Service Manual - The Easy Light Deluxe Foldable Scooter
Contents
1. ET1L EasyTravel Lite Service Manual Rev 0511 Table of contents 1 System components and details 5 2 Annual maintenance service 6 3 Spare parts replacement 7 4 Programming 38 5 Fault finding 40 6 Electrical wiring 41 7 Charger 42 8 Spare parts 43 9 List of Tool Types 45 NOTE Design details may change without notice ET1L EasyTravel Lite Service Manual Rev 0511 ET1L EasyTravel Lite Service Manual Rev 0511 1 SYSTEM COMPONENTS AND DETAILS 1 1 EasyTravel Lite parts Figure 1 1 Battery pack detachable 2 Front column foldable 3 Column lock release triggers 4 Controller cover 5 Charging socket 6 Front drive wheels 7 Foot platform 8 Seat shell 9 Seat cushions 10 Folding seat latch Figure 1 11 Rear wheel 12 Utility basket holding capacity 9kg 13 Control Panel 14 Freewheel switch 15 Charger and connecting cables Fig 1B Figure 1B 1 2 Control Panel Figure 2 1 Switch Hand control lever right and left Speed adjusting knob Battery indicator light LED Hand grips a A O N BELL If the user requires an audible warn ing device a standard bicycle bell can be attached to the handlebar Figure 2 6 ET1L EasyTravel Lite Service Manual Rev 0511 5 2 SERVICE For reasons of safety and the prevention of accidents caused by wear which is not detected in time the EasyTravel Lite should be tested and serviced once a year2. see instruc tion 3 3 2 Detach wiring from Controller 9a A 3 Remove Controller 9a A by unscrew ing Screws 9a B 4 Secure new Controller to Column Frame 5 Attach Wires to Controller Fig 6b from Battery Contacts Assembly the red wire A to B tab B the black C to B tab D from Interface Circuit Board in sert 11 pin connector into top socket P2 E the two white wires F to the white capped cables G from Power Cable from 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 9b ET1L EasyTravel Lite Service Manual Rev 0511 11 Kit Number E0 00 1 115 S Drive Controller Tools Phillips 2 Screwdriver Pliers REMARK The S Drive controller can be fit ted on a unit that originally was issued with a Solo controller this will require a new Inter face Circuit Board EO 00 1 116 1 Remove Controller Cover see instruc tion 3 3 Detach wiring from Controller 10a A Remove Controller 10a A by unscrew ing Screws 10a B 4 Secure new Controller to Column Frame with Screws 10b A 5 Attach Wires to Controller from Battery Contacts Assembly E the red wire to B tab the black to B tab the Con nector from the Interface Circuit Board B the two white wires C to the white and green yellow cables from Power Cable C from Power Cable
3. Cover 31 B 2 Secure new Cover 31 B to Case 31 H with Screws 31 A ET1L EasyTravel Lite Service Manual Rev 0511 31 3 19 Seat Assembly Kit Number E0 00 1 116 Tools Phillips 2 Screwdriver Loctite Adhesive 242 1312 1 Remove the four Screws 32 A holding the Seat to the Seat Guide Brackets 32 B 2 Remove the two Screws 32 D holding the Seat 32 F to the U shaped Seat Attachment Bracket 32 E the Sleeves and Seat 32 F 3 Attach the replacement Seat 32 F to the Bracket 32 E Place the Sleeves between the holes in the Bracket 32 E and tighten the two Screws 32 D until any lash is removed Over tightening Figure 32 may cause friction on the frame tube re sulting in higher folding effort 4 Place the metal strips 32 C with the holes aligned to those in the Seat and place the Seat Guide Brackets 32 B over the U shaped frame tube as shown in Figure 25 NOTE Ensure that the longer tab of the Guide Bracket is pointed towards the front as shown in Figure 25 5 Secure the Guide Brackets 32 B with the four Screws 32 A ET1L EasyTravel Lite Service Manual Rev 0511 32 3 20 Seat Back Pad Kit Number E0 00 1 060 for serial with7 digits Kit Number E0 00 1 201 for serial with 1 or 13 digits Tools Phillips 2 Screwdriver Remove the Screw Covers 33 A 2 Remove the Screws 33 B and Back Pad 33 C 3 Align the tubes 33 D of the Back Pad with
