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X-TREME XB-420M, User Manual, Page: 6 / 43

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X-TREME XB-420M User Manual Download Page 6

 

 

5 

How To Remove Batteries……………………………………………….. 25 

How To Adjust Brakes…………………………………………………….. 25 

How To Check Motor Armature Contracts………………………….. 25-26 

How To Remove Rear Brake Assembly……………………………… 26 

How To Install Bearings…………………………………………………… 27 

How To Adjust Chain Tension………………………………………….. 27 

How To Check Throttle Voltage………………………………………… 27-28 

How To Check Charger Output…………………………………………. 28 

How To Understand Charger Light Sequence………………………29 

How To Replace A Controller……………………………………………. 29-30 

How To Test Moto Direct To Battery…………………………………. 30 

How To Replace Throttle…………………………………………………. 30-31 

How To Do Basic System Check For Power……………………….. 31 

Troubleshooting Guide…………………………………………………………………… 31-38 

 

Brake Lights……………………………………………………………………. 21-32 

 

Scooter Won’t Run, Charger Light Stays Green…………………… 32 

 

Scooter Won’t Run, Charger Light Stays Red & Green………… 32 

 

Testing Motor Sensors…………………………………………………….. 32-34 

 

Scooter Will Not Turn Off…………………………………………………. 34 

 

Scooter On, But Will Not Move…………………………………………. 34 

 

Is It My Throttle Or My Controller?...................................... 34-35 

 

Throttle Voltage Test………………………………………………………. 35 

 

Intermitted Power Loss……………………………………………………. 35-36 

 

No Power……………………………………………………………………….. 36-37 

 

After Fully Charger, Powers Only For Short Distance Use……. 37-38 

Diagrams………………………………………………………………………………………. 39-41 

 

Battery Wiring Diagrams………………………………………………….. 39 

 

Wiring Diagram………………………………………………………………. 40 

 

Controller Wiring Diagram……………………………………………….. 41 

Warranty ……………………………………………………………………………………… 42 

 

 

Summary of Contents for XB-420M

Page 1: ...X Treme Electric Scooters XB 420M Electric Mobility Scooter Read this manual completely before riding ...

Page 2: ...rs or until the light on the charger turns red green 5 DO NOT allow this unit to deep discharge the battery 6 For safety purposes DO NOT charge for over 8 hours 7 Turn the unit OFF when not in use This PRODUCT IS NOT INTENDED FOR EXTREME or OFF ROAD Use Please take care of your scooter DO NOT JUMP or ABUSE THIS PRODUCT DO NOT RIDE IN WET ICY CONDITIONS Failure to follow these instructions will VOI...

Page 3: ...his product See Product Handbook for more information This product is recommended for riders 16 YEARS OF AGE and older SAFETY Persons without excellent vision balance coordination reflex muscle and bone strength and good decision making capabilities should not use this product Minors without adult supervision should not use this product Persons unwilling or unable to take responsibility for their ...

Page 4: ...arger if it has been damaged in any way Keep hands face feet and hair away from all moving parts Do not touch the motor or wheels while they are rotating Brakes are designed to control speed as well as stop the scooter Practice braking for proper slowing down and smooth stops Maintain your scooter as recommended in this Product Handbook Use only quality replacement parts as recommended by the manu...

Page 5: ...19 Battery Charging 19 21 Other Maintenance 21 Fuse 21 Brakes and Tires 21 Lubrication 22 Cleaning 22 Scheduled Maintenance 23 Troubleshooting 24 How to Guide 25 31 DO NOT RETURN TO STORE Do not use this vehicle for the first time until you have inflated the tires to the correct PSI and completely charged the battery Failure to follow these instructions may damage your vehicle and void your warran...

Page 6: ...How To Replace Throttle 30 31 How To Do Basic System Check For Power 31 Troubleshooting Guide 31 38 Brake Lights 21 32 Scooter Won t Run Charger Light Stays Green 32 Scooter Won t Run Charger Light Stays Red Green 32 Testing Motor Sensors 32 34 Scooter Will Not Turn Off 34 Scooter On But Will Not Move 34 Is It My Throttle Or My Controller 34 35 Throttle Voltage Test 35 Intermitted Power Loss 35 36...

