Tomberlin 2010 E-Merge Maintenance Manual

Tomberlin 2010 E-Merge Maintenance Manual

E-merge series electric vehicles
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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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Summary of Contents for Tomberlin 2010 E-Merge

  • 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 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: Table Of Contents

    Chapter 1 Overview Safety Precautions ..........................1-1 Preparation for Emergency ......................1-1 Safe Use of Lubricating Oil......................1-1 Safe Use of Battery ........................1-1 Protection of Vehicle Safety ......................1-2 Electrical Safety During Maintenance..................... 1-2 Use the Designated Lifting Jack ..................... 1-5 Use Appropriate Tools...........................
  • Page 5 Removal of Canopy Rods........................3-1 Remove............................3-1 Install.............................. 3-2 Removal of the Pillar ..........................3-2 Remove............................3-2 Install.............................. 3-3 Chapter 4 Body Removal of the Front Bumper ....................... 4-1 Remove............................4-1 Removal of the Rear Tray ........................ 4-1 Remove............................4-1 Removal of the Rear Bumper ......................
  • Page 6 Inspection............................. 6-11 Install............................6-12 Chapter 7 Brake System Brake System ............................7-1 Brake Pedal............................7-2 Parking brake handle ..........................7-3 Accelerator pedal ..........................7-4 Chapter 8 Steering System Steering System ............................ 8-1 Removal of the Steering System ....................8-2 Removal of the Steering Gear ......................8-3 Disassembly of the Steering Gear ....................
  • Page 7 Tail light installation ........................9-14 High mount stop lamp removal..................... 9-14 High mount stop lamp disassembly....................9-14 High mount stop lamp installation ....................9-14 Wiper removal ..........................9-15 Chapter 10 Troubleshooting Troubleshooting Instructions Part 1..................... 10-1 Check procedures ........................10-3 Index for check procedures ......................
  • Page 8 Battery charging ........................... 11-6 Deep discharge ..........................11-7 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 ..................
  • Page 9 Inspection of the excitation winding....................12-5 Motor element ..........................12-5 Bearing inspection........................12-6 Removal of the bearing ........................ 12-6 Mounting of the bearing........................ 12-6 Inspection of the speed sensor magnet..................12-6 Removal of the speed sensor magnet..................12-7 Mounting of the speed sensor magnet ..................12-7 Readjustment of the electric motor....................
  • Page 10: Safety Precautions

    Overview Chapter 1 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 should be prepared. For example: •...
  • Page 11: Electrical Safety During Maintenance

    Overview Chapter 1 battery should be placed in an area with good ventilation while charging. The electrolyte of the battery contains sulfuric acid, which is toxic and highly corrosive and should be prevented from being spilled onto the skins, eyes and clothes.
  • Page 12 Overview Chapter 1 • Exterior: Flush the area where acid is spilled with water, and visit the doctor immediately. • Oral medication: Drink a large quantity of milk or water before taking milk of magnesia or vegetable oil. Visit the doctor immediately. •...
  • Page 13 Overview Chapter 1 • Moveable elements! It is strictly prohibited to maintain the electric vehicle while it is in operation. • Hot! It is strictly prohibited to maintain a hot motor. Any violation of this warning may result in serious burns.
  • Page 14: Use The Designated Lifting Jack

    Overview Chapter 1 • To avoid unintentional start-up of the electric vehicle, please turn the Tow/Run switch to the First, remove the position before disconnecting positive electrode cable connecting the battery. Disconnect the • After disconnection of the battery, please wait for 90 storage battery cable here seconds to allow for the discharge of the capacitor...
  • Page 15: Use Appropriate Tools

    Overview Chapter 1 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: Tightening Torque

    We recommend that you use E-MERGE original parts for Original replaceable parts. grease recommended by TOMBERLIN during the assembly, inspection and repair. Washer, Grease Fitting and O-ring During the inspection and repair of vehicles, all the washers, grease fittings and O-rings removed should be cleaned up before being mounted.
  • Page 17: Chapter 2 Regular Inspection And Adjustment

