Easy Travel ET1B EasyTravel, ET1 EasyTravel electric scooter Service Manual

Service Manual

Easy Travel – Service Manual Rev. 0401 2

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

9.

List of Tool Types

NOTE: Design details may change without notice

48

49

50

51

54

6

46

4

5


1. SYSTEM COMPONENTS AND DETAILS

1.1 EasyTravel parts – (Figure 1)

1. Battery pack (detachable)

2. Front column (detachable)

5. Charging socket (Fig. 1A)

6. Front drive wheels

10. Serial # up to and including: folding seat latch

11. Rear wheel

12. Folded frame lock pin

13. Platform bottom lock pin

9kg)

15. Charger and connecting cables

(Fig. 1B).

16. Control Panel

17. Freewheel switch

1.2 Control Panel – Figure 2

1. Switch

2. Hand control lever (right and left)

3. Speed adjusting knob

4. Indicator light (LED)

5. From serial # 0307077and onwards or starting with 11B: Battery

Level Indicator

6. Hand-grips

BELL: If the user requires an audible warning device, a standard bicycle bell can be attached to the handlebar.


2. 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 manufacturer.

Test the following maintenance items:

The components of the EasyTravel frame for overload and initial cracks.

Wear of tires on wheels.

All screws and attachments for safe securing, cable connections for wear, and the mechanisms of the

EasyTravel for correct functioning.

The proper functioning of the electronic system and brakes.

 For serial # up to and including

0304599: the collector brushes of the electric motor (3-A) for wear.

Wear limit is approx. 7 mm.

Figure 3


3. SPARE PARTS REPLACEMENT

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.

1. Push Handgrips (4-A) outwards

2. Open Screws (4-B) and remove Control

Panel Cover (4-C)

3. Disconnect the Control Cable (4-D)

4. Open Screws (4-E) and remove Control

Panel (4-F)

5. Open Screws (4-N) and remove Panel

Bottom Cover (4-P)

6. Place new Bottom Cover (4-P) and secure it with Screws (4-N)

7. Secure new Control Panel (4-F) with

Screws (4-E)

8. Connect the Control Cable (4-D) to Control Panel (4-F)

9. Secure Control Panel Cover (4-C) with

Screws (4-B)

10. Push Handgrips (4-A) back over the

Cover

11. Check all Control Panel functions: indication, drive, brake and speed control

Easy Travel – Service Manual Rev. 0401

Figure 4

6

Kit Number E0-00-1-202

Kit Number E0-00-1-701

Tools:


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. Connect the Control Cable (5-D) to Control Panel (5-F)

6. Secure top and bottom Control Panel

Cover (5-B, C) with Screws (5-A)

7. Check all Control Panel functions: indication, drive, brake and speed control


Figure 5

7

Kit number E0-00-1-070

Tools:

Silicone spray


1. Remove Control Panel Assembly, see instructions 3.1

2. For serial # up to and including

0307076: open Screws (6-A) and remove Control Panel Bottom Cover (6-

B)

3. Remove the Handgrips, (7-A)

4. Spray Handlebars (7-B) of the Column

Frame and inside of the new Handgrips

lightly with Silicone Spray and push them onto the Column Frame

5. Reassemble Control Panel Bottom

Cover and Control Panel Assembly

6. Push the Handgrips back over both

Covers

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.


Figure 6

Figure 7

8

3.3 Controller Cover ET1B

Kit Number E0-00-1-034

Kit Number E0-00-1-705 (for serial # starting with 11B)

Tools:


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 Interface Circuit Board (8-D)

3. Check that the solder tabs of the Freewheel Switch on new Cover are bent apart

4. Insert Connector of new Cover (8-C) to

Interface Circuit Board

5. Secure the Cover on the Column

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 operation

Figure 8


3.4 Solo Controller ET1B

Kit Number E0-00-1-032


Tools:

Short Phillips #2 Screwdriver

Pliers

1. Remove Controller Cover, see instruction 3.3

2. Detach wiring from Controller (9-A)

3. Remove Controller (9-A) by unscrewing

Screws (9-B)

4. Secure new Controller to Column Frame

5. Attach Wires to Controller (Fig. 9a): from

Battery Contacts Assembly, the red wire

(A) to “B+” tab (B), the black (C) to “B-“ tab (D); from Interface Circuit Board insert 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


Figure 9


Figure 9a

10


Tools:


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. Secure new Controller to Column Frame

6. Attach Wires to Controller (Fig. 10a): a. Control Cable (C); b. from Contacts and Charging Socket

Assembly: i. the brown wire to connector (B), ii. the white wire to connector (F), iii. the red wire to “B+” tab, the black to “B-“ tab (D); iv. the two red capped wires (coming from connector (F)) to the white and yellow/green cables (G) from

