CTM HS-268M Service Manual
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CTM HS-268M Service Manual

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Service Manual
HS-268　/　HS-268M
Product Qualified as CE for EU ●GMP for Taiwan (ROC) ●ISO9001, 13485 Certification
581201-26800

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Summary of Contents for CTM HS-268M

  • Page 1 Service Manual HS-268　/　HS-268M Product Qualified as CE for EU ●GMP for Taiwan (ROC) ●ISO9001, 13485 Certification 581201-26800...
  • Page 2 Table of Contents: Front Cover - Shroud Component List ..........1 ..........3 Front Cover - Frame Component List Rear Cover - Shroud Component List •Manual Version •Automatic Version Rear Cover - Frame Component List •Manual Version •Automatic Version Seat and Seat Options Component List ...........9 Front Wheel and Steering Component List ........11...
  • Page 5 Manual...
  • Page 6 Automatic...
  • Page 7 Manual...
  • Page 8 Automatic...
  • Page 12 Manual...
  • Page 14 Automatic...
  • Page 18 Service manual Preparations for Repairs : •Please read this Service Manual carefully before attempting any repairs. Make sure you have identified the cause of the failure before you start. •Before starting to work on the scooter remove the battery to avoid electric shock or damage to components of the electrical system.
  • Page 19 Service manual Description of Failure : Chapter reference and Trouble - Parts involved Nature of Failure shooting Method Buzzer Buzzer function fault SERVICE-1-2 Buzzer repair Panel light controls abnormal SERVICE-1-1 Top control panel repair Control Panel Refer to "Self-Diagnostic Warning Failure lamp comes on Light"...
  • Page 20 Service manual Folding / Unfolding Errors : Code Description What to do Power On Turn off the main power switch Battery Low Charge the battery immediately Refer to SERVICE-7-1 Seat Spring Seat springs fall off Repair Flip down the seatback and restart the Seatback is not flipped down folding / unfolding procedure.
  • Page 21 Service manual Self-Diagnostic Warning Light : When the main power switch is turned on (4-2 Main power Switch Operation), The self-diagnostic warning light will flash if there be any malfunction or failure. Touch Version-self-diagnostic warning light, shared Manual Version-self-diagnostic warning light, shared with the battery indicator.
  • Page 22 Service manual Battery Indicator Instructions After turning on the main power switch, the scooter battery indicator should be checked : Number Lead-acid Lithium Remarks of lights battery battery LED - 5 ≥ 24.6V ≥ 27.4v lights LED - 4 <24.6v <27.4v lights Battery power may be...
  • Page 23 Service manual Basic Maintenance Instructions : Periodic maintenance of the scooter can prolong its life. This is particularly important after a rainy day, or. when humidity is high. Maintenance Recommendation : Seat : Clean with soap water and do not sit until the seat dries out. Frame : Please use clean water and a wet cloth for cleaning.

