Easy Travel Elite, Service Manual

Page 1: ...Elite Service Manual...

Page 2: ...EasyTravel Elite ET1E Service Manual Rev 0404 2...

Page 3: ...ntents 1 System components and details 5 2 Annual maintenance service 6 3 Spare parts replacement 7 4 Programming 52 5 Fault finding 54 6 Electrical wiring 55 7 Charger 56 8 Spare parts 57 9 List of T...

Page 4: ...EasyTravel Elite ET1E Service Manual Rev 0404 4...

Page 5: ...shions 10 Foldable Armrests 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 Freewh...

Page 6: ...nd functional tests should be performed It is important to detect initial wear in time and to use exclusively original spares or such parts that were authorized by the manufacturer Test the following...

Page 7: ...ve top and bottom Control Panel Cover 3 B C 2 Disconnect the Control Cable 3 D 3 Open Screws 3 E and remove Control Panel 3 F 4 Secure new Control Panel 3 F with Screws 3 E 5 Connect the Control Cable...

Page 8: ...andlebars 4 B of the Column Frame and inside of the new Handgrips lightly with Silicone Spray and push them onto the Column Frame 4 Reassemble Control Panel Bottom Cover and Control Panel Assembly 5 P...

Page 9: ...nnector 5 C from Inter face Circuit Board 5 D 3 Check that the solder tabs of the Free wheel Switch on new Cover are bent apart 4 Insert Connector of new Cover 5 C to Interface Circuit Board 5 Secure...

Page 10: ...roller Cover see instruc tion 3 3 2 Detach wiring from Controller 6a A 3 Remove Controller 6a A by unscrew ing Screws 6a B 4 Secure new Controller to Column Frame 5 Attach Wires to Controller Fig 6b f...

Page 11: ...Remove Controller 7a A by unscrew ing Screws 7a B 4 Secure new Controller to Column Frame with Screws 7b A 5 Attach Wires to Controller from Battery Contacts Assembly E the red wire to B tab the black...

Page 12: ...ng to Controller 8 A and Interface Circuit Board 8 B 3 Unscrew Screws 8 C and remove Bat tery Contacts Assembly 8 D 4 Secure new Battery Contacts Assembly 8 D with Screws 8 C 5 Connect Wiring 8 A to C...

Page 13: ...9a D 3 Unscrew 3 Screws 9a E and remove Interface Circuit Board 9a F 4 Secure new Interface Circuit Board 9a F with Screws 9a E 5 Connect Control Cable 9a A wiring to Controller 9a B Contact Pins Ass...

Page 14: ...nel 3 C and Interface Circuit Board 9 A 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 Cable is inserted see in...

Page 15: ...Frame out of tube and inside the Fork Assembly as shown in Fig 10 7 Connect the 1 red insulated Wire end to positive red colored Terminal the 2 black insulated Wire end to nega tive black Terminal the...

Page 16: ...h Power Cable 12 C from Hub Motor 12 E 4 Remove the Screws 12 D securing the Hub Motor to the Fork Assembly 5 Apply Loctite to the Screws 12 D and secure with them the new Hub Motor 12 E to the Fork A...

Page 17: ...13 D NOTE Ensure that the Column Release Pin 13 E is withdrawn before removing and replacing the Adapter Block 4 Slide new Fork Assembly 13 C in the Column Frame 5 Insert Screw 13 B and secure it wit...

Page 18: ...lumn Lock Pin 15 A and Spring 15 B onto the Column Lock Pin Cable 15 C 5 Thread the Cable through the large hole in Connecting Plate 15 D Column Lock Pin Housing 15 E and the small hole in Connecting...

Page 19: ...ks 15 L 12 Place the two Set Screws 15 P in the upper threaded holes of the Release Bushing 15 K and slide the two Vinyl Caps 15 Q onto them NOTE do not over tighten the Screws 15 P against the Cable...

Page 20: ...Roller 16 C 2 Place the new Roller 16 C between the two Plates 16 D and align with holes 3 Insert Threaded Rod 16 B though the holes and Roller and right hand Plate 4 Apply a drop of Loctite to the Ca...

Page 21: ...21 3 13 Black Vinyl Cap Kit Number E0 00 1 078 Tools Screwdriver and or Pliers Refer to Figure 16 1 Pry Cap 16 Q off with Screwdriver or pair of Pliers be careful not to chip the paint 2 Place new Cap...

Page 22: ...ning 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 Cover a...

Page 23: ...and detach Wires 18 D E 3 Place Batteries in new Case H and attach red Wire 18 D to positive red marked Tab 18 F and black Wire 18 E to negative black marked Tab 18 G NOTE It is recommended to attach...

