Doohan iTango User manual

iTango service manual
DH-MM1117-01

Contents
Chapter 1 Important instructions
Preface
Fault Report and suggestions
Warnings and Attentions
Chapter2 General information
VIN location
General specification
Chapter 3 Service materials
Standard parts specification &General torque
Preparation of dismantle & replace
Washer,oil seal
Bearing and oil seal
Check connecting parts
Chapter 4 Inspection & adjustment
Inspection & adjustment of steering column
Shock absorber inspection
Braking inspection & adjustment
Tire inspection
Cable inspection & lubrication
Adjustment of light beam of headlight
Chapter 5 Body of vehicles
Front wheel Front shock absorber assy
Rear shock absorber assy
Pull rod assy. Steering knuckle&wheel bearing assy
Swing arm assy, parking bracket holder.
Chapter 6 electric parts introduction & malfunction service
Location of electric parts
Function introduction of electric parts
Electrical schematic Plug access checking Fault phenomenon & service methods

Chapter 1 Important instructions
Preface
iTango's specifications, maintenance procedures, adjustments and diagnostics will be introduced in this service manual.
The service provider that authorized by Zhejiang Doohan Technology Co., Ltd. should well understanding this manual and provide
the best after service for the end users.
All products, special tools and parts has been referred in the user manual, you should obtain it from Zhejiang Doohan Technology
Co., Ltd.
The deadline of information is June 30, 2017
No part of this manual may be reproduced or transmitted in any form without the written permission of Zhejiang Doohan Technology
Co., Ltd.

Fault report & suggestion
We are willing to accept or update if you find any fault in the service manual or suggestions for us.
Any fault report and suggestions, you can sent mail to Zhejiang Doohan Technology Co., Ltd. The contact information as follows:
Zhejiang Doohan technology co.,ltd after sales department.
Additional information you should submit as follows:
Your name
Your VIN
The description for the problem you faced
Necessary information (sample or page of marked)
Zhejiang Doohan Technology Co., Ltd. will reply to your question as follows process:
Submit your questions to related service engineers
The related engineers will double analyzing,checking or testing to find answer
Update answers to you within 10 working days.
Welcome to submit any problems whatever you cared to the service department of Zhejiang Doohan Technology Co., Ltd.

Warnings and Attentions
Definition
The maintenance information listed in the service manual to assist the technician for diagnosing and servicing in order to the vehicle
can running normally; however, if not operated as recommended, some processes may be dangerous. The warning and caution
items are made to prevent danger, but not all of the dangers can be expected. These information is prominently placed in the service
manual in order to prevent the following items:
⚫Serious injury to the technician
⚫Damage the vehicle
⚫Unnecessary vehicle maintenance
⚫Unnecessary parts replacement
Warning definition
When you see the warning item, it means you should take the necessary measures or not take prohibited measures. If you ignore the
"warning", the following consequences will be faced:
⚫Serious injury to the technician
⚫Serious injury to the other technician on the same working area
⚫If the vehicle is improperly repaired, the driver will be seriously damaged.
Attention definition
"Attention" requires special attention to the necessary measures or prohibited measures. If you ignore "attention", the following
consequences will be faced:
⚫Vehicles damaged
⚫Unnecessary vehicle maintenance
⚫Unnecessary parts replacement
⚫System and parts abnormality or performance defects.
⚫System or parts damaged which support for maintenance of system or parts.
⚫System and parts abnormality or performance defects which support for maintenance of system or parts.
⚫Damage the fasteners, Basic tools or special tools.
⚫Brake Fluid leakage
Warning about disconnecting the power supply
Warning: the key must be on the "OFF" or "LOCK" position before maintains any electrical parts, and all electrical load must be
"OFF" unless it is available as defined by other instructions in the operation procedure. If the tool or the exposed electrical terminal,
the battery cable is necessary to disconnect. If violate these safety instructions, which may result in injury or damage to person and
vehicles.
Warning about irritation of brake fluid.
Warning: brake fluid is stimulus on the eyes and skin. take the following measures once in contact.
Eye –thoroughly wishing with water.
Skin- washing with soap and water.
If swallowed - see a doctor immediately
Attentions of fasteners
Special attentions: Use the correct fasteners in the correct position. The replaced part number of fastener must be correct. Do not
use paint, lubricants or corrosion inhibitors on fasteners or fastener connection surfaces unless other instructions. The torque and
coupling force of the fasteners will be affected or damaged by those materials. When installing the fasteners, be sure to tight the
fastener with correctly torque based on the right tightening sequence .