  • Page 24: Table Of Contents

    Service manual Repair Items : SERVICE - 01 - Steering Cover Repair ............23 S1-1 Top Control Panel Repair S1-2 Buzzer Repair S1-3 Starter VR Repair S1-4 Metal Power Switch Repair S1-5 RF Key Setting S1-6 Steering Head Charger Socket Repair SERVICE - 02 - Steering Bar Repair ............30 S2-1 Main Cable Repair...
  • Page 25 SERVICE - 1 Steering Cover Repair 1.Remove the steering head rear cover and panel screws (12mm, 2pcs) 2.Remove the three screws (12mm, 3pcs) on the steering head rear cover 3.Remove the starter rod screws (8mm, 2pcs) 4.Detach the steering head rear cover 5.Detach the panel and steering head top cover 6.Make sure all the connectors on the board are properly fastened ※When reassembling be sure to use the exact reverse sequence of operations.
  • Page 26 SERVICE - 1 - 1 Top Control Panel Repair 1.Remove the steering head rear cover and panel screws (12mm/2pcs) 2.Open the steering head top cover 3.Also remove all of the connectors on the top control board (refer to the instructions on the previous page for connectors) 4.Remove the four screws (8mm/2pcs) on the top control board 5.Remove the entire top control board and replace with a new one...
  • Page 27 SERVICE - 1 - 2 Buzzer Repair : Refer to SERVICE-1 Steering Cover Repair steps as follows : ※Find the buzzer connector (figure on the right) ※Re-connect the buzzer connector (figure on the right) ※If it is not effective, go to “Buzzer Replacement” below. Buzzer Replacement : Please refer to SERVICE-1...
  • Page 28 SERVICE - 1 - 3 Starter VR Repair : Please refer to SERVICE-1 Steering Cover Repair steps as follows: ※Find the starter VR connector (figure on the right) ※Re-connect the starter VR (figure on the right) ※If function is not restored go to “Starter VR Replacement” below.
  • Page 29 SERVICE - 1 - 4 Metal Power Switch Repair : Please refer to SERVICE-1 Steering Cover Repair steps as follows: ※Find the metal power switch connector (figure on the right) ※Reconnect the metal power switch connector ※If it is not effective, go to “Metal Power Switch Replacement” below.
  • Page 30 SERVICE - 1 - 5 RF Key Setting : Refer to SERVICE-1 Steering Cover Repair steps as follows : 1.Find the top control board setting button. 2.Press the metal switch once, and after turning on the power, the red metal switch light should be on.

  • Page 31: S1-6 Steering Head Charger Socket Repair

    SERVICE - 1 - 6 Steering Head Charger Socket Repair : Refer to SERVICE-1 Steering Cover Repair steps as follows : 1.Find the steering head charger socket and connector. 2.Remove the steering head charger connector. 3.Use a cross-head screwdriver to remove the charger socket screws (8mm, 2PCS) on the outside of the steering head.
  • Page 32 SERVICE - 2 Steering Bar Repair Remove covers as shown in SERVICE-3 Front Lamp Cover Repair, SERVICE-9 Front Lower Cover Repair, SERVICE-10 Front Top Cover Repair, and SERVICE-11 Rear Top Cover Repair. Then proceed as follows below : 1.Remove the rear frame - left side hook (2 pcs) main cable. 2.Cut and remove the cable tie (2 pcs) of the front frame at the left side.
  • Page 33 SERVICE - 2 - 1 Main Cable Repair : Follow the SERVICE-2 Steering Bar Repair steps and then 1.Please refer to SERVICE-1-2 Buzzer Repair / SERVICE-1-3 Starter VR Repair to remove the buzzer and VR controller. 2.Insert the front end of the main cable into the hole on the top of the steering bar. 3.Remove the adjustment screw.

  • Page 34: S3-1 Headlight Repair

    SERVICE - 3 Front Lamp Cover Repair: 1.Remove the screws (12mm, 2pcs) on the outside of the front lamp cover 2.Remove the screws (12mm, 2pcs) from the inside of the headlight cover 3.Push the front lamp cover gently upward to separate it from the frame ※After the replacement of parts or re-installation, please follow the exact reverse sequence for reassembly.
  • Page 35 SERVICE - 4 Front Wheel Repair : 1.Rotate the wheel to find the notch on the wheel cap 2.Insert a flat screwdriver into the notch and 3.Lift the wheel cap off to expose the hub 4.Remove the hexagonal headed bolt (#12) and washer in the center of the axle 5.Take the wheel off the axle.
  • Page 36 SERVICE - 5 Rear Wheel Repair : 1.Rotate the wheel to find the notch on the wheel cap. 2.Insert a flat screwdriver into the notch and. 3.Lift the wheel cap off to expose the hub. 4.Remove the hexagonal headed bolt (#12) and washer in the center of the axle. 5.Take off the wheel, and remove the black washer at the back.
  • Page 37 SERVICE - 6 Battery Pack Repair : 1.Remove the battery pack from the scooter 2.Turn it around and find the battery pack power socket 3.Use a multi-meter to measure the battery voltage. The black socket is negative the red socket is positive. 4.Observe the reading on the multi-meter.
  • Page 38 Battery Pack Wiring Inspection : 1.Remove the battery pack from the scooter. 2.Turn the battery pack over and locate the six screws that hold the cover. 3.Remove the screws (12mm, 6pcs). 4.Remove the cover and open the battery pack. 5&6.Remove the battery main cable connector first, then check the rest of the connectors. ※After removing the battery main cable connector, please set it aside safely.