4. the guide carefully before using the SP1b Programmer Setting parameters to incorrect values could damage controllers and motors and invalidate any war ranties ET1L EasyTravel Lite Service Manual Rev 0511 44 5 FAULT FINDING 5 1 Introduction Tzora Active Systems provides for profound training in Fault Finding to the major distributors of the Easy Travel Lite Please contact the authorized Tzora Distributor in your country or Tzora for more information 5 2 Electrical System 5 2 1 5 2 2 5 2 3 Detecting that a Fault has occurred A fault is signaled by a rapid flashing of the status indicator Care should be taken because the con troller gives a low battery warning by a slow flash of the status indicator This is not a fault just a re minder that you should charge your batteries To detect a fault in the Solo or S Drive Controller the SP 1b Programmer is used It can detect various faults for instance a motor wiring fault a throttle fault a possible controller fault or a fault in the solenoid brakes Fault Diagnosis using the SP1b The SP1b indications should only be used to decide the starting point of your own diagnosis as it 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 of vehicle electrical problems so it is necessary to examine these most vulnerabl
5. the holes in the Seat Back 33 E Secure Back Pad with Screws 33 B Place Screw Covers 33 A Figure 33 ET1L EasyTravel Lite Service Manual Rev 0511 33 3 21 Seat Bottom Pad Kit Number E0 00 1 062 for serial with7 digits Kit Number E0 00 1 203 for serial with 1 or 13 digits Tools Phillips 2 Screwdriver 1 Remove the Screws 34 A and Bottom Pad 34 B 2 Align the tubes 34 C of the Bottom Pad with the holes in the Seat Bottom 34 D 3 Secure Bottom Pad 34 B with Screws 34 A ET1L EasyTravel Lite Service Manual Rev 0511 Figure 34 34 3 22 Seat Backrest Lock kit Kit Number E0 00 1 063 for serial with 7 digits Tools Phillips 2 Screwdriver 1 Remove Screw 35 D Washer 35 C Knob 35 B and Stopping Snib 35 A 2 Insert new Stopping Snib 35 A in Seat Bottom 3 Attach Knob 35 B to Stopping Snib and secure it with Washer 35 C and Screw 35 D 4 Check that a some effort is needed to open and close Lock 5 Check opening and closing functions of Lock and Seat ET1L EasyTravel Lite Service Manual Figure 35 Rev 0511 35 3 23 Seat Attachment Bracket Kit Number E0 00 1 120 Tools Phillips 2 Screwdriver Loctite Adhesive 242 1312 Refer to Figure 25 1 Remove the two Screws 32 D holding the Seat 32 F to the U shaped Seat Attachment Bracket 32 E and the Sleeves Remove the Bracket 32 E Attach th
6. 23 Tools Allen Key 6 mm Wrench open end 13 mm Wrench open end 32 mm 1 Remove Steering Column and Stem see instruction 3 13 2 Unscrew the Counter Screw 28 A re move the Spacer 28 B and unscrew the Upper Bearing Housing 28 B Remove the Upper Bearing Remove the Motor Holder from the Sleeve and the Lower Bearing and the Spacer from the Motor Holder 5 Place new Spacer and Lower Bearing on the Motor Holder and slide it in the Sleeve 6 Place new Upper Bearing on top of it and secure it with new Upper Bearing Housing 28 C NOTE Do not use a wrench to tighten the Housing but do it by hand 7 Place new Spacer 28 B and secure the assembly with Counter Screw 28 A NOTE Do not over tighten Counter Screw Check free rotation of the Motor Holder Replace Steering Column and Stem see instruction 3 13 ET1L EasyTravel Lite Service Manual Figure 28 lt 4j m i a P Ti Figure 29 Rev 0511 26 3 15 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 Remove Cable End Cone Vinyl Caps and Screws 30x and open Cable Locks Slide Release Bushing out of Column Frame and remove Cable with Lock Pin and Spring Thread Column Lock Pin 303 A and Spring 303 B onto
7. All safety related components of the Easy Travel Lite 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 Test the following maintenance items Q The components of the EasyTravel Lite frame for overload and initial cracks Q The collector brushes of the electric motor 3 A for wear Wear limit is approx 7 mm QO Wear of tires on wheels Q All screws and attachments for safe securing cable connections for Figure 3 wear and the mechanisms of the EasyTravel Lite for correct function ing Q The proper functioning of the elec tronic system and brakes ET1L EasyTravel Lite Service Manual Rev 0511 6 3 SPARE PARTS REPLACEMENT 3 1 Control Panel Assembly Kit number E0 00 1 040 for models with front wheel drive Kit Number E0 00 1 202 for models with rear wheel drive Tools Phillips 2 Screwdriver For kit number E0 00 1 202 see next page 1 Push Handgrips 4 A outwards 2 Open Screws 4 B and remove Control Panel Cover 4 C f 3 Disconnect the Control Cable 4 D lj Qz A 4 Open Screws 4 E and remove Control Panel 4 F Sa 5 Open Screws 4 N and remove Panel Bottom Cover 4 P i 6 Place new Bottom Cover 4 P and secure it with Screws 4 N 7 Secure new Control Panel 4 F wit
