Tomberlin E-MERGE Technical Training Manual

This training provides instructions on how to diagnose, inspect, repair, bleed, and adjust the Tomberlin E-MERGE 4-wheel
braking system.
Brake Diagnostics and Inspection
The Tomberlin E-MERGE braking system should be inspected anytime there is a perceived or actual reduction in braking
performance. Indicators, possible causes, what to inspect and repairs are outlined below.
Indicator Possible Cause
"Softer" Air in the hydraulic system due to
brake loss of fluid and/or intake of air.
pedal Accumulation of braking fluid on
ground,
inside/outside
accompanied by lower fluid level
in the master cylinder.
Breakage of brake lines, rusted or
loose connectors, bleeders, etc.
Disk pads or drum shoes worn
Master cylinder
Brake fluid contamination
Grinding Worn out disk pads will cause a
noise grinding/growling noise.
when
brakes
applied
Worn out drum shoes will cause
a grinding/growling noise.
Pulsating Due to a warped rotor/drum, or
brakes fluid entering the drum or on a
disk pad
Tomberlin Technical Training
4-Wheel Braking System Level 2
Fix
Air must be removed via bleeding. See the section on how to bleed the
braking system.
Inspect, clean and tighten joints where braking fluid has accumulated.
hydraulic joints, Fill the master cylinder with DOT 3 brake fluid to the proper level. Test
drums brakes and reinspect the joints. If no additional fluid is found bleed the
system if necessary.
Inspect all components from the master cylinder to each wheel. See the
next section on visual brake inspection instructions.
broken/damaged parts, fill the brake fluid in the master cylinder and
bleed the system.
Inspect and replace pads/shoes if worn out.
After the above have been inspected and fixed—and softness still
exists—it could be a bad master cylinder. Inspect/replace if necessary.
DOT 3 brake fluid is clear or slightly tinted. Brake fluid is contaminated
when discolored, or has a swirl type pattern in it (possibly mixed with
oil), foreign debris, rust, etc. The reason for contamination must be
identified, repaired, and fluid must be replaced.
Note: Due to the majority of braking performed by the disk brakes, they
are more likely to wear out before the drum shoes. There is no wear
indicator tab on the disk pads. Replace the pads if worn. Inspect the
rotor for damage (scarring, warpage, etc.). If the rotor is damaged, they
are not turnable and must be replaced.
Replace the shoes if worn or cracked. Inspect the drum for damage
(scarring, etc.). If the shoes are simply glazed (and not too bad) you
may remove the glaze by using 60-120 grit sandpaper and reinstall. If
the drum is damaged by scarring (and not too deep) it is possible to
repair by simply using sand paper (start with 60 and finish with 120 grit)
to smooth out the inside surface. If oil is present in the drum, you must
replace the shoes and inspect/replace seals and wheel cylinder.
Identify and repair leak. Fill the master cylinder (if needed) and bleed
the system.
Page 1
Replace