Chapter 1 General information
VIN location
When the vehicle is registered or received a traffic license, it is necessary to report the vehicle identification number and the motor
number. also need to be provided the above number for quality claim.
①Vehicle identification number (VIN) sign belongs to the vehicle's legal identifier.
☆L1TSD4Z4*********☆
②Vehicles nameplate information.
③Motor series No.

General specification
Main dimension
length
1648mm
width
651mm
high
1110mm
wheelbase
1150mm
front track
460mm
Main performance
curb weight
74kg(not include battery)
Front and
rear axle
distribution
of curb
weight
Front 23kg/rear 33kg(not
include battery)
Top
designed
speed
iTango
Classic(DH-05-10):
25km/h;
iTango
HO(DH-05-12):
45km/h
rated
voltage
48V
load
capacity
200kg
Brake
distance(dry
road)
≤2m(20km/h)
≤3.5m(30km/h)
person
2
Standard
power
consumptio
n
iTango Classic: 50KM(25km/h)
iTango HO:
50KM(45km/h),70KM(25km/h)
Braking
distance(wet
road)
≤3m(20km/h)
≤4m(30km/h)
Frame
front shock absorber
Sleeve& oil damping
rear shock absorber
Sleeve & oil damping
front tire spec.
70/90-12×2
rear tire spec.
90/70-12
Front wheel tire
pressure(kpa)
225±10
rear wheel tire
pressure(kpa)
225±10
wheel model(aluminum
alloy)
front 2.15-12 inch aluminum wheel
rear motor
2.15-12 motor
front brake
disc brake
rear brake
disc brake
minimum ground
clearance
142mm
seat height
740mm
max leaning angle
≤30°
max steering angle
≤32°
turning radius
2.50m
max drop height of front
wheel
180mm
battery system
battery model
18650 lithium battery
voltage
48V

capacity
20AH（DH-05-10）
26AH (DH-05-12)
charger input voltage(V)
AC 220V or 110V(optional)
charger output voltage(V)
58V
standard charging
current
3A（iTango-C）
5A(iTango-H)
standard charging time
6H
max range
50KM
battery weight
10KG
battery recycle times
500 times
range of battery using
ambient temperature
-20℃to 60℃
range of battery storage
ambient temperature
-20℃to 60℃
range of battery charging
ambient temperature
0℃to 45℃
Battery protection system
over discharging protection, short circuit protection, overheat
protection, over charging protection, over current protection,
battery balance protection
others
USB charging port
5V、1A
dashboard
LCD dashboard
fuse spec.
5A
headlights spec.
12V LED
front locating lights spec.
12V LED
front turning lights spec.
12V LED
rear turning lights spec.
12V LED
taillights spec.
12V LED
license plate lights
12V LED
rear mirror
Non-circular paint rearview mirror ,M8 mirror pole
gross weight
84kg(include 1 set battery)