    Regular Inspection and Adjustment Chapter 2 Regular Maintenance Normal maintenance is of paramount importance to the optimal performance and safe operation of vehicles. B WARNING Unless otherwise required, the master switch must be turned off and the parking brake must be applied during the maintenance.
  • Page 18 Regular Inspection and Adjustment Chapter 2 Clean/Lubricate the pedal control area Semian Inspect all the insulated nual wires for rupture or inspecti dirtiness Inspect the shock damper for oil leakage and damage of spring Annual Conduct discharging test inspecti Use terminal protective agent Inspect the brake shoes for tightness and the rear...
  • Page 19: Periodic Lubrication Plan

    Regular Inspection and Adjustment Chapter 2 Periodic Lubrication Plan Periodic lubrication plan Lubricated Normal intervals Maintenance Recommend lubricating oil points Brake pedal shaft 3# Lithium based grease Parking brake 3# Lithium based grease The user or trained Accelerator pivot bar foot 3# Lithium based grease technician applies the lubricating oil once a...
  • Page 20: Braking System

    Regular Inspection and Adjustment Chapter 2 Braking System Main 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 Oil Pipeline ② ·...
  • Page 21: Inspection Of Parking Brake

    Regular Inspection and Adjustment Chapter 2 3. Measure: · Free play of the brake pedal Push against the pedal by hand (slightly) and measure the distance it travels before the pressure is lost. Defects are to be replaced. Free Travel of the brake pedal 13mm(0.512 in)...
  • Page 22: Inspection Of Brake Drum And Brake Shoe

    Regular Inspection and Adjustment Chapter 2 Procedures for the Adjustment of Free Travel · Loosen the locknut ④ · Adjust the free travel via adjusting nut ③ · Tighten the locknut · Re-inspect the free travel Inspection of Brake Drum and Brake Shoe 1.
  • Page 23 Regular Inspection and Adjustment Chapter 2 6. Measure In case the inside diameter of the drum does not meet the specification, it will be replaced with a new one. Standard inside diameter: 180mm(7.2 in) Maximum wearing value of the inside diameter: 1.5mm(0.06 in)...
  • Page 24 Regular Inspection and Adjustment Chapter 2 9. Install · Brake drum · Rear wheel WARNING: Verify that there is no oil or water on the surface of the brake drum and shoe block. 10. Install: Wheel nuts Tightening torque to 90N·m (66.4ft·1b) NOTICE: First, screw on the wheel nuts by hand, and then...
  • Page 25: Inspection Of The Accelerator Pedal

    Regular Inspection and Adjustment Chapter 2 Inspection of the Accelerator Pedal 1. Inspect: Operating condition of the pedal In case of unsmooth operation, the pivot should be lubricated. 2. Inspect: Lateral free travel 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: Inspection Of The Steering Linkage

    Regular Inspection and Adjustment Chapter 2 50N·m (36.9ft·1b) And tighten: Bolts (of universal joint) Upper fixing bolt Lower fixing bolt Tightening torque to 22N·m (16.2ft·1b) 3.Re-inspect: · Steering clearance Inspection of the Steering Linkage Removal of Tie Rod Ball Joint 2.
  • Page 27: Inspection Of Stub Axle

    Regular Inspection and Adjustment Chapter 2 Inspection of Stub Axle · Free gap of kingpin bolt, spacer and bushing a. Park the vehicle on flat surface and apply parking brake b. Jack up the front wheels of vehicle c. Move the wheels lightly In case the free clearance is too large, the bushing is to be replaced or the bearing clearance is to be adjusted.
  • Page 28: Inspection Of Tires And Wheel Rim

    Regular Inspection and Adjustment Chapter 2 Procedures for the Adjustment of Toe-in: Park the vehicle on the flat surface and apply · parking brake. Loosen the locknut(1) on the ends of the tie rod Turn the steering tie rod to adjust the toe-in increase→...
  • Page 29: Inspection Of The Front Wheel Bearing

    Regular Inspection and Adjustment Chapter 2 · Wheel tread thickness In case of non-compliance with the standard, replacement is to be made Maximum wearing value of wheel tread thickness (front and rear tires) 4.0mm(0.16in) Inspection of the Front Wheel Bearing 1.
  • Page 30: Inspection Of The Shock Damper

