Tomberlin E-MERGE 2007 Maintenance Manual
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Tomberlin E-MERGE 2007 Maintenance Manual

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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 voltage that can result in shock, fire and injury if not 
performed by a professional. Damage to the vehicle can also occur. Some procedures require 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 info@tomberlin.net. 

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  • Page 1 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 voltage that can result in shock, fire and injury if not  performed by a professional. Damage to the vehicle can also occur. Some procedures require 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 info@tomberlin.net. ...
  • Page 2 E-MERGE Maintenance Manual Revision as of August 9, 2007...
  • Page 3 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.
  • Page 4 Chapter 1 Overview Safety Precautions ......................1-Error! Bookmark not de fine d. Preparation for Emergency..................1-Error! Bookmark not define d. Safe Use of Lubricating Oil ..................1-Error! Bookmark not define d. Safe Use of Battery....................1-Error! Bookmark not define d. Protection of Vehicle Safety..................1-Error! Bookmark not define d. Protection for Electrical Safety................1-Error! Bookmark not define d.
  • Page 5 Removal of Canopy Rods ....................3-Error! Bookmark not de fine d. Remove ........................3-Error! Bookmark not define d. Install ........................3-Error! Bookmark not define d. Removal of the Pillar ...................... 3-Error! Bookmark not de fine d. Remove ........................3-Error! Bookmark not define d. Install ........................3-Error! Bookmark not define d.
  • Page 6 Inspect ........................6-Error! Bookmark not define d. Install ........................6-Error! Bookmark not define d. Gearbox..........................6-Error! Bookmark not de fine d. Removal of the Differential Gear .................6-Error! Bookmark not define d. Remove ........................6-Error! Bookmark not define d. Inspection.........................6-Error! Bookmark not define d. Install ........................6-Error! Bookmark not define d.
  • Page 7 Motor removal......................9-Error! Bookmark not define d. Motor installation....................9-Error! Bookmark not define d. Removal of bulb of headlight and front turn signal light........9-Error! Bookmark not define d. Headlight installation.....................9-Error! Bookmark not define d. Tail light removal ....................9-Error! Bookmark not define d. Tail light installation ....................9-Error! Bookmark not define d.

  • Page 8: Table Of Contents

    Premature excessive discharge ..........................11 -7 AC power supply line ..............................11 -7 Alternating use of vehicles............................11 -7 Electric vehicle and charger numbering........................11 -8 Battery troubleshooting diagram ..........................11 -9 Inspection and test of the battery..........................11-10 Inspection and test of the battery charger......................11-10 Charging vo ltage inspection............................
  • Page 9 Mounting of the bearing ..................12-Error! Bookmark not define d. Inspection of the speed sensor magnet ..............12-Error! Bookmark not define d. Removal of the speed sensor magnet..............12-Error! Bookmark not define d. Mounting of the speed sensor magnet...............12-Error! Bookmark not define d. Readjustment of the electric motor ..............12-Error! Bookmark not de fine d.

  • Page 10: Safety Precautions

    Safety Precautions WARNING During the maintenance of these vehicles, the following safety precautions can be taken to prevent serious accidents. Preparation for an Emergency To prevent a potential injury or fire hazard, the following simple articles shou ld be prepared. For example: •...
  • Page 11 WARNING During the maintenance of these vehicles, the following safety precautions can be adopted to prevent serious accidents. Vehicle Safety During Maintenance • The parking brake should be applied. • Blocks shou ld be placed in front of the front tires. •...
  • Page 12 WARNING • The electric vehicle can only be repaired or maintained b y technician with adequate training. Even the personnel who are in charge of simple repair or maintenance are required to have the knowledge or experience in relation to electrical and mechanical maintenance.
  • Page 13 • Hot! It is strictly prohibited to maintain a hot motor. Any violation of this warning may result in serious burns. • While working beside the battery or electrical element, the operator should use insulated tools with special care to avoid short circuit of the component or wiring.
  • Page 14 • To avoid unintentional start-up of the elec tric vehicle, please First, remove the turn the Tow/Run switch to the TOW po sition before positive electrode cable disconnec ting or connec ting the battery. • Disconnect the storage After disconnection of the battery, please wait for 90 seconds to battery cable here allow for the discharge of the capacitor in the controller.
  • Page 15 Use Appropriate Tools To prevent the components and the vehicle from damage, appropriate tools must be used. Special Tools The use of appropriate special tools is necessary for the improvement of vehicles, accurate adjustment and assembly. The use of appropriate special tools can prevent damage resulting from the use of inappropriate tools.
  • Page 16 We recommend that you use E-MERGE original parts for all replaceable parts. Use the oil or grease recommended by Original TOMBERLIN during the assembly, inspection and repair. parts Washer, Grease Fitting and O-ring During the inspection and repair of vehicles, all the washers, grease fittings and O-rings removed shou ld be cleaned up before being mounted.
  • Page 17 Chapter 2 Regular Inspection and Adjustment Regular Maintenance Normal maintenance is of paramount importance to the o ptimal performance and safe operation of vehicles. WARNING Unless otherwise required, the master switch must be turned off and the parking brake must be applied during the maintenance.
  • Page 18 inspection Use terminal protective agent Inspect the brake shoes for tightness and the rear axle bearing for normal operation Inspect the steering knu ckle bushing for normal operation/Adjust front wheel alignment Inspect the nuts of the wheel for tightness and the front-wheel bearing for normal operation Replace the lubricating oil in the gear box...

