685E-03

MODEL:JS-685E

EK JAPAN CO.,LTD. 2001

Keep the Instruction Manual ready at hand for use at any time.

SUPER SOLAR CAR

Lot.No.

2

Contents

・Product Information

1. Necessary Tools ••••••••••••••••••••••••••••••••••••••••••••••••••••

2. Before Assembly •••••••••••••••••••••••••••••••••••••••••••••••••••

3. Parts List •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

4. Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

5. Let’s Operate! •••••••••••••••••••••••••••••••••••••••••••••••••••••••

6. Operation Check •••••••••••••••••••••••••••••••••••••••••••••••••••

7. Solar Battery ••••••••••••••••••••••••••••••••••••••••••••••••••••••••

8. Spare Parts List •••••••••••••••••••••••••••••••••••••••••••••••••••••

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PRECAUTION

◆R ead this instruction manual carefully before getting started. Have your par-

ents or someone who can help you read the instruction manual with you.

Keep this instruction manual for future reference.

◆B e careful when handling the tools such as a penknife and a diagonal cutter.

◆Handle the small and sharp parts carefully.

◆K eep the product out of reach of small children. Do not assemble the product

where small children can reach and touch it. They may get injured or put the

parts / small vinyl bags into their mouth. Immediately dispose of the packaging

materials and the left over parts sensibly.

◆D o not short-circuit the printed circuit board, electronic parts, or power supply

terminals. It will result in overheating of the parts and batteries, causing injury

and fire.

◆D o not insert the wires into socket outlets. It will cause damage and injury.

◆K eep fingers out of the moving sections, such as wheels, legs, gears and

motor shafts.

◆D o not hinder the movement of moving sections by force. Remove the hin-

drances in the moving sections, such as a piece of thread, before operating.

Otherwise, the motor will overheat, causing injury and fire.

◆The specifications and forms of this product are subject to change without

prior notice

3

●Product Information・T he SUPER SOLAR CAR, with its high and low gear mechanisms, is suit-

able for use even in winter.

・T he angle and direction of the solar battery is adjustable, which are the im-

portant factors to decide the amount of power generation.

・U nique front wheel drive style. The steering mechanism will make turning

movement possible.

・T he front wheel, rear wheel and solar battery sections are separately at-

tachable to the body. If you attach them on your favorite material, such as a

plastic bottle, you can make your original solar car. The kit includes a clear

plastic body.

・T he energy source will be chosen from solar and "AA" battery with a switch

lever.

(A battery is not included.)

SpecificationsPower Source:

① Solar Battery

Output Power / 1.4V-350mA(MAX)

Size / 61×110mm

②Dry Cell Battery

“AA”Battery (1.5V)× 1pc

〔Not included〕Body Size:

Height / Approx. 45mm

Length / Approx. 225mm

Width / Approx. 145mm

DC Motor (Rated Load:4g.cm):

Rated Voltage / 1.9V

Rated Ampere / 145mA

NOTE: The CAR may not operate in shady places, dim sunlight and on cloudy

days. It also will not operate under fluorescent lighting; the fluorescent

light is different in quality from sunlight. When using a candescent lamp, put

the lamp near the solar battery in order for the car to run effectively.

4

1. Necessary Tools

Scissors

Electrical / Plastic TapePen Knife

Small Hammer

“AA”Alkaline Battery(not included)

1 pc

Used for cutting adhesive double coat-ed tapes and processing body parts. Used for driving the gear onto the motor.

Used for stripping the vinyl insulation offthe wire.

Used for taping exposed wires and forholding wires in place.

Use the following instructions if you would like to paint the body:

2. Before Assembly

1. Paint body first and complete assembly process

second.

2. Before painting, wash the plastic body gently with a

detergent and then dry completely.

3. Body part is made of plastic(P.V.C).Use color paints

compatible with plastic models.

4. For graphic designs (writing or drawing) on body,

use an oil based (enamel) marker.

5

CAUTION

◆Pay attention to the following instructions for the use of batteries.

1. Place the batteries in the correct polarity (+ & -).

2. Never short-circuit, dismantle, heat the batteries, or dispose of

them in a fire. They may leak or explode and cause injury.

3. When you finish playing, remove the battery. Exhausted batter-

ies are to be removed from the product.