    Regular Inspection and Adjustment Chapter 2 the operation, the quality of fit between half shaft and bearing or bearing sleeve may deteriorate. In this case, we usually recommend the replacement of a new rear axle half shaft assembly. Inspection of the Shock Damper 1.
  • Page 31: Inspection Of The Seat Belt

    Regular Inspection and Adjustment Chapter 2 Inspection of the Seat Belt Binding Force of the Seat Belt Pull down the seat belt swiftly and the retractor should respond quickly to seize the belt. The belt, when loosened, should be retracted back into the retractor.
  • Page 32: Chapter 3 Canopy

    Canopy Chapter 3 Removal of the Canopy Remove: 1. Disconnect high-mounted center light wire 2. Fixing bolts of the canopy 3. Canopy Install: Canopy In the reverse order of the removal procedures Tightening torque: 9N·m (6.6ft·1b) Removal of Canopy Rods Remove: 1....
  • Page 33: Install

    Canopy Chapter 3 Install: Connect the front canopy rod and rear canopy rod, and tighten the connecting slip bolt ③ In the reverse order of the removal procedures. Tightening torque for ①, ②, ⑤ : 22N·m (16.2 ft·1b) Removal of the Pillar Remove: 1....
  • Page 34: Install

    Canopy Chapter 3 Install: Pillar In the reverse order of the removal procedures ① Tightening torque: 22N·m (16.2 ft·1b) Tightening torque for ②, ④, ⑤: 22N·m (16.2 ft·1b) ③ Tightening torque: 30N·m (22.1 ft·1b) MERGE 3-3...
  • Page 35: Chapter 4 Body

    Body Chapter 4 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: Removal Of The Seat Cushion

    Body Chapter 4 Install: · Rear bumper · Rear bumper bracket Tightening torque: 63N·m (46.5 ft·1b) Install: · Clamping nut · Rear tray · Rear box cover Removal of the Seat Cushion Remove 1. Removal of the seat cushion: · Handrail fixing bolt ·...
  • Page 37 Body Chapter 4 · Rear seat backrest bracket ④ · Backrest ⑤ Install: · Front seat backrest · Tightening the torque of bolt: 22N·m (16.2 ft·1b) · Rear seat backrest (2+2 series) · Tightening the torque of bolt: 22N·m (16.2 ft ·1b) ·...
  • Page 38: Removal Of Front Cover

    Body Chapter 4 Removal of Front Cover Remove 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:...
  • Page 39: Removal Of The Dashboard

    Body Chapter 4 Removal of the Dashboard Remove 1.Remove: · Steering wheel cover ① · Steering wheel nuts ② · Steering wheel ③ NOTICE: To remove the scorecard clip, first remove the screws behind the steering wheel cover. Remove: · Combination switch connection sheath ·...
  • Page 40: Install

    Body Chapter 4 · Edging fender · Anti-slip pedal Install: In the reverse order of the removal procedures Tightening the torque of steering wheel nuts: 50N·m (36.9ft·1b) Removal of the Rear Cover Remove: 1. Remove: · Seat cushion · Seat backrest ·...
  • Page 41: Install

    Body Chapter 4 4. Remove: · Fixing bolts of lower hinge Tightening torque: 7N·m (5.2 ft·1b) · Hinge · Rear cover bolt Tightening torque: 9N·m (6.6 ft·1b) 5. Remove · Rubber nail of rear cover plate · Rear cover plate ·...
  • Page 42: Rear Cover

    Body Chapter 4 Rear cover 1. Rear cover 2. Rear cover plate 3. Rear box cover 4. Tray 5. Left rear light 6. Right rear light 7. On-board charging plug box 8. Left ventilating window 9. Right ventilating window 10. Lower hinge 11.
  • Page 43: Chapter 5 Front Axle

    Front Axle Chapter 5 Front axle 1. Upper swing arm 2. Split pin 3. Front shock absorber 4. Spindle 5. Lower swing arm 6. Brake disc 7. Oil seal 8. Cone bearing 9. Lower lug shaft 10. Hub connected plate 11.
  • Page 44: Removal Of The Front Axle

