a Fault Indica-
tor.
Shown Powered ON
Shown Powered OFF

Fault Indicator Panel Guide
Aside from indicating the speed setting of the EZ Lite Cruiser, the Speed Indicator LEDs (number
8 on the figure shown on the previous page) acts as an indicator of common faults in the control-
ler system. When these LEDs flash with the following Display as indicated below, the most com-
mon problems and their respective possible solutions are identified:
Display Problem Solution
Battery power is low. You must recharge or replace the battery.
Joystick cannot deliver signals to the
control module (CPU)
Check to see that all cable connections are firmly
attached. If they are, this would indicate a problem
with the joystick, and it may need to be replaced with
a working joystick. Joystick wire could be cut.
An electronic drive locking function is
engaged to prevent the EZ Lite Cruiser
from being operated. Also acts to indi-
cate that the battery is being charged.
Disconnect the 3-pin Charger cable from the front of
the Joystick component. If it is disconnected, this
would indicate a problem with the Joystick’s Charger
connector I/O port.
Brushless motors fail to move. Check to see that all cable connections are firmly
attached. If they are, this would indicate an open or
short circuit somewhere in the controller system.
Use a multimeter to detect an open or short circuit.
Electromagnetic lock on rear wheels is
disengaged.
Push the electromagnetic levers on the rear wheels
back towards yourself (when standing behind the EZ
Lite Cruiser) to engage the electromagnetic lock.

Maintenance & Replacement of Parts
Arm Rest Pads Replacement
Figure # 1
The EZ Lite Cruiser has foam arm rest pads for comfort. Over time, as they become worn, or loose the
arm rest pads may need to be removed and replaced. To remove the arm rest pads, lift the arm rest as
shown in Figure 3 on the next page, and loosen the two screws that attach the arm rest pad to the arm
rest frame, as shown in Figure 1.
Figure # 2
The screws will go all the way through the bottom of the arm rest frame, as shown in Figure 2, and will
run into the arm rest pads to fasten.

Maintenance & Replacement of Parts
Arm Rest Raising Hinge Test, Tightening & Replacement
Figure # 3 Figure # 4
The plastic piece underneath the arm rest acts as a hinge to allow for the raising of the arm rest. This
convenient feature allows the user to enter into and exit out of the seat of the EZ Lite Cruiser from the
sides.
Figure 3 shows the proper function of the arm rest hinge when raising. Flipping the circular piece at the
front of the metal cylinder underneath the arm rest pad will release the spring loaded pin that keeps it
locked in place and allow for the arm rest to be raised. Figure 4 shows the arm rest in the final resting
Figure # 5 Figure # 6
If the EZ Lite Cruiser is handled improperly, this hinge can be damaged or break. The arm rest hinge
can be removed with a hex wrench as shown in Figure 5. There are 2 bolts which need to be removed
in order to fully replace the arm rest hinge. One is at the back of the hinge, and one is towards the front
of the hinge, slightly off center.
When replacing the hinge, make sure to align the base of the arm rest that gives the main support for the
arm rests, back into the hinge as shown in Figure 6.

Maintenance & Replacement of Parts
Back Support Cushion and Straps Maintenance & Replacement
Figure # 7 Figure # 8
The back support cushion is held on by Velcro straps and can be removed completely as indicated in Fig-
ure 7 and Figure 8, exposing the supporting straps underneath.
Figure 9 below shows how to reattach the straps underneath the back support cushion. Over time the sup-
port straps may need to be retightened. While uncommon, and generally due to overloading of the maxi-
mum weight capacity for the EZ Lite Cruiser, the support straps may also need to be replaced. Use these
images to guide you in the replacement and maintenance as described.
Figure # 9

Maintenance & Replacement of Parts
Seat Cushion and Straps Maintenance & Replacement
Figure # 10 Figure # 11
The seat of the EZ Lite Cruiser is held on to the base support area by Velcro, and can easily be removed
as shown in Figure 10.
The inner cushion material can be replaced by undoing the zipper on the seat cushion cover, and expos-
ing the inner cushion material, as shown in Figure 11. The outer seat cushion cover can also be washed
or treated for cleaning.
The inner part can be replaced by another cushion of the same size.
Figure # 12 Figure # 13
Underneath the seat cushion, the base of the seat is made up of support straps, held together by Velcro
material. To undo the support straps, peel back the Velcro and release the straps from the supporting
metal brackets that allow the straps to wrap around the frame of the seat area.
To reattach the straps, ensure that they go around the base of the seat and through the brackets, as
shown in Figure 12. Reattach the Velcro straps by bringing them together firmly as shown in Figure 13.