  • Page 39: S6-1 Battery Pack -Charger Socket Repair

    •During the replacement of the battery pack, please remove the battery and prevent operation on the scooter directly to facilitate the replacement. •When turning the battery pack over, do not drop it, or put it down hard on the table. Place it down gently and avoid damage. Damage to a lithium battery may cause a serious accident.

  • Page 40: S6-2 Battery Pack -Power Socket Repair

    SERVICE - 6 - 2 Battery Pack-Power Socket Repair : Please refer to SERVICE-6 Battery Pack Repair steps first, then : ※Find the battery pack charger connector (Figure 1 below). ※Reconnect the battery pack charger socket connector. ※If it is not effective, please refer to the following “Replacement Instructions”. Replacement Instructions : After completing the SERVICE-6...
  • Page 41 SERVICE - 6 - 3 Battery Pack-Battery Removal Please carry out the SERVICE-6 Battery Pack Repair steps then : 1.Turn the battery pack over gently and remove the screws to open the battery pack. 2.Take the lithium battery out. 3.The sticker on the lithium battery has a serial number and all the relevant information about the pack, this including the battery specifications, warnings, date of manufacture, etc.

  • Page 42: S6-4 Charger Repair

    SERVICE - 1 - 1 Charger Repair 1.Lithium Battery Standard 2A Charger (see figure on the right) Output connector. Input range 100~240V (The mains plug may vary depending on the sockets used in the country or region.) Input connector : four pin. Description : The charging indicator shows Standby : red light / Charging : orange light / Charged : green light.
  • Page 43 SERVICE - 7 Seat Repair 1.Use wrench (#12) and hex key to loosen the bolts and nuts holding the seat in place at the back. 2.Remove the bolts, nuts and washers and set them carefully aside. 3.Compress the spring inwards with the fingers and pull it out of the hole in the seat slide bracket.

  • Page 44: S7-1 Seat Spring Repair

    SERVICE - 8 Seat Bar Mechanism Repair Follow the steps in SERVICE-7 Seat Repair to remove the seat. 1.Locate the rear fender and locking pin of the seat bar mechanism. 2.Push the rear fender outwards carefully to separate it from the seat bar mechanism. 3.Use an Allen key or driver to remove the socket head screws (5mm #10, 2pcs) on each side of the holding board.
  • Page 45 SERVICE - 8 - 1 Seat Base Repair Please refer to SERVICE-7 Seat Repair to remove the seat first, then : 1.Uses pliers to open the bar spring notch. 2.Separate the bar spring from the seat base. 3&4.Remove the hex screws (25mm #10, 4pcs) on both sides of the seat base and bar. 5.Take out the seat base.

  • Page 46: S8-3 Seat Locking Pin Repair

    SERVICE - 8 - 3 Seat Locking Pin Repair Please refer to SERVICE-8-1 Seat Base Repair to remove the seat base, then : 1.Loosen the quick-release screw. 2.Take the quick-release screw out. 3.Remove the top washer. 4.Remove the seat locking pin and spring from the other side of the seat base. 5.Take out the seat spring.
  • Page 47 SERVICE - 9 Front Lower Cover Repair 1.There are 9 holding screws at the bottom of the scooter front lower cover. 2.Remove the cover screws (12mm, 9pcs) and set them carefully aside. 3.Take off the cover. ※When reassembling, please follow the exact reverse sequence of these steps. •Before removing the cover, elevate the front of the scooter on blocks, or fold it, so that the front wheels are off the ground.