    Front Axle Chapter 5 Removal of the Front Axle Remove 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.
  • Page 45 Front Axle Chapter 5 8. Remove: · Dust cover 9. Remove: · Split pin · Slotted nut 10. Remove: · Brake tongs bolt Tightening torque 23N·m (17.0 ft·1b) · Brake tongs 11. Remove: · Hub connected plate (of front wheel) Knock at the connected plate with a soft hammer.
  • Page 46 Front Axle Chapter 5 12. Remove: · Brake disc bolt Tightening torque 23N·m (17.0 ft·1b) · Brake disc Standard thickness of brake disc 4 mm (0.16 in) Maximum wearing thickness 1 mm (0.04 in) 13. Remove: · Bolt Tightening torque 23N·m (17.0 ft·1b) ·...
  • Page 47 Front Axle Chapter 5 NOTICE: The inside space and bush should be replaced together. 15.Remove: · Removal of Drag Link Ball Joint Please refer to Chapter 2 "Removal of Drag Link Ball Joint". · Split pin · Pivot slotted nut ·...
  • Page 48: Inspect

    Front Axle Chapter 5 17. Remove: · Front shock absorber bolt Tightening torque 60N·m (44.2 ft·1b) · Front shock absorber · Swing arm bolt Tightening torque 60N·m (44.2 ft·1b) · Upper and lower swing arms · Dust cover · Inside spacer ·...
  • Page 49: Install

    Front Axle Chapter 5 · Remove the oil seal and bearing with the special bearing puller. · Install new oil seal cover and bearing in the installation procedures mentioned above. NOTICE: Use a hold-down clamp that is consistent with the diameter of bearing and inside loop of oil seal cover.
  • Page 50: Chapter 6 Driving Axle

    Driving Axle Chapter 6 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 51: Removal Of The Driving Axle

    Driving Axle Chapter 6 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".
  • Page 52 Driving Axle Chapter 6 8. Remove: · Lower fixing nut of rear shock absorber ① Tightening torque 63N·m (46.5ft·1b) · rear shock absorber · Rear axle and rear swing arm fixing nut ② Tightening torque 63N·m (46.5ft·1b) · U-bolt · Driving axle 9.
  • Page 53 Driving Axle Chapter 6 11. Remove · Clipping spring · Locating dowel ① · Upper and lower brake retracting spring · Brake shoe Turn the locating dowel with spring or pincer pliers to separate the clipping spring and locating dowel of brake shoe. 12.
  • Page 54: Inspect And Test

    Driving Axle Chapter 6 Inspect and test 1. Measure: · Inside diameter of brake drum · Thickness of brake shoe 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 ·...
  • Page 55: Install

    Driving Axle Chapter 6 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 ⑥ ·...
  • Page 56 Driving Axle Chapter 6 Procedures for the installation of brake shoe: · Apply the high temperature grease over the two ends of the metal support of the brake shoe. WARNING In handling the brake shoe, ensure that the hands are clean and the shoe plate surface is not tainted with grease.
  • Page 57: Gearbox

    Driving Axle Chapter 6 Gearbox 1. Gearbox 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.
  • Page 58: Removal Of The Differential Gear

    Driving Axle Chapter 6 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 59 Driving Axle Chapter 6 3.Disassemble: · Ring gear ① · Differential gear assembly ② 4.Remove: · Sealing rubber cover (both ends) 5.Remove: · Oil seal ① · Clip spring ② · Bearing fixing bush ③ · Bearing ④ · Input shaft ⑤ 6.Remove: ·...
  • Page 60: Inspection

    Driving Axle Chapter 6 Procedures for the removal of countershaft 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. Inspection 1.
  • Page 61 Driving Axle Chapter 6 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 62: Chapter 7 Brake System

    Brake System Chapter 7 Brake System 1. Brake pedal 2. Parking brake handle 3. Brake caliper 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.
  • Page 63 Brake System Chapter 7 Brake Pedal 1. Measure: · Free play of brake pedal; 13mm (0.512 in) In case of non-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 64 Brake System Chapter 7 Parking brake handle 1. Measure: · Free play of parking brake handle; 15mm (0.591in) In case of non-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 65: Accelerator Pedal