Power Cable; c. from Power Cable the #1/red wire to

“M+” tab, #2/black wire to “M-“ tab (E)

7. Place plastic protection sheet and secure Controller Top Cover with Screws

(10-A)

8. Secure Controller Cover, see 3.3



Figure 10

Figure 10a

11

Kit number E0-00-1-059

Tools:

Phillips #2 Screwdriver 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. Connect Wiring (11-A) to Controller (red to “B+” tab, black to “B-“ tab), Connector

(11-B) onto Interface Circuit Board

6. Reassemble Controller Cover, see instruction 3.3


Figure 11


3.6 Interface Circuit Board ET1B

Kit number E0-00-1-058

Tools:




2. Disconnect Control Cable (12-A), Freewheel Cable (12-B), wiring to Controller

(12-C), Contact Pins Assembly (12-D) and to Power Cable (12-E)

3. Unscrew 3 Screws (12-F) and remove

Interface Circuit Board (12-G)

4. Secure new Interface Circuit Board (12-

G) with Screws (12-F)

5. Connect Control Cable (Fig. 12-A),

Freewheel Cable (12-B), wiring to Controller (12-C), Contact Pins Assembly

(12-D) and Power Cable (12-E)

6. Reassemble Controller Cover


Figure 12


3.7 Contacts and Charging Socket Assembly

Kit number E0-00-1-703 (for serial # starting with 11B)

Tools:




2. Open Controller, see instruction 3.4

3. Disconnect wiring to Controller and to

Power Cable, see instruction 3.4

4. Unscrew 3 Screws (12a-A) and two

Screws (12a-B)

5. Remove Contacts and Charging Socket

Assembly (12a-C) and replace

6. Secure new Assembly (12a-C) with

Screws (12a-A, B)

7. Connect wiring to Controller and Power

Cable and close Controller, see instruction 3.4

8. Reassemble Controller Cover, see instruction 3.3


Figure 12a


Kit number E0-00-1-054


Tools:


1. Open Control Panel Cover, see instruction 3.1

2. Open Controller Cover, see instruction

3.3

3. Disconnect Control Cable from Control

Panel (5-C) and Interface Circuit Board

(12-A)/Controller (10a-C)

4. Remove Control Cable

5. Insert new Control Cable (if needed, remove the Paint Protector and replace it with a new one after the Control Cable is inserted, see instruction 3.32)

6. Connect Control Cable to Control Panel and Interface Circuit Board/Controller

7. Reassemble Controller Cover and Control Panel Cover, see instructions 3.1 and 3.4

8. Check all Control Panel and Controller functions: drive, brake, speed and indication


3.9 Motor End Cover ET1B

Kit Number E0-00-1-083 (for motor types

E0-00-1-036 and E0-00-1-092)

Tools:


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)

Kit Number E0-00-1-096 (for motor type

E0-00-1-094)

Tools:


1. Unscrew Screws (14-A) and remove

Cover (14-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 (14-B) with Screws

(14-A)

Figure 13

Figure 14


Kit Number E0-00-1-037 (for serial # up to and including 0304599)

Tools:


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. Remove the Motor End Cover, see instruction 3.8

2. Remove the plastic Brush Cap (C) and pull the Brush gently from its housing

3. Remove Power Cable wire

For serial # up to and including

0212052:

Remove heat-shrink insulation and unsolder the Brush (Fig. 15) being re-

placed

4. Insert the new Brush carefully into its housing and secure with Brush Cap (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 to contact tab


0212052: a. Place new heat-shrink insulation sleeves over wires and re-solder wiring to contact tab

NOTE: Ensure good tinning and secure connection b. Secure insulation sleeves in place

with hot air gun or soldering iron

6. Note the motor wire routing and maintain it in position.

7. Secure Motor Cover, see instruction 3.8

8. Check drive and brake operation


Figure 15

17

3.11 Power Cable to Motor ET1B

Kit Number E0-00-1-056 (for serial # up to

and including 0212052)


0212053 up to 0304599)


0304600 and onwards)


Tools:


Pliers

Cutter

Cable Tie Tensioning Tool

(For serial # up to and including 0212052:

Soldering Iron

Solder

Hot Air Gun)

The wheels MAY be removed to facilitate easier access for the replacement of parts, see instruction 3.11

Fig. 16a refers to serial # up to and including

0212052, fig. 16b refers to serial # 0212053 up to 0304599, fig. 16c refers to serial #

0304600 and onwards.