  • Page 48: S10-1 Front Top Cover- Side Cover Repair

    SERVICE - 10 Front Top Cover Repair Please follow the SERVICE-3 Front Lamp Cover Repair and SERVICE-9 Front Lower Cover Repair steps first, then : 1.Remove the front lamp cover and front lower cover. 2.Remove the central screw (16mm, 1pc) at the center of the front end of the top cover. 3.Take off the cover.
  • Page 49 •After removing the footplate spring, keep it aside carefully. The re-installation of the spring is more complicated. Refer to the following figures for instructions for its replacement •Step 5.When replacing the footplate spring, do not use too much force. This might deform it and cause a loss of function. •Please do not leave the footplate cover off, it must be replaced.
  • Page 50 SERVICE - 11 Rear Top Cover Repair 1.Remove the two inner screws (12mm, 2pcs) underneath the rear top cover. 2.Remove the rear footplate cover, by disengaging the three locking pins and pulling it upwards. 3.Take out the rear footplate cover. 4.Remove the four screws (12mm, 4pcs) at the rear of the top cover.
  • Page 51 SERVICE - 11 - 1 DR Controller Repair Picture showing rear top cover circuit connectors. Rear top cover - folding board control connector Rear top cover - taillight connector Rear top cover - battery power connector Remote control board - folding suppression connector Main cable connector Micro switch connector Electromagnetic brake connector...
  • Page 52 SERVICE - 11 - 2 Taillight Repair : Follow the SERVICE-1 Steering Top Cover Repair steps and then : ※Find the main cable connector (see picture on the right). ※Check the connector for security and reconnect if necessary (picture of the right). ※If this does not restore function, refer to the following method.

  • Page 53: S11-3 Power Socket Repair

    SERVICE - 11 - 3 Power Socket Repair Please follow the SERVICE-11 Rear Top Cover Repair steps, then : ※Find the rear top cover - power socket connector (picture on the right). ※Check the connector for security and reconnect (picture on the right).

