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Tzora Easy Travel Elite Service Manual

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Service Manual

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Summary of Contents for Tzora Easy Travel Elite

  • Page 1 Service Manual...
  • Page 2 Easy Travel – Service Manual Rev. 0401...

  • Page 3: Table Of Contents

    Table of contents: 1. System components and details 2. Annual maintenance service 3. Spare parts replacement 4. Programming 5. Fault finding 6. Electrical wiring 7. Charger 8. Spare parts List of Tool Types NOTE: Design details may change without notice Easy Travel –...

  • Page 4: System Components And Details

    SYSTEM COMPONENTS AND DETAILS EasyTravel parts – (Figure 1) 1. Battery pack (detachable) 2. Front column (detachable) 3. Column lock/release triggers 4. Controller cover 5. Charging socket (Fig. 1A) 6. Front drive wheels 7. Foot platform 8. Seat shell 9. Seat cushions 10.

  • Page 5: Annual Maintenance Service

    SERVICE For reasons of safety and the prevention of accidents caused by wear which is not detected in time, the EasyTravel should be tested and serviced once a year. All safety-related components of the EasyTravel should be checked and serviced, safety and 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 manu- facturer.

  • Page 6: Spare Parts Replacement

    SPARE PARTS REPLACEMENT Control Panel Assembly Kit number E0-00-1-040 (for serial # up to and including 0307076) Kit Number E0-00-1-202 (for serial # 0307077 and onwards) Kit Number E0-00-1-701 (for serial # with 13 digits, starting with 11B (Taiwan)) Tools: Phillips #2 Screwdriver For serial # and onwards, see next page.
  • Page 7 Kit Number E0-00-1-202 Kit Number E0-00-1-701 Tools: Phillips #2 Screwdriver 1. Open Screws (5-A) and remove top and bottom Control 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.
  • Page 8 Handgrip pair Kit number E0-00-1-070 Tools: Silicone spray Phillips #2 Screwdriver 1. Remove Control Panel Assembly, see instructions 3.1 2. For serial # up to and including 0307076: open Screws (6-A) remove Control Panel Bottom Cover (6- Figure 6 3. Remove the Handgrips, (7-A) 4.
  • Page 9 Controller Cover ET1B Kit Number E0-00-1-034 Kit Number E0-00-1-705 (for serial # start- ing with 11B) Tools: Phillips #2 Screwdriver 1. Remove Screws (8-A) at the top and bottom of the Controller Cover (8-B) and remove Cover 2. Disconnect Connector (8-C) from Inter- face Circuit Board (8-D) 3.
  • Page 10 Solo Controller ET1B Kit Number E0-00-1-032 Kit Number E0-00-1-704 (for serial # start- ing with 11B) Tools: Short Phillips #2 Screwdriver Pliers 1. Remove Controller Cover, see instruc- tion 3.3 2. Detach wiring from Controller (9-A) 3. Remove Controller (9-A) by unscrewing Screws (9-B) 4.
  • Page 11 Kit Number E0-00-1-704 (for serial # start- ing with 11B) Tools: Short Phillips #2 Screwdriver Pliers 1. Remove Controller Cover, see 3.3 2. Open Screws (10-A), remove Controller Top and plastic protection sheet 3. Detach wiring from Controller 4. Open Screws (10-B) on reverse side of Steering Column and remove Controller 5.
  • Page 12 Battery Contacts Kit number E0-00-1-059 Tools: Phillips #2 Screwdriver 1. Remove Controller Cover, instruction 3.3 2. Disconnect wiring to Controller (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.
  • Page 13 Interface Circuit Board ET1B Kit number E0-00-1-058 Tools: Phillips #1 Screwdriver Phillips #2 Screwdriver 1. Remove Controller Cover, see instruc- tion 3.3 2. Disconnect Control Cable (12-A), Free- wheel Cable (12-B), wiring to Controller (12-C), Contact Pins Assembly (12-D) and to Power Cable (12-E) 3.
  • Page 14 Contacts and Charging Socket Assembly Kit number E0-00-1-703 (for serial # start- ing with 11B) Tools: Phillips #1 Screwdriver Phillips #2 Screwdriver 1. Remove Controller Cover, see instruc- tion 3.3 2. Open Controller, see instruction 3.4 3. Disconnect wiring to Controller and to Power Cable, see instruction 3.4 4.