  • Page 20: Brake Inspection

    Braking System Brake Inspection 1. Remove: ·Anti-slip pedal ·Protective cover plate Care should be taken to avoid scraping the body. 2. Inspect： ·Brake master cylinder ① ·Brake pipe ② ·Tee joint ③ ·Front wheel brake tong ④ Oil leakage →if any, replacement is required ·Front wheel brake shoe Standard thickness 7.0 mm (0.28 in)
  • Page 21 distance it travels before the pressure is lost. Defects are to be replaced. Free play of the brake pedal 13mm(0.512 in） Inspection of Parking Brake 1. Turn the master switch to "OFF" position and take out the key. 2. Remove the protecting jacket of brake handle. 1.
  • Page 22 Procedure s for the Adjustment of Free Play: ·Loosen the locknut④ ·Adjust the free play via adjusting nut③ ·Tighten the locknut ·Re-inspect the free play Inspection of Brake Drum and Brake Shoe 1. Turn the master switch to the "OFF" position and take out the key.
  • Page 23 Maximum wearing value of the inside diameter: 1.5mm（0.06in） Standard inside diameter: 180 mm（7.2 in） Maximum wearing value of the inside diameter: 1.5 mm（0.06 in） 7. Inspect： · Surface of shoe block Oil → Replace the old one or fu lly clean until no oil is found Scrape →...
  • Page 24 9．Install · Brake drum · Rear wheel WARNING: Verify that there is no oil o r water on the surface of the brake drum a nd shoe bloc k. 10. Install: · Wheel nu ts Tightening torque 90N·m(66.4ft·1b) NOTICE: First, screw on the wheel nuts by hand, and then tighten the nuts diagonally.
  • Page 25 Inspection of the Accelerator Pedal 1. Inspect： · Operation conditio n of the pedal In case of unsmooth operation, the pivot should be lubricated. 2. Inspect： · Lateral free pla y of the pedal 4mm (0.158 in) Step on the pedal and replace the pivot in case the free play is too loose.
  • Page 26 3． Re-inspect: · Steering clearance Inspection of the Steering Linkage Removal of Drag Link Ball Joint 1. Remove: · Split pin · Locknut · Connecting link NOTICE: To remove the locknuts, support the connecting link with a 16mm spanner. 2. Inspect： Ball joints in the following conditio ns: ·...
  • Page 27 Inspection of Stub Axle · Free gap of kingpin bolt, spacer and bushing a. Park the vehicle on the flat surface and step on the parking brake b. Lift the front wheels of the vehicle with the lifting jack, and disengage the parking brake c.
  • Page 28 Procedures for the Adjustment of Toe-in: · Park the vehicle on the flat surface and apply the parking brake. · Loo sen the locknuts on the ends of the tie rod. · Turn the steering tie rod to adjust the toe-in. Inc rease →...
  • Page 29 Maximum wearing value of wheel tre ad thickness（ front and rear tire s) 4.0mm(0.16in) Inspection of the Front Wheel Bearing 1. Wedge blocks onto the rear lower part of the rear wheels and lift the front body with lifting jack. 2.
  • Page 30 In case of decay, scrape or damage, the shock damper is to be replaced Mounting bolts of front shock damper Tightening torque 63Nm (46.5ft1 b) Mounting bolts of the rear shock damper: Tightening torque 63Nm (46.5ft1 b) Inspection of the Seat Belt 1.
  • Page 31 2. Seat Belt Buckle Buckle the seat belt and pull with fo rce the belt near the buckle to verify if the buckle can hold the belt securely. NOTICE: In case of damage/scrape/insensitive reaction, the seat belt assembly is to be replaced with a new one. Chapter 3 Canopy...
  • Page 32 Removal of the Canopy Remove: 1．Disconnect high mount stop lamp wire 2．Fixing bolts of the canopy 3．Canopy Install: Canopy In the reverse order of the removal procedures Tightening torque： 9 Nm (6.6ft1b) Removal of Canopy Rods Remove: 1．Fixing bolt on the rear pillar○ 2．Fixing bolt on the center pillar ○...
  • Page 33 Install: Connect the front canopy rod and rear canopy rod, and tighten the connecting slip bolt ○ In the reverse order of the removal procedures. Tightening torque for ○ , ○ , ○ ： 23 Nm ( 17.0 ft1b) Removal of the Pillar Remove: 1．Fixing bolt of backrest bracket ○...
  • Page 34 Install: Pillar In the reverse order of the removal procedures ○ Tightening torque： 9 Nm(6.6 ft1b) Tightening torque for ○ 2 , ○ 4 , ○ 5 ： 63 Nm(46 .5 ft1b) ○ 3 Tightening torque： 23 Nm(17 .0 ft1b)
  • Page 35 Chapter 4 Body 1. Removal of the Front Bumper Remove: · Bolt · Front bumper 2. Removal of the Rear Tray Remove: · Rear box cover · Rubber nail · Screw · Rear tray · Clamping nut 3. Removal of the Rear Bumper Remove: ·...
  • Page 36 Tightening torque： 63 Nm(46.5 ft·1b) Install: · Clamping nut · Rear tray · Rear box cover...
  • Page 37 Removal of the Seat Cushion Pull up the seat cushion 1. Remove: · Handrail fixing bolt · Handrail · Handrail bracket fixing bolt · Handrail bracket · Upper hinge fixing bolt · Upper hinge · Bolts on seat cushion botto m plate ·...
  • Page 38 · Seat cushion · Bottom plate of seat cushion · Bolts on seat cushion botto m plate · Handrail bracket · Handrail bracket fixing bolt Tightening torque： 23 Nm(17.0 ft ·1b)
  • Page 39 Removal of Front Cover 1. Remove: · Front canopy rod NOTICE: Refer to "Removal of Canopy Rod" on page 3-1 . · Instrument panel · Rubber nail on the upper dashboard · Fixing nuts on the lower dashboard Tightening torque： 9 Nm(6.6 ft·1b) ·...
  • Page 40 Removal of the Dashboard： 1． Remove · Steering wheel co ver ○ · Steering wheel nuts ○ · Steering wheel ○ NOTICE: To remove the scorecard clip, first remove the screws behind the steering wheel cover. 2. Remove: · Combination switch connection sheath ·...
  • Page 41 Tightening the torque of steering wheel nu ts： 50Nm(36.9ft·1b) Removal of the Rear Cover 1. Remove: · Seat cushion · Seat backrest · Pillar NOTICE: Refer to "Removal of Seat Cushion" on page 4-3. Refer to "Removal of Pillar" on page 3 -2. 2.
  • Page 42 7 Nm (5.2 ft·1b) 5. Remove · Rubber nail of rear cover plate · Rear cover plate · Rear cover Installation In the reverse order of the removal procedures...
  • Page 43 Rear cover 1. Rear cover 2. Rear cover plate 3. Rear box cover 4. Tra y 5. Left rear light 6. Right rear light 7. On-board charging plu g box 8.Left ventilating window 9. Right ventilating window 10. Lower hinge 11.