4. Do not wet the batteries or battery holder. If they get wet, remove

the batteries from the holder and wipe them off thoroughly.

5. Do not mix old and new batteries. Do not mix alkaline, standard

(carbon-zinc) or rechargeable (nickel-cadmium) batteries. Do not

use the rechargeable batteries. Use only the batteries of the

same types as recommended.

※ Please carefully follow the instructions supplied by paint manufacture.

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3. Parts ListCheck each box to confirm that all parts are enclosed.

□Front wheel (without a gear)

1pc

□Front tires

2pcs

□Gear-mounted front wheel 1pc □Rear tires 2 pcs

□Rear wheels

2 pcs

□Wheel stoppers

2 pcs

□Solar battery pedestals

2 pcs

□Drive shaft stopper

1 pc

□Solar battery support

1 pc

□Switch lever

1 pc

□Motor cover 1 pc □Power panel 1 pc □Power chassis 1 pc

□Rear chassis 1 pc □Motor 1 pc

□Flat spur gear (24cogs)

with pinion (12 cogs) 1 pc

□Metal shaft 1 pc

□SOLAR CAR body 1 pc

□A dhesive double

sided tape 1 pc

□Red wire 1 pc

□Black wire 1 pc

□Battery box 1 pc

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□Solar battery 1 pc

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4. Assembly1. Assembling the rear wheels

Assemble the rear wheels in order of steps ① to ② .

When removing thewheels, hold this sec-tion firmly and carefullyremove the wheels toavoid breaking the rearchassis.

After assembling the rear wheels,

check to see whether the wheels

spin freely. If they do not spin

easily, pull and push on the

wheels with the stoppers attached

to loosen the wheels.

Illustration of the completed rear unit

Wheel stopperRear tire

Rear wheelRear chassis

① Attach the rear tires onto the

rear wheels.

Wheel stopper

Rear wheel

Rear tire

Shaft

Shaft

② Insert the assembled wheels

onto the shafts on the rear

chassis, then attach the wheel

stoppers.

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2. Attaching the front wheels and the motor

Illustration of thecompleted frontwheels

1) Assemble the front wheels by following steps ① and ② .

Front wheel (without a gear)

Front tire

Front tire

Gear-mountedfront wheel

Metal shaft

① Attach the front tires to the gear-mounted

front wheel and the other front wheel with-

out a mounted gear.

② Insert the wheels, which

are fabricated in step ①,

onto the metal shaft.

1 Gently tap the shaft into

one of the front wheel.

2 Next, gently tap the other

front wheel onto the shaft as

illustrated.

IncorrectCorrect

Be sure to stand the metal shaft vertically and tap. When the

shaft is not tapped vertically the wheel might break or crack.

Gently tap themetal shaft witha small hammer

Stand the metalshaft vertically

Metal shaft

Front wheel(without a gear)

Gently tap thewheel onto theshaft with asmall hammer

Stand the metalshaft vertically

Metal shaftGear-mount-ed front wheel

Incorrect tapping

causes a break

or a crack of this

part.

2) Attach the motor as shown.

Run the motor wirethrough this cut-out.

*Align the hole made in the middle of the motor with the projected

part provided on the reverse side of the power panel.

Power panel

Motor

Motor cover

IMPORTANT

Gently tap in the front wheels, so that the wheel assembly come to

match the wheel width as illustrated. The distance illustrated is the actu-

al size of the wheel assembly.

If the assembly is too wide, the gears may not engage well , and will not

operate correctly.

Actual size

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3) Attach the flat spur gear with pinion as below. (Set the gear by selecting either low-speed or high-speed rotation.)

*Carefully see the illustration when fitting the flat spur gear with pinion, because the fitting

direction of the flat gear is different between “ L” and “ H ” (face and reverse) rotations.

Fit the flat spur gear with pinion intothe boss which has an “H” marking.*Setting the flat gear to the high-speedrotation will decrease the power of run-ning, but the speed will rise. So thehigh-speed would be better to use onclear and strong-sunlight summerdays, when generating capacity of thesolar battery is increased.

When setting the high-speed rotation

Attach the flat spur gear with pinion tothe boss which has an “L” marking.*Setting the flat gear to the low-speedrotation will slow down the speed ofrunning, but the power will be in-creased. So the low-speed would be abetter selection to run the CAR oncloudy and weak-sunlight winter days.