Chapter 2 Services materials
Standard parts specifications and general torque
To inform the customer about the standard parts specifications and corresponding maintenance tools.
According to the ISO standard thread depth to define the locking torque of the standard firmware. The locking torque of the special
components or assembly is described in the relevant sections of the manual. To tighten the multi-firmware assembly to the specified
torque in a crisscross and progressive manner avoid bend. Unless otherwise specified, the locking torque should be based on the
cleaning and drying threads, and the components should be kept at indoor temperature.
1, The national standard GB / T 5789-2000 for hexagonal flange bolts, standard parts specifications, maintenance tool specifications
and general torque as following table:
2, The national standard GB / T70.1-2000 for hexagon head bolts, standard parts specifications, maintenance tool specifications and
general torque as following table:
3. The national standard GB / T 6177.1-2000 for hexagonal flange nuts, GB / T6187.1 for hexagonal flange self-locking nuts,
standard parts specifications, maintenance tool specifications and general torque as following table:
4, The national standard GB / T70.2-2000 for hexagon flat round head bolts, standard parts specifications, maintenance tool
specifications and general torque as following table:
A
B (spec.)
Open/wre
nch&sock
et
General torque( N.m)
10mm
M6
10#
10～13
12mm
M8
12#
25～35
14mm
M10
14#
63～80
A
B (spec.)
Open/wre
nch&sock
et
General
torque( N.
m)
4mm
M5
4#
4～7
5mm
M6
5#
10～13
6mm
M8
6#
25～35
8mm
M10
8#
63～80
A
B (spec.)
Open/wre
nch&sock
et
General
torque( N.
m)
7mm
M4
7#
2～3
8mm
M5
8#
4～7
10mm
M6
10#
10～13
12mm
M8
12#
25～35
14mm
M10
14#
63～80

5, The national standard GB / T 845-1985 for cross-slot head tapping screws, GB / T818-2000 for cross-groove round head screws,
maintenance tools for the unity of the screwdriver. Torque is not required, only need to be tighten.
Preparation of disassemble & replacement
①Before cleaning or removing, clean the dust, dirt and foreign matter on the vehicle.
②When disassembling, be sure to place the pairing parts with groups. Pairing parts must be reused or replaced in groups.
③When disassembling, clean all parts and place them in the tray based on disassembly order. In doing so, it can save assembly
time and ensures that parts are installed correctly.
④Keep all parts in a location away from fire and water
Washer and oil seal
The washer surface, oil seal must be cleaned before assembled.
Bearing & oil seal
To keep clearly for the mark of manufacturer and series number when install the bearing and oil seal, When installing the oil seal, to
spread on the oil seal lip by a small amount of grease of lithium soap base. To lubricate the bearing by lubricating oil after installed.
Attention:
Do not use compressed air to rotate the bearing, which can damage the bearing surface.
Inspect the connecting parts
Check wiring, coupler joints whether with dirt, dust or water and so on.
1.Connection:
①wiring
②coupler
③connector
2. Inspection
①wiring
②coupler
③connector
Water stain - dry with air guns
Dust, dirt - repeated remove and connection several times
3. Inspection
①check all connecting part
②Loosen joint parts: correct connection
Attention
Regain it If the pin on the terminal is flattened.
4.connection
①wiring
②coupler
③connector
A
B (spec.)
Open/wre
nch&sock
et
General
torque( N.
m)
3mm
M5
4#
4～7
6mm
M8
5#
25～35

Attention
Make sure all joint part have been locked.
5.Inspection
(Using multimeter) to continuously check other related items.
Attention
If there is no need to continue to check the items, please
clean the terminals.
follow up steps 1 to 3 to check the wire jacket.
To correct it quickly, use the contact 【Contact restorer】.

Chapter 3 Inspection & adjustment
This chapter contains all the information what is items must be checked and adjusted. If regularly implement these maintenance
procedures, it will make the vehicle more smoothly driving and life can be extended. The cost of relative maintenance will be down.
The information has been described in this chapter applies to vehicles that are not sold and sold. All service technicians should be
familiar with all information in this chapter.
Steering column inspection&adjustment.
1. Place the vehicle on a flat table. Put up the main stander to let the front wheel off the ground.
2.inspection
⚫Steering column
Hold the front wheel and shake it up and down.
Steering column is jammed or loosened –adjust it
3. Remove
⚫Front panel and tools box(refer to chapter 4 :plastic parts)
4. Adjustment
⚫Steering column
a. Remove the locking nuts 1.
b. Loose locking nuts 2, then use the ring wrench to lock based on the specified torque.
Attention
Don’t allow to lock the round nuts too tight.
C. Check the rotation of steering column whether it is loosen or stuck. If stuck, please check the top & lower bearing of top tube. If
damaged - replace.
D. Use the ring wrench to fix the lock nut 2 and lock the upper locking nut 1.
5. Installation
⚫Front panel and tool box(refer to chapter 4 plastic parts).
Inspection of shock absorber
Inspection
⚫Inner pipe of shock absorber
Damage/scratch--replace.
⚫oil seal
leakage-replace
⚫Check whether the action of shock absorber is working smoothly.
If not working smoothly--please change a new one.
Inspection & adjustment of brake
1. Inspection
⚫free clearance of brake handle
⚫Over standard value-adjustment.