1. Remove the Motor Cover, see instruction 3.8 (for serial # starting with 11B:

remove heat shrink)

2. Remove Cable Ties (16-A) from Motor and Securing Clip (16-B) on the underside of the Adapter Block

3. Remove Wires from Terminals (16-C) and Brakes (16-D)


0212052:

Remove heat-shrink insulation and unsolder the Wires from the Terminals (16-

C) and Brakes (16-D) on the Motor


5. Detach the Wires from the Controller

(17-A) and Interface Circuit Board (17-B)

6. Carefully pull the Power Cable out of the

Column Frame


Figure 16a

Figure 16b

18

7. Thread the new Power Cable from the

Controller-end into the hole in the Column 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 negative/black Terminal, the #3 and green

Wire to white Wires from electromagnetic Brake

(For serial # up to and including

0212052: a. Place new heat-shrink insulation sleeves over wires and solder the #1 long Wire end to positive/red colored

Terminal, the #2 short Wire end to negative/black colored Terminal, the #3 and green wire to white Wires from the electromagnetic Brake b. Secure insulation sleeves in place with hot air gun or soldering iron)

9. Secure the Cable to the Motor with Cable Ties (16-A) and trim ends (for serial

# starting with 11B: Place new heat

shrink over Motor

10. Secure the cable to the underside of the

Adapter Block with Clip (16-B)

11. Secure the Motor Cover over the end of the Motor

NOTE: If force is needed to fit Motor

Cover, check the wire routing and ensure that it will not be pinched

12. 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

13. Secure Controller Cover to the Frame, ensure that no wires will be pinched or damaged by the Cover or the Screws

14. Check drive, brake and freewheel function


Figure 16c

Figure 17

19

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. Slide the Wheel (18-D) onto Axle (18-E) aligning the groove in the Adapter with the Roll Pin on the Axle

4. Place Disk (18-C) on Screw (18-B) and apply Loctite #242 (1312) adhesive to the screw thread

5. Secure the assembly with Screw (18-C).

6. Fit new Cap (18-A) on the Wheel (18-D) by gently tapping it with a mallet

Figure 18


Kit Number E0-00-1-035 (ET1)

Kit Number E0-00-1-094 (ET1B)

Tools:


Allen Key 5 mm



(For serial # up to and including 0212052:

Soldering Iron

Solder)

1. Remove Front Wheels, see instruction

3.11

2. Remove the Motor End Cover, see instruction 3.8 (for serial # starting with

11B it is not needed to remove Motor

End Cover)

3. Detach Power Cable from Gear Motor, see instruction 3.10

4. Remove the Screws (19-A) securing the

Gear Motor to the Adapter Block

5. Apply Loctite to the Screws (19-A) and secure with them the new Gear Motor to the Adapter Block

6. Attach Power Cable to Gear Motor, see instruction 3.10

7. Secure Motor End Cover, see instruction

3.8

8. Secure Front Wheels, see instruction

3.11

Figure 19


3.14 Adapter Block Assembly

Kit Number E0-00-1-038


Tools:

Allen key 5 mm

Allen Key 8 mm

Wrench, open end 19 mm

Torque Wrench


Light Grease/Lubricant

The wheels MAY be removed to facilitate easier access, see instruction 3.11

1. Open Screw (20-A) and remove Clip

(20-B)

2. Unscrew the four Screws (20-D) securing Gear Motor (20-E) to the Adapter

Block (20-F) and put Gear Motor aside

3. Remove “Nylock” Lock Nut (21-A) and

Screw (21-B)

4. Slide Adapter Block (21-C) from Column

Frame (21-D)

NOTE: Ensure that the Column Release

Pin (21-E) is withdrawn before removing and replacing the Adapter Block

5. Apply some Lubricant on the inside of the connecting plates of the Column

Frame (21-D) and slide new Adapter

Block (21-C) in the Column Frame

6. Insert Screw (21-B) and secure it with

“Nylock” Lock Nut (21-A)

7. Apply Loctite to Screws (20-D) and secure Gear Motor (20-E) to Adapter Block

(20-F)

8. Secure Power Cable (20-C) with Clip

(20-B) and Screw (20-A) to Adapter

Block


Figure 20

Figure 21

22

9. Remove Screw (22-A) holding Pin (22-

B)

10. Remove the Pin from the new Quick Release 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.

Figure 22


3.15 Upgrade from ET1 to ET1B

Kit Number E0-00-1-097

Tools:



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. Disconnect cables connected to Controller (23-C) and Power Cable (23-D)

3. Disconnect Control Cable (24-A), wiring to Controller (Fig. 24-B) and Contact

Pins Assembly (24-C)