  • Page 44 Front axle 1. Upper cradle 2. Split pin 3. Front shock damper 4 . Stub axle 5. Lower cradle 6. Brake disc 7. Oil seal 8 . Cone bearing 9. Lower lug shaft 10. Hub coupling 11. Large du st cover 12.
  • Page 45 Removal of the Front Axle： 1. Park the vehicle on level ground. 2. Apply the parking brake. 3. Loosen: (front wheel) nuts 4. Lift up the front wheels with lifting jack. Refer to Chapter 1 "Uses of Lifting Jack". 5. Remove: ·...
  • Page 46 · Split pin · Slotted nut 10. Remove: · Brake tongs bolt Tightening torque 23 Nm (17.0 ft·1b) · Brake tongs 11. Remove: · Hub coupling (of front wheel) Knock at the coupling with a soft hammer. 2. Remove: · Brake disc bolt Tightening torque 23 Nm (17.0 ft·1b) ·...
  • Page 47 13. Remove: · Bolt Tightening torque 23 Nm (17.0 ft·1b) · Fore wheel brake shoe Standard thickness 7 mm (0.28 in) Maximum wearing thickness 1 mm (0.04 in) 14. Inspect: · Stub axle free gap Swing the stub axle. In case the free gap is fairly large, the inside spacer and bush of the stub axle are to be replaced.
  • Page 48 · Inside spacer of stub axle · Bush of stub axle 16. Inspect: · Free gap of cradle Swing the cradle. In case the free gap is fairly large, the inside spacer and nylo n bush of the cradle are to be replaced.
  • Page 49 · Upper and lower cradles · Dust cover · Inside spacer · Nylon sheath Inspect: 1. Wheel： In case of scrape/bending/deformation, the wheel is to be replaced. 2. Hub coupling In case of scrape/damage, the hub coupling is to be replaced.
  • Page 50 In case of spring deflection/oil leakage and su rface scrape, the front shock damper is to be replaced. 7. Cradle In case of damage/deformation, the cradle is to be replaced. Install: In the reverse order of the “removal” procedures Note the following: 1、WARNING The split pin, once removed, must be replaced with new one.
  • Page 51 Chapter 6 Driving Axle Driving axle 1. Outer tube of left half axle 2. Left half axle 3. Electric motor 4. Differential gear 5. Outer tube of right half axle 6. Right half axle 7. Brake drum 8. Brake base plate 9.
  • Page 52 Removal of the Driving Axle: 1. Park the vehicle on level ground. 2. Lift the rear body with the lifting jack before putting a suitable bracket under the frame. Refer to Chapter 1 "Use of Designated Lifting Jack" 3. Wedge blocks onto the front lower part o f the front wheels.
  • Page 53 8. Remove: · Lower fixing nut of rear shock damper Tightening torque 63 Nm(46.5ft·1b) · Rear shock damper · Rear axle and rear swing arm fixing nut ② Tightening torque 63 Nm(46.5ft·1b) · U-bolt · Driving axle 9. Remove: Brake hub NOTICE: In case the brake hub is difficult to remove, knock out the hub with rubber hammer.
  • Page 54 11. Remove · Clipping spring · Locating dowel① · Upper and lower brake retracting spring · Brake shoe plate Turn the locating dowel with spring or pincer pliers to separate the clipping spring and shoe plate locating dowel. 12. Remove: ·...
  • Page 55 · Brake shoe plate thickness Refer to Chapter 2. In case of non-compliance with the specification, replacement is to be made. 2. Inspect · Bottom plate of brake shoe plate · Brake drum In case of deformation/scrape/damage, replacement is to be made. ·...
  • Page 56 Install: In the reverse order of the “removal” procedures Note the following. 1. Lubricate： · External surface of the bearing Basic grease 2. Install: · Brake base plate · Half axle assembly of rear axle ○ · Bolt · Spring ⑦ ○...
  • Page 57 WARNING In handling the brake shoe plate, ensure that the hands are clean and the shoe plate surface is not tainted with grease . 5. Install · Brake drum · Rear wheel assembly · Wheel nut (of rear wheel) Tightening torque 90 Nm(66.4 ft·1b) 6.
  • Page 58 Gearbox 1. Gearbo x body 2. Bottom cover of differential gear 3. Input shaft 4. Middle gear 5. Middle shaft 6. Oil filler plug 7. Ring gear 8. Differential gear 9. Bearing pressing block 10. 6008 bearing 11. Bearing 6303RS 12.
  • Page 59 Removal of the Differential Gear 1．Remove: · Differential gear · Fixing bolt of differential gear · Bottom cover of differential gear Caution The bottom cover of the differential gear should be pried up by a flat-head screwdriver. Please note not to damage the sealing surface of the box or deform the bottom cover of the differential gear.
  • Page 60 3．Disassemble: · Ring gear · Differential gear assembly 4．Remove: · Sealing rubber cover (both ends) 5．Remove: ○ · Oil seal ○ · Clip spring ○ · Bearing fixing bush ○ · Bearing ○ · Input shaft 6．Remove: · Clip spring (from countershaft gear） ○...
  • Page 61 P rocedure s for the re moval of counte rshaft gear： 1． Push out the countershaft gear from the bearing inner ring. 2． Remove the bearing with bearing extractor. 3． Repeat Step 1 to remove the countershaft gear on the other side.
  • Page 62 3. Tighten · Differential bearing pressing block bolt NOTICE: Clean the surface of differential gear and box bottom cover. Apply 856 sealant to differential gear surface and 10 bolt holes. 4. Tighten: Differential gear bottom cover bolt NOTICE: Tighten the bolts diagonally from the smallest type in two phases.
  • Page 63 Chapter 7 Brake System 1. Brake pedal 2. Parking brake handle 3. Brake tong 4. Rear brake 5. Front brake disc 6. Brake master cylinder 7. Brake drum 8. Boot 9. Brake pedal base 10. Brake pedal sealant 11. Brake shoe plate 12 .
  • Page 64 Brake Pedal 1. Measure: · Free play of brake pedal; 13mm(0 .512 in） In case of no n-compliance with the specification, the brake master cylinder is to be replaced. 2. Remove · Anti-slip pedal · Protective cover plate Refer to relevant content in Chapter 2. ·...
  • Page 65 15mm (0.591in) In case of no n-compliance with the specification, the free play is to be adjusted. 2. Remove · Boot 3. Inspect: · Hand brake cable In case of oil leakage/deformation/fall-off, replacement is to be made.
  • Page 66 Accelerator pedal 1. Accelerator pedal 2. Accelerator 3. Accelerator bracket 4 . Pivot 5. Split pin 6. Pin axle 7. Washer 8 . Split pin...