When setting the low-speed rotation

4) Mount the power chassis in order of steps ① to ③.

Mounting would be easier if the

power panel was opened a little

as shown below.

② Insert the power

panel projected

part (rear) into

the curved

opening in the

power chassis.

※ Note position of gear※ Note position of gear

③ Insert the power

panel projected part

(front) and the boss

on the bottom into

the opening and the

round hole of the

power chassis.

*Recheck the fit-tings to see if allthe parts havebeen properly seat-ed in place.

① Run the motor wire

through this hole.

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5) Mount the front wheel in order of ① to ②.

Drive shaft stopper*Watch the orientation when insert-ing.

*Align the gear-mounted front wheel, so that it engages the spur gear

on the motor

Illustration of the completed front wheel unit

① Insert the front wheel

shaft into the groove.

② Insert the drive shaft

stopper as shown.

Front wheel

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3. Wiring

1)Routing the wire to the switch lever

Motor wire (red)

Switch lever

*Make sure not to wire theswitch lever the wrong way.The lever has a face and areverse.

Put the wire through the twoholes in the switch lever, thentwist the exposed wires together.

2 cm (Approx. 3/4”)

Also remove the insula-tion from both red andwhite (or black) wire.

② After removing, twist the stripped

wire.

① Remove the insulation on themotor wire approx. 3/4”more.

2)Routing the wire to the front wheel unit

Red wire (Loose)

Battery boxwire (red /+)

*Twist the stripped wire.

BATT sideSOLAR side

From the bat-tery box (red)

From the solarbattery (LooseRed wire)

To the terminal (+) of the solarbattery

Illustration seenfrom the side

Illustration seen fromthe side

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4) Combining the wires

Motor wire (white or black)

Combine the exposed ends of the three wires (white / black motor wires,black battery box wire and the loose black wire) by twisting them together,then completely tape the exposed wires with electrical tape together.

Motor wire(white or black )

Loose black wire

To the solar bat-tery terminal (+)

To the solar bat-tery terminal (-)

Red wire

Battery box wire (red / +)

Motor wire (red)

Battery box wire (black / -)

4. Wiring diagram

3) Attaching the switch lever

Loose black wire

Battery box wire (black / -)

Solar Battery

Battery Box

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5. Attachment of the front and rear wheels to the body

Stick the front and rear wheel units

to the inside of the body by using

the double sided adhesive tape.

*Carefully align the unitas illustrated. Then, at-tach the unit to the bodywith the double sidedadhesive tape.

Insert the Red and Black loosewires through this hole.

●P ositions at which to stick theadhesive double sided tape

●T he illustration below showsthe correct attachment of thewheel units.

Cut the tape to an ap-propriate size for use.

Position to stick thefront wheel unit

Position to stick the rearwheel unit

*Be careful not to allow the tires to touch the body.

*Be careful not to let theadhesive tape touch thebosses.

Bosses

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7. Attaching the solar battery

1) Assemble thebattery standas shown.

2) Attach the solar battery as shown.

Solar battery

*Cut the tape to an appro-priate size.

Solar battery pedestal

Solar bat-tery sup-port

*Attach the bat-tery in the center.

3) Wire the battery stand as shown.Solar battery (+) side

Red wire

Solar battery (-) side

Black wire

Route the wire coming out ofthe body as illustrated below.

6. Attaching the battery box

Attach the battery box at this

position, using an adhesive

double sided tape.

Adhesive double sided

Solar bat-terypedestal

1.Loosen the nut(s)

2.Rotate and expose the terminal(s)

3.Tighten the nut(s)

Nut

Backside

Terminal

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4) Wire the black and red wire onto the solar battery as shown.

As in the illustration, wire the black and red wire into theterminal metal fitting provided on the solar battery.

Twist it many times, so thatthe wire will not come loose.

Make sure to tighten up the nut.Otherwise it will not operate.

Solar battery terminal (＋) → Red wire

Solar battery terminal (−) →�Black wire

*Tape the excess wiresto the inside surface ofthe body to keep thewires from interferingwith the movements.

5) Attach the solar bat-tery unit to the bodyas shown.

*Cut the tape toan appropriatesize to use.

Stick the tape here.