Maintenance & Replacement of Parts
CPU Replacement
Figure # 14
Figure # 15 Figure # 16
To replace the CPU component of the controller system, disconnect all the ports—Power/Input, and the
Left & Right Motor ports—as indicated in Figure 14.
Loosen the two screw at the sides of the CPU. Note, there is a nut on the reverse side of each screw so
you will need a wrench of a pair of pliers, as shown in Figure 15. To gain access to the screw on the inner
top side of the CPU, it is best to remove some of the seat cushion support straps as indicated in Figure 12
(previous page.) Remove the CPU and handle it gently as shown in Figure 16.

Maintenance & Replacement of Parts
Joystick and Fork Replacement
Figure # 17
To replace the Joystick component of the controller system, disconnect the middle I/O port of the CPU
component — labeled with the Power/Input — as shown in Figure 17.
To dismount the joystick from the arm rest, loosen the circular knob at the base of the arm rest, as shown
in Figure 18 below. This will allow the removal of the fork that the Joystick component is mounted to.
The fork of the Joystick component can be removed by loosening the two screws at the base of the Joy-
stick component, as shown in figure 19 below.
Figure # 18 Figure # 19

Maintenance & Replacement of Parts
Front Wheel Maintenance & Replacement
To replace either of the Front Wheels, use a hex wrench to release the bolt which runs through the center
of the wheel, as shown in Figure 20. When the bolt loosened from the nut on the opposing end, it can be
pulled out with ease. The nut will usually remain in the fork on the opposing end that is fitted for the nut.
When the wheel is removed, it will release two 5/16” washers on each end, do not lose them and ensure
they are reinstalled when the wheel is reinstalled, to prevent damage of the bearings due to the impact the
front wheels will incur.
The center of the wheel has a bearing on each side, which can be removed as shown in Figure 21.
To attach the wheel back on to the fork, first insert partially the bolt with the washer installed on the tip that
protrudes into the inner part of the fork, as shown in Figure 22.
Then, insert the wheel, and slide the bolt through to the opposing end, to let it protrude out of that end.
With a part of it exposed, slide the other washer over the tip, as shown in Figure 23.
Then gently slide the wheel with the washer properly installed over the bolt, so it meets the nut on the op-
posing end.
Figure # 20 Figure # 21
Figure # 22 Figure # 23

Maintenance & Replacement of Parts
Front Wheel Fork Replacement
To replace the Front Wheel Fork, first remove the front wheel, as shown in Figure 24, and remove the plas-
tic cap located over the fork assembly nut as shown in Figure 25.
We recommend using a pair of vice grips on the underside bolt as shown in Figure 26, and a socket
wrench on the top nut, also shown in Figure 26.
Keep note of all of the parts as the front wheel fork assembly is removed, as shown in Figure 27, replacing
them in the same manner as they are removed.
Figure # 24
Figure # 26
Figure # 25
Figure # 27

Maintenance & Replacement of Parts
Foot Rest Maintenance & Replacement
Over time, as the foot rest is folded in and out, the bolts which hold it on to the frame may become loose
and will need to be tightened as shown in Figure 28. If for some reason the foot rest needs to be removed,
it can be done by removing the bolts, also as shown in Figure 28.
When reattaching the foot rest to the frame, ensure that the plastic washer is installed on the inner part be-
tween the joining part of the foot rest plate and the frame, as shown in Figure 29.
Figure # 14
Figure # 29
Figure # 28

Maintenance & Replacement of Parts
Mud Guard Replacement
To replace the mudguards, we recommend removing the motor to gain better access to the nuts that hold
the mudguard to the frame, as shown in Figure 30.
It can also be done without removing the motor, by using needle nose pliers to gain access to the nuts.
Figure # 30

Maintenance & Replacement of Parts
Rear Wheel Replacement
To replace either of the Rear Wheels, use a small flat head screw driver to release the plastic bolt cover in
the center of the wheel, as shown in Figure 31.
When the bolt cover is removed, it will expose the 3 hex bolts found in the center of the wheel, as shown in
Figure 32.
Remove the 3 bolts from the center of the wheel, as shown in Figure 33, to dismount the wheel from the
motor. Then, replace the wheel, and refasten the bolts to the motor tightly, using these same steps in re-
verse. If the plastic bolt cover breaks during removal, you can requisition another from the manufacturer.
Figure # 31 Figure # 32
Figure # 33