  • Page 67: Steering System

    Chapter 8 Steering System Steering System 1. Steering wheel 2. Steering wheel cover 3. Steering wheel nuts 4. Bearing 5. Inner clasp 6. Steering shaft 7. Outer clasp 8. Jacket tube 9. Combination switches 10. Combination switch harness jacket 11. Steering colu mn pressing block 12.
  • Page 68 Re moval of the Steering Syste m 1. Park the vehicle on level ground. 2. Apply the parking brake. 3. Put a suitable bracket under the frame and lift up the front wheels with lifting jack. Refer to Chapter 1 "Recommendation for Use of Lifting Jack".
  • Page 69 Disassemble: ○ · Outer clasp ○ · Inner clasp · Steering shaft ④ ○ · Bearing NOTICE: Press the steering shaft out of the bearing on one side with the hydraulic press, and extract the bearing with universal bearing extractor. Extract the bearing on the other side in the same method.
  • Page 70 NOTICE: The tape, once removed, will be a destroyed, and should be replaced with a new one. 2. Disassemble: · Inner clasp · Large flat washer · Dust boot of steering gear 3、Disassemble: · Thrust washer · Drawbar of steering gear...
  • Page 71 EMPHASES： Observe whether there is a skewed slot on one side of the rack of steering gear. This skewed slot is designed to prevent the drawbar of steering gear from loosening. To re-install it, the thrust washer should be fixed in the skewed slot. 4.
  • Page 72 NOTICE: We do not recommend the replacement of worn parts in the steering gear individually. To ensure sound operating performance, we usually reco mmend the replacement of a new steering gear assembly. · Whether the operation of rack is smooth. NOTICE: Improper adjustment or lack of lubrication of the gear teeth may result in irregular abrasion.
  • Page 73 Install: No te the following: Lubricate： ○ · Bearing ○ · Rack ○ · Pinion shaft ○ · Oil seal Apply a thin laye r of grease Install: · In the reverse order of the removal procedures. Refer to the schematic diagram of system parts. Adjust the tightening torque of the cover: 1.5 -2 Nm (1.1ft·1b-1.48 ft·1b) NOTICE: The steering gear should have no clamping...
  • Page 74 Chapter 9 Electric Component WARNING • Plea se refer to Chapte r 1 “Protection for Electric al Safe ty”. Key switch removal 1. Turn Tow/Run switch to TOW. Please re fe r to Chapter 1 “Protection for Electrical Safe ty”. 2.
  • Page 75 4. Remove the middle electrical regaining plate. 5. Remove the connecting wire from gear switch. 6. Press the snap locks on the upper and lo wer ends of the switch, push switch out of the housing. 7. Check: Continuity of the gear switch. Refer to “Check Procedure 10—forward/reverse gear switch”...
  • Page 76 Battery discharge meter installation: Back to the removal steps NOTE: The red, red/green and black wires must be connected correctly at relevant positions on the battery discharge meter. Horn removal 1. Take out the key from the ke y switch. 2.
  • Page 77 Combination switch removal 1. Take out the key from the ke y switch. 2. Apply the parking brake. 3. Turn Switch Tow/Run to TOW. Plea se refer to Chapte r 1 “Protection for Electrical Safe ty”. 4. Remove the protective sleeve for the wire harnesses of combination switch.
  • Page 78 Controller removal 1. Take out the key from the ke y switch. 2. Apply the parking brake. 3. Turn Switch Tow/Run to TOW. Plea se refer to Chapte r 1 “Protection for Electrical Safe ty”. 4. Remove the trunk lid. 5.
  • Page 79 Lighting circuit 10. Unscrew the 4 screws on the controller mount and remove the controller. Controller installation: Back to the removal steps. Check the electric vehicle for normal o peration: • When Forward/Reverse gear switch is on FORWARD position, make sure the electric vehicle is running forward. •...
  • Page 80 Charger receptacle removal 1. Take out the key from the ke y switch. 2. Apply the parking brake. 3. Disconnect the battery cable according to the directions. Plea se refer to Chapte r 1 “Protection for Electrical Safe ty”. 4. Remove the red wire and the black wire from the positive binding post on the rear of charger receptacle.
  • Page 81 NOTE: The battery must be remo ved with a special battery lifting tool. DC converter removal: 1. Take out the key from the key switch. 2. Apply the parking brake. 3. Remove the seat pad assembly. 4. Turn Tow/Run switch to TOW. Please refer to Chapte r 1 “Protection for Electric al Safe ty”.
  • Page 82 Removal of DC changeover contactor and diode assembly: 1. Take out the key from the key switch. 2. Apply the parking brake. 3. Remove the seat pad assembly 4. Turn Tow/Run switch to TOW. Please refer to Chapte r 1 “Protection for Elec tric al Safe ty”.
  • Page 83 Installation of DC changeover contactor and diode assembly: Back to the removal steps. Low resistor High resistance Select Select NOTE: Forward bias Reverse bias DVOM is f or reference only; for specific instruction, see user's m anual provided by m anufacturer. The diode must be installed with a correct polarity.
  • Page 84 NOTE: The motor is heavy, lift and place with care. 8. Check: • Inside short circuit Use a multi meter set to 200Ω, connect the black probe (-) to the motor case. Scrape o ff the paint to ensure a good contact.
  • Page 85 • Exciting circuit opening Use a multi meter set to 200Ω, connect the red probe (+) to F1 and connect the black probe (-) to F2. The multi meter should show connection. In case of above reading errors, have the mo tor repaired by a professional.
