Tomberlin E-Merge E2 Assembly Manual
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Tomberlin E-Merge E2 Assembly Manual

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Summary of Contents for Tomberlin E-Merge E2

  • Page 1    ...
  • Page 2 Foreword   This   manual   is   designed   primarily   for   use   by   Tomberlin   Emerge   assembly   personnel   in   a   properly   equipped   shop.   Persons   using   this   manual   should   have   a   sound   knowledge   of  ...
  • Page 3   Throughout   t hese   i nstructions,   i mportant   i nformation   i s   b rought   t o   y our   a ttention   b y   t he   f ollowing   s ymbols:    ...

  • Page 4: Table Of Contents

      TABLE   O F   C ONTENTS   Vehicle   I dentification   N umber   ( VIN)     .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   1   VIN  ...
  • Page 5   Index     .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .     4 9   User’s  ...

  • Page 6: Vehicle   I Dentification   N Umber   ( Vin)

    World   M fg.   I D                       V ehicle   D escriptor                                                                           V ehicle   I dentifier   10 11 12 13 14 15 16 17 0     TOMBERLIN            ...

  • Page 7: Standard   T Orque   S Pecifications

      SPECIFICATIONS     MODEL   E2   –   E merge   E2   –   E merge   L E   E2   –   E merge   S S   Battery   US   B attery   8 VGCXC   US  ...

  • Page 8: Lubricant   A Nd   M Aintenance   P Roducts

      LUBRICANT   A ND   M AINTENANCE   P RODUCTS       Gear   C ase   /   S pline   L ubricants   Gear   c ase     SAE   8 0W-­‐90   G ear   O il   Rotating  ...
  • Page 9 Screwdrivers   Torque   W rench       #2   P hilips     Head,   B ox   E nd,   1 /2",   1 2   p t.     #3   P hilips     Body,  ...

  • Page 10: Torque   C Onversions   T Able

    TORQUE   C ONVERSIONS   Newton   M eter   t o   I nch/Foot   P ound   in lb ft lb ft lb ft lb     8.65 0.74   36.14   71.55 17.30 1.48   36.88   72.28 25.95 2.21...
  • Page 11 TORQUE   C ONVERSIONS   Newton   M eter   t o   F oot   P ound   ft lb ft lb ft lb     106.95   142.36   177.76 107.69 143.09 178.50     108.43   143.83  ...
  • Page 12 DECIMAL   E QUIVALENTS     1/64     -­‐ -­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐  .0156     1/32     -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐   -­‐     .0312     -­‐ -­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐  1   m m   =   . 0394”   3/64  ...

  • Page 13: Decimal   E Quivalent   C Hart

      SAE   T AP   D RILL   S IZES     Thread   S ize   Drill   S ize   Thread   S ize   Drill   S ize   #0-­‐80   3/64   1/2-­‐13   27/64   #1-­‐64  ...

  • Page 14: Crate   O Pening   A Nd   U Nit   I Nspection

    CRATE   O PENING   A ND   U NIT   I NSPECTION             CAUTION:   Always  insure  the  end  of  the  forks  extend  beyond  the  cradle  openings   on   t he   s hipping   c rate   w henever   a   c rated   u nit   i s   l ifted   a nd/or   m oved.    ...
  • Page 15 Use   a   1 4mm   s ocket   a nd   a   1 4mm   b ox   wrench   t o   r emove   a ll   s hipping   c rate   assembly  ...
  • Page 16 Carefully   r emove   t he   l ower   p ortion   o f   t he   shipping   c rate   w ithout   c ausing   d amage   t o   the   u nit  ...
  • Page 17 While   u npacking   t he   u nit   c arefully   i nspect   for   d amage   a nd/or   m anufacturing   f laws     The   p lastic   c anopy   b ag   c an   b e   u sed   a s   a   convenient  ...

  • Page 18: Steering   C Olumn   A Nd   I Nstrument   P Anel   A Ssembly

    Inventory   t he   b ag   w ell   p rotector   s hipping   package     STEERING   C OLUMN   A ND   I NSTRUMENT   P ANEL   ASSEMBLY       Remove   t he   u pper   m ounting   h ardware   from  ...
  • Page 19   WARNING!   Always   insure   the   steering   column   and   its   hardware   are   fully   tightened  by  checking  for  free-­‐play     Remove   t he   h ardware   f or   t he   i nstrument   panel  ...
  • Page 20 Mount   t he   t urn-­‐signal   s talk   o n   t he   s teering   column   a pproximately   o ne   i nch   b elow   t he   end   o f   t he   s teering   c olumn   t ube   j acket  ...
  • Page 21 Install   t he   t wo   r ubber   p ush   s crews   i nto   t he   upper   p ortion   o f   t he   i nstrument   p anel   u sing   a  ...