Page 7: ...ll as the speed control toggle switch on high increases its ability to Pop a Wheelie when the throttle is engaged Use caution Like any sport cycling carries the risk of injury and damage By choosing to ride the XB 420M you assume all responsibility for these risks Thus you need to know and practice the rules of safe and responsible riding YOUR INSURANCE POLICIES MAY NOT PROVIDE COVERAGE FOR ACCIDE...

Page 8: ...m carrying capacity is 350 lbs o Never ride barefoot or wearing sandals o Don t jump with your XB 420M It puts great stress on everything from frame and forks to drive train Riders who jumping their XB 420M risk serious damage to their XB 420M and will void their warranty o Never carry anything which obstructs your vision or your complete control of the XB 420M or which could become entangled in t...

Page 9: ...o Familiarize yourself with all the bike s features Practice signal lights braking and use of the horn o Don t carry packages or passengers that will interfere with your visibility or control of the bike Don t use items that may restrict your hearing o Maintain a comfortable stopping distance from all other riders vehicles and objects Safe braking distance and forces are subject to the prevailing ...

Page 10: ... Ensure that the front lights are on Wear light colored reflective clothing and accessories any reflective device or light source that moves will help you get the attention of approaching motorists pedestrians and other traffic Ride slowly Avoid hazards such as potholes and curbs Avoid areas of heavy traffic dark areas and roads with speed limit over 35 mph If possible ride on routes already famil...

Page 11: ...10 Do not store your XB 420M in direct sunlight for an extended time Store your XB 420M in a dry place Exposing your XB 420M to rain snow or other precipitation may result in damage ...

Page 12: ...ly 300 cycles Charger input AC 110V Charging time 2 6 hours Charger output 50V 1 8A Tire size 16 x 3 0 SPECIFICATIONS Product size L x W x H 64 x 28 x 40 Net Weight 195 lbs Carrying capacity 350 lbs Maximum range 40 miles Maximum speed 20 mph Motor type Geared brush Motor power 500W Battery 48V 20 Ah Battery type Sealed lead acid battery Battery cycle life Approximately 300 cycles Charger input AC...

Page 13: ...COMPONENTS 1 Battery Storage Access Tilt Seat Forward 4 Batteries Total 2 Seat Recline Adjuster 3 Drop Down Arm Rests 4 Forward Reverse Switch 5 Instrument Panel 6 Throttle 7 Brake Lever 8 Ignition Switch ...

Page 14: ...13 1 Brake lever 2 Headlight switch 3 Rearview mirror 4 Instrument Panel 5 Rearview mirror 6 Headlight switch 7 Throttle 8 Ignition switch 9 Forward Reverse switch 10 Turn Signal 1 2 3 4 5 6 7 8 9 10 ...

Page 15: ...does not contain the brake assembly e Slide the axle bolt through the center of the wheel hub f Tighten the nut on the axle bolt and insert the cotter safety pin g Inflate the front and rear tires to 35 psi h With front wheel installed lift and remove the spacer under the floorboard i Remove the wire ties holding the two rear wheels and roll XB 420m off of steel frame 3 To make sure the alignment ...

Page 16: ...artment located under the seat Locate the circuit breaker and switch it from off to on 8 Your XB 420M has been in transit and storage You must charge the batteries before riding it See page 21 for battery charging instructions ROUTINE OPERATION A Pre Ride Check 1 Be sure the tires 35 PSI air pressure A low tire pressure risk rim pinching tube failure lowers your range distance per charge and may d...

Page 17: ...rther damage 4 Lights Light switch is located on the right side of the handle bars and can be controlled by thumb Push to center position for driving lights and to the left position for the headlight 5 Hold onto the handlebars with both hands Assume a well balanced position Your right hand will control the throttle Twist the throttle slowly to avoid a sudden rush of speed forward The speed of the ...

