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Easy Travel Elite Service Manual - page 15
EasyTravel Elite – ET1E – Service Manual
Rev. 0404
15
3.8
Power Cable to Motor ET1E
Kit Number E0-00-1-209
Tools:
Allen Key 3 mm
1. Remove the Slot Cover, see instruction
3.8
2. Disconnect Power Cable from Hub Mo-
tor, see instruction 3.9
3. Remove Controller Cover, see instruc-
tion 3.3
4. Detach the Wires from the Controller
(11-A) and Interface Circuit Board (11-B)
5. Carefully pull the Power Cable out of the
Column Frame
6. Thread the new Power Cable from the
Controller-end into the hole in the Col-
umn 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 #3 and green
Wire to white Wires from electromag-
netic Brake
8. Fit connectors in tube and secure Slot
Cover over tube
9. 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
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 10
Figure 11
Summary of Elite
Page 1
Elite service manual.
Page 2
Easytravel elite – et1e – service manual rev. 0404 2.
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Easytravel elite – et1e – service manual rev. 0404 3 table of contents: 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 tool types 59 note: design ...
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Easytravel elite – et1e – service manual rev. 0404 4.
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Easytravel elite – et1e – service manual rev. 0404 5 1. System components and details 1.1 easytravel elite 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 platf...
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Easytravel elite – et1e – service manual rev. 0404 6 2. Service for reasons of safety and the prevention of accidents caused by wear which is not detected in time, the easytravel elite should be tested and serviced once a year. All safety-related components of the easy- travel elite should be checke...
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Easytravel elite – et1e – service manual rev. 0404 7 3. Spare parts replacement 3.1 control panel assembly kit number e0-00-1-202 tools: phillips #2 screwdriver 1. Open screws (3-a) and remove top and bottom control panel cover (3-b, c) 2. Disconnect the control cable (3-d) 3. Open screws (3-e) and ...
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Easytravel elite – et1e – service manual rev. 0404 8 3.2 handgrip pair kit number e0-00-1-070 tools: silicone spray phillips #2 screwdriver 1. Remove control panel assembly, see instructions 3.1 2. Remove the handgrips (4-a) 3. Spray handlebars (4-b) of the column frame and inside of the new handgri...
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Easytravel elite – et1e – service manual rev. 0404 9 3.3 controller cover kit number e0-00-1-034 tools: phillips #2 screwdriver 1. Remove screws (5-a) at the top and bottom of the controller cover (5-b) and remove cover 2. Disconnect connector (5-c) from inter- face circuit board (5-d) 3. Check that...
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Easytravel elite – et1e – service manual rev. 0404 10 3.4 controller kit number e0-00-1-032 (solo controller) figure 6 kit number e0-00-1-115 (s-drive controller) figure 7 tools: short phillips #2 screwdriver pliers remark: the s-drive controller can be fit- ted on a unit that originally was issued ...
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Easytravel elite – et1e – service manual rev. 0404 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, e0-00...
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Easytravel elite – et1e – service manual rev. 0404 12 3.5 battery contacts kit number e0-00-1-059 tools: phillips #2 screwdriver 1. Remove controller cover, see instruc- tion 3.3 2. Disconnect wiring to controller (8-a) and interface circuit board (8-b) 3. Unscrew screws (8-c) and remove bat- tery c...
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Easytravel elite – et1e – service manual rev. 0404 13 3.6 interface circuit board et1b kit number e0-00-1-058 (for solo controller) (for serial # up to 12000401999) kit number e0-00-1-116 (for s-drive controller) (from serial # 12000402001onwards) tools: phillips #1 screwdriver phillips #2 screwdriv...
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Easytravel elite – et1e – service manual rev. 0404 14 3.7 control cable kit number e0-00-1-054 tools: phillips #2 screwdriver 1. Open control panel cover, see instruc- tion 3.1 2. Open controller cover, see instruction 3.3 3. Disconnect control cable from control panel (3-c) and interface circuit bo...
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Easytravel elite – et1e – service manual rev. 0404 15 3.8 power cable to motor et1e kit number e0-00-1-209 tools: allen key 3 mm 1. Remove the slot cover, see instruction 3.8 2. Disconnect power cable from hub mo- tor, see instruction 3.9 3. Remove controller cover, see instruc- tion 3.3 4. Detach t...
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Easytravel elite – et1e – service manual rev. 0404 16 3.9 hub motor kit number e0-00-1-208 tools: allen key 3 mm allen key 5 mm allen key 6 mm loctite adhesive 1. Open screws and spring washers (12- a) 2. Remove slot cover (12-b) 3. Detach power cable (12-c) from hub motor (12-e) 4. Remove the screw...
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Easytravel elite – et1e – service manual rev. 0404 17 3.10 fork assembly kit number e0-00-1-038 tools: allen key 3 mm allen key 5 mm allen key 6 mm wrench, open end 13 mm wrench, open end 19 mm torque wrench loctite adhesive #242 (1312) 1. Remove hub motor, see instruction 3.9 2. Remove “nylock” loc...
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Easytravel elite – et1e – service manual rev. 0404 18 3.11 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- str...
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Easytravel elite – et1e – service manual rev. 0404 19 9. Apply loctite to screw (15-n) and se- cure column latch bushing (15-m) with it onto release bushing (15-k) 10. Take up the slack in the cable (15-c) so that the end of the column lock pin (15- a) is flush with the outside of connect- ing plate...