  • Page 86 Removal of bulb of headlight and front turn signal light: 1. Take out the key from the ke y switch. 2. Apply the parking brake. 3. Turn Tow/Run switch to TOW. P lease refer to Chapter 1 “Protec tion for Elec tric al Safety”.
  • Page 87 Tail light removal: Any defective or dim tail light shall be replaced. 1. Take out the key from the key switch. 2. Apply the parking brake. 3. Turn Tow/Run switch to TOW. Plea se refer to Chapte r 1 “Protection for Electric al Safe ty”.
  • Page 88 High mount stop lamp disassembly: 1. Remove the screw. 2. Rotate the lamp receptacle; remove the wire harness with the bu lb. 3. Check the continuity, Replace the bulb assembly with wire harness in case of un-continuity. High mount stop lamp installation: Back to removal steps Wiper removal: 1.
  • Page 89 Chapter 10 Troubleshooting Troubleshooting Instructions Part 1 Symptom Possible causes Correc tion action Battery - dead Charge the battery. Check the wiring of the electric vehicle. Re fe r to the Battery - battery wiring wiring diagram on page 9-7. Circuit of key switch and Check the wire of key switch and accelerator switch for accelerator switch...
  • Page 90 Part 1 of Trouble shooting Instruc tions, continue Symptom Possible causes Correction action The elec tric vehic le Check the wiring of the electric vehicle. Refer to the Circuit – incorrect wiring can be started, but the wiring diagram on page 9-7. motor braking device Speed sensor disconnection or Refer to “Check Procedure 9—Motor speed sensor”.
  • Page 91 Check procedures With the following procedures, the e ntire electrical system can be checked without disasse mbling the e lectric ve hicle. WARNING • If the wires are removed or replace d, make sure that the wires and harnesses are arranged and fixe d correc tly.
  • Page 92 Check Procedure 1-- Battery/ voltage check Note: to pe rform the following check proce dures, the battery should be maintained properly and charge d fully. Use a DC multimeter set to 200V, connect the black (-) probe to the negative output binding post of the battery and connect the red (+) probe to the positive wire of the battery.
  • Page 93 Use a multimeter, set it at diode testing positio n, connect the black (-) pro be to one connecting terminal of towing switch and put the red (+) probe on the connecting terminal on the other side. When TOW/RUN switch is on position RUN, the multimeter should show a co nducting state. When TOW/RUN switch is on position TOW, the multimeter should show a disconnect state.
  • Page 94 9． Check accelerator pedal switch. Note : Be fore operation, make sure the ke y switc h ope rates properly and the ke y switc h and the instrument pane l are installe d correctly. 9.1 When the battery is connected, use a multimeter set at 200V DC, connect the black (-) probe to the negative binding post of Battery 6 and connect the red (+) pro be to the pedal switch output wire (Wire 3).
  • Page 95 Check Procedure 7--Controller signal 8-wire connector of controlle r plug Function (Pin 1)-red wire Battery - positive electrode FORWARD input signal provided by Forward/Reverse switch--when (Pin 4) - black/yellow wire Forward/Reverse switch is on FORWARD position, the switch provides a voltage of +48V to the controller. REVERSE input signal provided by Forward/Reverse switch--when (Pin 5) - blue/white wire Forward/Reverse switch is on REVERSE position, the switch provides a...
  • Page 96 to the following Note. Connect the black (-) probe to the negative binding post of the battery pack. Δ Note • Never insert the comple te probe into the 8-wire plug for fear of poor contac t. When Tow/Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the multimeter should display a 0V DC voltage.
  • Page 97 Check Proce dure 7D—Pin 6 1． Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 6 (red/green wire). Refer to the following Note. Connect the black (-) probe to the negative binding post of the battery pack. 2．...
  • Page 98 Check Procedure 9—Motor speed sensor Please refer to Chapter 1 “Protection for Electrical Safe ty”. Δ Note • The fo llowing operations must be conducted on a flat surface. To prevent injury or pro perty loss, make sure that the passage of the elec tric vehicle is unblo cke d before moving it. Turn the key switch to OFF and turn Forward/Reverse gear switch to NEUTRAL.
  • Page 99 Disconnect the battery cable according to the directions. P lease refer to Chapter 1 “P rotec tion for Elec trical Safe ty”. Disconnect the 3 wires from the gear switch. Use a multimeter set at 200Ω,connect the black (-) probe to Position 7 (or 8) of the gear switch, then connect the red (+) probe to Position 3 (or 4).
  • Page 100 Check as follows with a multimeter: Turn Tow/Run switch to RUN, use a multimeter set to 200V DC, connect the red (+) probe to the red wire and connect the black (-) probe to the negative binding post of Battery 6. The voltage reading shou ld be 48V. If the voltage is 0V, check the continuity of the red wire and Tow/Run switch.
  • Page 101 The voltage should be 12V. Perform the following checks if the voltage is 0: Check whether the DC converter outputs a 12V voltage. Check the converter for failure and replace it if necessary. Continue with Step 2 if it is ok. Check the fuse in the fuse box and replace it if necessary.
