C.T.M. HS-559 User manual

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ServiceManual‐ CTMHS‐559
2
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Content
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GeneralInformation...........................................................................................................................................3
CheckListformaintenance................................................................................................................................4
TroubleShooting................................................................................................................................................5
Disassembly........................................................................................................................................................7
Maintenance....................................................................................................................................................12
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ServiceManual‐ CTMHS‐559
3
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GeneralInformation
1‐1Introduction,
Thisservicemanualonlycontainsbasictechnicalinformationaboutthecommondisassemblyand
replacementtoenabledealerstoprovidegoodafterservice.Yourscooterfeatureandrelatedparts
mightdifferentfromthisservicemanual,whichisbasedondifferentdemandinvariousmarkets.Ifyou
needmoreproductinformationortechnicalsupport,pleasecontactwithCTM,wewillprovidemore
detailedinformation.
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1‐2TheManufacturer,
Thescooterisdesignedandmanufacturedby
ChienTiEnterpriseCo.,Ltd.
No.13,Lane227,FuYingRd.,HsinChuangDistrict,NewTaipeiCity,Taiwan
Tel :+886‐2‐29032987
Email:[email protected]om.tw
Web.www.chienti.com.tw
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1‐3InformationofEuropeanRepresentative
EmergoEurope
Prinsessegracht20
2514APTheHague
TheNetherlands
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1‐4WarrantyPolicy
PleaserefertoCTMwarrantypolicy.
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1‐5Servicelife
Weestimateaservicelifeoffiveyearsforthisproduct,provideditisusedinstrictaccordancewiththe
intendeduseassetoutinthisdocumentandallmaintenanceandservicerequirementsaremet.The
estimatedservicecanbeexceedediftheproductiscarefullyusedandproperlymaintained,and
providedtechnicalandscientificadvancesdonotresultintechnicallimitations.Theservicelifecanalso
beconsiderablyreducedbyextremeorincorrectusage.Thefactthatweestimateaservicelifeforthis
productdoesnotconstituteanadditionalwarranty.
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ServiceManual‐ CTMHS‐559
4
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CheckListformaintenance
CheckPoint Inspection Remark
N‐Dlever Checkforthecorrectfunction
Horn Checkforcorrectfunction 
Throttles Pullthewigwagtotestthescootermovement 
Electro‐mechanical
brakeandemergency
handbrake
Pullthewigwagalittlebitandreleaseittotestifbrake
works.Ifyourscootercomeswithemergencyhandbrake,
pleasecheckitaswell.
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BatteryGaugeCheckifthebatterygaugeisdisplayedandwhetheritisat
lowpower.
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Rearmirror(s) Checkifthepartsarecleanandfirmlytightentothescooter
anddonotwobble
‐Cleanupthedirtandtightenthescreworclamping
stemthatholdsthemirror(s)
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LightingCheckifalllights,suchasheadlights,rearlights,andturn
signalarefunctioningcorrectly.
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SpeedDialKnobCheckforcorrectfunction
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Armrests
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Seat/Upholstery
Checkifthepartsarecleanandfirmlytightentothescooter
anddonotwobble.Tightenthescrewknobthatholdsthe
armrest.
Checkformovementandifit’sworn
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Wheels/Tires
Inflatethetiretothecorrectpressureandcheckthat
1. Drivewheelsrotatewithoutwobbling.
2. Tiretreaddepthisnotlessthan0.5mm.
3. Noforeignobjectsintires.
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MotorCheckforcorrectfunction
BatteryChargerCheckifthechargerisfunctioningcorrectlyandthe
batteriesarecharged.
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ElectronicsCheckifallthebatterycablesandconnectorsarefirmly
tightentothescooter
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ServiceManual‐ CTMHS‐559
5
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TroubleShooting
3‐1Scooterwon’tmovewhenkeyinturnedon,
CheckPoint Solution
Checkifthepowerisoff Turnthepoweron.
CheckiftheN‐DleverisinNeutralposition SwitchtoD(drive)position.Turnoffthepowerand
turnonagain.
Checkifthebatterypowerisenough.(Battery
gaugeisunder25%)
Rechargethebatteryandthenretest.
Checkifthechargerpowercordisstillpluggedin
scooter
Unplugthechargerpowercord.
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3‐2ErrorCode
FlashDescription InitialCheckPoints
1Batterylow Thebatteriesarerunninglow.
‐Rechargethebatteries
2Lowbatteryfault Thebatterieshaverunoutofcharge
‐Rechargethebatteries
‐Checkthebatteryandassociatedconnectionsandwiring.
3Highbatteryfault Batteryvoltageistoohigh,thismayoccurifoverchargedand/or
travelingdownalongslope.
‐Iftravelingdownaslope,reducethespeedtominimizethe
amountofregenerativecharging.
4Currentlimittime‐outor
controlleroverheat
Themotorhasbeenexceedingitsmaximumcurrentratingfortoo
long.
‐Thescootermayhavestalled.Turnthecontrolleroff,leavefora
fewminutesandturnbackonagain.
‐Themotormaybefaulty.Checkthemotorandassociated
connectionsandwiring.
5ParkbrakeEitheraparkbrakereleaseswitchisactiveortheparkbrakeisfaulty.
‐Checktheparkbrakeandassociatedconnectionsandwiring.
‐Ensureanyassociatedswitchesareintheircorrectpositions.
6Driveinhibit EitherastopfunctionisactiveorchargerinhibitsorOONAPU
conditionhasoccurred.
‐Releasethestopcondition(seatraisedetc.)
‐Disconnectthebatterycharger.
‐EnsurethethrottleisinNeutralwhenturningthecontrolleron.