  • Page 54: S11-5 Folding / Unfolding Board Repair

    SERVICE - 11 - 4 Rear Fender Repair Please follow the SERVICE-11 Rear Top Cover Repair steps for removal, then : 1.Disengage the locking pins on both sides of the rear fender and seat bar mechanism. 2&3.Remove the screws (12mm, 4pcs) on both sides of the rear fender. 4.Pull the rear fender back to separate it from the frame.
  • Page 55 SERVICE - 12 Rear Lower Cover Repair Please follow the SERVICE-11 Rear Top Cover Repair steps for removal, then : 1.Remove the rear top cover, and find the cable ties on both sides. 2.Cut and remove the cable ties on the wires on both sides. 3&4.Unplug all the connectors on the rear lower cover and DR controller.
  • Page 56 Connector Instructions : Solenoid valve connector-left. Solenoid valve connector-right. For other connectors, please refer to the instructions in SERVICE-11 Rear Top Cover Repair For solenoid valve repair, please refer to SERVICE-12-3 Re-installation Instructions : 1.Connector wiring needs to be passed through the rectangular areas marked in the figure, and the wires must be sorted according to the connector codes shown in the picture.
  • Page 57 SERVICE - 12 - 2 Remote Control Board Repair Remote Control Board Repair : Please carry out the SERVICE-12-1 Micro Switch Repair steps for removal, then : 1.Locate the waterproof cover of the remote control board inside the rear lower cover. 2.Remove the four screws on the cover.
  • Page 58 Remote Controller Internal Frequency Pairing Setting : Refer to the SERVICE-12-2 Remote Control Board Repair steps, then : 1.Remove the waterproof cover and set it aside. 2.Check all the connectors on the rear lower cover with the DR controller (only connectors without locking).
  • Page 59 Remote Control Board Replacement Refer to the SERVICE-12-2 Remote Control Board Repair steps, then : 1.Detach the battery connectors from the hooks on the rear lower cover. 2.Remove the connectors from the remote control board. 3.Remove the remote control board main cable. 4.Remove the four screws (8mm, 4pcs) holding the remote control board in place.
  • Page 60 SERVICE - 12 - 3 Supporting Wheel Repair Refer to SERVICE-9 Front Lower Cover Repair SERVICE-10 Front Top Cover Repair SERVICE-11 Rear Top Cover Repair SERVICE-12 Rear Lower Cover Repair, and after removing the above items, then : 1.Secure the two fastening points on the supporting heel and the rear frame. 2&3.Use an Allen key or wrench (#10) to remove the holding screws (14mm, 2pcs) on both sides.
  • Page 61 150+-15kgf-cm 150+-15kgf-cm Re-installation Instructions : ※During re-installation of the screws and washers, please be careful about the placement of the gears on each side. The flat side of the gear must be flush with the front frame and the white dot must face upwards. An incorrect installation can result in a failure and will damage the scooter.
  • Page 62 SERVICE - 13 - 1 Solenoid Valve Repair : Please refer to SERVICE-12 Rear Lower Cover Repair steps first, then : ※Find the left and right -solenoid valve wiring inside the lower cover. ※Check the connections and re-connect the wires if necessary. ※If this does not restore function refer to the following “Solenoid Valve Replacement”.
  • Page 63 SERVICE - 13 - 2 Folding Unit Repair (manual only) Carry out all the SERVICE-11 Rear Top Cover Repair SERVICE-12 Rear Lower Cover Repair SERVICE-11-5 Rear Fender Repair steps, and when this has been done, then : 1.Locate the folding unit locking pins on each side of the bottom of the scooter frame. 2.Use a wrench (#17) to remove the locking pins.
  • Page 64 SERVICE - 13 - 3 Sliding Track Repair : Please carry out the SERVICE-11 Rear Top Cover Repair SERVICE-12 Rear Lower Cover Repair steps, and then : 1.Use a wrench (#13) to hold the nut and a hex driver (#5) to unfasten the Allen socket screw (1pcs) holding the inner side of the sliding track.
  • Page 65 SERVICE - 13 - 4 Motor Repair : Please carry out the SERVICE-11 Rear Top Cover Repair SERVICE-12 Rear Lower Cover Repair SERVICE-5 Rear Wheel Repair steps, and then : 1.Use a wrench (#13) to hold the nuts on the right side of the frame and an Allen driver (#5) to unfasten the bolts (30mm, 2pcs).
  • Page 66 SERVICE - 13 - 5 Electromagnetic Brake Repair : Please follow the steps in SERVICE-13-4 Motor Repair , and then: 1.Remove the motor, and locate the four screws holding the electromagnetic braking device to the motor. 2.Use a cross-head screw driver to remove the screws and separate the device from the motor.
  • Page 67 SERVICE - 13 - 6 Sliding Base Repair : Carry out all the SERVICE-13 Frame Repair SERVICE-13-1 Solenoid Valve Repair SERVICE-13-2 Sliding Track Repair, steps and then : 1.Remove the two screws in the middle of the frame. 2.Take out the U-shaped saddle. 3.Remove the screws under the linear actuator (gas spring for the manual version).
  • Page 68 SERVICE - 13 - 7 Linear Actuator Repair : Please refer to SERVICE-13-6 Sliding Base Repair. 1.The linear actuator and sliding base fastening point is located at the side of the top end of the gas spring. 2.Use an Allen driver (#5) to remove the holding screw (40mm, 1pc). 3.The linear actuator can then be separated from the sliding base.

This manual is also suitable for:

Hs-268

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