Attention
The free clearance of brake handle is 10-20 mm subject to the end of the brake handle.
Inspection & adjustment of rear drum brake
1. brake operation
2. inspection
⚫wear indicator
Attention
When the wear indicator points to the wear limit line, replace the whole brake block.
3. adjustment
⚫free clearance of brake handle
⚫Rotate the rear brake nut 1 with clockwise and counterclockwise direction until to fit the specified free clearance of brake
handle.
clockwise
Increased, free clearance of brake
handle
countercloc
kwise
Decreased, free clearance of
brake handle
Attention
To make sure the brakes are not towed after adjusting the free clearance of brake handle.
Tire inspection
The following procedure is suits for inspection of front & rear tire
1. Tire checking
①Tire pressure
Over standard value( standard:225±10KPa): Adjust tire pressure.
Attention
⚫Please check and adjust the tire pressure when the tire temperature is equal to the outdoor temperature.
⚫Riding an overloaded vehicle can cause damage to the tire or accidental injury.
⚫Do not overload.
2.tire surface
Ⅰtire tread depth
Ⅱwear indicator
Min tire tread depth
front tire
rear tire
1.5mm
2.0mm

If damaged or scratched, please replace.
Attention
Don’t try to repair a tire which has been punctured. If must to repair it, please be careful and replace with high quality tires as soon as
possible.
tire spec.
front tire
rear tire
70/90-12
90/70-12
1:The tire has a sign of the direction of rotation
Attention
When the tires are installed, keep the symbols of tire tread to
toward the rotating direction of the wheel.
3. Rim inspection
⚫rim
⚫If damaged or scratched, please replace.
Attention
If rime is damaged or deformed, do not repair it, please replace with a new one.
Inspection & lubrication of cable
The following procedures applies to all cables.
1.Inspection
⚫cable
Damaged--replacement
2. Inspection
⚫cable operation
Poor operation -lubrication
lubricant
Engine oil or suitable wire rope lubricants
Attention
⚫The damaged cable will affect the function. Please replace the cable as soon as possible.
⚫Hold the cable end vertically and drip little lubricants in the cable or use the appropriate lubrication equipment.
⚫
Adjustment of headlights beam
1. Remove
⚫front panel
2. adjustment
⚫Rotate the adjusting screw with clockwise ①, the headlight beam down
⚫Rotate the adjusting screw with counterclockwise ①, headlight beam up

Chapter 4 Vehicles Body
Plastic parts
Sequence of Operation
Spare parts name
Quantities
Remarks
1
2
3
4
5
6
7
8
9
Remove plastic parts
Front panel
Helmet hook
Tool box
Lower interior lining panel,Front
panel lower liner
Lower part, Tool box
Frame left/right fender
Right/left strip
Frame base plate
Pedal
2
1
4
1
1
1
1
1
1
Remove parts as sequence.
Parts assembling with the
reverse order of
disassembling.
Front wheel

Sequence of Operation
Spare parts name
Quantiti
es
Remarks
1
2
3
4
5
Remove front wheel
Hexagon socket head cap screws, M5×10
Trim strip, Front axle.
Hexagon socket head cap screws M10×25
Front aluminum rim
Front tire
2
1
4
1
1
Disassemble parts in order
Attention
To hold up the vehicle by
appropriate bracket to
suspend.
Parts assembling with the
reverse order of
disassembling.
Disc brake & bearing
Sequence of Operation
Spare parts name
Quantities
Remarks
1
2
3
4
5
6
7
Remove disc brake
Round nut
Retaining washer
Disc brake holder
( 6004-2Z )bearing
Bushing
Screw,Disc brake screw
Front disc brake
1
1
1
2
1
4
1
Disassemble parts in order
Attention
To hold up the vehicle by
appropriate bracket to suspend.
Parts assembling with the
reverse order of disassembling.