4. Remove Front Wheel Assembly, see instruction 3.11

5. Remove Securing Clip (page 21, 20-B) on the underside of the Adapter Block

6. Carefully pull the Power Cable out of the

Column Frame

7. Insert new Power Cable from the motor end into Frame, using the attached ironwire tool

8. Attach Power Cable to Controller, see instruction 3.10

9. Place new Controller Cover, see instruction 3.3

10. Secure new Gear Motor, see instruction

3.12

11. Check drive, brake and freewheel function

Figure 23

Figure 24


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. 25-

A)

3. Place the new Bearing (26-A) in the Top Pin

Housing (26-B) and press/tap it into the Pin

Housing

! NOTE: Make sure the bottom of the

Bearing reaches its seating in the Pin

Housing

4. Reassemble the Adapter Block, see instruction 3.13

Figure 25


Figure 26

25

3.17 Column Release Cable Kit

Kit Number E0-00-1-080

Tools:



Allen key 3 mm

Wire Cutter

Pliers

Crimp Tool

Loctite Adhesive # 496 (3854)

Light grease/lubricant

1. Remove Control Panel Cover, see instruction 3.1

2. Remove Cable End Cone, Vinyl Caps and Screws (2x) and open Cable Locks

3. Slide Release Bushing out of Column

Frame and remove Cable with Lock Pin and Spring

4. Thread Column Lock Pin (27-A) and

Spring (27-B) onto the Column Lock Pin

Cable (27-C)

5. Thread the Cable through the large hole in Connecting Plate (27-D), Column

Lock Pin Housing (27-E) and the small hole in Connecting Plate (27-F)

6. Apply some lubricant to Lock Pin (27-A)

7. Thread the Cable Guide (27-G) onto the

Cable and thread the cable into the Cable Guide Adjustable Stop (27-H) and through the Tube of Column Frame (27-

J)

8. Thread the Release Bushing (27-K) with the threaded hole down onto the Cable making sure that the Cable passes through the two Cable Locks (27-L).

Bring the Release Bushing (27-K) to its approximate position and lightly secure it with the Cable Locks (27-L)


Figure 27

26

9. Apply Loctite to Screw (27-N) and secure 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 Connecting Plate (27-D)

11. Release the two Cable Locks (27-L) and bring the Release Bushing (27-K) to its final position, Latch Bushing (27-M) reaching the bottom of slot in Column

Frame Tube (27-J). Tighten the two Cable Locks (27-L)

12. Place the two Set Screws (27-P) in the upper threaded holes of the Release

Bushing (27-K) and slide the two Vinyl

Caps (27-Q) onto them.

NOTE: do not over-tighten the Screws

(27-P) against the Cable.

13. Trim Cable to approximately 25 mm. (1") beyond the end of the Column Frame

Tube. Crimp the Cable End Cone (27-R) onto the end of the Cable.

14. Test the function of the Column Lock Pin

Assembly and adjust as necessary.

15. Fold Frame with Column attached to it, ensure the short pin (27-N) slides over the frame latch without forcing it and holds the frame in a latched position.

16. Release the latch, ensure the short pin

(27-N) releases over the frame latch crown without jamming (low effort)


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)


3.19 Protector Roller Kit

Kit Number E0-00-1-081

Tools:

Allen Key 5 mm


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. Insert Threaded Rod (28-B) though the holes and Roller and right hand Plate

4. Apply a drop of Loctite to the Cap Nut

(28-A) and screw it onto the Rod (28-B); avoid excess spill of Loctite which may lock the Roller

5. Ensure that the assembly is not overtightened and that the Roller can rotate freely

Figure 28


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:



Soldering Iron

Allen Key 2 mm

Allen Key 5 mm

Allen Key 6 mm

Pliers

Cutter


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 instruction 3.1 b. Controller Cover and Controller, see instructions 3.3 and 3.4 c. Battery Contacts, see instruction 3.5 d. Interface Circuit Board, see instruction 3.6 e. Adapter Block, see instruction 3.13; there is no need to disassemble

Gear Motor from Adapter Block, just unsolder Power Cable from Motor

End, see instruction 3.10

2. Assemble the removed articles to the new Column Frame


Figure 29

30

3.21 Battery Case / Battery Replacement

Kit Number E0-00-1-020 (Normal size)

Kit Number E0-00-1-021 (Jumbo size)

Tools:


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. Place Batteries in new Case (-H) and attach red Wire (30-D) to positive/red marked Tab (30-F) and black Wire (30-

E) to negative/black marked Tab (30-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 (30-B) to Case with Screws (30-A)

Kit Number E0-00-1-022 (Normal size)

Kit Number E0-00-1-025 (Jumbo size)

Tools:


1. Remove Screws (30-A) and Battery

Cover (30-B)

2. Secure new Cover (30-B) to Case (30-

H) with Screws (30-A)


Figure 30

31

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



Allen Key 2 mm

Allen Key 4 mm (2x)

Cutter

Crimp tool


Small Rod (diameter 15 mm)

Figure 32 refers to Seat model E0-00-1-060,

Figure 33 refers to Seat model E0-00-1-201.