  • Page 15 Control Cable Kit number E0-00-1-054 Kit Number E0-00-1-702 (for serial # start- ing with 11B) Tools: Phillips #2 Screwdriver 1. Open Control Panel Cover, see instruc- tion 3.1 2. Open Controller Cover, see instruction 3. Disconnect Control Cable from Control Panel (5-C) and Interface Circuit Board (12-A)/Controller (10a-C) 4.
  • Page 16 Motor End Cover ET1B Kit Number E0-00-1-083 (for motor types E0-00-1-036 and E0-00-1-092) Tools: Phillips #2 Screwdriver 1. Unscrew Screw (13-A) and remove Cover (13-B) 2. Note the motor wire routing and main- tain it in position NOTE: If force is needed to fit Cover, check the wire routing and ensure that it will not be pinched 3.
  • Page 17 3.10 Motor Brushes Kit Number E0-00-1-037 (for serial # up to and including 0304599) Tools: Phillips #2 Screwdriver Flat Blade Screwdriver (For EasyTravel with serial number up to and including 0212052: Hot Air Gun (if available) Soldering Iron and Solder) Please refer to Figure 13 1.
  • Page 18 3.11 Power Cable to Motor ET1B Kit Number E0-00-1-056 (for serial # up to and including 0212052) Kit Number E0-00-1-093 (for serial # 0212053 up to 0304599) Kit Number E0-00-1-095 (for serial # 0304600 and onwards) Kit Number E0-00-1-706 (for serial # starting with 11B) Tools: Phillips #2 Screwdriver...
  • Page 19 7. Thread the new Power Cable from the Controller-end into the hole in the Col- umn Frame out of tube and under the Adapter Block, as depicted in Fig. 16 8. Connect the #1/red insulated Wire end to positive/red colored Terminal, the #2/black insulated Wire end to nega- tive/black Terminal, the #3 and green Wire to white Wires from electromag-...
  • Page 20 3.12 Front Wheel Assembly Kit Number E0-00-1-069 Tools: Allen Key 6 mm Loctite Adhesive #242 (1312) Soft Mallet 1. Remove old Cap (18-A), Screw (18-B), Disk (18-C) and Wheel (18-D) 2. Thoroughly clean the threaded hole in the end of the Axle (18-E) of adhesive residue 3.
  • Page 21 3.13 Gear Motor Kit Number E0-00-1-035 (ET1) Kit Number E0-00-1-094 (ET1B) Tools: Phillips #2 Screwdriver Allen Key 5 mm Cable Tie Tensioning Tool Loctite Adhesive #242 (1312) (For serial # up to and including 0212052: Soldering Iron Solder) 1. Remove Front Wheels, see instruction 3.11 2.
  • Page 22 3.14 Adapter Block Assembly Kit Number E0-00-1-038 Kit Number E0-00-1-707 (for serial # starting with 11B) Tools: Allen key 5 mm Allen Key 8 mm Wrench, open end 19 mm Torque Wrench Loctite Adhesive #242 (1312) Light Grease/Lubricant The wheels MAY be removed to facilitate easier access, see instruction 3.11 1.
  • Page 23 9. Remove Screw (22-A) holding Pin (22- 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 (22-A) using a torque wrench, torque to 40 N-m.
  • Page 24 3.15 Upgrade from ET1 to ET1B Kit Number E0-00-1-097 Tools: Phillips #1 Screwdriver Short Phillips #2 Screwdriver Allen Key 5 mm Allen Key 6 mm 1. Remove Screws (23-A) at the top and bottom of the Controller Cover (23-B) and remove Cover 2.
  • Page 25 3.16 Top Bearing for Steering Axis Kit number E0-00-1-067 Tools: Drive Punch Press/Vise/Mallet 1. Remove Adapter Block, see instruction 3.13 and place it so that the bearing is free 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.
  • Page 26 3.17 Column Release Cable Kit Kit Number E0-00-1-080 Tools: Phillips #2 Screwdriver Wrench, open end 8 mm Allen key 3 mm Wire Cutter Pliers Crimp Tool Loctite Adhesive # 496 (3854) Light grease/lubricant 1. Remove Control Panel Cover, see in- struction 3.1 2.
  • Page 27 9. Apply Loctite to Screw (27-N) and se- cure Column Latch Bushing (27-M) with it onto Release Bushing (27-K) 10. Take up the slack in the Cable (27-C) so that the end of the Column Lock Pin (27- A) is flush with the outside of Connect- ing Plate (27-D) 11.
  • Page 28 3.18 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 sure it covers the whole Set Screw (27-P) Easy Travel –...
  • Page 29 3.19 Protector Roller Kit Kit Number E0-00-1-081 Tools: Allen Key 5 mm Loctite Adhesive # 242 (1312) 1. Open Cap Nut (28-A), remove Threaded Rod (28-B) and Roller (28-C) 2. Place the new Roller (28-C) between the two Plates (28-D) and align with holes 3.