  • Page 102 Troubleshooting Instructions Part 2 (controller failure indication code): Draught state State desc ription Cause of state indication signal code When the voltage of accelerator at P7 is greater than 1.4V Start switch turning off failure. volts, this state co de is displayed and the start switch is turned on (P3 is higher than 50% of battery voltage) Memory Trouble shooting diagram...
  • Page 103 Draught state Sta te description Cause of state indication signal code Direction selection is not available when the This state code is displayed when the voltage of accelerator pedal is depressed. accelerator at P7 is 1.4V and direction selection is not available (both P4 and P5 are lower than 50% of battery voltage).
  • Page 104 Draught state State description Cause of state indication signal code When the key switch is closed, the accelerato r This state code is displayed if the accelerator input voltage input voltage is excessively high. at P7 is greater than 0.9V when the start switch or key switch is turned on and off.
  • Page 105 Draught Cause of state indica tion sig nal State description state code This state code is displayed when P4 and P5 are greater Forward/Reverse switches are closed at the same time. than 50% of battery voltage. Troubleshooting diagram Memory Correction action Symptom Draught regulator...
  • Page 106 Draught state State desc ription Cause of state indication signal code When the ke y switch is closed, the start switch is This state code is displayed if the voltage at P3 is closed to turn on the power. greater than 50% of battery voltage when the key switch is closed.
  • Page 107 Draught state State desc ription Cause of state indication signal code When the ke y switch is closed, the battery This state code is displayed if the battery voltage is lower voltage is low. than 68.3V voltage when the key switch is initially opened.
  • Page 108 Draught sta te State desc ription Cause of state indic ation signal code When the key switch is closed, the battery voltage is This state code is displayed if the battery voltage is higher high. than 68V voltage when the key switch is initially opened. Memory Troubleshooting diagram Correction action...
  • Page 109 code Motor field current is high when the key switch is closed. This state code is displayed in case of a high current consumption in motor field when starting. Memo ry Troubleshooting diagram Correc tion action Symptom Draught regu lator The controller does not operate.
  • Page 110 Draught state State description Cause of state indication signal code This state code is displayed when the internal electric 12V bus is low. source of the controller is lower than 9 .35V. Memory Trouble shooting diagram Correction action Charger sw itch K ey switch Symptom Draught...
  • Page 111 Draught state State desc ription Cause of state indica tion signal code Over temperature protection (TP) short circuit or This state code is displayed when the voltage of the over transistor over temperature. temperature protection is low. Memory Correction action Trouble shooting diagram Start Sentry Draught...
  • Page 112 Draught state State desc ription Cause of state indic ation signal code High offset voltage of motor armature. This state code is displayed when the motor current is greater than 138A (corresponding to 2.7V) and no current is in motor circuit. Correction action Memory Troubleshoo ting diagram...
  • Page 113 Draught state State description Cause of state indication signal code Low offset voltage of mo tor armature. This state co de is displayed when the motor cu rrent is lower than 117A (co rresponding to 2.3V) and no current is in motor circuit. Memory Correction action Troubleshooting diagram...
  • Page 114 code The armature transistor is turned on This state code is displayed when the armature transistor incorrectly. can't be turned on correctly. This will result in PMT condition. Memory Troubleshooting diagram Correc tion action Symptom Draught regulator circu it The controller does not operate. active Possible causes No diagram for this state code...
  • Page 115 Low motor field current in RUN mode. This state code is displayed when motor field current consumption is lower than 1.3A and the armature current is greater than 100A for 1.27s in RUN mode. Memory Correc tion action Trouble shooting diagram Draught Symptom regulator...
  • Page 116 Draught state State desc riptio n Cause of state indic ation signal code Low input power of “motor current sensor” o f This state code is displayed when the voltage input controller du ring operation. power from the current sensor is low (less than 1.0V, 416 A).
  • Page 117 Draught state State description Cause of state indic ation signal code This state code will be displayed. Memory Troubleshooting diagram Correc tion action Symptom Draught regulator The controller does not operate. circuit Circuit* Possible causes active Sho rt circuit of circuit contactor. Positive electrode Power supply wiring to contro ller Negative electrode...
  • Page 118 Draught state State description Cause of state indic ation signal code High capacitor (C) voltage when the This state code will be displayed when the voltage at regenerative brake is released. 1C is higher than 79V in the cycle period of regenerative brake.
  • Page 119 Chapter 11: Battery and Charger Battery Overview The battery provided for the electric vehicle must be able to provide all (100%) the energy it requ ires. Therefore, the battery will make a deep discharge of 70% to 80% of its full capacity before being recharged, which is a process named “deep cycle”.