1. Close the Seat in the folded down position (for the model with a lock, which is situated on the upper left hand side of the Seat: lock it)

2. Cut the Cone End (32-M, 33-D) from the

Cable (31-C) and remove Cable

3. Thread the Bottom Lock Pin (31-A) and

Spring (31-B) onto the Bottom Lock Pin

Cable (31-C)

4. Thread the Cable through the Bottom

Lock Pin Housing (31-D)

5. Thread the Cable Backstop (31-E) onto the Cable and screw it into the Housing so that approximately 3 mm. of thread is still visible and tighten it

6. Thread the Bottom Lock Cable Guide

(31-F) onto the Cable and thread the

Cable Guide through the Cable Sleeves

(31-G)

7. For Seat model E0-00-1-060: a. Thread the Cable Guide through the

Cable Guide Bracket (32-H) b. Thread the first Cable Lock (32-J) onto the Cable and thread the Cable through the Cable Bush (32-K)


Figure 31

Figure 32

32

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. Thread the second Cable Lock (32-L) onto the Cable, take up the slack and tighten the Lock against the Bushing

(32-L) f. Trim the Cable to approximately 20 mm. and crimp the Cable End Cone

(32-M) onto the end of the Cable

8. For Seat model E0-00-1-201: a. Insert Cable through Cable Stops (33-

A) in Cable Holder (33-B), ensure that the Cable does not slack and close

Cable Stops

NOTE: Seat Backrest needs to be in an upright position

NOTE: Keep Cable Holder in place with a small rod (diameter 15 mm) b. Secure End (33-C) with Cable End

Stopper (33-D); ensure that the bend is outwards

Groove (33-E) d. Place Pivot Cap (33-F) over Cable

Holder e. Apply some Loctite in Nut (33-G) and screw on Pivot Screw (33-H) f. Apply some Loctite in Nut (33-J) g. Assemble Pivot Cap (33-F) with Pivot

Screw (33-H) and secure with Nut

(33-J)

9. Test the efficiency of the assembly by unfolding the Frame Assembly, adjust as necessary

Figure 33


Kit Number E0-00-1-060 (serial # up to and including 0304999)


Tools:


Pliers

Cutter

Crimp Tool


1. Disconnect the Lock Pin Cable from the seat, see instruction 3.22

2. Remove the two Screws (34-A) holding the Seat (34-D) to the "U" shaped Seat

Attachment Bracket (34-B), the Sleeves

(34-C) and Seat (34-D)

3. Insert the two frame seat support

"horns" (34-E) through the seat holes

(34-F)

4. Attach the replacement Seat (34-D) to the Bracket (34-B). Place the Sleeves

(34-C) between the holes in the Bracket

(34-B) and tighten the two Screws (34-

A) until any lash is removed. Over tightening may cause friction on the frame tube resulting in higher folding effort.

5. Attach the Lock Pin Cable and adjust its locking function, see instruction 3.22

Figure 34a


Figure 34b

34

3.25 Seat Back Pad

Kit Number E0-00-1-061 (up to and including serial # 0304999)


Tools:


1. Remove the Screw Covers (35-A)

2. Remove the Screws (35-B) and Back

Pad (35-C)

3. Align the tubes (35-D) of the Back Pad with the holes in the Seat Back (35-E)

4. Secure Back Pad with Screws (35-B)

5. Place Screw Covers (35-A)

Figure 35


3.26 Seat Bottom Pad



Tools:



For removal and attachment of Seat, refer to

Figure 38, but without removing the Lock

Pin Cable.


Attachment Bracket (34-B) and the

Sleeves (34-C)

2. Remove the Screws (36-A) and Bottom

Pad (36-B)

3. Align the tubes (36-C) of the Bottom

Pad with the holes in the Seat Bottom

(36-D)

4. Secure Bottom Pad (36-B) with Screws

(36-B)

5. Attach the Bracket (34-B) to Seat (34-

C). Place the Sleeves (34-C) between the holes in the Bracket (34-B)

6. Apply Loctite to the two Screws (34-A) and tighten them until any lash is removed. Over tightening may cause friction on the frame tube resulting in higher folding effort.

