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Easy Travel Elite Service Manual

Easytravel elite – et1e
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Elite
Service Manual

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Summary of Contents for Easy Travel Elite

  • Page 1 Elite Service Manual...
  • Page 2 EasyTravel Elite – ET1E – Service Manual Rev. 0404...

  • Page 3: Table Of Contents

    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 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 4 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 5 5. From serial # and onwards: Bat- tery Level Indicator 6. Hand-grips BELL: If the user requires an audible warn- ing device, a standard bicycle bell can be attached to the handlebar. EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 6 EasyTravel Elite should be tested and serviced once a year. All safety-related components of the Easy- Travel Elite 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 manufacturer.

  • Page 7: Spare Parts Replacement

    Panel (3-F) 6. Secure top and bottom Control Panel Cover (3-B, C) with Screws (3-A) 7. Check all Control Panel functions: indi- cation, drive, brake and speed control Figure 3 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 8 NOTE: Check that Handgrips do not slide off of Covers easily – this can cause a safety hazard if control lever gets caught under Handgrip edge. Remove excess silicon if needed. EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 9 NOTE: Ensure that the Power Cable is routed under the Controller (see Figure 10) and that it will not be pinched when closing and securing the Cover 6. Check drive, brake and freewheel op- eration Figure 5 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 10 Power Cable the #1 wire to “M+” tab (H), the #2 to “M-“ tab (J) 6. Secure Controller Cover to Column Frame 7. Check drive, brake and freewheel op- eration Figure 6b EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 11 6. Secure Controller Cover to Column Frame, ensure that no wires will be pinched or damaged by the Cover or the Screws 7. Check drive, brake and freewheel op- eration Figure 7b EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 12 “B+” tab, black to “B-“ tab), Connector (8-B) onto Interface Circuit Board 6. Reassemble Controller Cover, see in- struction 3.3 7. Check drive, brake and freewheel op- eration Figure 8 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 13 E) with Screws (9b-D) 5. Connect Control Cable (9b-A), wiring to Controller (9b-B) and Contact Pins As- sembly (9b-C) 6. Reassemble Controller Cover 7. Check drive, brake and freewheel op- Figure 9b eration EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 14 Interface Circuit Board 7. Reassemble Controller Cover and Con- trol Panel Cover, see instructions 3.1 and 3.4 8. Check all Control Panel and Controller functions: drive, brake, speed and indi- cation EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 15 10. Secure Controller Cover to the Frame, ensure that no wires will be pinched or damaged by the Cover or the Screws 11. Check drive, brake and freewheel func- tion Figure 11 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 16 3.10 7. Apply a drop of Loctite to Screws (12-A) 8. Secure Slot Cover (12-B) with Spring Washers and Screws (12-A) 9. Check drive, brake and freewheel func- tion Figure 12 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 17 Conical Cap (14-C) 9. Secure the Pin (14-B) to the Cap with Screw (14-A) using a torque wrench, torque to 40 N-m. Figure 14 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 18 Cable making sure that the Cable passes through the two Cable Locks (15-L). Bring the Release Bushing (15-K) to its approximate position and lightly secure it with the Cable Locks (15-L) EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 19 16. Release the latch, ensure the short pin (15-N) releases over the frame latch crown without jamming (low effort) EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 20 (16-A) and screw it onto the Rod (16-B); avoid excess spill of Loctite which may lock the Roller 5. Ensure that the assembly is not over- tightened and that the Roller can rotate Figure 16 freely EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 21 1. Pry Cap (16-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 (16-P) EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 22 Battery Contacts, see instruction 3.5 d. Interface Circuit Board, see instruc- tion 3.6 e. Fork Assembly, see instruction 3.10 2. Assemble the removed articles to the new Column Frame Figure 17 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 23 Battery closest to Handlebar 4. Ensure that no Wires are caught under the Batteries 5. Secure Battery Cover (18-B) to Case with Screws (18-A) Figure 18 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 24 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-B) to Case (18- H) with Screws (18-A) EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 25 Pivot Screw (20-H) 11. Apply some Loctite in Nut (20-J) and Figure 20 secure assembly 12. Test the efficiency of the assembly by unfolding the Frame Assembly, adjust as necessary EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 26 4. Attach the replacement Seat (21-C) to "U" shaped frame with Brackets (21-B) and Screws (21-A). 5. Attach the Lock Pin Cable and adjust its locking function, see instruction 3.17 Figure 21 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 27 3. Align the tubes (22-D) of the Back Pad with the holes in the Seat Back (22-E) 4. Secure Back Pad with Screws (22-B) 5. Place Screw Covers (22-A) Figure 22 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 28 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 Bottom (23-D) 3. Secure Bottom Pad (23-B) with Screws (23-B) Figure 23 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 29 4. Apply Loctite to the two Screws (21-A) and tighten them until any lash is re- moved. Over tightening may cause fric- tion on the frame tube resulting in higher folding effort. EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 30 3. Remove protective film from Tape sec- tions (24-C) 4. Secure Platform (24-A) to Frame (24-B) with two clamps 5. Leave for 15 minutes before removing the clamps Figure 24 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 31 4. Insert the Pull Ring (25-F) into the hole in the end of the Pin Figure 25 5. Test the assembly to ensure that the Pin returns to its original position after pull- ing on the Pull Ring EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 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 the Pin EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 33 NOTE: Protect the End Cap with rubber or a cloth; direct sharp blows will deform the Cap 5. Ensure that the Wheel rotates freely on the Axle Figure 26 Figure 27 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 34 NOTE: Be sure to apply the correct clip on each side of the column: the left-side clip has a notch for the column release slide. Figure 28 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 35 2. Remove the old Cap (29-A) 3. Tap the Cap (29-A) gently into the Tube end (29-B) using a mallet NOTE: Sharp blows will deform the Cap Figure 29 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 36 3. Align the new Clip’s slotted stud (30-A) with the hole in the Tube (30-B). Tap it into place using a mallet or by squeez- ing with your fingers Figure 30 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 37 2. Remove the old Cap (31-A) 3. Tap the Cap (31-A) gently into the Tube end (31-B) using a mallet NOTE: Sharp blows will deform the Cap Figure 31 EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 38 3. Align the new Clip’s slotted stud (32-A) with the hole in the Tube (32-B). Tap it into place using a mallet or by squeez- Figure 32 ing with your fingers. EasyTravel Elite – ET1E – Service Manual Rev. 0404...

