Tzora Easy Travel Elite, Service Manual

Page 1: ...Service Manual...

Page 2: ...Easy Travel Service Manual Rev 0401 2...

Page 3: ...s 1 System components and details 4 2 Annual maintenance service 5 3 Spare parts replacement 6 4 Programming 46 5 Fault finding 48 6 Electrical wiring 49 7 Charger 50 8 Spare parts 51 9 List of Tool T...

Page 4: ...fold ing seat latch 11 Rear wheel 12 Folded frame lock pin 13 Platform bottom lock pin 14 Utility basket holding capacity 9kg 15 Charger and connecting cables Fig 1B 16 Control Panel 17 Freewheel swi...

Page 5: ...wear in time and to use exclusively original spares or such parts that were authorized by the manu facturer Test the following maintenance items The components of the EasyTravel frame for overload an...

Page 6: ...sh Handgrips 4 A outwards 2 Open Screws 4 B and remove Control Panel Cover 4 C 3 Disconnect the Control Cable 4 D 4 Open Screws 4 E and remove Control Panel 4 F 5 Open Screws 4 N and remove Panel Bott...

Page 7: ...ntrol Panel Cover 5 B C 2 Disconnect the Control Cable 5 D 3 Open Screws 5 E and remove Control Panel 5 F 4 Secure new Control Panel 5 F with Screws 5 E 5 Connect the Control Cable 5 D to Con trol Pan...

Page 8: ...6 B 3 Remove the Handgrips 7 A 4 Spray Handlebars 7 B of the Column Frame and inside of the new Handgrips lightly with Silicone Spray and push them onto the Column Frame 5 Reassemble Control Panel Bo...

Page 9: ...ve Cover 2 Disconnect Connector 8 C from Inter face Circuit Board 8 D 3 Check that the solder tabs of the Free wheel Switch on new Cover are bent apart 4 Insert Connector of new Cover 8 C to Interface...

Page 10: ...A by unscrewing Screws 9 B 4 Secure new Controller to Column Frame 5 Attach Wires to Controller Fig 9a from Battery Contacts Assembly the red wire A to B tab B the black C to B tab D from Interface Ci...

Page 11: ...n Frame 6 Attach Wires to Controller Fig 10a a Control Cable C b from Contacts and Charging Socket Assembly i the brown wire to connector B ii the white wire to connector F iii the red wire to B tab t...

Page 12: ...ntroller 11 A and Interface Circuit Board 11 B 3 Unscrew Screws 11 C and remove Battery Contacts Assembly 11 D 4 Secure new Battery Contacts Assembly 11 D with Screws 11 C 5 Connect Wiring 11 A to Con...

Page 13: ...wheel Cable 12 B wiring to Controller 12 C Contact Pins Assembly 12 D and to Power Cable 12 E 3 Unscrew 3 Screws 12 F and remove Interface Circuit Board 12 G 4 Secure new Interface Circuit Board 12 G...

Page 14: ...r see instruction 3 4 3 Disconnect wiring to Controller and to Power Cable see instruction 3 4 4 Unscrew 3 Screws 12a A and two Screws 12a B 5 Remove Contacts and Charging Socket Assembly 12a C and re...

Page 15: ...trol Panel 5 C and Interface Circuit Board 12 A Controller 10a C 4 Remove Control Cable 5 Insert new Control Cable if needed re move the Paint Protector and replace it with a new one after the Control...

Page 16: ...orce is needed to fit Cover check the wire routing and ensure that it will not be pinched 3 Secure new Cover 13 B with Screw 13 A Kit Number E0 00 1 096 for motor type E0 00 1 094 Tools Phillips 2 Scr...

Page 17: ...emove heat shrink insulation and un solder the Brush Fig 15 being re placed 4 Insert the new Brush carefully into its housing and secure with Brush Cap C NOTE Ensure that the Brush is fully in serted...

Page 18: ...1 Fig 16a refers to serial up to and including 0212052 fig 16b refers to serial 0212053 up to 0304599 fig 16c refers to serial 0304600 and onwards 1 Remove the Motor Cover see instruc tion 3 8 for ser...

Page 19: ...m the elec tromagnetic Brake b Secure insulation sleeves in place with hot air gun or soldering iron 9 Secure the Cable to the Motor with Ca ble Ties 16 A and trim ends for serial starting with 11B Pl...

