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SCOOTER CONTROLLER FAULT CODESFlashCode Fault Description1Battery Needs RechargingControllerActionsThe battery voltage has dropped below 23.3Vin neutral. Recharge the batteries soon.Remember Our c24.0vdc23.0vdc17.0vdcAt 23.3 vdc, you are not“a little bit low”. You arenearly EMPTY!A Scooter giving a FlashCode #1 will not betraveling much further.
SCOOTER CONTROLLER FAULT CODES2ControllerThe battery voltage has dropped to 16.5 vdc.Battery Voltage Too LowCheck the condition of the battery connections .Again, The Graph 1009080706050403020100At 16.5 vdc, theScooter can no dc17.0vdcAn Intermittent Code#2 could point to aloose or corrodedconnection.
SCOOTER CONTROLLER FAULT CODES3ControllerThe battery voltage is greater than 32V.Check the battery condition and theconnections. Suspect a charger malfunction.For a temporary solution, turn on the lightingsystem for a while in order to lower theBattery Voltage Too High battery voltage. The best thing to do in this case is to PROVE or RULEOUT the Charger as being the cause. Do this bymeasuring the VOLTAGE being delivered AT theBattery, while the Charger is connected and ON. Some models of CTM Scooters feature “RegenerativeBraking”, which allows the motor to act as a generatorduring coasting or while driving downhill. If this is thecase, instruct the user to set the Speed Pot to aSLOWER position before an extended downhill run tominimize this ‘overcharge’ condition.
SCOOTER CONTROLLER FAULT CODES4Current LimitTime OutControllerThe controller has detected a shorted motor. Check thehigh current electrical harness for shorts and check themotor. See your authorized dealer. The most likely fault condition here is aBroken, Abraded or Pulled Wire, somewhere inthe High Current Harness. You may want toinspect the wiring visually to see if there isanything obviously shorting to ground. In some cases a severely worn or brokenCarbon Motor Brush can cause the same fault. Further diagnosis may require additional toolsand training. Please contact a CTM CertifiedTechnician for Assistance.
SCOOTER CONTROLLER FAULT CODES5Free Wheeling Lever FaultControllerCheck the Free Wheel Lever connections,the condition of the motor and harness(es).See your authorized dealer. The most likely fault condition here is thatsomeone failed to return the “FreewheelLever” to the ‘D’ position. Or that the leverbecame disengaged to the ‘N’ position bysome other means. The wiring may be chafed or broken. Further diagnosis will require removal anddismantling of the motor. Additional tools andtraining will also be needed. Please contact aCTM Certified Technician for Assistance.
SCOOTER CONTROLLER FAULT CODESControllerCycle the Throttle Lever back and forth with the KEYOFF. Allow the Throttle Lever to center itself back toneutral. Turn the Key ON and see if code has cleared.6Throttle LeverOut Of NeutralSee your authorized dealer to readjust the wigwag zeropoint calibration if necessary. 45 d Sometimes a sticky or wornthrottle pot can be loosened up, ifonly temporarily by racking thethrottle back and forth to fulldeflection several times. A person who rests heavy handpressure downward on the throttlewhile driving will make it worse.
SCOOTER CONTROLLER FAULT CODES6Throttle LeverOut Of Neutral*SPECIAL* The following data is intendedto be used ONLY by those whohave been adequately trainedby CTM! Throttle Pot is a 45 degreeactive sweep from 0–5k Ohms. Wiper “Zero Point” forNEUTRAL is 2.50 k Ohms, /0.05 k Ohms Max Dev.Controller
GLOSSARY OF TERMSBATTERYBRAKECells arranged under the seat for storing electricityElectro-Mechanical Friction Plate which locks themotor upon throttle release, to prevent roll-away.CARBON BRUSH A spring loaded, solid conductive block that deliversDC current to a rotating armature inside the motor.CHARGERCONTROLLERDevice used for refilling battery with electricity.KEY SWITCHMOTORMaster switch for turning vehicle ON and OFF.THROTTLETRANSAXLEInput lever to regulate Forward and Reverse speed.The ‘brains’ of the scooter. Regulates power comingin from battery and out to motor (s).Converts electricity into rotating power to drive thevehicle wheels via a gear set.A gear set to modify motor output into a slowerspeed and higher torque to the drive wheels.
SCOOTER CONTROLLER FAULT CODES 0 10 20 30 40 50 60 70 80 90 100 25.2 vdc 24.0 vdc 23.0 vdc 17.0 vdc Battery Potential Again, The Graph At 16.5 vdc, the Scooter can no longer function. An Intermittent Code #2 could point to a loose or corroded connection. Check the condition of the battery connections . The battery voltage has dropped to 16.5 vdc. 2 Battery Voltage Too Low Controller .
