CTM HS-268M, HS-268 Service Manual
Service Manual
HS-268 / HS-268M
Product Qualified as CE for EU ●GMP for Taiwan (ROC) ●ISO9001, 13485 Certification
581201-26800
Table of Contents:
Front Cover - Shroud Component List
1
Front Cover - Frame Component List
2
Rear Cover - Shroud Component List
3
•Manual Version
•Automatic Version
Rear Cover - Frame Component List
4
•Manual Version
•Automatic Version
Seat and Seat Options Component List
5
Front Wheel and Steering Component List
6
Rear Wheel and Motor Assembly Component List
7
..............................................1
...............................................3
...........................................9
4
6
8
9
.....................................11
..........................12
Steering Component List
8
•Manual Version
•Automatic Version
Accessory Component List
9
Repair Items
10
•Preparations for Repairs
•Basic Maintenance
•Service procedures
SERVICE - 01 - Steering Head Cover
SERVICE - 02 - Steering Bar
SERVICE - 03 - Front Lamp Cover
SERVICE - 04 - Front Wheel
SERVICE - 05 - Rear Wheel
SERVICE - 06 - Battery Pack
SERVICE - 07 - Seat
SERVICE - 08 - Seat Bar Mechanism
SERVICE - 09 - Front Lower Cover
SERVICE - 10 - Front Top Cover
SERVICE - 11 - Rear Top Cover
SERVICE - 12 - Rear Lower Cover
SERVICE - 13 - Frame
.....................................................................22
.............................................................17
13
15
16
21
23
30
32
33
34
35
41
42
44
46
48
53
59
123
Manual
Automatic
4
Manual
5
Automatic
6
789
Manual
10
11
Automatic
12
131415
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.
•This Service manual has been prepared for the automatic version of the scooter. However, it can be used
when making repairs to the manual version. Some special repair procedures are marked as being “manual
version only”.
•Some repair procedures are relatively complicated and may need the operation of two persons.
•Please refer to the torque specifications when you use electric, pneumatic, or even manual tools to tighten
bolts, screws and nuts, to prevent damage to scooter parts.
•The drawings and diagrams in the manual may be slightly different from the appearance of the actual
scooter. However the repair procedures remain the same.
•After disassembl,make sure the parts are set aside carefully to avoid losing any of them.
•When old parts are replaced with new ones, the screws, washers, pads or auxiliary fixation parts are not
provided with the news parts. It may be necessary to use original parts when reassembling the scooter.
However, if any screw, washer or other part should appear to be worn, corroded, 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 condition to avoid accidents or injury to riders
or others.
•After the repair and reassembly has been completed, a test drive should be done to check that the fault
has been eliminated and that the scooter functions properly.
•The following is a list of tools necessary for this work: For details of tool specifications, please refer to
the instructions provided in the repair steps.
The Service manual
Flathead
screwdrivers
Socket tool set
Diagonal pliers
Cross screwdrivers
Adjustable wrench
Service manual Reading Instructions :
•Please follow all the steps in the order they appear
Step 1 → Step 2 as shown in the illustrations.
•Please refer to the pictures for instructions and details.
The pictures appear on the right and include detailed
descriptions of the procedures to be followed.
•Operation step code
•Key location indication
•Arrow direction indication
Lineman’s pliers Rubber hammer
Allen keys or drivers
Brush
•Detailed item code
•Tools needed
•Torque limits
•Indication for notes
Caution
If these instructions are not followed
carefully the result could be damage
to the scooter, or even personal injury.
18+-2kgf-cm
18+-2kgf-cm
(This drawing is for illustration only)
Recommendation
Frequent reference to the manual
during the repairs will facilitate the
operation.
16
Service manual
Description of Failure :
Parts involved Nature of Failure
Buzzer
Buzzer function fault
Panel light controls abnormal
Control Panel
Failure lamp comes on
Headlight failure
Headlight / T aillight
Taillight failure
N-D lever
Throttle
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 not charge
Battery pack
Battery pack power connection failure
Lithium battery ← Conversion → Lead-acid
battery
Remote controller
RF key
Speed regulator
button
Remote control faulty or lost
Sensor abnormal or lost
Speed regulator does not work
Chapter reference and Trouble -
shooting Method
SERVICE-1-2
SERVICE-1-1
Buzzer repair
Top control panel repair
Refer to "Self-Diagnostic Warning
Light" on the next page
SERVICE-3-1
SERVICE-11-2
SERVICE-13-5
SERVICE-1-3
SERVICE-11-1
SERVICE-6
SERVICE-6-1
SERVICE-6-2
SERVICE-6-3
SERVICE-12-2
SERVICE-1-5
SERVICE-1-1
Headlight repair
Taillight repair
Electromagnetic brake
repair
Starter VR repair
DR controller repair
Battery pack
Battery pack - Charger
socket repair
Battery pack - power
socket repair
Change the battery
Remote control board
repair
RF key setting
Upper control board repair
Tire
Motor
Seat
Steering bar
Rear fender
Shroud
frame
Crack/deformation/yellowing/or puncture
Wheel track depth less than 0.5mm
Tire wobbles or is unstable
Motor action abnormal or makes noisy sound
Seat damage repair or seat replacement
Seat has become loose
Seat spring action abnormal
Height adjustment problem
Rear fender damaged or makes an unusual
sound
Damage to the exterior plastic shroud
Frame has been deformed or broken
SERVICE-4
SERVICE-5
SERVICE-13-4
SERVICE-7
SERVICE-8-3
SERVICE-8-2
SERVICE-2
SERVICE-11-4
SERVICE-1
SERVICE-9
SERVICE-10
SERVICE-11
SERVICE-12
SERVICE-13
Front wheel repair.