  • Page 120: Premature Excessive Discharge

    plate to form lead dioxide (PbO ) (see Fig 11-4). The result is the chargeable battery that can re-generate the electrical energy. Charger Fig 11-3: Discharged battery Fig 11-4: Charging battery Common misconceptions about battery Common misconceptions about the deep cycle battery of electric vehicle and the maintenance of the battery are shown in the table below.
  • Page 121 Under-watering is harmful to the “It takes too much time to inspect battery. The water level should be the water, and the inspection can inspected once a week. Please Under-watering be made one a month.” refer to “liquid le vel of e lectrolyte”.

  • Page 122: Battery Maintenance

    First, remove the positive electrode cab le Disconnect storage battery cable here Please turn the Tow/Run switch to the TOW position before disconnecting or connecting the battery. Fig 11-5: Sche matic diagra m of elec tric vehic le battery Inspect and clean the battery support and hold-down gear. The nuts and bolts on the hold-down gear may ru st. Therefore, it is suggested that they are cleaned on a regular basis, and be replaced when necessary.
  • Page 123 The battery should be charged every day after it is used. Inspect the battery periodically to ensure that the battery is fully charged. Please refer to “batte ry charging”. Tighten the ho ld-down gear. Please refer to “vibration damage”. Self discharge The dirt on the battery may form weak battery passage, which may result in slow discharge of the battery and therefore waste the precious electrical energy.
  • Page 124 Mineral content To prolong battery life to the longest possible degree, the battery should be filled with distilled water. In case tap water is to be used, the water must be ensured to contain minerals of which the contents are below the level specified below: Impuritie s Allowable content (ppm)

  • Page 125: Ac Power Supply Line

    Deep discharge It is strictly prohibited to charge the battery until it has no enough power to drive the vehicle. This may shorten the cycle life of the battery remarkably, and may result in the irremediable defect of the battery. In case the battery is fully discharged, it may be unable to be charged any longer.

  • Page 126: Battery Troubleshooting Diagram

    Battery troubleshooting diagram T he vehicle performance falls short of expectation Fully charge the battery Inspect and test the battery charger The reading is not lower than 6A. The reading is lower than 6A and the charging voltage is higher Inspect the electrical system and the charger for defects.

  • Page 127: Inspection And Test Of The Battery

    Inspection and test of the battery Please refer to Chapter 1 “Protection for Electrical Safe ty”. Carry out four inspections to find out the cause to the battery performance reduction. As these inspections are more and more detail and time-consuming, please carry o ut the inspection from the beginning before proceeding to other inspections until the problem is identified as shown in “battery troubleshooting diagram”...

  • Page 128: Calibration Of Hydrometer

    inspection with hydrometer. Remove the air bleeder cover. Measure with the thermometer and take down the electrolyte temperature at Battery Compartment No.2. Extrude the rubber bag of the hydrometer before inserting the battery compartment. Release the rubber bag slowly so that the electrolyte is sucked into the glass tube of hydrometer. Adjust the liquid level of the electrolyte when the buoy floats above the bottom to such a degree that the buoy is in neither contact with the bottom nor the top of the glass tube.

  • Page 129: Discharge Test

    Fig 11-8: Hydrometer Measures Co rrected specific gravity Vehicle Battery Electro lyte Correction should be number number temperature facto r Battery 1 Battery 2 Battery 3 Battery 4 taken N ormal 1.275 –.024 1.280 –.024 1.280 –.024 1.280 –.024 –.024 20°F (-6.6°C) battery-fully =1.251...

  • Page 130: Procedures For Discharge Test

    Procedures for discharge test Ensure that the battery is fully charged and that the liquid level of electrolyte in battery compartment is normal. Connect the tester with the positive (＋) terminal of battery No.1 and the negative terminal of battery No. 6 (see Fig 11-9).

  • Page 131: Battery Troubleshooting Example

    (25.6 ) usually cannot sustain a vehicle shift. However, the discharge time is dependent on the temperature of the electrolyte. The table below shows the discharge time under different temperatures of the battery pack o f (26.7 ). which the discharge time exceeds 62 minutes under 80 Discharge time whe n Discharge time whe n Electrolyte temperature...

  • Page 132: Battery Storage

    *After the hydrometer inspection, the problem seems to lie with Battery 1. Pro ceed with the discharge test. Discharge test result: Ba ttery numbe r Discharge voltage 5.44*V 7.33V 7.73V 7.15V 7.43V 7.41V *It is apparent that the problem lies with Battery 1 after the 45 minutes discharge test. After further observation of Battery 4, the battery proves to be normal.

  • Page 133: B Attery Charger

    Battery charger Overview E-merge charger is fully automatic and designed to charge the storage battery of the electric vehicle. The battery charger can be connected to the vehicle of any mileage, and will continue to charge the battery as long as it is not disconnected.

  • Page 134: Get To Know The Charger

    Fig 11-11: Elec trical outle t The charger will start automatically a few seconds after the connectors are plugged in. When the storage battery is fully charged, the charger will automatically stop the charging. Unplug the DC connector to use the vehicle. NOTICE It is a good way to fasten the DC wire on the steering wheel when the battery is charged, which can work pe rfectly as a reminder so that the user can store up the wires not to be used after the charging.

  • Page 135: Maintenance Of The Battery Charger

    to repair the charge r. Please extreme ly care ful not to make the non-insulated part o f the testing spike touch any other parts or the charger frame . Remove the bolt (1 and 2) on the charger co ver and other bolts on the side. Hold the handle on the cover of the charger and lift up the charger cover.

  • Page 136: Diode Test Procedure

    the AC and DC mains. To inspect the continuity, please set the DVOM (digital volt/ohm meter) to kilo-ohm and select “continuity”. The DVOM will send an audible signal when the connection is detected. In case the DVOM has no connectio n configuration, then configure the DVOM at kilo-ohm.