ServiceManual‐ CTMHS‐559
6
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‐Thethrottlemayrequirere‐calibration.
7Speedpot ThethrottlespeedlimitpotSRWortheirassociatedwiringmaybe
faulty.
‐Checkthethrottleandspeedpotandassociatedconnectionsand
wiring.
8Motorvoltage Themotororitsassociatedwiringisfaulty.
‐Checkthemotorandassociatedconnectionsandwiring.
9OthererrorThecontrollermayhaveaninternalfault.
‐Checkallconnectionandwiring.
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3‐3Otherproblem
Tire:Thetiresshouldbeinspectedfrequentlyfordamage,thepresenceofforeignbodies,unusualwear
andsufficienttreaddepth.Ifreplacementtiresareneeded,pleasecontactthenearestdealer.
Thefollowingareasrequireperiodicinspection:
‐Tirepressurebetween35‐40psi
‐Treaddepthdropsbelow0.5mm
Recommendedrangeofstorage,Tempe rature:‐30oc~+50oc,Humidity:25%~85%
Followtheseeasystepstoreplacethetire:
‐Turnoffthescooterandremovethekey.MakesuretheleverisinDpositionbeforeyouliftthescooter.
‐Usearatchetandsockettoremovethedrivewheelscrewfromthecenterhubofthewheel.Pullthe
wheeloffoftheaxle.
‐Separatethetirefromtherim.
‐Removetheoldtireandreplaceitwithanewtire.
‐Slidethewheelbackontotheshaft.
‐Installthedrivewheelnutintothecenterhubandverifythekeyislinedupwithaxleandwheel,and
thentightentosecureitinplace.(Torque300±30kgf‐cm)
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Charger:Duringcharging,lightonchargerdoesn’tchangetogreen.IfLED(POWER)lightisoff
‐Checktheinputvoltage(115V/230V)isthesameasyouadjust.
‐Iflightisstilloff,pleasecheckandrepairthebatterycharger.(B)IfLED(CHARGE)lightisoff
‐Checktoseeclipsconnectioniscorrect.
‐Ifthebatteryisfullycharged,theLED(CHARGE)lightwillbeoff.
‐Iflightisstilloff,thebatterymaybedefective.(C)IfORANGElightcanturntoGREEN
‐Thebatterycannotbecharged.Pleasecheckandrecoverit.(D)IfORANGElightturnstoGREEN
immediately
‐Checktoseethebatteryisfullycharged,ifnot,thebatterymaybedefectiveCheckandrecoverit.
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ServiceManual‐ CTMHS‐559
7
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Disassembly
4‐1Steering‐Starterassembly/VariableResistor
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Toolrequirement,
‐PhilipScrewdriver
‐12mmoffsetwrench
Instructionfordisassembly
A. Takeoutthebarofangleadjustablelever.
B. Removetherearmirrorbyhandor12mmoffsetwrench.
C. RemovethesteeringcoverbyPhilipscrewdriver
D. RemovethesteeringrearcoverbyPhilipscrewdriver.
E. Removethestarterassembly/variableresistorcomp.(30KΩ)
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Inspectionpoints
Whenassembling,pleaseusethetorquewrenchtomakesurethetighteningtorqueasthedrawing.
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ServiceManual‐ CTMHS‐559
8
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4‐2Frontframe–BarAssembly
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Toolrequirement,
29mmoffsetwrench
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Instructionfordisassembly
‐Whenchangingthepartsinthisarea,paymoreattentionaboutthissequence.Shouldtakenotethe
sequencewhendisassemble.
‐Belowlistisfromabove
12526680‐52800PADLOCK1
11536228‐56010NUT,STEERINGSTEMLOCK1
10536212‐56000WASHER1
9536211‐56000WASHERTOOTH1
8536213‐56000RACE,STEERINGOUTERUPPER1
7536215‐56000BALLSSET.2
Inspectionpoints
Whenassembling,pleaseusethetorquewrenchtomakesurethetighteningtorqueasthedrawing.
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ServiceManual‐ CTMHS‐559
9
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4‐3Frontwheel
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Toolrequirement,
12mmhex‐keywrench
13mmsocketwrench
12mmoffsetwrench/17mmoffsetwrench/32mmoffsetwrench

Instructionfordisassembly
A. Pleaseturnoffthescooterandremovethekey.MakesuretheNDleverisinDpositionbeforethisjob.
B. Leaksomeairfromwheelbeforeyoudisassemblethewheel.(referto4‐4)
C. Usearatchetandsockettoremovethefrontwheelscrewfromthecenterhubofthewheel.
D. Separatethetirefromtherim.
E. Replacetheparts(innertubeoroutertube)asthedemand.
F. Installthefrontwheelnutintothecenterhub,tightenitasthetorqueastheabovedrawing.
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Inspectionpoints
Whenassembling,pleaseusethetorquewrenchtomakesurethetighteningtorqueasthedrawing.
Rangeoftirepressureisaround35~40psi.
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ServiceManual‐ CTMHS‐559
10

4‐4Airtire

Toolrequirement,
5mmhex‐keywrench

Instructionfordisassembly
‐Beforeremovingthefrontandrearwheels,pleasedoremovesomepressurefromwheelstoprevent
anyaccident.
‐Use12mmhex‐keywrenchtorotatethecapasdrawing,
‐Thenremovesomepressurefromtire.
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