Pitsco Education SunEzoon Car User manual

User Guide
59021 V0808

Exploring the Sun’s energy is easy with this SunEzoon Car Kit. No soldering
is necessary – only simple assembly and cutting skills are required.
Materials Included
• 2largerearwheels
• 2smallfrontwheels
• 2axles
• 4nylonaxlebushings
• Gearfont
• Motor
• Motormount
• Chassisplate
• Carbodycutout
• Solarpanelwithalligator
clips
• Adhesivetabs,
double-sided
Required Tools (not included)
• Craftknife
• Scissors
Assembly
1) Findthefouraxlebushings.Pickupthechassisplateandlookattheside
ofit.Noticeitiscorrugatedandthereareholesalongbothlongsides.
Counttwoholesbackfromoneend.Placeoneoftheaxlebushingsinthat
hole.Dothesameontheothersideoftheplate.Thetwoaxlebushings
shouldbeparallel.Thisiswherethefrontaxlewillgo.
2) Fromeachside,count16holesbackfromthefrontaxlebushings.Place
anaxlebushinginthishole.Dothesameontheotherside.Thisiswhere
the back axle will go.
3) Fromthegearfont,detachGearI(40-tooth,1/8"bore).Thisisthedrive
gear.Theremaybesomeashing,orburrs,onthegear,whichwillkeep
thegearfromrunningsmoothly.Usingthecraftknife,carefullycutoff
anyashing.NowdetachGearGorN(20-tooth,2-millimeterbore)from
thegearfont.Thisisthepiniongear.Cutoffanyashing.
4) Pressanaxleintothedrivegear.Pushitthroughsoapproximately1/4"
oftheaxleisextendedontheothersideofthegear.Pressoneoftherear
wheelsonthat1/4"end(Figure1).

Wheels
Axle
Bushing Drive
Gear
2nd row
18th row
Axle Bushing
5) Inserttheaxleintooneofthebackaxlebushings.Pushituntiltheend
comesouttheaxlebushingontheotherside.Pushtheotherrearwheelon
theaxleend(Figure1).Makesurethepartsarenottootightorthewheels
and gear will not turn properly.
6) Pushtheotheraxleintooneofthefrontwheels.Slidethisaxlethrough
thefrontaxlebushings.Pushtheotherfrontwheelontothefreeendofthe
axle(Figure1).Again,makesurethepartsarenottootight.
7) Pushthepiniongearontothemotorshaft.Snapthemotorintothemotor
mount.
8) Turnthemotorsothepiniongearisontopofthedrivegearandthe
motor is between the two rear wheels. Let the gears mesh together and the
piniongearrollforwarduntilthemotormountrestsontopofthechassis
 (Figure2).Thegearsshouldstillbemeshedbutnottootightly.Iftheyare
tootight,thegearswillnotworkproperly.Practicethisuntilyouaresure
youcanpositionitcorrectly.Thenpeeloffthepaperbackingofthemotor
mountadhesiveandpositionthemotorandgearaspracticed.
Axle Bushing
Wheels
Drive Gear
Motor in
Motor Mount
Pinion
Gear
Figure 1
Figure 2

9) Cliptheblackandredwiresfromthesolarpaneltothemotor
connection terminals. You might need to turn the motor in the mount so
theconnectionclipsdonotstickupandinterferewiththesolarpanel
placement.
10)Placeanadhesivetabonthebackofthesolarpanelnearthewireend.
Peelthepaperbackingoffthetabandcarefullyplacethesolarpanelon
thecarsoitanglesdownfromthemotortothechassis.Thetabshould
restonthemotorandtheotherendofthepanelwillbenearthefrontof
thecar(Figure3).
11)Followingthedirectionsonthecarbodycutout,cutandfoldthecarbody.
12)Withtheblankundersideofthecutoutfacingup,placeanadhesivetabon
thetwotabsthatextendfromthecutout.Practicefoldingthecutoutover
the car so the tab on the wide end is aligned with the car’s back and the
tabonthenarrowendisatthefront.Thecutoutshouldtoverthecarso
the solar panel shows through the hole in the cutout.
13)Whenyouarecomfortablewiththepositioningofthecutout,removethe
backing on the tabs and adhere the cutout to the chassis. Note: You may
needtorepositiontheclipsiftheyarepushingonthecutoutsoitrubs
against the gear or wheels.
14)TakethecompletedSunEzoonCaroutsideonaclear,brightdayandplace
itonasmooth,levelsurface.Ifproperlyconnected,itwilltakeoff.Ifit
runsbackward,switchtheredandblackwiresonthemotorconnection
terminals.
59021 V0808
Solar Panel
Motor in
Motor Mount
Adhesive
Tab
Chassis
Figure 3