Page 20: ...18 D 2 Thoroughly clean the threaded hole in the end of the Axle 18 E of adhesive residue 3 Slide the Wheel 18 D onto Axle 18 E aligning the groove in the Adapter with the Roll Pin on the Axle 4 Place...

Page 21: ...3 11 2 Remove the Motor End Cover see in struction 3 8 for serial starting with 11B it is not needed to remove Motor End Cover 3 Detach Power Cable from Gear Motor see instruction 3 10 4 Remove the Sc...

Page 22: ...0 E to the Adapter Block 20 F and put Gear Motor aside 3 Remove Nylock Lock Nut 21 A and Screw 21 B 4 Slide Adapter Block 21 C from Column Frame 21 D NOTE Ensure that the Column Release Pin 21 E is wi...

Page 23: ...22 A holding Pin 22 B 10 Remove the Pin from the new Quick Re lease Mechanism apply some Loctite in the thread and position it under the Conical Cap 22 C 11 Secure the Pin 22 B to the Cap with Screw...

Page 24: ...Cable 24 A wiring to Controller Fig 24 B and Contact Pins Assembly 24 C 4 Remove Front Wheel Assembly see instruction 3 11 5 Remove Securing Clip page 21 20 B on the underside of the Adapter Block 6...

Page 25: ...ee to come out of the Pin Housing 26 B 2 Remove the Bearing by tapping it with a Drive Punch alternatively through each one of the holes in the Top Pin Housing Fig 25 A 3 Place the new Bearing 26 A in...

Page 26: ...Lock Pin 27 A and Spring 27 B onto the Column Lock Pin Cable 27 C 5 Thread the Cable through the large hole in Connecting Plate 27 D Column Lock Pin Housing 27 E and the small hole in Connecting Plate...

Page 27: ...L 12 Place the two Set Screws 27 P in the upper threaded holes of the Release Bushing 27 K and slide the two Vinyl Caps 27 Q onto them NOTE do not over tighten the Screws 27 P against the Cable 13 Tr...

Page 28: ...18 Black Vinyl Cap Kit Number E0 00 1 078 Tools Screwdriver and or Pliers Refer to Figure 27 1 Pry Cap 27 Q off with Screwdriver or pair of Pliers be careful not to chip the paint 2 Place new Cap make...

Page 29: ...r 28 C 2 Place the new Roller 28 C between the two Plates 28 D and align with holes 3 Insert Threaded Rod 28 B though the holes and Roller and right hand Plate 4 Apply a drop of Loctite to the Cap Nut...

Page 30: ...sioning Tool The new Column Frame is issued with a Control Cable Power Cable and Column Release Cable 1 Remove from the old Column Frame a Control Panel Assembly see in struction 3 1 b Controller Cove...

Page 31: ...F and black Wire 30 E to negative black marked Tab 30 G NOTE It is recommended to attach first the appropriate Wires to the Battery closest to the base of the Case and then insert it fully into the ca...

Page 32: ...r left hand side of the Seat lock it 2 Cut the Cone End 32 M 33 D from the Cable 31 C and remove Cable 3 Thread the Bottom Lock Pin 31 A and Spring 31 B onto the Bottom Lock Pin Cable 31 C 4 Thread th...

Page 33: ...0 00 1 201 a Insert Cable through Cable Stops 33 A in Cable Holder 33 B ensure that the Cable does not slack and close Cable Stops NOTE Seat Backrest needs to be in an upright position NOTE Keep Cable...

Page 34: ...A holding the Seat 34 D to the U shaped Seat Attachment Bracket 34 B the Sleeves 34 C and Seat 34 D 3 Insert the two frame seat support horns 34 E through the seat holes 34 F 4 Attach the replacement...

Page 35: ...0304999 Kit Number E0 00 1 204 serial 0305001 and onwards Tools Phillips 2 Screwdriver 1 Remove the Screw Covers 35 A 2 Remove the Screws 35 B and Back Pad 35 C 3 Align the tubes 35 D of the Back Pad...

Page 36: ...34 A holding the Seat 34 D to the U shaped Seat Attachment Bracket 34 B and the Sleeves 34 C 2 Remove the Screws 36 A and Bottom Pad 36 B 3 Align the tubes 36 C of the Bottom Pad with the holes in the...

Page 37: ...ips 2 Screwdriver 1 Remove Screw 37 D Washer 37 C Knob 37 B and Stopping Snib 37 A 2 Insert new Stopping Snib 37 A in Seat Bottom 3 Attach Knob 37 B to Stopping Snib and secure it with Washer 37 C and...