Rear wheel repair
Motor repair
Seat repair
Seat locking pin repair
Seat spring repair
Steering bar repair
Rear fender repair
Repairs to Steering cover
Front lower cover
Front top cover
Rear top cover
Rear lower cover
Frame repair
17
Service manual
Folding / Unfolding Errors :
Code
1
2
3
4
5
6
7
8
Description What to do
Power On Turn off the main power switch
Battery Low Charge the battery immediately
Seat springs fall off
Seatback is not flipped down
Scooter is not on flat ground
Foreign Object on footplate.
Optional accessories
interference
Folding / unfolding light indicator
on scooter is not in orange
(enter into sleep mode)
Refer to SERVICE-7-1 Seat Spring
Repair
Flip down the seatback and restart the
folding / unfolding procedure.
Scooter cannot be folding / unfolding if
it’s not placed (lay down) on a flat ground.
Please place the scooter on a flat ground
and restart the folding / unfolding
procedure.
Check and remove the object on the
footplate and restart the folding /
unfolding procedure.
Remove obstructions such as :
handrails or baggage etc.
Acton :
1.Please wake up the
folding / unfolding function
(see figure on the right)
2. SERVICE-11-5 Folding / Unfolding
Board Repair.
9
10
11
12
13
Tapping error on the folding /
unfolding buttons
Scooter folds incorrectly
Scooter anti-tipping angle is too
great
Remote control inactive
Folding / unfolding button inactive.
If the “Folding button” is pressed when
the scooter has already been folded
it will fold further. Press “Unfolding
button” again and do this until the
scooter has been fully expanded.
Possible Solution :
1. SERVICE-13-1 Solenoid Valve Repair
SERVICE-13-2 Folding Unit Repair
(manual version only)
2. SERVICE-13-3 Sliding Track Repair
3. SERVICE-13-7 Linear Actuator Repair
4. SERVICE-13-8 gas spring Repair
5. SERVICE-13 Frame Repair
6. SERVICE-13-6 Sliding Base Repair
Scooter has anti-tipping protection,
please place it on flat ground and to
correct the problem.
Solution :
1.Battery needs to be replaced.
2.Refer to SERVICE-12-2 Remote
Board.
Refer to SERVICE-11-5 Folding /
Unfolding Board.
18
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
with the battery indicator.
Manual Version-self-diagnostic warning light, shared
with the main power light.
Normal : remains on, as does the battery power
indicator.
Failure : flashes according to the nature of the
failure, see the table below.
Self-Diagnostic Warning Light
Number
of Flashes
1
2
3
4
Possible Cause Handling Method
Battery Low
Low Battery Fault
High Battery Fault
Current limit time-out or controller
overheat
N-D lever not set to D-position
5
Electromagnetic brake failure
The throttle is not in Neutral or the
folding / unfolding procedure is
uncompleted.
Normal : constant green light.
Failure : flashes according to the nature of failure,
refer to the table below.
The batteries are running low.
•Recharge the batteries.
The batteries have run out of charge.
•Recharge the batteries.
•Check the battery and associated connections
and wiring.
Handling method:
1.Disconnect the battery pack, and check
the battery condition.
2. SERVICE-6 Battery Pack Repair.
Do not drive up steep slopes or overload
the scooter.
Switch to D (drive) position. Turn off the power and
turn on again.
SERVICE-13-5 Electromagnetic Brake Repair.
Solution:
1. Repeat the folding or unfolding procedure.
2. SERVICE-1-3 Starter VR Repair.
6
7
8
9
The folding / unfolding procedure is
uncompleted
Scooter battery is being charged
Micro switch failure
Speed pot
Motor or relevant circuit failure
Main cable, controller failure or
controller temperature too high
Repeat the folding or unfolding procedure.
Turn off the main power and disconnect the
charger.
SERVICE-12-1 Micro Switch Repair.
SERVICE-1 Steering Cover Repair.
Solution:
1. SERVICE-11-1 DR Controller Repair
2. SERVICE-13-4 Motor Repair
Solution:
1. SERVICE-11-1 DR Controller Repair
2. SERVICE-2-1 Main Cable Repair
19
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