  • Page 30 3.20 Column Frame Kit Number E0-00-1-001 (Red ET1) Kit Number E0-00-1-003 (Red ET1B) Kit Number E0-00-1-002 (Blue ET1) Kit Number E0-00-1-004 (Blue ET1B) Kit Number E0-00-1-005 (Silver ET1B) Tools: Phillips #1 Screwdriver Phillips #2 Screwdriver Soldering Iron Allen Key 2 mm Allen Key 5 mm Allen Key 6 mm Pliers...
  • Page 31 3.21 Battery Case / Battery Replacement Kit Number E0-00-1-020 (Normal size) Kit Number E0-00-1-021 (Jumbo size) Tools: Phillips #2 Screwdriver Pliers 1. Remove Screws (30-A) from Battery Case and remove Cover (30-B) 2. Remove Batteries (30-C) from Case and detach Wires (30-D/E) 3.
  • Page 32 3.23 Platform Lock Pin Kit Kit Number E0-00-1-079 (serial # up to and including 0304999) Kit Number E0-00-1-206 (serial # 0305001 and onwards) Tools: Pliers Wrench, open end 8 mm Phillips #2 Screwdriver Allen Key 2 mm Allen Key 4 mm (2x) Cutter Crimp tool Loctite Adhesive #242 (1312)
  • Page 33 c. Take up the slack in the Cable and tighten the first Lock against the Bracket (32-H) d. Push the Spring (31-B) and Lock Pin (31-A) into the Housing (31-D) so that the end of the Pin is flush with the end of the Housing e.
  • Page 34 3.24 Seat Assembly Kit Number E0-00-1-060 (serial # up to and including 0304999) Kit Number E0-00-1-201 (serial # 0305001 and onwards) Tools: Phillips #2 Screwdriver Pliers Cutter Crimp Tool Loctite Adhesive # 242 (1312) 1. Disconnect the Lock Pin Cable from the seat, see instruction 3.22 2.
  • Page 35 3.25 Seat Back Pad Kit Number E0-00-1-061 (up to and includ- ing serial # 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.
  • Page 36 3.26 Seat Bottom Pad Kit Number E0-00-1-062 (up to and includ- ing serial # 0304999) Kit Number E0-00-1-203 (serial # 0305001 and onwards) Tools: Phillips #2 Screwdriver Loctite Adhesive # 242 (1312) For removal and attachment of Seat, refer to Figure 38, but without removing the Lock Pin Cable.
  • Page 37 3.27 Seat Backrest Lock kit Kit Number E0-00-1-063 (up to and includ- ing serial # 0304999) Tools: Phillips #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.
  • Page 38 3.28 Seat Attachment Bracket Kit Number E0-00-1-064 (up to and includ- ing serial # 0304999) Kit Number E0-00-1-204 (serial # 0305001 and onwards) Tools: Phillips #2 Screwdriver Loctite Adhesive # 242 (1312) Refer to Figure 37 1. Remove the two Screws (34-A) holding the Seat (34-D) to the "U"...
  • Page 39 3.29 Footrest Platform Kit Number E0-00-1-077 Tools: Cleaning detergent 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.
  • Page 40 3.30 Folding Lock Pin Kit Kit Number E0-00-1-065 Tools: Circlip pliers 1. Remove the old Pull Ring (39-F), Circlip (39-E) and Washer (39-D). Extract the old Spring (39-A) and old Pin (39-C) from the Pin Housing (39-B) 2. Insert new Spring (39-A) and Pin (39-C) into Pin Housing (39-B) 3.
  • Page 41 3.32 Rear Wheel Assembly Kit Number E0-00-1-068 Tools: Circlip Pliers Screwdriver Soft Mallet Extractor with scratch protection 1. Remove old End Cap (40-C) using a screwdriver. Remove old Circlip (40-B) and Wheel. If needed use an extractor to remove the bearing from the Axle (41) 2.
  • Page 42 3.33 Front Column Paint Protector Clips Kit Number E0-00-1-072 Tools: Screwdriver 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 (42-A) from the Tube (42-B) by prying on the end 3.
  • Page 43 3.34 Flat Cap (front platform) Kit Number E0-00-1-074 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 (43-A) 3. Tap the Cap (43-A) gently into the Tube end (43-B) using a mallet NOTE: Sharp blows will deform the Cap Figure 43...
  • Page 44 3.35 Front Platform Paint Protector Clips Kit number E0-00-1-073 Tools: Screwdriver 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 (44-A) from the Tube (44-B) by prying on the end 3.
  • Page 45 3.36 Domed Caps (Seat Supports) Kit Number E0-00-1-075 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 (45-A) 3. Tap the Cap (45-A) gently into the Tube end (45-B) using a mallet NOTE: Sharp blows will deform the Cap Figure 45...