8. D the red wire to M tab the black to M tab 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 10b ET1L EasyTravel Lite Service Manual Rev 0511 12 3 5 Battery Contacts Kit number E0 00 1 059 Tools Phillips 2 Screwdriver Remove Controller Cover see instruc tion 3 4 Disconnect wiring to Controller 11 A and Interface Circuit Board 11 B Unscrew Screws 11 C and remove Battery Contacts Assembly 11 D Secure new Battery Contacts Assembly 11 D with Screws 11 C Connect Wiring 11 A to Controller red to B tab black to B tab Connector 11 B onto Interface Circuit Board Reassemble Controller Cover see in struction 3 4 Check drive brake and freewheel operation ET1L EasyTravel Lite Service Manual Rev 0511 Figure 11 13 3 6 Interface Circuit Board Kit number E0 00 1 058 for Solo controller for serial with 7 digits Kit Number E0 00 1 116 for S Drive controller for serial with 11 or 13 digits Tools Phillips 1 Screwdriver Phillips 2 Screwdriver 1 Remove Controller Cover see instruc tion 3 3 oo Solo amp 4 2 Disconnect Control Cable 12a A o wiring to Controller Fig 9a B Contact R Pins Assembly 12a C and Power ye Cable 12a D NE 3 Unscrew 3 Screws 12a E and remove ST a y l RE Interfac
9. E0 00 1 112 Control Cable 13 E0 00 1 133 Motor End Cover Screw 14 E0 00 1 108 Motor Brushes 15 E0 00 1 113 Power Cable Securing Clip Screw 16 E0 00 1 125 Front Wheel Assembly Front Wheel Allen Screw Washer Flat Cap 18 E0 00 1 107 Gear Motor 19 E0 00 1 122 Steering Column Stem 20 E0 00 1 123 Top Bearing for Steering Axis 21 E0 00 1 132 Column Release Cable Kit Pin Spring Cable Cable Guide Adjustable 22 Stop Cable Stops Release Bushing Set Screws End Cone Vinyl Caps E0 00 1 131 Black Vinyl Cap 24 E0 00 1 101 Battery Case Electric Wiring Screws 25 E0 00 1 102 Battery Cover EasyTravel Lite Screws 26 E0 00 1 116 Seat Assembly Seat Bottom Pad Seat Back Pad 27 E0 00 1 117 Seat Back Pad Screws Washers Screw Covers 28 E0 00 1 118 Seat Bottom Pad Screws 29 E0 00 1 119 Seat Backrest Lock 30 E0 00 1 120 Seat Attachment Bracket Bracket Sleeves Screws 31 E0 00 1 121 Seat Guide Brackets 32 E0 00 1 130 Footrest Platform 33 E0 00 1 124 Rear Wheel Assembly Rear Wheel Circlip End Cap 34 E0 00 1 129 Flat Cap Front Platform 2 Caps 35 E0 00 1 127 Seat Support Paint Protector Clips 2 Semicircle Clips 36 E0 00 1 128 Rear Frame Paint Protector Clips 2 Full Circle Clips 37 ET1L EasyTravel Lite Service Manual Rev 0511 48 8 2 Spare Parts Kit Index Part Number Description Page E0 00 1 101 Battery Case 25 E0 00 1 102 Battery Cover EasyTrav
10. NGE WHITE PANEL a ZZK CONTROL CABLE 2345678 0 5 M oeeneone FREEWHEEL ROCKER SWITCH 1 dia op 4 SOLO a is CONTROLLER fens eeeeeseceeece BOX 3 234567 89 1011 12 15 14 t W M B CHARGING Af y SOCKET o y 3 BATT h BATT lalala 1 2 fo DRIVE MOTOR UNIT SOLENOID BRAKE Figure 42 ET1L EasyTravel Lite Service Manual Rev 0511 46 7 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 Width 80 mm 3 1 Height 50 mm 2 0 Weight 550 grams 1 2 Ibs ET1L EasyTravel Lite Service Manual Rev 0511 47 8 SPARE PARTS 8 1 List of Spare Parts Kits Part Number Description Included in Kit Page E0 00 1 109 Control Panel Assembly EasyTravel Control Panel Top and Bottom Cover Screws 7 Lite E0 00 1 126 Handgrip pair 8 E0 00 1 106 Controller Cover Controller Cover Screws 9 E0 00 1 105 Solo Controller 10 E0 00 1 115 Battery Contacts Battery contacts Screws 11 E0 00 1 114 Interface Circuit Board Screws 12