Figure 36


3.27 Seat Backrest Lock kit


Tools:


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. Attach Knob (37-B) to Stopping Snib and secure it with Washer (37-C) and

Screw (37-D)

4. Check that a some effort is needed to open and close Lock

5. Check opening and closing functions of

Lock and Seat

Figure 37


3.28 Seat Attachment Bracket



Tools:



Refer to Figure 37


Attachment Bracket (34-B) and the

Sleeves (34-C)

2. Remove the Bracket (34-B)

3. Attach the new Bracket (34-B) to Seat

(34-C). Place the Sleeves (34-C) between the holes in the Bracket (34-B)

4. Apply Loctite to the two Screws (34-A) and tighten them until any lash is removed. Over tightening may cause friction on the frame tube resulting in higher folding effort.


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 detergent and wipe dry with a clean cloth

3. Remove protective film from Tape sections (38-C)

4. Secure Platform (38-A) to Frame (38-B) with two clamps

5. Leave for 15 minutes before removing the clamps

Figure 38


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. Apply pressure to the end of the Pin so that it projects through the Pin Housing, place Washer (39-D) and fit Circlip (39-

E) into its groove at the end of the Pin

4. Insert the Pull Ring (39-F) into the hole in the end of the Pin

5. Test the assembly to ensure that the Pin returns to its original position after pulling on the Pull Ring

3.31 Ring for folding lock

Kit Number E0-00-1-066

Refer to Figure 39.

1. Remove old Pull Ring from the Pin

2. Insert the Pull Ring (39-F) into the hole in the end of the Pin

Figure 39


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. Place new Wheel (40-A) on Axle of

Rear Frame (40-D)

3. Fit new Circlip (40-B) into its groove at the end of the Axle

4. Fit new End Cap (40-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

Figure 40


Figure 41

41

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 prevent paint damage

2. Remove the old Clip (42-A) from the

Tube (42-B) by prying on the end

3. Align the new Clip’s slotted stud with the hole in the Tube. Tap it into place using a mallet or by squeezing with your fingers

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 42


3.34 Flat Cap (front platform)

Kit Number E0-00-1-074

Tools:

Screwdriver and/or

Pliers

Soft Mallet


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


3.35 Front Platform Paint Protector Clips

Kit number E0-00-1-073

Tools:

Screwdriver

Soft Mallet


2. Remove the old Clip (44-A) from the

Tube (44-B) by prying on the end

3. Align the new Clip’s slotted stud (44-A) with the hole in the Tube (44-B). Tap it into place using a mallet or by squeezing with your fingers

Figure 44


3.36 Domed Caps (Seat Supports)

Kit Number E0-00-1-075

Tools:

Screwdriver and/or

Pliers

Soft Mallet


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

3.37 Rear Frame Paint Protector Clips

Kit number E0-00-1-071

Tools:

Screwdriver

Soft Mallet


2. Remove the old clip (46-A) from the

Tube (46-B)

3. Align the new Clip’s slotted stud (46-A) with the hole in the Tube (46-B). Tap it into place using a mallet or by squeezing with your fingers.


Figure 45

Figure 46

45

4. PROGRAMMING OF THE SOLO CONTROLLER

4.1 Introduction

The EasyTravel electric system is operated by the Solo Controller manufactured by Penny & Giles Technologies Ltd. (UK).

The SP1 is a handheld programmer for use with the Solo 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 characteristics, 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 identified and corrected quickly.

?

Yes

No

Enter

WARNING

Figure 47

Programming should only be conducted by competent personnel with in-depth knowledge of Penny

& 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.

46 Easy Travel – Service Manual Rev. 0401

The following table shows the Solo Controller settings for the EasyTravel as defined by Tzora Active Systems.

Function Fast Slow

Forward Acceleration

Forward Deceleration

Reverse Acceleration

Reverse Deceleration

Forward Speed

Reverse Speed

Invert Throttle Polarity

*Power Down Timer*

Current Limit

Motor Compensation

Hold Factor

Mid Current

Brake Time

ISO Tests

Inhibit Polarity

Bridge Hold Time

Throttle Gain

Pulse Reverse Alarm

Wig-wag Throttle

Low Battery Flash Inhibit

Throttle Deadband

Output Voltage

TruCharge Cable Resistance

TruCharge Cal.

2.0 s

0.9 s

3.0s

2.5s

100%

50%

No

10 min

20A

200mΩ

152%

50%, 10 s

0.1s

Off

Lo

200 ms

750%

No

Yes

No

15%

24V

40mΩ

95

2.0 s

1.3 s

3.0 s

2.5 s

50%

30%

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 the guide carefully before using the SP1b

Programmer.

Setting parameters to incorrect values could damage controllers and motors, and invalidate any warranties.


5.1 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.

5.2.1. Detecting that a Fault has occurred

A fault is signaled by a rapid flashing of the status indicator. Care should be taken because the controller gives a low battery warning by a slow flash of the status indicator. This is not a fault, just a reminder that you should charge your batteries. To detect a fault in the Solo Controller, the SP1b

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.

5.2.2. 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 vulnerable areas first.