  • Page 137: Troubleshooting

    Charger trouble-shooting procedure Start-up begins, and the charger shuts off; Connect the DC cable on the vehicle Disconnect the Plug AC wire into Transformer has AV and DV the electrical sound wires outlet Close sound Start the charger of the relay Complete the Electric meter inspection of the...
  • Page 138 Low Resistance High Resistance Select Select Reverse bias Forward bias DVOM is for reference only. For detailed instructions, please refer to the m anufacturer's user manual. Fig 11-16 : diode test procedure Fig 11-17 : lester full a utomatic controllable silicon cha rge r wiring diagram...
  • Page 139 On-board charger Ope rating Instruc tions 1. Always use a grounded outlet. When using an extension cord, avoid excessive voltage drops by using a grou nded 3-wire 12 AWG cord. 2. The charger will automatically turn on and go through a short LED indicator self-test(Models 912-xx0x will flash all LED’s in an up-down sequence and Models 912-xx1x will alternatively flash its LED RED-GREEN) for two seconds.
  • Page 140 Voltage-max(v) 67.2 Current-max(A) Battery Type Specific to selected algorithm Reverse Polarity Electronic protection-auto-reset Short Circuit Electronic current limit Ac input All models Voltage-max(Vrms) 85—265 Frequency(Hz) 45—65 Current-max(Arms) 12 A @ 104VAC(reduced 20%<104) Current-nominal(Arms) 10 A @ 120VAC/5A @ 230VAC AC Power Factor >0.98 at nominal input current Ope ration Charger Model:912-...
  • Page 141 Environmental Enclosu re:IP46 -30 ℃ to +50℃(-22℉to 122℉),derated Operating Temperature Above 30℃,below 0℃ -40 ℃ to +70℃(-40 ℉ to 158 ℉) Storage Temperature AC input connector IEC320/C14(require>=1.8m localized cord) DC outpu t connector OEM specific w/ 12AWG wire Reg ulatory Safety EN 60335-1/2-29 Safely o f Appliances/Battery Chargers...
  • Page 142 After desired Algorithm # is displayed, touch the charger connecto r to the battery positive until the output relay is heard to click (~10 seconds)-algorithm is now in permanent memory. c) Remove AC power from the charger and reconnect the charger positive co nnector to the battery pack. It is highly recommended to check a newly changed algorithm by repeating step4) above.
  • Page 143 The electric vehicle is provided with a 48V DC separately excited reversible traction motor. The separately excited motor can only be used on the E-merge electric vehicles. TOMBERLIN suggests that the electric motor that is in a bad state of repair should be sent to the special service store for repair. The technician who has knowledge and expertise about the service of the electric motor can perform some simple reparation.
  • Page 144 Disconnect the battery cable as specified. Please refer to Chapter 1 "Protection for Electrical Sa fe ty". Secure the terminals with two spanners, and disconnect wires from connecting terminals F1 and F2 of the electric motor. Attach the red probe (＋) of the multimeter set at 200Ω（ohm）to F1 and the black probe (－) to F2 terminal.
  • Page 145 Removal of the electric motor Remove the elec tric motor from the electric vehicle. Please re fe r to Chapter 9 "Removal o f Motor". Before removal, first mark match marks on the end shield of the electric motor and the stator enclosure, and then secure the electric motor to the pincer pliers with wooden block as shown (see Fig 12-2).
  • Page 146 • Tip-off • The armature winding spreads outwards • Armature core iron sheet is damaged • The commutator is damaged or burnt • The commutator is very dirty or has oil strain • The commutator bar bulges up • Armature bearing shaft is abraded Clean and wipe o f the water on the dirty or stained commutator.
  • Page 147 Commutator Commutator core Fig 12-4 Armature inspec tion and test Fig 12-5 Brush spring elastic ity te st Fig 12-6 Bearing inspection Inspection of the excitation winding The burnout or charring of the insulating material of the excitation winding means the electric motor is overheated due to the overloaded or grounded or short circuit coil winding.
  • Page 148 Once the brush is removed, the replacing one should be mounted. This can ensure that the connecting terminal and brush be properly aligned in the transmission gear. For the mounting of brush, please refer to "Assembly of the electric motor". Once one brush is replaced, all the o ther brushes should also be replaced at the same time.
  • Page 149 Readjustment of the electric motor The electric motor should be readjusted by professional motor maintenance technician. The use of co rresponding activities and procedures is crucial to the success of readjustment to the electric motor.
  • Page 150 Specifications for the electric motor Any readjustment must be carried out by professional technicians. The maintenance specifications for the electric motor are shown in the table below. Fig 12-7 Elec tric motor...
  • Page 151 Items Adjustment limits Commu tator diameter（min) 2.265inch（66.675mm） Commu tator coaxial shaft with armature shaft 0.001inch（0.0254mm） Maximum kerf depth in processing commutator 0.005inch（0.127mm） Oscillation of the commutator bars should not exceed: 0.002inch（0.00508mm） In case the undercut of the commu tator segment insulator is smaller than 0.16 inch （0.406mm）...
  • Page 152 Bearing puller Fig 12-8 Removal of the bearing 2.3. Face the bearing end forward, and put the armature into the stator enclosure. While the positioning armature ensuring good contact of commutator/brush, the brush should be ensured to be held. Release the brush, and place the spring outside the brush so that the brush ho lds against the commutator.
  • Page 153 Terminal contacts Fig 12-9 Mounting of the brush Fig 12-10 Mounting of the e nd shie ld Mounting of the electric motor Clean the input shaft of the driving axle. 1.1. Spray detergent over the input shaft. 1.2. Wipe the input shaft with a piece of clean cloth. 1.3.
  • Page 154 Grease Inch 1/8Inch 3/8Inch (9.5MM) Fig 12-11 Apply grease onto putty knife Fig 12-12 Apply grease into input shaft grooves 2.6. Inspect the chamfer and end of the input shaft to ensure that areas shown in the figure are free of grease (see Fig 12-14).
  • Page 155 1/16inch（1.6MM） Chamfer Shaft end Fig 12 -13 Clea n the chamfer a nd input s haft e nd F ig 12-14 Clearance of elec tric motor a nd driving a xle ○ ○ ○ ○ ○ 6 in turn with a to rque of 6.3 foot-pound （9N·m). （see Fig 12 4.4.
  • Page 156 Inspection of the speed sensor of the electric motor Please refer to Chapter 10 "Check Procedure 9". Fig 12-15 Electric motor frame Removal of the speed sensor 1. Disconnect the battery cable as specified. Please refer to Chapter 1 "P rotec tion for Ele ctrical Safety". ○...
  • Page 157 Fig 12-16 E-merge e lectric motor spee d sensor...

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