  • Page 22: Rear   B Umper   A Nd   B Ag   W Ell   P Rotector   A Ssembly

    REAR   B UMPER   A ND   B AG   W ELL   P ROTECTOR   ASSEMBLY       Open   h ardware   p acket   f or   t he   b ag   w ell   protector  ...
  • Page 23 Tighten   t he   r ear   b umper   m ounting   hardware   u sing   a   1 5mm   s ocket   a nd   a   1 3mm   box   w rench  ...

  • Page 24: Canopy   P Illar   A Ssembly

    CANOPY   P ILLAR   A SSEMBLY           Remove   t he   r ear   s eat   a nd   a ll   t he   a ssembly   components   t hat   w ere   s tored   i n   t he   b attery   compartment  ...
  • Page 25 Loose   f it   r ight   c anopy   p illar   o n   p illar   b ase     Insert   e nd   o f   c anopy   w ire   h arness   i nto   p illar   base  ...
  • Page 26 Loose   f it   l eft   c anopy   p illar   s upport   o n   p illar   base   w ith   l eft   c anopy   p illar   s upport    ...
  • Page 27 Connect   t he   c anopy   w iring   h arness   t o   t he   main   w iring   h arness   i nsuring   w ire   c olor   codes   m atch  ...
  • Page 28 Use   t he   a id   o f   a   d ead   b low   h ammer   i f   t he   holes   i n   t he   c anopy   p illar   d o   n ot   a lign   w ith   the  ...

  • Page 29: Battery   I Nstallation

    BATTERY   I NSTALLATION       WARNING!   Battery   e lectrolyte   i s   p oisonous.     L ead   a cid   b atteries   c ontain   h ydrogen-­‐ oxygen   g ases   t han   c an   b e   e xplosive   a nd   s ulfuric   a cid.   Serious  ...
  • Page 30 Remove   t he   h ardware   a nd   b lack   p lastic   battery   b aseboards     CAUTION:   To   avoid   injury   always   wear   back   support   when   handling   batteries  ...
  • Page 31 Place   t he   b atteries   i n   t he   r ear   b ank   w ith   t he   terminal   p ost   s ide   o f   t he   b attery   t oward   t he   rear  ...
  • Page 32 Continue   t he   p rocess   a long   b oth   b anks   o f   batteries   t owards   t he   r ight   s ide   o f   t he   u nit   ending  ...
  • Page 33 Place   t he   s mall   r ed   o r   b lack   t erminal   b oots   over   t he   t erminal   c onnections     NOTE:   Using   a   pair   of   slip   joint   pliers   to   carefully   pull  ...

  • Page 34: Seat   A Ssembly

    Once   t he   b atteries   h ave   b een   f ully   i nstalled   the   s eat   b ottom   c an   b e   r e-­‐installed   a nd   lowered  ...
  • Page 35 Carefully   u nwrap   a nd   i nspect   t he   s eat   b ack   assembly     Place   t he   s eat   b ack   a ssembly   o n   t he   s eat   bottom  ...

  • Page 36: Windshield/Canopy   F Rame   A Ssembly

    Check   t o   i nsure   t hat   A LL   m ounting   hardware   i s   t ight   o n   t he   s eat   b ack   a ssembly    ...
  • Page 37 With   t he   w indshield   l aying   f acedown   i nsert   the   p assenger   s ide   c anopy   b racket   connector   i nto   t he   w indshield   f rame    ...
  • Page 38 Standing   i n   f ront   o f   t he   u nit   c arefully   p lace   the   w indshield   a nd   c anopy   f rame   a ssembly   on  ...
  • Page 39 Use   a   1 3mm   s ocket   t o   t ighten   t he   windshield   f rame   h ardware     CAUTION:   USE   EXTREME   CARE   WHEN   ASSEMBLING   THE  ...

  • Page 40: Windshield   A Ssembly

    Use   d iagonal   c utters   t o   r emove   t he   e xcess   Ty-­‐wrap   m aterial     WINDSHIELD   A SSEMBLY       When   u sing   a   g lass   w indshield   b egin   b y   removing  ...
  • Page 41 Once   t he   L exan™   w indshield   h as   b een   prepared   t he   p rotective   p aper   c an   b e   removed     Starting   a t   o ne   e nd   b egin   i nserting   t he   windshield  ...
  • Page 42 In   o rder   t o   e ase   t he   a ttachment   o f   t he   windshield   c hannels   o nto   t he   w indshield   spray   e ither   t he   w indshield   i tself   o r   t he   slots  ...