11. e Circuit Board 12a F l a ii 4 Secure new Interface Circuit Board 12a F with Screws 12a E Figure 12a 5 Connect Control Cable 12a A wiring to Controller 12a B Contact Pins As sembly 12a C and Power Cable 12a D S Drive 2 Disconnect Control Cable 12b A wir ing to Controller Fig 9b B and Contact Pins Assembly 12b C 3 Unscrew 3 Screws 12b D and remove Interface Circuit Board 12b E 4 Secure new Interface Circuit Board a 12b E with Screws 12b D gi 5 Connect Control Cable 12b A wiring to Controller 12b B and Contact Pins As sembly 12b C NI S Reassemble Controller Cover Check drive brake and freewheel op Figure 12b eration ET1L EasyTravel Lite Service Manual Rev 0511 14 3 7 Control Cable Kit number E0 00 1 054 Tools Phillips 2 Screwdriver Open Control Panel Cover see instruc tion 3 1 Open Controller Cover see instruction 3 4 Disconnect Control Cable from Control Panel 5 C and Interface Circuit Board 12 A Remove Control Cable Insert new Control Cable Connect Control Cable to Control Panel and Interface Circuit Board Reassemble Controller Cover and Con trol Panel Cover see instructions 3 1 and 3 4 Check all Control Panel and Controller functions drive brake speed and indi cation ET1L EasyTravel Lite Service Manual Rev 0511 15 3 8 Motor Cover Kit Number E0 00 1 082 for models with front wheel drive serial 7 di
12. e Column Frame Tube Crimp the Cable End Cone 303 R onto the end of the Cable Test the function of the Column Lock Pin Assembly and adjust as necessary ET1L EasyTravel Lite Service Manual Rev 0511 28 3 16 Black Vinyl Cap Kit Number E0 00 1 078 Tools Screwdriver and or Pliers Refer to Figure 30 1 Pry Cap 30 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 30 P ET1L EasyTravel Lite Service Manual Rev 0511 29 3 17 Battery Case Battery Replacement Kit Number E0 00 1 101 Tools Phillips 2 Screwdriver Pliers 1 Remove Screws 31 A from Battery Case and remove Cover 31 B 2 Remove Batteries 31 C from Case and detach Wires 31 D E 3 Place Batteries in new Case H and attach red Wire 31 D to positive red marked Tab 31 F and black Wire 31 E to negative black marked Tab 31 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 case repeat in same order for Battery closest to Handlebar 4 Ensure that no Wires are caught under the Batteries 5 Secure Battery Cover 31 B to Case with Screws 31 A Figure 31 ET1L EasyTravel Lite Service Manual Rev 0511 3 18 Battery Cover Kit Number E0 00 1 102 Tools Phillips 2 Screwdriver 1 Remove Screws 31 A and Battery
13. e areas first Further information is to be found in the Programming and Fault Finding Guide that is shipped with the SP1b Programmer Servicing of Defective Solo or S Drive Controllers There are no serviceable parts within the Solo or S Drive Controller Consequently any defective units must be returned to Tzora Active Systems for repair Opening or making any unauthorized adjustments or modifications to the controller or its components will invalidate any warranty and may result in hazards to the vehicle user and is strictly forbidden WARNING Faultfinding and repairs should only be conducted by competent personnel authorized by Tzora Ac tive Systems Incorrect repair or tampering could result in a hazardous defect in the EasyTravel Lite Tzora Active Systems accept no liability for losses of any kind arising from unauthorized adjustment or modification to the EasyTravel Lite ET1L EasyTravel Lite Service Manual Rev 0511 45 6 CONTROL CONNECTIONS AND ELECTRICAL WIRING Please refer to the connection diagram Figure 42 For more information please contact your authorized Tzora Distributor or Tzora Active Systems WIG WAG SPEED LIMIT INDICATOR THROTTLE POTENTIOMETER CKER LED POTENTIOMETER SWITCH SWITCH RD RD K 8 ah o BLACK GREEN YELLOW BROWN CONTRO ORA
14. e new Bracket 32 E to Seat 32 F Place the Sleeves between the holes in the Bracket 32 E Apply Loctite to the two Screws 32 D and tighten them until any lash is re moved Over tightening may cause fric tion on the frame tube resulting in higher folding effort ET1L EasyTravel Lite Service Manual Rev 0511 36 3 24 Seat Guide Brackets Kit Number E0 00 1 121 Tools Phillips 2 Screwdriver Refer to Figure 25 1 Remove the four Screws 32 A holding the Seat to the Seat Guide Brackets 32 B Place the metal strips 32 C with the holes aligned to those in the Seat and place the Seat Guide Brackets 32 B over the U shaped frame tube as shown in Figure 25 NOTE Ensure that the longer tab of the Guide Bracket is pointed towards the front as shown in Figure 25 Secure the Guide Brackets 32 B with the four Screws 32 A ET1L EasyTravel Lite Service Manual Rev 0511 37 3 25 Footrest Platform Kit Number E0 2 30 Tools Cleaning detergent Clamps 1 Remove old Platform 36 A and any remainders of Adhesive Tape 2 Clean Frame surface 36 B with a de tergent and wipe dry with a clean cloth 3 Remove protective film from Tape sec tions on the inside of the Platform 4 Secure Platform 36 A to Frame 36 B with two clamps 5 Leave for 15 minutes before removing the clamps ET1L EasyTravel Lite Service Manual Rev 0511 Figure 36 38 3 26 Rear Wheel A
