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Tanaka PB-SM804SA, Service Manual

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                                           XTR Electric Powerboard  

             

Service Manual

 

 

www.tanaka-usa.com                             

 

                                                          [email protected] 

Revison 002 

 

 

                

1 

 

Table of Contents 

 

 

 

 

Specifications  

2 

 

 

 

Troubleshooting  

3 

 

 

 

Safety & Shop Practices 

 

4 

 

 

 

Routine Maintenance 

 

4 

 

 

 

Tools  

5 

 

 

 

Brake System 

 

6 

 

 

 

Wheel Removal 

 

7-8 

 

 

 

Steering Head Components 

 

9-12 

 

 

 

Chain Maintenance 

 

13 

 

 

 

Deck Removal 

 

14 

 

 

 

Electric Drive Components 

 

15-16 

 

 

 

Circuit Breaker 

 

16 

 

 

 

Cables / Controls 

 

17-18 

 

 

 

Batteries  

19 

 

 

 

Electric Drive Motor 

 

20 

 

 

 

Warranty Statement 

 

21 

Summary of Contents for PB-SM804SA

Page 1: ...B SM804SA SM804SB Date 03 31 03 ISM Inc 1028 4th Street SW Auburn WA 98001 Phone 253 333 1200 Fax 253 333 1212 www tanaka usa com custsvc tanaka ism com Revison 002 PB SM806 SM807 SM808 TPB 450EX Elec...

Page 2: ...ifications 2 Troubleshooting 3 Safety Shop Practices 4 Routine Maintenance 4 Tools 5 Brake System 6 Wheel Removal 7 8 Steering Head Components 9 12 Chain Maintenance 13 Deck Removal 14 Electric Drive...

Page 3: ...h Wood Deck Dimensions 40 High 9 5 Wide Tires 10 Kenda Pneumatic Tire Pressure 50 60 psi Wheels Composite Core Split Rim Brakes Disc Caliper Range 60 75 Minutes Approx 12 Miles Charge Time 4 5 Hours B...

Page 4: ...lt in lack luster performance that can appear to be electrical Other issues that can present themselves as electrical problems are operator usage If the unit is used in very hilly areas in excessive t...

Page 5: ...g to repair or operate any equipment read and understand all information provided by the instruction manual for the equipment o Never attempt to service a unit that is running or still heated from run...

Page 6: ...ot Phillips Mallet Head Wrench Part No 31254 Wrenches 8 10 13 17mm Long Handle Allen Wrenches 3 4 5 6mm Test Wire Part No 31644 Jumper Wire Set Part No 31655 This is a switch that is also a replacemen...

Page 7: ...rds throw of the brake lever Figure 3 Figure 4 The design of the brake lever mounted on the handlebar provides another type of adjustment to the brake cable Simply loosen the lock nut and turn the adj...

Page 8: ...ch of the four bolts use spacers between the disc and the wheel With the disc removed it is possible to access the four bolts and nuts that secure the two halves of the wheel assembly together Fig 6 T...

Page 9: ...d the entire rear wheel can be separated from the PowerBoard To disassemble the wheel begin by removing the rear drive sprocket which is attached with four hex hole screws on newer models and is threa...

Page 10: ...four spacers and lock nuts that secure the forks to the steering head This requires either a 5mm or 6mm hex wrench and a 13mm wrench or socket Remove the lock nuts on the bolts and gently tap them thr...

Page 11: ...adjustment and is closest to the steering head and the one directly beneath it is a jamb nut to ensure they do not come loose in operation With these bottom nuts removed remove the lower bearing and s...

Page 12: ...re NOT adjustable WARNING Never attempt to disassemble the lower fork tubes They contain a factory installed spring under considerable tension Disassembling the forks will release the spring and cause...

Page 13: ...e bearing adjustment nut fig 16 With these components removed the fork unit can be removed from the steering head through the bottom Note If it is not necessary to service the brake or wheel component...

Page 14: ...TNING after every re charge of the batteries is ideal Follow the directions provided by the chain lube manufacturer Fig 17 Figure 18 To adjust the chain tension begin by checking the slack in the uppe...

Page 15: ...cking nuts and some of the bolts are simply threaded into the frame itself For those bolts secured with nuts on the underside remove the nuts prior to attempting to remove the bolts from the top Addit...

Page 16: ...A Power is managed by a CPU controller board mounted to the front of the battery compartment Fig 21 High tension leads connect the system to a circuit breaker to protect the controller board from over...

Page 17: ...the result of several different factors For example the weight capacity of the unit has been exceeded the unit is run in excessively hot temperature or the operator attempts to climb a hill beyond th...

Page 18: ...repaired before any further use of the PowerBoard A defect in the system could indicate a problem with the lever and it s wire or a problem within the circuit board Testing is done by bypassing the sw...

Page 19: ...circuit board Remove the plug from the board and attach the test switch part 31644 to the plug receptacle intended for the throttle wire Make sure the switch is in the OFF position before attaching t...

Page 20: ...tains less than this amount after adequate charging time it will be necessary to replace the batteries A battery with a reading of 10 volts or less indicates a completely dead battery that will not ac...

Page 21: ...t from batteries to the motor NOTE Attaching lead wires to battery will create a spark NOTE Newer models do not have lead wires form the motor that are detachable from the circuit board Instead they u...

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