    Brake System Chapter 7 Accelerator pedal 1. Accelerator pedal 2. Accelerator 3. Accelerator bracket 4. Pivot 5. Split pin 6. Pin axle 7. Washer 8. Split pin EMERGE 7-4...
  • Page 66: Chapter 8 Steering System

    Steering System Chapter 8 Steering system 1、steering wheel 2、cover of steering cover 3、nut of steering wheel 4、bearing 5、inner snap ring 6、steering shaft 7、outer snap ring 8、protective sleeve of steering shaft 9、turn signal stalk 10、protective sleeve for wire harness 11、block of steering column 12、bolt 13、bolt 14、nut...
  • Page 67: Removal Of The Steering System

    Steering System Chapter 8 Removal of the Steering System 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 68: Removal Of The Steering Gear

    Steering System Chapter 8 Tightening torque 50N·m (44.6 ft·1b) · Upper fixing bolt of universal joint ③ Tightening torque 25N·m (18.4 ft·1b) · Steering column assembly 7. Disassemble: · Outer clasp ⑤ · Inner clasp ③ · Steering shaft ④ ·...
  • Page 69: Disassembly Of The Steering Gear

    Steering System Chapter 8 Tightening torque 45N·m (33.2 ft·1b) · Steering gear Disassembly of the Steering Gear 1. Disassemble: · Drag link ball joint of the steering gear · Secure the drawbar of the steering gear with one spanner, and loosen the locknut with another spanner.
  • Page 70 Steering System Chapter 8 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.
  • Page 71 Steering System Chapter 8 6. Disassemble: · Rack of steering gear ① 7. Inspect: · Steering gear bush · Deep groove ball bearing NOTICE: We do not recommend the replacement of worn parts in the steering gear individually. To ensure sound operating performance, we usually recommend the replacement of a new steering gear assembly.
  • Page 72: Install

    Steering System Chapter 8 · Whether the ball joint has the following symptom: Unsmooth operation ① Over-loose free gap ② Bending or deformation ③ Damage of dust boot ④ NOTICE: In case of any of the above condition, replace with a new ball joint. Install: Note the following: 1.
  • Page 73: Chapter 9 Electric Component

    Electric Component Chapter 9 WARNING • Please refer to Chapter 1 “Protection for Electrical Safety”. Key switch removal 1. Turn Tow/Run switch to TOW. Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3.
  • Page 74: Removal Of Forward/Reverse Gear Switch

    Electric Component Chapter 9 Removal of forward/reverse gear switch 1. Turn Tow/Run switch to TOW Please refer to Chapter 1 “Protection for Electrical Safety”. 2. Take out the key from the key switch. 3. Apply the parking brake. 4. Remove the middle electrical regaining plate. 5.
  • Page 75 Electric Component Chapter 9 5. Remove the connecting wire from emergency switch. 6. Press the snap locks on the upper and lower ends of the switch, push switch out of the housing. check Continuity of the emergency switch Installation of emergency switch Back to the removal steps Note The red, black/yellow and blue/white wires must be...
  • Page 76: Battery Discharge Meter Installation

    Electric Component Chapter 9 Check: Refer to “Check Procedure 12 -- Battery discharge meter” in Chapter 10 1. Take out the key from the key switch. 2. Apply the parking brake. 3. Turn Tow/Run switch to TOW. Battery discharge meter installation Back to the removal steps NOTE: The red, red/green and black wires must be...
  • Page 77: Horn Installation

    Electric Component Chapter 9 Horn installation Return to disassembling steps NOTE: The horn wire must be connected correctly. The tightening torque of the horn set bolt is: 9N·m (6.6ft·1b) Combination switch removal 1. Take out the key from the key switch. 2.
  • Page 78: Combination Switch Installation

    Electric Component Chapter 9 8. Turn the switch lever and check the relevant gears for continuity, replace the part in case of un-continuity. Combination switch installation Back to disassembling steps Controller removal 1. Take out the key from the key switch. 2.
  • Page 79 Electric Component Chapter 9 Control circuit MERGE 9-7...
  • Page 80: Controller Installation