  • Page 39: Programming

    PROGRAMMING OF THE SOLO CONTROLLER Introduction The EasyTravel Elite electric system is operated by the Solo Controller manufactured by Penny & Giles Technologies Ltd. (UK). The SP1 Programmer The SP1 is a handheld programmer for use with the Solo controller.
  • Page 40 The following table shows the Solo Controller settings for the EasyTravel Elite as defined by Tzora Active Systems. 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 41: Fault Finding

    Introduction Tzora Active Systems provides for profound training in Fault Finding to the major distributors of the Easy- Travel Elite. 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 If a system trip occurs than a series of flashes on the LED will display the trip type.

  • Page 42: Electrical Wiring

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

  • Page 43: Charger

    - Automatic Cut-off and then true Float. Can be left connected indefinitely without harming the battery - Size Length: 165 mm (6.5") Width: 80 mm (3.1") Height: 50 mm (2.0") - Weight 550 grams (1.2 lbs.) EasyTravel Elite – ET1E – Service Manual Rev. 0404...

  • Page 44: Spare Parts

    Flat Cap (Front Platform) 2 Caps E0-00-1-073 Front Platform Paint Protector Clips 2 Semicircle Clips E0-00-1-075 Domed Caps (Seat Supports) 2 Domed Caps E0-00-1-071 Rear Frame Paint Protector Clips 2 Full Circle Clips EasyTravel Elite – ET1E – Service Manual Rev. 0404...
  • Page 45 Control Panel Assembly – EasyTravel Elite E0-00-1-203 Seat Bottom Pad E0-00-1-204 Seat Back Pad E0-00-1-205 Seat Attachment Bracket E0-00-1-206 Platform Lock Pin Kit E0-00-1-208 Hub Motor E0-00-1-209 Power Cable E0-00-1-210 (Silver) Column Frame EasyTravel Elite – ET1E – Service Manual Rev. 0404...

  • Page 46: List Of Tool Types

    Open End 19 mm #242 (1312) Torque wrench #496 (3854) The EasyTravel Elite and its accessories have been designed, manufactured and tested in accordance with the specification of the following: DIRECTIVE: Medical devices 93/42 EEC Manufactured by: EC Authorized Representative: Medical Specialities Ltd.

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