Tomberlin E-MERGE 2007 Maintenance Manual

TOMBERLIN®CONSUMERDISCLAIMER



Tomberlin®reservestherighttochangethesuggestionsgainedinthisconsumersupportsite.Itis

intendedprimarilyforeducationalpurposesonly.Someexperiencedconsumersprefertodothe

maintenanceandservicethemselves,forthe"DoItYourself"owners,Tomberlinstronglyencourages

interactionwithyourlocaldealerfirstandtoneverattemptaprocedureyouareunfamiliarwithsafely

performing.Anelectricvehiclehasasignificantvolta gethatcanresultinshock,fireandinjuryifnot

performedbyaprofessional.Damagetothevehiclecanalsooccur.Someproceduresrequir especific

torquesettingsthatwhennotfollowedcanresultindangerous,possiblylifethreateningsituations.

Manyerrorswillnotsurfaceimmediately.Theinformationhereinhasgenerallyproventoenhancethe

lifecycle,safetyandoverallownershipexperiencewhenproperlyfollowed.Tomberlinassumesno

liabilityforthecontentprovidedinthisconsumereducationalsectionanditispossiblethatanerror

withregardtospelling,grammar,nomenclature,andtranslationispresent.Notethattheinformation

providedshouldbetreatedaslivedocumentsmeaningtheyarealwaysinastateofrefinement,

correctionandimprovement.Checkbackoftenandifprinted,checkbackpriortoreliancetoassurethey

remaincurrent.Neverattempttomanipulatethevehicletoexceedthespeedasrequiredby

regulations.ThehighestspeedrangeforTomberlin®E‐Merge™PTV'sandLSV'sarefactorysetat15‐19

mphasaPTVor22‐25mphasanLSV.Consumersshouldalwaysexerciseprudentcommonsense

measures,usepropersafetygearwithtoolsdesignedspecificallyforthetask.Alwaysutilizeinsulated

toolsaroundelectricalconnections.Neverexceedyourcomfortlevelandwhenindoubt,stopandcall

yourlocaldealer.TomberlinAuthorizedDealersarealwaysyourbestresource.Ifyounoticeanerroror

haveanideathatwillimproveoureffortshere,pleaseemailyourideato[email protected].

1

E-MERGE

Maintenance Manual

Revision as of August 9, 2007

2

INTRODUCTION

This Maintenance Manual is compiled by TOMBERLIN Company for dealers authorized by the

Company and their technicians. The Manual is only for the maintenance and repair of electric vehicles

of E-MERGE series.

TOMBERLIN reserves the rights to revise the specifications and design from time to time and the

electric vehicles and other products. are subject to improvement that may influence the maintenance

procedure with no notice, nor obligation to alternate devices sold previously.

Before starting any service on the electric vehicle, read the Manual carefully and note the difference of

the following symbols:

This indicates Note! Alarm! Watch your safety!

WARNING The symbol indicates a danger may occur, calling the attentions of the

driver, passenger, by stander or inspection and maintenance personnel.

CAUTION It describes some special precautions to avoid vehicle damage.

3

Chapter 1 Overview

Safety Precautions........................................................................................................... 1-Error! Bookmark not defined.

Preparation for Emergency....................................................................................1-Error! Bookmark not defined.

Safe Use of Lubricating Oil..................................................................................1-Error! Bookmark not defined.

Safe Use of Battery.................................................................................................1-Error! Bookmark not defined.

Protection of Vehicle Safety..................................................................................1-Error! Bookmark not defined.

Protection for Electrical Safety.............................................................................1-Error! Bookmark not defined.

Use the Designated Lifting Jack...........................................................................1-Error! Bookmark not defined.

Use Appropriate Tools.................................................................................................... 1-Error! Bookmark not defined.

Special Tools...........................................................................................................1-Error! Bookmark not defined.

Instrumentation for Electric Control System......................................................1-Error! Bookmark not defined.

Cautions............................................................................................................................ 1-Error! Bookmark not defined.

Washing and Cleaning ...........................................................................................1-Error! Bookmark not defined.

Keep Tidy.................................................................................................................1-Error! Bookmark not defined.

Parts Replacement..................................................................................................1-Error! Bookmark not defined.

Washer, Grease Fitting and O-ring.......................................................................1-Error! Bookmark not defined.

Bearing and Oil Seal..............................................................................................1-Error! Bookmark not defined.

Recommendations on Disassembly and Assembly............................................1-Error! Bookmark not defined.

Chapter 2 Regular Inspection and Adjustment

Regular Maintenance...................................................................................................... 2-Error! Bookmark not defined.

Periodic Lubrication Plan............................................................................................... 2-Error! Bookmark not defined.

Braking Inspection .......................................................................................................... 2-Error! Bookmark not defined.

Inspection of Parking Brake........................................................................................... 2-Error! Bookmark not defined.

Inspection of Brake Drum and Brake Shoe................................................................. 2-Error! Bookmark not defined.

Inspection of the Accelerator Pedal.............................................................................. 2-Error! Bookmark not defined.

Inspection of the Steering System................................................................................. 2-Error! Bookmark not defined.

Inspection of the Steering Linkage ............................................................................... 2-Error! Bookmark not defined.

Inspection of Stub Axle .................................................................................................. 2-Error! Bookmark not defined.

Inspection of the Front Wheel Alignment.................................................................... 2-Error! Bookmark not defined.

Procedures for the Adjustment of Toe-in:.................................................................... 2-Error! Bookmark not defined.

Inspection of Tires and Wheel Rim.............................................................................. 2-Error! Bookmark not defined.

Inspection of the Front Wheel Bearing........................................................................ 2-Error! Bookmark not defined.

Inspection of the Rear Axle Bearing............................................................................. 2-Error! Bookmark not defined.

Inspection of the Shock Damper................................................................................... 2-Error! Bookmark not defined.

Inspection of the Seat Belt............................................................................................. 2-Error! Bookmark not defined.

Chapter 3 Canopy

Removal of the Canopy.................................................................................................. 3-Error! Bookmark not defined.

Remove ....................................................................................................................3-Error! Bookmark not defined.

Install........................................................................................................................3-Error! Bookmark not defined.

4

Removal of Canopy Rods .............................................................................................. 3-Error! Bookmark not defined.

Remove ....................................................................................................................3-Error! Bookmark not defined.

Install........................................................................................................................3-Error! Bookmark not defined.

Removal of the Pillar...................................................................................................... 3-Error! Bookmark not defined.

Remove ....................................................................................................................3-Error! Bookmark not defined.

Install........................................................................................................................3-Error! Bookmark not defined.

Chapter 4 Body

Removal of the Front Bumper....................................................................................... 4-Error! Bookmark not defined.