15. el Lite 26 E0 00 1 105 Solo Controller 10 E0 00 1 106 Controller Cover 9 E0 00 1 107 Gear Motor 19 E0 00 1 108 Motor Brushes 15 E0 00 1 109 Control Panel Assembly EasyTravel Lite 7 E0 00 1 112 Control Cable 13 E0 00 1 113 Power Cable 16 E0 00 1 114 Interface Circuit Board 12 E0 00 1 115 Battery Contacts 11 E0 00 1 116 Seat Assembly 27 E0 00 1 117 Seat Back Pad 28 E0 00 1 118 Seat Bottom Pad 29 E0 00 1 119 Seat Backrest Lock 30 E0 00 1 120 Seat Attachment Bracket 31 E0 00 1 121 Seat Guide Brackets 32 E0 00 1 122 Steering Column Stem 20 E0 00 1 123 Top Bearing for Steering Axis 21 E0 00 1 124 Rear Wheel Assembly 34 E0 00 1 125 Front Wheel Assembly 18 E0 00 1 126 Handgrip pair 8 E0 00 1 127 Seat Support Paint Protector Clips 36 E0 00 1 128 Rear Frame Paint Protector Clips 37 E0 00 1 129 Flat Cap Front Platform 35 E0 00 1 130 Footrest Platform 33 E0 00 1 131 Black Vinyl Cap 24 E0 00 1 132 Column Release Cable Kit 22 E0 00 1 133 Motor End Cover 14 ET1L EasyTravel Lite Service Manual Rev 0511 49 9 LIST OF TOOL TYPES Screwdrivers Phillips 1 Phillips 2 Short Phillips 2 Flat Blade Allen Keys 3mm 4mm 5mm 6 mm Wrenches Open End 8 mm Open End 13 mm Open End 32 mm 242 1312 Other Tools Cable Tie Tensioning Tool Circlip Pliers normal Circlip Pliers small Clamps Cleaning detergent Crimp Tool Cutter Extractor Light Grease Lubricant Pliers Silicone Spray Soft Mallet The EasyT
16. er Cable to Motor see in struction Place Motor Cover see instruction Check drive brake and freewheel func tion ET1L EasyTravel Lite Service Manual Rev 0511 Figure 24 gt vomo 24 3 13 Steering Column Stem Kit Number E0 00 1 122 Tools Allen Key 6 mm Open End Wrench 13 mm 1 Remove Nylock Nut 25 A and Screw 25 B 2 Carefully lift Steering Column from Stem as shown in Figure 26 and rest it along side on the Footrest Platform without de Figure 25 taching the Power Cable NOTE Ensure that the Column Release Pin is withdrawn before removing and replacing the Steering Column 3 Unscrew Screw 25 C and lift the Stem 27 A out of the Sleeve 27 B 4 Place new Stem 27 B in Sleeve 27 B notice the correct position of the Trun cated Nut 27 C 5 Tighten Screw 25 C Apply some Lubricant on the inside of the connecting plates of the Steering Column and slide it over the Stem align ing the holes in the connecting plates and the Stem 7 Insert Screw 25 B and tighten with Ny lock Nut 25 A NOTE Ensure that the Power Cable Figure 26 runs behind the Screw as shown in Fig ure 18 NOTE Ensure not to over tighten the Nut in order to allow smooth movement when folding and to prevent paint damage on the inside of the connecting plates Figure 27 ET1L EasyTravel Lite Service Manual Rev 0511 25 3 14 Upper and Lower Bearings Kit Number E0 00 1 1
17. er end into the hole in the Col umn Frame out of tube and under the Screw 18 D 8 Connect the 1 long Wire end to the positive red colored Terminal the 2 short Wire end to the negative black colored Terminal the 3 and green wire to the white wires from the electromag 2 netic Brake 4 9 Secure the Cable to the Motor with the Q two Cable Ties 22 A and trim ends 10 Secure the Motor Cover over the end of Figure 19 the Motor see instruction 3 8 ET1L EasyTravel Lite Service Manual Rev 0511 19 11 12 13 NOTE If force is needed to fit Motor Cover check the wire routing and en sure that it will not be pinched Attach from the Power Cable the black insulated 1 Wire End to M tab the red insulated 2 to M tab on Controller and the two white insulated Wire Ends to the Wires from Interface Circuit Board Secure Controller Cover to the Frame ensure that no wires will be pinched or damaged by the Cover or the Screws Check drive brake and freewheel func tion ET1L EasyTravel Lite Service Manual Rev 0511 20 Kit Number E0 00 1 702 for models with rear wheel drive Tools Phillips 2 Screwdriver Pliers Cutter Cable Tie Tensioning Tool The wheels MAY be removed to facilitate easier access for the replacement of parts see instruction 3 11 1 10 Remove the Motor Cover see instruc tion 3 8 Disconnect Powe