Page 18: ...xpect Realistically The battery can keep its performance for about 200 charge discharge cycles with high current and deep 80 discharging The storage capacity of the battery will decline after 200 times recharging If you re charge the battery before it is exhausted you will dramatically extend the battery s cycle life In Summary Always try to recharge the Battery Pack within 24 hours after use to m...

Page 19: ...re exposed to the solution flush the affected area with water If you must handle the battery wear disposable gloves Replace the battery if there are leaks visible breaks or cracks Dispose of used batteries by taking them to a recycling center or according to state and local laws Battery Temperature Sensitivity Ambient temperature will affect almost every kind of battery Usually the battery shows g...

Page 20: ...ll cost a lot of battery energy In these conditions the XB 420M will not reach its normal range Battery Charging Be sure to charge the battery completely if you will not use it for a long period Ideally you should charge it every 20 days Even a healthy battery will discharge itself slowly Even with its power off the XB 420M Battery state of charge will decline gradually over time Remember to fully...

Page 21: ... to re charge and a long ride will require a longer time A complete 90 discharge may require 6 hours to recharge To prevent electrolysis battery fluid loss by hydrogen generation do not charge for longer than eighteen hours Before riding the electric scooter for the first time you must charge the batteries for 4 6 hours using the supplied charger To charge pull the protective cover from the chargi...

Page 22: ...e third of their original thickness The rear drum brake is very similar to the brakes on electric scooter products When this brake is exhausted a squealing sound will be heard upon brake application Front and Rear Tires The changing method of the front tire is the same as common bicycle It is more complex to change the rear tire because of the motor and brake assemblies and associated wiring and c...

Page 23: ...axle rim and the axle ball bearing with SH T0386 lubricant scooter or lithium grease Maintenance period one year Cleaning 1 Never wash the scooter using high pressure water as it will cause damage to the electric bike 2 Never use lubricant to clean the metal parts of the scooter and never apply lubricant to the drum brake and the tire ...

Page 24: ...t Wheel rim to ensure it is not distorted Steering Linkage to ensure it is not distorted Front light bugle to ensure functioning properly Brake to ensure it is working properly Throttle to ensure that it is working properly Steering system to ensure operation is normal Wheel axle to ensure if it is loose Motor to see if it is working properly If you find problems that you cannot solve them yoursel...

Page 25: ...rns to original position Controller or Throttle is defective Replace Controller or Throttle Customer service can assist in diagnosis Vehicle is losing speed 1 Battery is low 2 Defective battery 3 Defective Throttle 1 Charge battery 2 Replace battery 3 Replace Throttle Distance per charge is reduced 1 Tire pressure is low 2 Battery is not fully charged 3 Battery is damaged 4 Headwind slopes overloa...

Page 26: ...l They are what you call floating brakes but are locked in place by a pin on the hub 2 You should also see the brake arm which is attached to the brake cable and an adjusting nut on end of cable Notice the length of screw coming out of the adjusting nut Keep about the same length on both brakes 3 Push the arm forward and tighten the adjusting nut clockwise a few turns 4 Turn the wheel to make sure...

Page 27: ...he controller to assure that the wire is locked into the connector They have a little tab and if not locked into place and connected the connector together the wire will just slide out of hole How To Remove Rear Brake Assembly 1 Remove rear bodywork 2 Remove seat pins from hinges at front of seat 3 Disconnect wires to breaker 4 Remove storage box screws on top of black box 5 Cut wire tie on wire h...

Page 28: ...his can make the scooter wheel and chain out of balance 3 When you tighten the nuts on these bolts they pull the whole axle and wheel back tightening the chain 4 Adjust the chain until when pushing down in middle you achieve 1 8 to 1 4 inch movement 5 These bolts also controls wheel alignment be sure to center the wheel in the center of frame 6 After you have adjusted your chain and aligned your w...