    Electric Component Chapter 9 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 operation: • When Forward/Reverse gear switch is on FORWARD position, make sure the electric vehicle is running forward.
  • Page 81: Charger Receptacle Removal

    Electric Component Chapter 9 Forward/Reverse gear switch is on REVERSE position, the reverse buzzer should sound a warning tone. • When Forward/Reverse gear switch is on NEUTRAL position, make sure the electric vehicle remains still. Charger receptacle removal 1. Take out the key from the key switch. 2.
  • Page 82: Battery Installation

    Electric Component Chapter 9 4. Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection for Electrical Safety”. 5. Remove the nut on the battery hold down. 6. Remove the battery hold down 7. Remove the battery with a special battery lifting tool.
  • Page 83: Dc Converter Installation

    Electric Component Chapter 9 7. Remove the DC converter. DC converter installation Back to the removal steps. 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.
  • Page 84: Installation Of Dc Changeover Contactor And Diode Assembly

    Electric Component Chapter 9 Installation of DC changeover contactor and diode assembly Back to the removal steps. NOTE: The diode must be installed with a correct polarity. Motor removal 1. Take out the key from the key switch. Marking line 2.
  • Page 85 Electric Component Chapter 9 7. Wrap the motor at the mid position with a wide band, lift the motor carefully and move it to the left horizontally, then place it on the ground gently. NOTE: The motor is heavy, lift and place with care. 8.
  • Page 86: Motor Installation

    Electric Component Chapter 9 Motor installation Back to the removal steps. NOTE: Match the marking line during motor installation. Removal of bulb of headlight and front turn signal light 1. Take out the key from the key switch. 2. Apply the parking brake. 3.
  • Page 87: Tail Light Removal

    Electric Component Chapter 9 Back to the above operation steps NOTE: Wiring of positive/negative poles of the bulb, wiring position of high/low beam. Tail light removal Any defective or dim tail light shall be replaced. 1. Take out the key from the key switch. 2.
  • Page 88: High Mount Stop Lamp Disassembly

    Electric Component Chapter 9 5. Disconnect the connector of the high mount stop lamp③. High mount stop lamp disassembly 1. Remove the screw①. 2. Rotate the lamp receptacle; remove the wire harness with the bulb②. 3. Check the continuity, Replace the bulb assembly with wire harness in case of un-continuity②.
  • Page 89 Electric Component Chapter 9 Removal of inner mirror 1.Take out the key from the key switch. 2. Apply the parking brake 3. Turn Tow/Run switch to TOW. 4. Take off the connector of inner mirror 5. Take off fixed nut of inner mirror 6.
  • Page 90 Electric Component Chapter 9 5 Cover the light with white lense. 6.fix the wire clip on the windshield frame along left side of it. 7.connect the connector( connect one side of the two output of connector of inner mirror with wire, the other side with the output wire of wiper 8.
  • Page 91: Chapter 10 Troubleshooting

    Troubleshooting Chapter 10 Troubleshooting Instructions Part 1 Symptom Possible causes Correction action Battery - dead Charge the battery. Check the wiring of the electric vehicle. Refer 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 accelerator switch for poor contact and disconnection.
  • Page 92 Troubleshooting Chapter 10 Part 1 of Troubleshooting Instructions, continue Symptom Possible causes Correction action The electric vehicle Check the wiring of the electric vehicle. Refer to Circuit – incorrect wiring can be started, but the the wiring diagram on page 9-7. motor braking device Speed sensor disconnection or Refer to “Check Procedure 9—Motor speed...
  • Page 93: Check Procedures

    Troubleshooting Chapter 10 Check procedures With the following procedures, the entire electrical system can be checked without disassembling the electric vehicle. WARNING • If the wires are removed or replaced, make sure that the wires and harnesses are arranged and fixed correctly. Wires and harnesses not arranged and fixed correctly can result in electric vehicle failure, property damage and casualties.
  • Page 94: Check Procedure 1-Battery / Voltage Check

    Troubleshooting Chapter 10 Check Procedure 1—Battery / voltage check NOTE: to perform the following check procedures, the battery should be maintained properly and charged 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 95: Check Procedure 4 - Tow/Run Switch