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Easytravel elite – et1e – service manual rev. 0404 20 3.12 protector roller kit kit number e0-00-1-081 tools: allen key 5 mm loctite adhesive # 242 (1312) 1. Open cap nut (16-a), remove threaded rod (16-b) and roller (16-c) 2. Place the new roller (16-c) between the two plates (16-d) and align with ...
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Easytravel elite – et1e – service manual rev. 0404 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, make sure it covers the whole set screw (...
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Easytravel elite – et1e – service manual rev. 0404 22 3.14 column frame kit number e0-00-1-210 tools: phillips #1 screwdriver phillips #2 screwdriver soldering iron allen key 2 mm allen key 5 mm allen key 6 mm pliers cutter cable tie tensioning tool the new column frame is issued with a control cabl...
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Easytravel elite – et1e – service manual rev. 0404 23 3.15 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 (18-a) from battery case and remove cover (18-b) 2. Remove batteries (18-c) fr...
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Easytravel elite – et1e – service manual 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-b) to case (18- h) with screws (18-a).
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Easytravel elite – et1e – service manual rev. 0404 25 3.17 platform lock pin kit kit number e0-00-1-206 tools: wrench, open end 8 mm allen key 2 mm allen key 4 mm (2x) cutter crimp tool loctite adhesive #242 (1312) small rod (diameter 15 mm) 1. Open nut (20-j) and remove pivot cap (20-f) 2. Cut stop...
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Easytravel elite – et1e – service manual rev. 0404 26 3.18 seat assembly kit number e0-00-1-201 tools: phillips #2 screwdriver pliers cutter crimp tool loctite adhesive # 242 (1312) 1. Disconnect the lock pin cable from the seat, see instruction 3.17 2. Remove screws (21-a) and seat at- tachment bra...
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Easytravel elite – et1e – service manual rev. 0404 27 3.19 seat back pad kit 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) 4. Secure ...
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Easytravel elite – et1e – service manual rev. 0404 28 3.20 seat bottom 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 bottom (23-d) 3. Sec...
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Easytravel elite – et1e – service manual rev. 0404 29 3.21 seat attachment bracket kit number e0-00-1-205 tools: phillips #2 screwdriver loctite adhesive # 242 (1312) refer to figure 21 1. Remove the two screws (21-a) holding the seat (21-d) to the "u" shaped seat attachment bracket (21-b) and the s...
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Easytravel elite – et1e – service manual rev. 0404 30 3.22 footrest platform kit number e0-00-1-077 tools: cleaning detergent 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...
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Easytravel elite – et1e – service manual rev. 0404 31 3.23 folding lock pin kit kit number e0-00-1-065 tools: circlip pliers 1. Remove the old pull ring (25-f), circlip (25-e) and washer (25-d). Extract the old spring (25-a) and old pin (25-c) from the pin housing (25-b) 2. Insert new spring (25-a) ...
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Easytravel 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 the pin.
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Easytravel elite – et1e – service manual rev. 0404 33 3.25 rear wheel assembly kit number e0-00-1-068 tools: circlip pliers screwdriver soft mallet extractor with scratch protection 1. Remove old end cap (26-c) using a screwdriver. Remove old circlip (26-b) and wheel. If needed use an extractor to r...
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Easytravel elite – et1e – service manual rev. 0404 34 3.26 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 (28-a) from the tube (28-b)...
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Easytravel elite – et1e – service manual rev. 0404 35 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 2. Remove the old cap (29-a) 3. Tap the cap (...
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Easytravel elite – et1e – service manual rev. 0404 36 3.28 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 (30-a) from the tube (30-...
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Easytravel elite – et1e – service manual rev. 0404 37 3.29 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 (31-a) 3. Tap the cap ...
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Easytravel elite – et1e – service manual rev. 0404 38 3.30 rear frame paint protector clips kit number e0-00-1-071 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 (32-a) from the tube (32-b) 3...
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Easytravel elite – et1e – service manual rev. 0404 39 figure 33 4. Programming of the solo controller 4.1 introduction the easytravel elite electric system is operated by the solo controller manufactured by penny & giles technologies ltd. (uk). 4.2 the sp1 programmer the sp1 is a handheld programmer...
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Easytravel elite – et1e – service manual rev. 0404 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 decel...
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Easytravel elite – et1e – service manual rev. 0404 41 5. Fault finding 5.1 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 informat...
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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..
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Easytravel elite – et1e – service manual rev. 0404 43 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 in...
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Easytravel elite – et1e – service manual rev. 0404 44 8. Spare parts 8.1 list of spare parts kits part number description included in kit page e0-00-1-202 control panel assembly – easytravel elite control panel, top and bottom cover, screws 7 e0-00-1-070 handgrip pair 8 e0-00-1-034 controller cover ...
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Easytravel elite – et1e – service manual rev. 0404 45 8.2 spare parts kit index part number description page e0-00-1-020 (normal) e0-00-1-021 (jumbo) battery case 23 e0-00-1-022 (normal) e0-00-1-025 (jumbo) battery cover – easytravel elite 24 e0-00-1-032 solo controller 10 e0-00-1-034 controller cov...
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Easytravel elite – et1e – service manual rev. 0404 46 9. 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 ...