Completed Sketch

Adhesive doublesided tape

5. Let’s Operate!

ATTENTION

●Before operating the CAR, check again for incorrect wiring and attachment of

parts. Errors in wiring and attaching the parts may lead to malfunction of the

CAR.

●N ote that the CAR will not run on the cloudy days or in the shaded

places, or under the light of a fluorescent lamp, which has a different

light from that of the sun. Under the light of the candescent lamp, the

CAR can run if the lamp is placed near the solar battery.

●I f the CAR does not run, check again for any incorrect wiring or

whether parts are fitted in wrong locations or directions.

●D o not to allow the CAR to get wet. Failure to prevent this may

cause the unit to become inoperative.

●D o not use or keep the CAR in dusty places or where temperature fluc-

tuates too high and low. Failure to do so may result in malfunction.

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※ How to install the battery.

Install 1pc of “AA” alkaline battery in a battery box, observingcorrect polarity (＋ and − ).

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Solar cell batterymode

1) Turn on the switch.

Rotate the switch to-ward SOLAR or BATT.

2) Adjust the angle sothe sunlight shinesonto the solar bat-tery at right angles.

1. How to operate the CAR

“AA” battery mode

Solarbattery mode

“AA” battery mode

3) Place the CAR on the ground and operate it.

*The front wheels can turn right and left (steering mechanism). This

mechanism is used to cause the CAR to run in a circle.

With the switch lever properly fitted,

turning the lever toward the SOLAR

side sets the CAR ready for running by

the solar battery. Turning the lever to-

ward the BATT side sets the CAR ready

for running by the battery. In the battery

position, you can run the CAR even in

dark areas.

Incorrect

Correct

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2. Ideas to custom build your CAR

How to raise or lower the body.◆T here are two ways to attach the wheels as shown below. (The illustra-

tions below show the side views of the front and the rear wheel units.)

To raise the body level

To lower the body level

Car body

Car body

You can create your own original SOLAR

CAR by sticking the front-rear wheel units

and solar battery unit to a plastic soda

bottle as shown.

◆To make a car body smaller

Attach the rearwheel here andfasten it with awheel stopper.

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6. Operation Check

The CAR be-

comes inopera-

tive when fitted to

the body.

The CAR does

not move on

cloudy days.

Check whether the tires are touching the body.

The CAR runs

backward.

Check whether the sunlight is sufficiently falling on the

solar battery. When the weather turns cloudy, the sun-

light becomes weak, the lowering generating capacity of

the solar battery, as a result causing the motor power to

weaken.

In some cases, setting the gear to a low speed can often

run the CAR.

Check if the solar battery is correctly wired in connec-

tion with the terminals (+) and (-). Check also that the

motor wiring is correct.

Check that the front wheels are securely pushed into the

metal shaft. Go back to page 9 recheck steps 1) “Assem-

ble the front wheels by following step ① and ② ”.

Recheck the spacing of the wheels on the shaft.

Check that the switch is turned on. If not, turn the switch

lever toward the SOLAR.

Check that the gear is correctly fitted. Note that the di-

rection is different in setting the gears between low

speed and high speed rotations. Go back to page 11

recheck step 3) “Attach the flat spur gear with pinion as

below.”

Check the polarity of the battery (+,-).

Check all wirings are correct.

Check if a new battery is used.

(Use “AA” Alkaline battery.)

The CAR does

not move out-

doors even on a

sunny day.

The gears do not

engage.

The CAR does

not move on “AA”

battery mode.

7. Solar battery●Mechanism of the solar battery

The solar battery is made from materials called semiconductors (silicon, ger-

manium, etc.). This battery has characteristics that electricity flows when a

light falls on the battery. There are three types of semiconductors which are,

a little different in their properties, respectively called p-type semiconductor,

intrinsic semiconductor and n-type semiconductor. The solar battery is made

up of layers of these three semiconductors. Each is a very thin layer.

In the intrinsic semiconductors, electrons are properly arranged in the holes

(hollow places without electrons staying in). P-type semiconductors have a

larger number of holes than electrons, while N-type semiconductors have

more electrons than holes.

Then, let’s see how electricity is generated in the solar battery when it re-

ceives a light on its surface.