18. gits Kit Number E0 00 1 099 for models with front wheel drive serial 11 digits Kit Number E0 00 1 721 for models with rear wheel drive Tools Phillips Screwdriver 2 1 Unscrew Screw 13 A and remove Cover 13 B 2 Note the motor wire routing and maintain it in position NOTE If force 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 Figure 13 ET1L EasyTravel Lite Service Manual Rev 0511 16 Kit Number ES 00 1 721 for models with rear wheel drive Tools Phillips 2 Screwdriver Wrench 10 mm Allen Key 4 mm Drill bit 3 7 mm Some models have the Motor Cover fitted with velcro instead of screws 1 Open Screws 14 A and remove Free wheel Lever 14 B Open on both sides Screw 15 A and Nut 15 B and fold Seat Support for ward Open Screws 16 C and remove Cover Place new Cover 16 A over motor Ensure that Cover 16 A is aligned with Motor and Frame 16 B Secure Cover 16 A with Screws Replace Seat Support and secure with Screw 15 A and Nut 15 B Replace Freewheel Lever 14 B and secure with Screws 14 A ET1L EasyTravel Lite Service Manual Figure 15 C A Figure 16 Rev 0511 17 3 9 Motor Brushes Kit Number E0 00 1 037 for serial with 7 digits Tools Phillips 2 Screwdriver Flat Blade Screwdriver Refer to Figure 12 1 Remove the Motor End Cover see in st
19. h Screws 4 E 8 Connect the Control Cable 4 D to Con Gow LAG trol Panel 4 F 9 Secure Control Panel Cover 4 C with i Screws 4 B Ca NI 10 Push Handgrips 4 A back over the a l l Cover 11 Check all Control Panel functions indi s ie A cation drive brake and speed control Figure 4 ET1L EasyTravel Lite Service Manual Rev 0511 Kit Number E0 00 1 202 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 Hl 4 Secure new Control Panel 5 F with iii Screws 5 E iri o D 5 Connect the Control Cable 5 D to Con Jii trol Panel 5 F oo 6 Secure top and bottom Control Panel Cover 5 B C with Screws 5 A 7 Check all Control Panel functions indi cation drive brake and speed control Figure 5 ET1L EasyTravel Lite Service Manual Rev 0511 3 2 Handgrip pair Kit number E0 00 1 070 Tools Silicone spray Phillips 2 Screwdriver 1 Remove Control Panel Assembly see C ji instructions 3 1 E F Ps 2 Open Screws 6 A and remove Control Panel Bottom Cover 6 B AZN X XY Figure 6 3 Remove the Handgrips 7 A a 4 Spray Handlebars 7 B of the Column Frame and inside of the new Handgrips lightly with Silicone Spray and push them o
20. ified and corrected quickly Figure 41 WARNING Programming should only be conducted by competent personnel with in depth knowledge of Penny amp 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 ET1L EasyTravel Lite Service Manual Rev 0511 43 The following table shows the Solo or S Drive Controller settings for the EasyTravel Lite as defined by Tzora Active Systems Function Fast Slow Forward Acceleration 2 0s 2 0s Forward Deceleration 0 9s 1 35 Reverse Acceleration 3 0s 3 0s Reverse Deceleration 2 58 2 58 Forward Speed 100 50 Reverse Speed 50 30 Invert Throttle Polarity No Power Down Timer 10 min Current Limit 20A Motor Compensation 200mQ Hold Factor 152 Mid Current 50 10s 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 Throttle Deadband 15 Output Voltage 24V TruCharge Cable Resistance 40mQ TruCharge Cal 95 4 3 Using The SP1b Please contact Tzora Active Systems for more information about and the acquiring of the SP1b Programmer The Programmer is shipped with an extensive guide Please read
21. llet ET1L EasyTravel Lite Service Manual Rev 0511 Figure 22 22 3 12 Gear Motor Kit Number E0 00 1 094 for models with front wheel drive Kit Number E0 00 1 722 for models with rear wheel drive Tools Phillips 2 Screwdriver Allen Key 5 mm Cable Tie Tensioning Tool Loctite Adhesive 242 1312 1 Remove Front Wheels see instruction 3 11 2 Remove the Motor End Cover see in struction 3 8 3 Detach Power Cable from Motor As sembly see instruction 3 10 4 Remove the Screws 23 A securing the Motor Assembly to the Motor Holder 5 Apply Loctite to the Screws 23 A and secure with them the new Motor As sembly to the Motor Holder 6 Solder and attach Power Cable to Motor Figure 23 Assembly see instruction 3 10 7 Secure Motor End Cover see instruction 3 8 8 Secure Front Wheels see instruction 3 11 ET1L EasyTravel Lite Service Manual Rev 0511 23 Kit number E0 00 1 722 for models with rear wheel drive Tools Phillips 2 Screwdriver Allen Key 5 mm Cable Tie Tensioning Tool Loctite Adhesive 242 1312 Remove Motor Cover see instruction 3 11 Disconnect Power Cable from Motor see instruction Open Nuts 24 A Remove Washer 24 B Motor 24 E and Spacers 24 C Place new Motor 24 E on Screws 24 D NOTE Ensure that one Spacer 24 C sits between Motor 24 E and Frame Place Spacers 24 C and Washers 24 B Secure with Nuts 24 A Connect Pow