Page 38: ...er to Figure 37 1 Remove the two Screws 34 A holding the Seat 34 D to the U shaped Seat Attachment Bracket 34 B and the Sleeves 34 C 2 Remove the Bracket 34 B 3 Attach the new Bracket 34 B to Seat 34...

Page 39: ...Clamps 1 Remove old Platform 38 A and any remainders of Adhesive Tape 2 Clean Frame surface 38 B with a de tergent and wipe dry with a clean cloth 3 Remove protective film from Tape sec tions 38 C 4 S...

Page 40: ...ly pressure to the end of the Pin so that it projects through the Pin Housing place Washer 39 D and fit Circlip 39 E into its groove at the end of the Pin 4 Insert the Pull Ring 39 F into the hole in...

Page 41: ...d Circlip 40 B and Wheel If needed use an extractor to remove the bearing from the Axle 41 2 Place new Wheel 40 A on Axle of Rear Frame 40 D 3 Fit new Circlip 40 B into its groove at the end of the Ax...

Page 42: ...tape or electrical tape to pre vent paint damage 2 Remove the old Clip 42 A from the Tube 42 B by prying on the end 3 Align the new Clip s slotted stud with the hole in the Tube Tap it into place usi...

Page 43: ...074 Tools Screwdriver and or Pliers Soft Mallet 1 Cover the flat tip of a screwdriver with masking tape or electrical tape to pre vent paint damage 2 Remove the old Cap 43 A 3 Tap the Cap 43 A gently...

Page 44: ...t Mallet 1 Cover the flat tip of a screwdriver with masking tape or electrical tape to pre vent paint damage 2 Remove the old Clip 44 A from the Tube 44 B by prying on the end 3 Align the new Clip s s...

Page 45: ...gently into the Tube end 45 B using a mallet NOTE Sharp blows will deform the Cap 3 37 Rear Frame Paint Protector Clips Kit number E0 00 1 071 Tools Screwdriver Soft Mallet 1 Cover the flat tip of a...

Page 46: ...nd allows different settings to be tried out while the programmer is still plugged into the controller A context sensitive help function is available to guide users through the menus and the SP1b can...

Page 47: ...Hold Factor 152 Mid Current 50 10 s Brake Time 0 1s ISO Tests Off Inhibit Polarity Lo Bridge Hold Time 200 ms Throttle Gain 750 Pulse Reverse Alarm No Wig wag Throttle Yes Low Battery Flash Inhibit No...

Page 48: ...t is possible for the controller to indicate a fault in another component even though the controller itself is at fault Nevertheless experience has shown that connectors and wiring are the major cause...

Page 49: ...Easy Travel Service Manual Rev 0401 49 Figure 48 6 CONTROL CONNECTIONS AND ELECTRICAL WIRING For more information please contact your authorized Tzora Distributor or Tzora Active Systems...

Page 50: ...equivalent to 3A tapered charger in charging time Universal Input 100VAC to 240VAC Suitable anywhere in the world Automatic Cut off and then true Float Can be left connected indefinitely without harmi...

Page 51: ...00 1 069 Front Wheel Assembly Front Wheel Allen Screw Washer Flat Cap 20 E0 00 1 035 Gear Motor ET1 21 E0 00 1 094 E0 00 1 708 Gear Motor ET1B 21 E0 00 1 038 E0 00 1 707 Adapter Block Assembly Adapter...

Page 52: ...bly Rear Wheel Circlip End Cap 41 E0 00 1 072 Front Column Paint Protector Clips Full Circle Clip Full Circle Clip with Notch 42 E0 00 1 074 Flat Cap Front Platform 2 Caps 43 E0 00 1 073 Front Platfor...

Page 53: ...00 1 071 Rear Frame Paint Protector Clips 45 E0 00 1 072 Front Column Paint Protector Clips 42 E0 00 1 073 Front Platform Paint Protector Clips 44 E0 00 1 074 Flat Cap Front Platform 43 E0 00 1 075 D...

Page 54: ...Extractor 5 mm Hot Air Gun 6 mm Light Grease Lubricant 8 mm Pliers Press Vise Mallet Wrenches Silicone Spray Open End 8 mm Soft Mallet Open End 14 mm Solder Open End 19 mm Soldering Iron Torque wrench...