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CTM HS-268, Service Manual

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Service Manual

Product Qualified as CE for EU ●GMP for Taiwan (ROC) ●ISO9001, 13485 Certification

HS-268

　

/

　

HS-268M

581201-26800

Summary of Contents for HS-268

Page 1: ...Service Manual Product Qualified as CE for EU GMP for Taiwan ROC ISO9001 13485 Certification HS 268 HS 268M 581201 26800...

Page 2: ...Steering Component List Manual Version Automatic Version Accessory Component List Repair Items Preparations for Repairs Basic Maintenance Service procedures SERVICE 01 Steering Head Cover SERVICE 02 S...

Page 3: ...1...

Page 4: ...2...

Page 5: ...3 Manual...

Page 6: ...4 Automatic...

Page 7: ...5 Manual...

Page 8: ...6 Automatic...

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Page 12: ...10 Manual...

Page 13: ...11...

Page 14: ...12 Automatic...

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Page 18: ...rroded or damaged it should be replaced When reassembling the scooter please make sure to reassemble it in the proper order Make sure all the parts are secure and the scooter is in a good roadworthy c...

Page 19: ...ht failure Taillight failure N D lever abnormal does not work or is jammed Scooter forwards or backwards travel abnormal Electromagnetic brakes failure Battery pack has been damaged Battery pack does...

Page 20: ...the folding unfolding function see figure on the right 2 SERVICE 11 5 Folding Unfolding Board Repair Tapping error on the folding unfolding buttons If the Folding button is pressed when the scooter h...

Page 21: ...is being charged Turn off the main power and disconnect the charger Micro switch failure SERVICE 12 1 Micro Switch Repair Speed pot SERVICE 1 Steering Cover Repair Motor or relevant circuit failure So...

Page 22: ...ient for folding or unfolding Riding is not recommended and battery should be charged immediately 23 7v 23 4v Lead acid battery Lithium battery Remarks Number of lights LED 6 lights LED 5 lights LED 4...

Page 23: ...p it in a suitable dry place When parking ensure the seat is secured the N D lever set to D position and the power switch is Off Before carrying out any maintenance turn off the power and make sure it...

Page 24: ...Repair S6 4 Charger Repair SERVICE 07 Seat Repair S7 1 Seat Spring Repair SERVICE 08 Seat Bar Mechanism Repair S8 1 Seat Base Repair S8 2 Seat Base Spring Repair S8 3 Seat Locking Pin Repair SERVICE 0...

Page 25: ...unfolding board 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 t...

Page 26: ...g replacement of the top control board do not disturb the metal power switch in the center Make sure to match the connector colors and do not make modifications to any cables or connections Do not for...

Page 27: ...nnector figure on the right If it is not effective go to Buzzer Replacement below Buzzer Replacement Please refer to SERVICE 1 Steering Cover Repair steps first and then 1 Remove the screws 16mm 2pcs...

Page 28: ...llows 1 Remove the screws 16mm 2pcs on the handle and steering head front cover 2 Remove the steering head front cover and set it aside carefully 3 Remove the starter rod connector on the board 4 Remo...

Page 29: ...ws 1 Use needle nosed pliers to unfasten the nut 2 Remove the metal power switch nut 3 Take out the switch and replace it with a new one After the replacement of parts or re installation please follow...

Page 30: ...ng stops place the RF key near the metal switch the scooter can be unlocked and setting has been completed Replace the steering head top cover If this has not been effective refer to SERVICE 1 1 Top C...

Page 31: ...ing head charger socket After the replacement of parts or re installation please follow the exact reverse sequence for reassembly Lithium battery charger socket has 4 holes the Lead acid battery charg...

Page 32: ...ont 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...

Page 33: ...le on the top of the steering bar 3 Remove the adjustment screw 4 Disengage the central locking pin to separate the steering bar into upper and lower sections 5 Remove the main cable from the upper se...

Page 34: ...parts or re installation please follow the exact reverse sequence for reassembly Headlight Repair Refer to SERVICE 1 Steering Top Cover Repair steps first and then Find the headlight connector Reconn...

Page 35: ...in the middle so the wheel will go on properly 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...

Page 36: ...el 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 wash...

Page 37: ...v please refer to the following Battery Failure Instructions If the battery voltage is within the normal range but it cannot be charged the charger may be faulty Refer to SERVICE 6 4 Charger Inspectio...

Page 38: ...es special instructions for the removal and replacement of each kind of battery for the rest of the repair steps refer to SERVICE 6 1 Battery Pack Charger Socket SERVICE 6 2 Battery Pack Power Socket...