22. nto the Column Frame 5 Reassemble Control Panel Bottom R Cover and Control Panel Assembly 6 Push the Handgrips back over both Covers Fi 7 NOTE Check that Handgrips do not slide off HAER of Covers easily this can cause a safety hazard if control lever gets caught under Handgrip edge Remove excess silicon if needed ET1L EasyTravel Lite Service Manual Rev 0511 9 3 3 Controller Cover Kit Number E0 00 1 034 Tools Phillips 2 Screwdriver 1 Remove Screws 8 A at the top and bottom of the Controller Cover 8 B and remove Cover Disconnect Connector 8 C from Inter face Circuit Board 8 D Check that the solder tabs of the Free wheel Switch on new Cover are bent apart Insert Connector of new Cover 8 C to Interface Circuit Board Secure the Cover on the Column NOTE Ensure that the Power Cable is routed under the Controller see Figure 13 and that it will not be pinched when closing and securing the Cover Check drive brake and freewheel op eration ET1L EasyTravel Lite Service Manual Rev 0511 Figure 8 10 3 4 Controller Kit Number E0 00 1 032 Solo Controller Figure 9 Kit Number E0 00 1 115 S Drive Controller Figure 10 Tools Short Phillips 2 Screwdriver Pliers REMARK The S Drive controller can be fit ted on a unit that originally was issued with a Solo controller this will require a new Inter face Circuit Board E0 00 1 116 1 Remove Controller Cover
23. ole in the Tube Tap it into place using a mallet or by squeezing with your fingers ET1L EasyTravel Lite Service Manual Rev 0511 41 3 29 Rear Frame Paint Protector Clips Kit number E0 00 1 071 Tools Screwdriver Soft Mallet Cover the flat tip of a screwdriver with masking tape or electrical tape to pre vent paint damage Remove the old clip 40 A from the Tube 40 B Align the new Clip s slotted stud 40 A with the hole in the Tube 40 B Tap it into place using a mallet or by squeez ing with your fingers ET1L EasyTravel Lite Service Manual Rev 0511 Figure 40 42 4 PROGRAMMING OF THE CONTROLLER 4 1 Introduction The EasyTravel Lite electric system is operated by the Solo or S Drive Controller manufactured by Penny amp Giles Technologies Ltd UK 4 2 The SP1 Programmer The SP1 is a handheld programmer for use with the Solo or S Drive Controller The programmer is a menu driven device which plugs directly into the controller The SP1b Programmer Engineering Version can set all of the key controller speed acceleration and braking characteris 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 SP1b can also display error messages from the controller This allows any problems with the vehicle electrical system to be ident
24. r Cable from Motor see instruction Disconnect Power Cable from Control ler see instruction Carefully pull the Power Cable out of the Column Frame and the Cable Guides Fig Thread new Power Cable through Cable Guides Thread the new Wire Assembly from the Controller end into the hole in the Col umn Frame out of tube and under the Screw 14 D Connect Power Cable to Motor see in struction Replace Motor cover see instruction Connect Power Cable to Controller see instruction Check drive brake and freewheel func tion ET1L EasyTravel Lite Service Manual Cable guides Cable guides Figure 21 Rev 0511 21 3 11 Front Wheel Assembly Kit Number E0 00 1 069 for models with front wheel drive Kit Number E0 00 1 068 for models with rear wheel drive Tools Allen Key 6 mm Loctite Adhesive 242 1312 Soft Mallet The figure shows the model with front wheel drive these instructions apply to both mod els front and rear wheel drive 1 Remove old Cap 22 A Screw 22 B Disk 22 C and Wheel 22 D Thoroughly clean the threaded hole in the end of the Axle 22 E of adhesive residue Slide the Wheel 22 D onto Axle 22 E aligning the groove in the Adapter with the Roll Pin on the Axle Place Disk 22 C on Screw 22 B and apply Loctite 162 1312 adhesive to the screw thread Secure the assembly with Screw 22 C Fit new Cap 22 A on the Wheel 22 D by gently tapping it with a ma