    Troubleshooting Chapter 10 Check Procedure 4 - TOW/RUN switch Please refer to Chapter 1 “Protection for Electrical Safety”. 1. Use a multimeter, set it at diode testing position, connect the black (-) probe to one connecting terminal of towing switch and put the red (+) probe on the connecting terminal on the other side. 2.
  • Page 96 Troubleshooting Chapter 10 5.When the key switch is on position OFF, the multimeter should show an open circuit condition. 6.When the key switch is on position ON, the multimeter should show a conducting state. 7.If other readings are obtained, replace the key switch. Refer to "Key switch removal" in Chapter 9. 8.If the key switch operates as above, install the instrument panel in the reverse sequence of removal and perform the following operations.
  • Page 97: Check Procedure 7--Controller Signal

    Troubleshooting Chapter 10 Check Procedure 7--Controller signal 9-wire connector of controller plug Function (Pin 1)-red wire Battery - positive electrode Input signal of motor speed sensor - a pulse input signal (Pin 2)- yellow wire provided to controller by motor speed sensor. FORWARD input signal provided by Forward/Reverse switch--when Forward/Reverse switch is on FORWARD (Pin 4) - black/yellow wire...
  • Page 98: Check Procedure 7B-Pin 4 And 5

    Troubleshooting Chapter 10 Check Procedure 7B—Pin 4 and 5 Please refer to Chapter 1 “Protection for Electrical Safety”. Pin 4 and 5 of the 9-wire connector are designed to connect Forward/Reverse switch and the controller. When Forward/Reverse switch is on FORWARD position, the switch sends a +48V signal to the controller through Pin 4;...
  • Page 99: Check Procedure 7C-Pin 7

    Troubleshooting Chapter 10 Check Procedure 7C—Pin 7 1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 7 (pink wire). Refer to the following Note. Connect the black (-) probe to the negative binding post of the battery pack.
  • Page 100: Check Procedure 9-Motor Speed Sensor

    Troubleshooting Chapter 10 Δ Note: • Never insert the complete probe into the 9-wire plug for fear of poor contact. 2. When Tow/Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the multimeter should display a 0V DC voltage. 3.
  • Page 101: Check Procedure 10-Forward/Reverse Gear Switch

    Troubleshooting Chapter 10 6. Reconnect the 3-wire connector on the motor speed sensor. Use a multimeter set to 20V DC, connect the black (-) probe to the negative binding post of the battery pack and connect the red (+) probe to green wire which is between the 3-wire connector on the motor speed sensor. 6.1 Jack up a rear wheel so that it is off the ground.
  • Page 102: Check Procedure 12 -- Battery Discharge Meter

    Troubleshooting Chapter 10 5. Turn Tow/Run switch to RUN. 6. 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 (+) probe to the disconnected red terminal of the reverse buzzer.
  • Page 103: Check Procedure 13-- High Mount Stop Lamp

    Troubleshooting Chapter 10 Check Procedure 12-- High mount stop lamp Please refer to Chapter 1 “Protection for Electrical Safety”. With Tow/Run switch on RUN and key switch ON, check the high mount stop lamp interface on main cable with a multimeter set at 200V DC (connect the red probe to green/yellow wire and connect the black probe to black wire) while depressing the brake pedal.
  • Page 104: Troubleshooting Instructions Part 2

    Troubleshooting Chapter 10 3. If no problem is found in the above Step 1 and 2 and there is no 12V output, replace the main cable. 4. If the above checks are satisfactory (ie. there is a 12V output), connect the flashing light interface to the main cable to check the flashing light for normal operation, replace the flashing light if it does not operate normally.
  • Page 105 Troubleshooting Chapter 10 is not fit 4、 The extreme work condition 1、 The order of direction and throttle is wrong 2、 Choose wrong HPD type HPD failure 3、 Wrong adjustment on the throttle potentiometer 4、 Order delay is too short 1 、...
  • Page 106 Troubleshooting Chapter 10 2、 Choose wont type of SRO 3、 Interlock or direction switch is open circuit 4、 Order delay is too short CURRENT SENSE FAULT Excitation currency sensor 1、controller is broken failure M- SHORTED Inner M-is short circuit to B- 1、controller is broken 1、...
  • Page 107 Troubleshooting Chapter 10 ¤ ¤¤¤ Speed sensor failure ¤ ¤¤¤¤ HPD failure ¤ ¤¤¤¤¤ Motor failure ¤¤ ¤ Low voltage in the battery ¤¤ ¤¤ Over voltage ¤¤ ¤¤¤ Over/less temperature off ¤¤ ¤¤¤¤ Lack of currency on the driving output in the main contactor ¤¤...
  • Page 108: Chapter 11 Battery And Charger