Further information is to be found in the Programming and Fault Finding Guide that is shipped with the

SP1b Programmer.

5.2.3. Servicing of Defective Solo Controllers

There are no serviceable parts within the Solo 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 Active Systems. Incorrect repair or tampering could result in a hazardous defect in the EasyTravel.

Tzora Active Systems accept no liability for losses of any kind arising from unauthorized adjustment

or modification to the EasyTravel.


6. CONTROL CONNECTIONS AND ELECTRICAL WIRING

For more information please contact your authorized Tzora Distributor or Tzora Active Systems.

Easy Travel – Service Manual

Figure 48

Rev. 0401 49

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

Width: 80 mm (3.1")

Height: 50 mm (2.0")


E0-00-1-056

E0-00-1-093

E0-00-1-095

E0-00-1-706

E0-00-1-069

E0-00-1-035

E0-00-1-094

E0-00-1-708

E0-00-1-038

E0-00-1-707

E0-00-1-097

E0-00-1-067

8.1 List of Spare Parts Kits

Part Number

E0-00-1-046

E0-00-1-202

E0-00-1-701

Description

Control Panel Assembly – MobiGo

E0-00-1-034

E0-00-1-705

E0-00-1-032

E0-00-1-704

E0-00-1-059

E0-00-1-058

E0-00-1-703

E0-00-1-054

E0-00-1-702

E0-00-1-083

E0-00-1-096

Included in Kit Page

Control Panel, Top and Bottom Cover, Screws 6

Controller Cover ET1B Controller Cover, Screws

Controller

Battery Contacts

Interface Circuit Board ET1B

Battery contacts, Screws

Screws

Contacts and Charging Socket Assembly Screws

Control Cable

Motor End Cover ET1B

Motor End Cover ET1B PV

Screw

Screws

8

9

10

12

13

14

15

16

17

E0-00-1-080

Power Cable ET1B

Front Wheel Assembly

Gear Motor ET1

Gear Motor ET1B

Adapter Block Assembly

Upgrade Kit from ET1 to ET1B

Top Bearing for Steering Axis

Column Release Cable Kit

E0-00-1-078

E0-00-1-081

E0-00-1-001 (Red ET1)

Black Vinyl Cap

Protector Roller Kit

E0-00-1-002 (Blue ET1)

E0-00-1-003 (Red ET1B)

E0-00-1-004 (Blue ET1B)

E0-00-1-005 (Silver ET1B)

Column Frame

E0-00-1-020 (Normal)

E0-00-1-021 (Jumbo)

Battery Case

Securing Clip, Screw

Front Wheel, Allen Screw, Washer, Flat Cap

Adapter Block, positioning plate, quick release mechanism

Gear Motor PV, Power Cable PV, Interface

Circuit Board ET1B, Controller Cover ET1B

Pin, Spring, Cable, Cable Guide, Adjustable

Stop, Cable Stops, Release Bushing, Allen

Screw, Latch Bushing, Set Screws, End Cone,

Vinyl Caps

Roller, Threaded Rod, Cap Nuts

20

21

21

22

24

25

26

28

29

Handgrip pair, Column Release Cable, Paint

Protector Clips, Protector Roller, Control Cable, Power Cable

30

Electric Wiring, Screws

18

31


E0-00-1-022 (Normal)

E0-00-1-025 (Jumbo)

E0-00-1-079

E0-00-1-206

E0-00-1-060

E0-00-1-201

E0-00-1-061

E0-00-1-204

E0-00-1-062

E0-00-1-203

E0-00-1-063

E0-00-1-064

E0-00-1-204

Battery Cover – MobiGo

Platform Lock Pin Kit

Seat Assembly

Seat Back Pad

Seat Bottom Pad

Seat Backrest Lock

Seat Attachment Bracket

Screws 31

Pin, Spring, Cable, Adjustable Stop, Cable

Guide, Cable Locks, End Cone

Seat Bottom + Pad, Seat Back + Pad

Screws, Washers, Screw Covers

Screws

Bracket, Sleeves, Screws

32

34

35

36

37

38

E0-00-1-065

E0-00-1-066

E0-00-1-068

E0-00-1-072

E0-00-1-074

E0-00-1-073

E0-00-1-075

Folding Lock Pin Kit

Ring for Folding Lock

Rear Wheel Assembly

Front Column Paint Protector Clips

Flat Cap (Front Platform)

Front Platform Paint Protector Clips

Domed Caps (Seat Supports)

Pin, Spring, Washer, Circlip, Pull Ring

Rear Wheel, Circlip, End Cap

Full Circle Clip, Full Circle Clip with Notch

2 Caps

2 Semicircle Clips

2 Domed Caps

39

40

40

41

42

43

44

45

E0-00-1-071 Rear Frame Paint Protector Clips

8.2 Spare Parts Kit Index

Part Number

E0-00-1-001 (Red ET1)