Page 24: ...nual Rev 0404 24 3 16 Battery Cover Kit Number E0 00 1 022 Normal size Kit Number E0 00 1 025 Jumbo size Tools Phillips 2 Screwdriver 1 Remove Screws 18 A and Battery Cover 18 B 2 Secure new Cover 18...

Page 25: ...thread is still visible and tighten it 6 Thread the Cable Guide 19 F onto the Cable and thread it through the Cable Sleeves 19 G 7 Insert Cable 20 C through Cable Stops 20 A in Cable Holder 20 B ensu...

Page 26: ...isconnect the Lock Pin Cable from the seat see instruction 3 17 2 Remove Screws 21 A and Seat At tachment Brackets 21 B 3 Insert the two frame seat support horns 21 D through the seat holes 21 E 4 Att...

Page 27: ...t Number E0 00 1 204 Tools Phillips 2 Screwdriver 1 Remove the Screw Covers 22 A 2 Remove the Screws 22 B and Back Pad 22 C 3 Align the tubes 22 D of the Back Pad with the holes in the Seat Back 22 E...

Page 28: ...tom Pad Kit Number E0 00 1 203 Tools Phillips 2 Screwdriver Loctite Adhesive 242 1312 1 Remove the Screws 23 A and Bottom Pad 23 B 2 Align the tubes 23 C of the Bottom Pad with the holes in the Seat B...

Page 29: ...s 21 A holding the Seat 21 D to the U shaped Seat Attachment Bracket 21 B and the Sleeves 21 C 2 Remove the Bracket 21 B 3 Attach the new Bracket 21 B to Seat 21 C Place the Sleeves 21 C be tween the...

Page 30: ...gent Clamps 1 Remove old Platform 24 A and any remainders of Adhesive Tape 2 Clean Frame surface 24 B with a de tergent and wipe dry with a clean cloth 3 Remove protective film from Tape sec tions 24...

Page 31: ...rom the Pin Housing 25 B 2 Insert new Spring 25 A and Pin 25 C into Pin Housing 25 B 3 Apply pressure to the end of the Pin so that it projects through the Pin Housing place Washer 25 D and fit Circli...

Page 32: ...l Elite ET1E Service Manual Rev 0404 32 3 24 Ring for folding lock Kit Number E0 00 1 066 Refer to Figure 25 1 Remove old Pull Ring from the Pin 2 Insert the Pull Ring 25 F into the hole in the end of...

Page 33: ...ve old Circlip 26 B and Wheel If needed use an extractor to remove the bearing from the Axle 27 2 Place new Wheel 26 A on Axle of Rear Frame 26 D 3 Fit new Circlip 26 B into its groove at the end of t...

Page 34: ...sking tape or electrical tape to pre vent paint damage 2 Remove the old Clip 28 A from the Tube 28 B by prying on the end 3 Align the new Clip s slotted stud with the hole in the Tube Tap it into plac...

Page 35: ...00 1 074 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 29 A 3 Tap the Cap 29 A g...

Page 36: ...r 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 Clip 30 A from the Tube 30 B by prying on the end 3 Align the new Cli...

Page 37: ...0 00 1 075 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 31 A 3 Tap the Cap 31 A...

Page 38: ...rewdriver 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 clip 32 A from the Tube 32 B 3 Align the new Clip s slotted s...

Page 39: ...s tics and 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 S...

Page 40: ...n 200m 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 Inh...

Page 41: ...cure 5 Flashes Not used 10 Flashes An excessive voltage has been ap plies to the controller This is usually caused by a poor battery connection Check the battery connections 5 2 2 Fault Diagnosis usin...

Page 42: ...EasyTravel Elite ET1E Service Manual Rev 0404 42 Figure 34 6 CONTROL CONNECTIONS AND ELECTRICAL WIRING For more information please contact your authorized Tzora Distributor or Tzora Active Systems...

Page 43: ...rent 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...

Page 44: ...l Cap 21 E0 00 1 210 Silver Column Frame Handgrip pair Column Release Cable Paint Protector Clips Protector Roller Control Ca ble Power Cable 22 E0 00 1 020 Normal E0 00 1 021 Jumbo Battery Case Elect...

Page 45: ...E0 00 1 070 Handgrip pair 8 E0 00 1 071 Rear Frame Paint Protector Clips 38 E0 00 1 072 Front Column Paint Protector Clips 34 E0 00 1 073 Front Platform Paint Protector Clips 36 E0 00 1 074 Flat Cap...

Page 46: ...m Drive Punch 4 mm Extractor 5 mm Light Grease Lubricant 6 mm Pliers 8 mm Press Vise Mallet Silicone Spray Wrenches Soft Mallet Open End 8 mm Open End 14 mm Loctites Open End 19 mm 242 1312 Torque wre...