  • Page 43: Windshield   W Iper   A Ssembly

    When   c ompleted   t he   w indshield   f rame   should   b e   f ully   s eated   i n   t he   w indshield   channel     In   m ost   c ases   a n   a udible   C LICK   c an   b e   h eard   when  ...
  • Page 44 Insert   m ounting   h ardware   n ut   i n   h ousing   h alf     Place   w iper   m otor   i n   h ousing   h alf     Replace   o ther   h ousing   h alf   a nd   s ecure   w ith   c ase   hardware  ...
  • Page 45 Insert   w iper   m otor   s haft   t hrough   h ole   o n   w iper   motor   b racket     Loose   f it   t he   m ain   r ubber   b ushing,   w asher   a nd   nut  ...
  • Page 46 Loose   f it   w iper   m otor   m ounting   h ardware     Use   a n   8 mm   n ut   d river   a nd   1 9mm   b ox   w rench   to  ...
  • Page 47 Attach   t he   w iper   a rm   t o   t he   w iper   m otor   s haft   using   t he   l ock   w asher   a nd   n ut    ...

  • Page 48: Canopy   A Ssembly

    CANOPY   A SSEMBLY       Unpack   a nd   i nspect   h igh   m ount   s top   l ight     Place   t he   g asket   a round   t he   b ase   o f   t he   p lastic   housing  ...
  • Page 49 Use   a   # 3   P hilips   s crewdriver   t o   i nsert   t he   b rake   light   h ardware         NOTE:   The  larger  screw  goes  closest  to  the  center   of  ...
  • Page 50 Once   t he   c anopy   b olt   h as   b een   i nserted   through   t he   c anopy   p lace   t wo   a dditional   r ubber   bushings  ...
  • Page 51 While   d epressing   t he   b rake   p edal   l ook   t hrough   the   c anopy   w iring   h ole   t o   s ee   i f   t he   h igh   m ount   lamp  ...

  • Page 52: Final   A Ssembly

    Attach   t he   g utter   s pouts   t o   t he   c anopy   g utter   ports   w ith   t he   s pring   c lips   p rovided    ...
  • Page 53 Attach   t runk   l id   b y   i nserting   t he   l id   h inges   i nto   the   s lots   o f   t he   b ag   w ell   p rotector  ...
  • Page 54 Once   t he   u nit   h as   b een   a ssembled   t he   s teering   wheel   c an   b e   s et   a nd   t he   n ut   t ightened   u sing   a   breaker  ...
  • Page 55       INDEX       Instrument   P anel,   1 0-­‐11       Bag   W ell   P rotector,   1 4     Batteries   Seat   a ssembly     Lifting,   2 1    ...
  • Page 56   User’s   G uide   f or:   QuiQ   9 12-­24xx   /   3 6xx   /   4 8xx   /   7 2xx SAVE THESE IMPORTANT INFORMATIONS IMPORTANTES SAFETY INSTRUCTIONS DE SÉCURITÉ Conserver ces instructions.
  • Page 57 LED indications following “Power-On Self Test”: Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short:<80% Charge. Long:>80% Charge. When battery is not connected: Algorithm Number display. Flashing: Reduced Power Mode: Low AC Voltage or Amber High internal charger temperature. Flashing: Charger error.
  • Page 58 pose an energy and/or shock hazard under normal use. These units must be installed in the host equipment in such a manner that the output cable and battery connections are only accessible with the use of a tool by qualified personnel. Mounting: 1) Mount the charger with adequate ventilation.
  • Page 59 200909     Page   5 4  ...
  • Page 60   Page   5 5   200909  ...
  • Page 61 ON-­‐BOARD   C HARGER   I NSTALLATION           Inspect   u nit   f or   d amage   p rior   t o   i nstallation         Carefully   i nsert   c harger  ...
  • Page 62   Use   a   1 0mm   s ocket   a nd   a   1 0mm   b ox   wrench   t o   t ighten   t he   o n-­‐board   c harger   hardware  ...
  • Page 63   Heat   t he   s hrink   t ubing   t o   s eal   c onnection   Gather   t he   m ain   n egative   b attery   t erminal   cable,   t he   o n-­‐board   c harger   c able   a nd   m ain   wiring  ...
  • Page 64   Attach   t he   h arness   t o   t he   b atteries   a s   specified   i n   t he   a ssembly   m anual NOTES 200909     Page   5 9  ...
  • Page 65     200909     Page   6 0  ...

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