P-typesemiconductors

Intrinsicsemiconductors

N-typesemiconductors

Electron hole

Electron

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(2) The electron, which has jumped

out of the intrinsic semiconductor,

is pulled toward the n-type semi-

conductor. The electron then dri-

ves an electron out of the n-type

semiconductor and creeps into the

hole. And into the hole which has

been left empty in the intrinsic

semiconductor, an electron jump

from the p-type semiconductor.

With this repetition, more holes are

added to the p-type semiconductor,

and more electrons are added to

the n-type semiconductor.

(3) When the n-type semiconductor

is connected by a conductor

with the p-type semiconductor,

electrons accumulated in the n-

type semiconductor move to the

p-type semiconductor through

the conductor. In other words,

electricity has run. (This means

that electrons have run from a

minus electrode to a plus elec-

trode.)

In this way, the solar battery con-

tinues flowing electricity as long as

it is exposed to the light.

Conduc-tor

(1) When the battery receives a light

energy, an electron jumps out of

the intrinsic semiconductor, leaving

a hole behind.

P-typesemiconductors

Intrinsicsemiconductors

N-typesemiconductors

Electronhole

Electron

P-typesemiconductors

Intrinsicsemiconductors

N-typesemiconductors

Electronhole

Electron

P-typesemiconductors

Intrinsicsemiconductors

N-typesemiconductors

Electron hole

Electron

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●Characteristics of the solar battery

A silicon solar battery receives a light on its cell surface and takes out elec-

tricity from the lead provided on the electrodes mounted respectively on the

face and reverse. Irradiation of the light is called “ input of the light ”, while

electric output that can be taken out is simply named “ output . ” When the

sunlight strikes the cell at right angles, the highest output can be obtained.

In the solar battery, output electric power becomes almost directly proportion-

al to the area. (Example: Assuming that a panel having an area of 1m2 can

obtain an electric power of 100W, and when the panel has an area of 10m2,

the formula will be 100(W)x10(m2)=1000(W).

And if the weather is cloudy, the power would drop to 1/2 or 1/3 and on a

rainy day it would be further reduced to 1/5 or 1/10. With the solar battery

fixed at a position, the power will fall in the morning and evening due to the

sunrise and sunset, and to zero at night.

●Advantages of the solar battery

・S ince the energy source for this battery is the sunlight, it is free of charge

and infinite.

・D ifferent from other powers, such as wind power, solar battery has no me-

chanical moving units and it is quiet during operation.

・Service life is long.

・ It is safe to use the Solar battery even in the cities and crowded area.

・T he battery is free from discharging wastes which deteriorate environ-

ments.

・Electricity can be generated and consumed at the same time.

●Disadvantages of the solar

・Output varies with every change of weather and time, and also with sea-

sons and temperatures.

・B ecause of these facts, it is necessary to install a unit to accumulate elec-

tricity if a constant output is desired.

・Output is small per unit area and energy conversion efficiency is low.

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Part No. Description

4010135 Solar battery

4210191 Red wire

4210207 Black wire

4510314 Metal shaft

4600022 Pinion gear (10 cogs)

4600176 Flat spur gear (24cogs)

with pinion (12cogs)

4610519 Adhesive double sided tape

4610588 Motor

4000099 Battery box

4701156 Power chassis

4701163 Power panel

4701170 Motor cover

4701187 Gear-mounted front wheel

4701194 Front wheel(without a gear)

4701200 Switch lever

4701217 Rear chassis

4701224 Drive shaft stopper

4701231 Solar battery support

4701248 Rear wheel

4701255 Wheel stopper

4701262 Solar battery pedestal

4701279 Front tire

4701286 Rear tire

4710370 SOLAR CAR body

7003790 Instruction Manual JS-685E

Model: JS-685E

25

When ordering parts, please include the

following:

1. Name, address and phone number.

2. Model name and Model number.

3. Part number, description, and quantity.

8. Spare Parts List

NOTICE①�MOVIT and ELEKIT are registered trademarks of EK Japan Co.,Ltd.②�All rights reserved. Reprinting any of this instruction manual without

our permission is forbidden.③�The specifications, form, and contents of this product are subject to

change without prior notice.④�We do not accept any responsibility for disadvantage or damage

caused by improper use or assembly.

EK Japan Co.,Ltd.FUKUOKA, JAPAN.

Manufactured by

Recycled paper is used for this instruction manual.