1.Inspection
⚫Wheel bearings: if front wheel rotation is not smooth or loose, please replace the wheel bearings.
⚫Bushing
Damaged or scratched-replace.
Inspection of front disc brake
To inspect and adjust the brake block as follows.
1. Inspection
⚫Shoe block, Front hydraulic brake.
Shiny parts - repair
To polish with raw emery paper
Attention
To clean the shoe block after grinded by raw emery paper.
2. Measurement
⚫The thickness of the shoe block of front hydraulic brake
Overstep standard value - replacement.
The limited thickness of shoe block: 1.5mm
Attention
⚫Do not leave oil or butter on shoe block.
⚫Replace whole shoe block if abrasion is out of limited value for any side of shoe block.
3. Measurement
⚫Thickness of brake disc
If overstep the standard value - replace the brake disc.
The limited thickness of shoe block: 3 mm
4. Inspection
⚫Cross section of brake disc.
if adhesive oil - cleaning
To wipe with cloth of lacquer diluent or oil cleaner.
Scratched - maintenance.
To polish the scratched parts with raw emery paper
Front Shock Absorber Assy

Sequence
of
Operation
Spare parts name
Quantities
Remarks
1
2
3
Disassemble the front shock
absorber assy
Front shock absorber assy
M10×45 ,Hexagonal flange bolt
M10,Hexagonal flange nylon
self-locking nut
1
2
2
Disassemble parts in order
Parts assembling with the reverse order
of disassembling.
Inspection of shock absorber
⚫Shock absorber rod
Deformed/damaged--replace shock absorber assy.
⚫Shock absorber
Leakage--replace shock absorber assy.
⚫Spring
Wear/damaged--replace.
⚫Oil seal of dust proof
Wear/damaged--replace
⚫Bolt
Deformed/damaged/worn out--replace
Rear Shock Absorber Assy
Sequence of Operation
Spare parts name
Quantities
Remarks
1
2
3
4
Disassemble rear shock absorber
assy
M10×40 ,Hexagonal flange
Rear shock absorber
M10 Hexagonal flange nylon
self-locking nut
M10×60,Hexagonal round head
screws
2
2
2
2
Disassemble parts in order
Parts assembling with the
reverse order of
disassembling.

Ass,Pull rod of ball head, Steering knuckle axletree assy
Sequence
of
Operation
Spare parts name
Quantities
Remarks
1
2
3
4
5
Disassemble the ball head rod assy
M10,Hexagonal flange iron self-locking
nut
Pull rod of ball head, assy
M10×60,Hexagonal flange bolt
Steering knuckle axle assy
Spacer assy,bracket plate of steering
knuckle.
2
1
2
1
1
Disassemble parts in order
Attention
Both sides is symmetrical, Don’t
need to remove both sides when one
side need to service.
Parts assembling with the reverse order
of disassembling.

Inspection, pull rod of ball head.
⚫Pull rod
Bend/damaged——replace the assy of pull rod of ball head.
⚫Ball head bearing
Rotation is not flexible——clean the surface mud
Damage/loosen——replace ball head assy
⚫Hex nut
Loosen——adjustment
⚫Bolt
Bend/damage/wear——replace
Inspection of steering knuckle axletree assy
⚫Steering knuckle axletree
Bend/damage——replace the steering knuckle axletree assy
⚫Spacer assy of steering knuckle bracket plate
Bend/damage——replace
⚫Bearing
Rotation is not flexible——clean the surface mud
Damage/loose——replace steering knuckle axletree assy
⚫Oil seal of dust proof
Damage/scratched——replace.
⚫Steering knuckle rotary bearing
loosen——adjustment.
⚫Bolt、nut
Bend/damage/scratched——replace.
Swing arm assy
Fixed seat of parking bracket