Page 29: ... while black probe left on the black wire and both sides of breaker will have 48 and breaker off and 0 on output of breaker 10 Move the probes to the motor wire connectors and slide up the rubbers and test if you see voltage on meter but no motor then the armatures need to be removed and put back in they are stuck How To Check Charger Output Tools Needed Multi meter set to DC voltage 1 Determine t...

Page 30: ...icate the charger wires are crossed and or touching each other In most cases if the scooter runs a shorter distance the batteries may be beyond their life cycle How To Replace A Controller 1 Remove Main Fuse 2 Gain access to where the Controller is located 3 Place the New Controller alongside the Original Controller 4 Disconnect and re connect One 1 Connector at a time We recommend starting with t...

Page 31: ...nd the Batteries are charged the wheel will spin at full power in which case the Controller may need to be replaced If the Motor did not run then the Batteries will need to be checked to confirm they are holding a charge If Batteries are holding a charge then the Motor will need to be checked or replaced How To Replace Throttle 1 Open the footplate Run the new throttle wires down to the battery co...

Page 32: ...e Charger appears to be operating correctly and the Batteries are fully charging 6 The other electrical such as lights are working OK 7 Lift the rear wheels off the ground and support the scooter so the rear wheels DO NOT touch the ground will the motor wheels spin with normal operation of the Throttle Troubleshooting Guide Troubleshooting Brake Lights On both brake handles on the handlebars have ...

Page 33: ...and check the wires in this area You may find a wire that is not connected a connector that is not pushed together properly or a fuse holder that is not letting the fuse connect properly Troubleshooting Scooter Won t Run Charger Light Stays Red Green When you plug your charger into your scooter and the wall outlet the charger light stays green This is telling me that somewhere between the batterie...

Page 34: ...tor leaving the red and black wire attached While the motor is connected to the controller powered and at rest or alternatively powered with 5 volts from a workbench power supply set up a multi meter to monitor the sensor s output on one of the 3 wires Connect the Black Voltmeter Lead to the small black wire by inserting the probe in where the wire goes into the connector Attach the Red Voltmeter ...

Page 35: ...e magnet If you have a digital VOM I would not use an analog resistance meter of any kind as it could damage the chip if it s a Hall effect chip you can test whether it s a potentiometer or not If it is you should get 5K ohms across red and black and of course 0 5K from red or black to the third wire usually green or yellow If it isn t you ll get readings in the megohms in one direction and no con...

Page 36: ...olts Block rear wheel off the ground so scooter will not take off Turn the scooter on Place the red meter test lead on the Red wire and the black meter lead on the Black wire The meter should measure 5 volts Now place the meter red lead on the Green wire With out turning the throttle you should read around 0 8 volts Now turn the throttle wide open You should now read around 4 volts If everything e...

Page 37: ...umper to the white wire and reinsert it back into the white connector You may need to pull out the little lock tab so it will lock into place Reattach the connector back onto the controller as shown in my drawing above Plug your cord into the charger socket for the voltmeter just set the seat and seat barrel in the scooter without bolting it When ready plug the main battery cord in bottom of batte...

Page 38: ...tivated to the On position Troubleshooting After Fully Charging Powers Only For Short Distance Use 1 Suspect the battery charger or the battery as the primary cause of short distance riding after a lengthy or full charge If your battery charger does not have charging indicator lights then you may not be charging the battery at all if the charger is defective 2 The battery may be self charging to o...

Page 39: ...ery to a shop capable of testing the battery under a loaded condition Fully charge the battery and carefully remove it Let a technician determine the condition of the battery for you 4 We recommend a high quality Battery Charger as sold on our scooter parts page You can purchase by visiting our website at http www xtremescooters com electric_bicycles xb502 parts html or contacting our Parts Depart...

Page 40: ...39 ...

Page 41: ...40 Wiring Diagram See notes above ...

Page 42: ...41 Controller Wiring Diagram ...

Page 43: ...42 DO NOT RETURN TO STORE IF YOU NEED HELP CALL OR GO ONLINE 1 253 777 0690 www x tremescooters com support For General Information or Parts Visit www x tremescooters com Revised 02 28 12 ...

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