25. ravel Lite and its accessories have been designed manufactured and tested in accordance with the specification of the following DIRECTIVE Medical devices 93 42 EEC C Manufactured by Web Site www tzora com EC Authorized Representative Medical Specialities Ltd Blackburn BB2 4HT UK ET1L EasyTravel Lite Service Manual Rev 0511 50
26. ruction 3 8 2 Remove the plastic Brush Cap 12 C and pull the Brush 17 A gently from its housing Remove Power Cable wire 17 B Insert the new Brush carefully into its housing and secure with Brush Cap 12 C NOTE Ensure that the Brush is fully inserted freely and smoothly and that the spring is not caught in the housing 5 Connect Power Cable wire 17 B to contact tab 17 A Bend contact tab towards motor Note the motor wire routing and maintain it in position Secure Motor Cover see instruction 3 9 Figure 17 Check drive and brake operation ET1L EasyTravel Lite Service Manual Rev 0511 18 3 10 Power Cable to Motor Kit Number E0 00 1 093 for models with front wheel drive Kit Number E0 00 1 702 for models with rear wheel drive Tools Phillips 2 Screwdriver Pliers Cutter Cable Tie Tensioning Tool The wheels MAY be removed to facilitate easier access for the replacement of parts see instruction 3 11 For instructional purposes the Footrest Plat form has been removed in figure 14 1 Remove the Motor Cover see instruction 3 8 Remove Cable Ties 18 A from Motor Remove the Wires from the Terminals 18 B and Brakes 18 C on the Motor 4 Remove Controller Cover see instruc tion 3 3 Figure 18 5 Detach the Wires from the Controller 19 A and Interface Circuit Board 19 B 6 Carefully pull the Wire Assembly out of the Column Frame 7 Thread the new Wire Assembly from the Controll
27. ssembly Kit Number E0 00 1 068 Tools Circlip Pliers Screwdriver Soft Mallet Extractor with scratch protection 1 Remove old End Cap 37 C using a screwdriver Remove old Circlip 37 B and Wheel If needed use an extractor to remove the bearing from the Axle Figure 38 2 Place new Wheel 37 A on Axle of Rear Frame 37 D 3 Fit new Circlip 37 B into its groove at the end of the Axle 4 Fit new End Cap 37 C to the end of the Axle using a mallet 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 ET1L EasyTravel Lite Service Manual Figure 37 Figure 38 Rev 0511 39 3 27 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 Remove the old Cap 39 A Tap the Cap 39 A gently into the Tube end using a mallet NOTE Sharp blows will deform the Cap ET1L EasyTravel Lite Service Manual Rev 0511 A Figure 39 40 3 28 Seat Support Paint Protector Clip Kit Number E0 00 1 073 Tools Screwdriver and or Pliers Soft Mallet Refer to Figure 39 1 Cover the flat tip of a screwdriver with masking tape or electrical tape to pre vent paint damage Remove the old Cap 39 B Align the new Clip s slotted stud 39 B with the h
28. the Column Lock Pin Cable 303 C Thread the Cable through the large hole in Connecting Plate 303 D Column Lock Pin Housing 303 E and the small hole in Connecting Plate 303 F Apply some lubricant to Lock Pin 303 A Thread the Cable Guide 303 G onto the Cable and thread the cable into the Cable Guide Adjustable Stop 303 H and through the Tube of Column Frame 303 J Thread the Release Bushing 303 K with the single hole down onto the Cable making sure that the Cable passes through the two Cable Locks 303 L Bring the Release Bushing 303 k to its approximate position and lightly secure it with the Set Screws 303 P ET1L EasyTravel Lite Service Manual Rev 0511 Figure 30 27 Ab 0S ee m oa 10 11 12 13 14 Take up the slack in the Cable 303 C so that the end of the Column Lock Pin 303 A is flush with the outside of Con necting Plate 303 D Release one of the two Set Screws 303 P and bring the Release Bushing 303 K to its final position Set Screws 303 P reaching the bottom of slot in Column Frame Tube 303 J Lift the Cable by the top of it not by the Set Screws until the lower Cable Lock is flush with the lower hole and tighten the two Cable Locks 303 L Tighten the two Set Screws 303 P and slide the two Vinyl Caps 303 Q onto them NOTE do not over tighten the Screws 303 P against the Cable Trim Cable to approximately 25 mm 1 beyond the end of th
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