Page 39: ...ery inside the battery pack this can be very dangerous and represents a severe hazard Please refer to SERVICE 6 Battery Pack Repair steps and then Find the charger socket connector inside the battery...

Page 40: ...k Repair steps 1 Remove the battery pack charger socket 2 Squeeze the two sides of the charger socket inside the battery pack and 3 push it out of the battery pack gently 4 Replace the battery pack po...

Page 41: ...ft Lithium battery or PB right Lead acid battery 3 This switch resets the parameters to suit the type of battery Make sure to push the switch completely to the end either left or right If this is not...

Page 42: ...the country or region Input connector four pin Description The charging indicator shows Standby red light Charging orange light Charged green light 3 Lithium Battery Standard 4A Charger see figure on...

Page 43: ...he seat springs to release the seat latch 5 Push the seat bracket by thumbs towards the back of scooters to release the seat from latch 6 When the seat is released from latch grab the seat and push it...

Page 44: ...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...

Page 45: ...se 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 s...

Page 46: ...ick 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 When reassembling follow the exact reverse sequen...

Page 47: ...When removing the screws start with those on the sides and when replacing them start with those in the middle This makes it easier to set the cover outer locking pins in place 1 There are 9 holding sc...

Page 48: ...then 1 Find the three locking pins at the sides of the front lower cover left and right side cover 2 Push the pins outwards 3 Take the side cover off both sides When reassembling please follow the ex...

Page 49: ...he user and may also damage the scooter Spring Re installation Instructions Spring location Figure a on the right Long end to the left short end to the right Re install at the locking pin on the left...

Page 50: ...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 5 Rais...

Page 51: ...in cable connector Micro switch connector Electromagnetic brake connector Motor power connector Linear actuator power connector Remote control board power connector If the connections are good the wir...

Page 52: ...the right Check the connector for security and reconnect figure on the right If this is not effective go to the following Replacement Instructions Replacement Instructions Please follow the SERVICE 11...

Page 53: ...e possible to reinstall the battery pack Replacement Instructions Complete the SERVICE 11 Rear Top Cover Repair to remove the cover then 1 Unplug the rear top cover power socket connector 2 Squeeze th...

Page 54: ...separate it from the frame 5Take the rear fender off For re installation follow the exact reverse sequence of these steps Complete the steps of SERVICE 11 Rear Top Cover Repair to remove the cover th...

Page 55: ...ble 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 5 Locate the four screws 12mm 4pcs holding the...

Page 56: ...nector 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 2 When r...

Page 57: ...and unlock the scooter 2 Long press the folding and unfolding buttons at the same time for 2 seconds The board indicator orange light comes on to indicate it is ready for setup 3 Press either the fold...

Page 58: ...er and set it aside 2 Check all the connectors on the rear lower cover with the DR controller only connectors without locking Refer to the connector instructions in SERVICE 12 Rear Lower Cover for det...

Page 59: ...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...

Page 60: ...VICE 11 Rear Lower Cover Repair SERVICE 12 Rear Top Cover Repair SERVICE 5 Rear Wheel Repair SERVICE 2 Steering Bar Repair SERVICE 11 1 DR Controller Repair and after removing the above items then 1 U...

Page 61: ...ing 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 u...

Page 62: ...Before re installation apply a little gel to the threads on the valve to ensure they do not come loose see the picture on the right Be careful not to get any gel on the plunger because this will cause...

Page 63: ...tie x1pc on the frame and remove the steel cable 4 Use a cross head screwdriver to remove the screws 12mm 2pcs from the plastic shroud 5 Use a cross head screwdriver to remove the screws 20mm 2pcs th...

Page 64: ...driver 5 to unfasten the Allen socket screw 1pcs holding the inner side of the sliding track 2 Use the hex driver 5 to unfasten the other screw 1pcs at the front of the sliding track 3 Push the left...

Page 65: ...plates and the bolts and nuts need to be kept because they will not be provided with a new motor Please carry out the SERVICE 11 Rear Top Cover Repair SERVICE 12 Rear Lower Cover Repair SERVICE 5 Rea...

Page 66: ...cable which would disturb the connections 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...

Page 67: ...or gas spring for the manual version 4 Use an Allen driver 6 to hold the hex screws and turn the quick release nut by hand for removal 5 Take out the sliding base 6 At this stage the rear frame is com...

Page 68: ...pair manual version only Please carry out the SERVICE 13 Frame Repair SERVICE 13 1 Folding Unit Repair SERVICE 13 2 Sliding Track Repair SERVICE 13 6 Sliding Base Repair steps and then 1 Locate the ga...

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