  • Page 46: Programming

    & Giles electronic controllers. Incorrect programming could result in an unsafe set-up of a vehicle for a user. Tzora Active Systems accepts no liability for losses of any kind if the programming of the controller is altered from factory pre-set values.
  • Page 47 The following table shows the Solo Controller settings for the EasyTravel as defined by Tzora Active Sys- tems. Function Fast Slow Forward Acceleration 2.0 s 2.0 s Forward Deceleration 0.9 s 1.3 s Reverse Acceleration 3.0s 3.0 s Reverse Deceleration 2.5s...

  • Page 48: Fault Finding

    FAULT FINDING Introduction Tzora Active Systems provides for profound training in Fault Finding to the major distributors of the Easy- Travel. Please contact the authorized Tzora Distributor in your country or Tzora for more information. Electrical System 5.2.1. Detecting that a Fault has occurred A fault is signaled by a rapid flashing of the status indicator.

  • Page 49: Electrical Wiring

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

  • Page 50: Charger

    CHARGER Technical data: - 24 Volts, 2Amp Constant Current (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 harming the battery - Size Length: 165 mm (6.5")

  • Page 51: Spare Parts

    SPARE PARTS List of Spare Parts Kits Part Number Description Included in Kit Page E0-00-1-046 E0-00-1-202 Control Panel Assembly – MobiGo Control Panel, Top and Bottom Cover, Screws E0-00-1-701 E0-00-1-070 Handgrip pair E0-00-1-034 Controller Cover ET1B Controller Cover, Screws E0-00-1-705 E0-00-1-032 Controller E0-00-1-704...
  • Page 52 E0-00-1-022 (Normal) Battery Cover – MobiGo Screws E0-00-1-025 (Jumbo) E0-00-1-079 Pin, Spring, Cable, Adjustable Stop, Cable Platform Lock Pin Kit E0-00-1-206 Guide, Cable Locks, End Cone E0-00-1-060 Seat Assembly Seat Bottom + Pad, Seat Back + Pad E0-00-1-201 E0-00-1-061 Seat Back Pad Screws, Washers, Screw Covers E0-00-1-204 E0-00-1-062...
  • Page 53 E0-00-1-706 E0-00-1-058 Interface Circuit Board ET1B E0-00-1-059 Battery Contacts E0-00-1-060 Seat Assembly E0-00-1-201 E0-00-1-061 Seat Back Pad E0-00-1-204 E0-00-1-062 Seat Bottom Pad E0-00-1-203 E0-00-1-063 Seat Backrest Lock E0-00-1-064 Seat Attachment Bracket E0-00-1-204 E0-00-1-065 Folding Lock Pin Kit E0-00-1-066 Ring for Folding Lock E0-00-1-067 Top Bearing for Steering Axis E0-00-1-068...

  • Page 54: List Of Tool Types

    LIST OF TOOL TYPES Screwdrivers: Other Tools Phillips #1 Cable Tie Tensioning Tool Phillips #2 Circlip Pliers (normal) Short Phillips #2 Circlip Pliers (small) Flat Blade Clamps Cleaning detergent Allen Keys: Crimp Tool 2 mm Cutter 3 mm Drive Punch 4 mm Extractor 5 mm...

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