Table of Contents
Related Manuals for Tanaka PB-SM804SA
Summary of Contents for Tanaka PB-SM804SA
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Page 1: Service Manual
Service Manual PB-SM804SA,SM804SB Date 03-31-03 Revison 002 PB-SM806,SM807,SM808 TPB-450EX Electric PowerBoard ISM, Inc. • 1028 4 Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212 www.tanaka-usa.com custsvc@tanaka-ism.com... -
Page 2: Table Of Contents
Troubleshooting Safety & Shop Practices Routine Maintenance Tools Brake System Wheel Removal Steering Head Components 9-12 Chain Maintenance Deck Removal Electric Drive Components 15-16 Circuit Breaker Cables / Controls 17-18 Batteries Electric Drive Motor Warranty Statement www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 3: Specifications
60-75 Minutes, Approx. 12 Miles Charge Time 4-5 Hours Battery Lead Acid, 24 Volt Drive System Chain Motor 450 Watt, 24 Volt Continuous Output Max Rider Weight 270 lbs. Unit Weight 55 lbs. (approximately) Charger 2 AH www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 4: Troubleshooting
Still no good - replace circuit board. PowerBoard will not go far: • Charge for twelve hours and re-try. • Still no good - test batteries and charger. • Still no good - replace circuit board. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 5: Safety & Shop Practices
Tools, instruments, and parts needed for work should be clean and readily available before any job is started. (Special tools available for servicing TANAKA equipment are listed in this manual.) o Scooter should be cleaned before repair work starts. Cleaning will often help reveal a source of trouble. -
Page 6: Tools
(see page 18) Screwdrivers – Slot/Phillips Mallet Head Wrench (Part No. 31254) Wrenches – 8,10,13,17mm Long Handle Allen Wrenches – 3,4,5,6mm www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 7: Brake System
Brake pads are simply slid into place (Fig. 4), but it requires that tension be taken off of the cable to allow the new pads to be fitted. Note that the pads are not identical, and it is necessary to match the pad with the appropriate brake actuator arm. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 8: Wheel Removal
With the wheel disassembled, it is advisable to check the integrity of the two ball bearings that ride within the hub of the wheel. If they feel worn or do not turn freely, replace them. Upon re-assembly, ensure that the three axle spacers are properly positioned. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... - Page 9 With the wheel disassembled (Fig. 8), it is advisable to check the integrity of the two ball bearings that ride within the hub of the wheel. If they feel worn or do not turn freely, replace them. Upon re-assembly, ensure that the three axle spacers are properly positioned. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...
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Page 10: Steering Head Components
(Fig. 9). Use caution not to damage the threads as you remove the bolts. With the entire front wheel and forks removed (Fig. 10), the steering head can now be disassembled. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... - Page 11 (Fig. 11) to allow enough slack in the control cables for the steering stem to be lifted from the steering head. Take the opportunity to thoroughly clean all parts with cleaning solvent, and inspect bearings. If they feel worn or do not turn freely, replace them. Re-grease the bearings and carefully re-assemble. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...
- Page 12 Begin by separating the top steering stem from the fork assembly by removing the three hex bolts that secure the clamp bracket around the stem, (fig. 13), followed by removal of the locking nut, (fig. 14). www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...
- Page 13 Take the opportunity to thoroughly clean all parts with cleaning solvent, and inspect bearings. If they feel worn or do not turn freely, replace them. Re-grease the bearings and carefully re-assemble. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...
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Page 14: Chain Maintenance
A worn sprocket will quickly damage a new chain and vice- versa. Chains and sprockets should be replaced as a set. Figure 19 www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 15: Deck Removal
Inspect the board for any damage and replace as necessary. When re-installing a deck, always ensure that all fasteners are used, and that an adequate amount of grip tape is re-applied to ensure sound footing when in operation. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 16: Electric Drive Components
(Fig. 22). Newer models utilize a controller board mounted inside a sealed case. This helps prevent contamination from dirt and moisture. (Fig. 22A) www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 17: Circuit Breaker
The breaker is reset on earlier models with the kick-stand. When the stand is down, it trips a switch on the circuit board, (see fig. 23). Moving the stand up/down/up will reset the breaker. On newer models, turning the on/off switch on/off/on will reset the breaker, (see fig.’s 24 and 25). www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 18: Cables / Controls
/ wire assembly. If the switch fails to shut off the power when tested as described above, then the circuit board has failed and will Figure 28 need to be replaced. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... - Page 19 If power is transmitted to the rear wheel, then the problem is NOT with the circuit board function, and the throttle lever / wire assembly will need to be replaced. Figure 32 www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...
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Page 20: Batteries
25.5 volts, (as high as 29.5 volts is normal). If the voltage registers in this range, the charger is working correctly to supply current to the batteries. Less than 24 volts would indicate a defective charger. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002... -
Page 21: Electric Drive Motor
If the motor does not turn when tested this way, it is defective and must be replaced as an assembly. Removal of the motor is made simple by the two sub-frame pieces on either side of the frame. Removal of the bolts on chain side only will allow the removal of the motor. www.tanaka-usa.com custsvc@tanaka-ism.com Revison 002...