E0-00-1-002 (Blue ET1)

E0-00-1-003 (Red ET1B)

E0-00-1-004 (Blue ET1B)

E0-00-1-005 (Silver ET1B)

E0-00-1-020 (Normal)

E0-00-1-021 (Jumbo)

E0-00-1-032

E0-00-1-704

E0-00-1-034

E0-00-1-705

E0-00-1-035

Description

Column Frame

Battery Case

Controller 10

Controller Cover ET1B

Gear Motor ET1

2 Full Circle Clips

Page

30

31

9

45

21

17

E0-00-1-038

E0-00-1-707

E0-00-1-054

E0-00-1-702

E0-00-1-056

E0-00-1-093

E0-00-1-095

Adapter Block Assembly

Control Cable

Power Cable ET1B

22

15

18


E0-00-1-706

E0-00-1-058

E0-00-1-060

E0-00-1-201

E0-00-1-061

E0-00-1-204

E0-00-1-062

E0-00-1-203

E0-00-1-063

E0-00-1-064

E0-00-1-204

E0-00-1-065

E0-00-1-066

E0-00-1-067

Interface Circuit Board ET1B

Seat Assembly

Seat Back Pad

Seat Bottom Pad

Seat Backrest Lock

Seat Attachment Bracket

Folding Lock Pin Kit

Ring for Folding Lock

Top Bearing for Steering Axis

E0-00-1-071

E0-00-1-072

E0-00-1-073

E0-00-1-074

E0-00-1-075

E0-00-1-078

E0-00-1-079

E0-00-1-206

E0-00-1-080

E0-00-1-081

E0-00-1-083

E0-00-1-096

E0-00-1-094

E0-00-1-708

E0-00-1-097

E0-00-1-703

E0-00-1-022 (Normal)

E0-00-1-025 (Jumbo)

E0-00-1-046

E0-00-1-202

E0-00-1-701

Rear Frame Paint Protector Clips

Front Column Paint Protector Clips

Front Platform Paint Protector Clips

Flat Cap (Front Platform)

Domed Caps (Seat Supports)

Black Vinyl Cap

Platform Lock Pin Kit

Column Release Cable Kit

Protector Roller Kit

Motor End Cover ET1B

Motor End Cover ET1B PV

Gear Motor ET1B

Upgrade Kit from ET1 to ET1B

Contacts and Charging Socket Assembly

Battery Cover – MobiGo

Control Panel Assembly – MobiGo

13

12

34

35

21

24

14

31

32

26

29

16

36

37

38

40

40

25

41

20

8

45

42

44

43

45

39

28

6


9. LIST OF TOOL TYPES

Phillips #1

Phillips #2

Short Phillips #2

Flat Blade


Circlip Pliers (normal)

Circlip Pliers (small)

Clamps

Allen Keys:

2 mm

3 mm

4 mm

5 mm

6 mm

8 mm

Crimp Tool

Cutter

Drive Punch

Extractor

Hot Air Gun

Light Grease/Lubricant

Pliers

Press/Vise/Mallet

Wrenches: Silicone Spray

Open End 8 mm

Open End 14 mm

Soft Mallet

Solder

Open End 19 mm

Torque wrench

Loctites:

#242 (1312)

Soldering Iron

#496 (3854)

The EasyTravel 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.

Blackburn, BB2 4HT UK


Easy Travel ET1B EasyTravel, ET1 EasyTravel electric scooter Service Manual

Assistant Bot

Service Manual

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

48

49

50

51

6

46

4

5

Yes

No

Enter

WARNING

WARNING

Key Features

Frequently Answers and Questions

What are the battery specifications for the EasyTravel electric scooter?

What are the recommended maintenance intervals for the EasyTravel electric scooter?

How do I program the Solo Controller for the EasyTravel electric scooter?

What is the weight of the EasyTravel electric scooter charger?

What should I do if I encounter a fault with the EasyTravel electric scooter?

Related manuals

Easy Travel ET1B EasyTravel, ET1 EasyTravel electric scooter Service Manual

Assistant Bot

Service Manual

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

48

49

50

51

6

46

4

5

Yes

No

Enter

WARNING

WARNING

Key Features

Frequently Answers and Questions

What are the battery specifications for the EasyTravel electric scooter?

What are the recommended maintenance intervals for the EasyTravel electric scooter?

How do I program the Solo Controller for the EasyTravel electric scooter?

What is the weight of the EasyTravel electric scooter charger?

What should I do if I encounter a fault with the EasyTravel electric scooter?

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