    Battery and Charger Chapter 11 Battery Overview The battery provided for the electric vehicle must be able to provide all (100%) the energy it requires. 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 109: Common Misconceptions About Battery

    Battery and Charger Chapter 11 The result is two metalloids, the lead sulfate (PbSO ) immerse in water (H O). As the battery is fully discharged, no electric energy can be generated. After the connection of discharged battery and the charger, in the reverse procedures, the sulfate ion ) enters the electrolyte from the positive and negative plates to form sulfuric acid (H ).
  • Page 110: Battery Replacement

    Battery and Charger Chapter 11 The dirt and rust may form “The dirt and rust on the battery current passage, which results Self discharge will do no harm.” in the self discharge of battery. Please refer to “self discharge”. “Fill water into the battery to the In most cases, water must be liquid level in the evening.
  • Page 111: Battery Maintenance

    Battery and Charger Chapter 11 Fig 11-5: Schematic diagram of electric vehicle battery 4. Inspect and clean the battery support and hold-down gear. The nuts and bolts on the hold-down gear may rust. Therefore, it is suggested that they are cleaned on a regular basis, and be replaced when necessary.
  • Page 112: Self Discharge

    Battery and Charger Chapter 11 entering the battery. Ensure the connecting terminals are tightly secured. When all terminals are dried, apply the terminal protection oil to all the connecting terminals. Please refer to “self discharge”. 3. Maintain the electrolyte at normal liquid level. Please refer to “electrolyte liquid level”. 4.
  • Page 113: Mineral Content

    Battery and Charger Chapter 11 liquid level benchmark. This is because the liquid level of electrolyte may rise when the battery is charged. Some electrolyte may burst out of the battery cover. Therefore, filling water to the liquid level before battery charging may result in the spillage. This will reduce the battery capacity and corrode its neighboring metal components.
  • Page 114: Battery Charging

    Battery and Charger Chapter 11 Battery charging The charger provided for the E-merge electric vehicle has brought a solution to the common problem relating to the battery charging. The charger can shut off automatically to prevent undercharge and overcharge. Meanwhile, all battery compartments are automatically distributed with balanced electric quantity by the light current in such a way to prolong the service life of the battery.
  • Page 115: Alternating Use Of Vehicles

    Battery and Charger Chapter 11 Alternating use of vehicles Use the electric vehicles alternately. In case the vehicle came back the last yesterday evening is dispatched as the first one the next morning, its battery is hard to sustain. The workload should be equally allocated so that all electric vehicles are equally used.
  • Page 116: Battery Troubleshooting Diagram

    Battery and Charger Chapter 11 Battery troubleshooting diagram The vehicle performance falls short of expectation Fully charge the battery Inspect and test the battery charger The reading is lower than 6A and the The reading is not lower than 6A. charging voltage is higher than 56V.
  • Page 117: Inspection And Test Of The Battery

    Battery and Charger Chapter 11 Inspection and test of the battery Please refer to Chapter 1 “Protection for Electrical Safety”. 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 out the inspection from the beginning before proceeding to other inspections until the problem is identified as shown in “battery troubleshooting diagram”...
  • Page 118: Procedures For Inspection With Hydrometer

    Battery and Charger Chapter 11 Procedures for inspection with hydrometer 1. Before inspection, first ensure that the battery has sufficient electrolyte to cover the electrode plates by about 1/2 inch (13mm) and is fully charged. In case it is a must to fill water, the batter should be recharged before the inspection with hydrometer.
  • Page 119: Discharge Test

    Battery and Charger Chapter 11 Fig 11-8: Hydrometer Measures Corrected specific gravity Vehicle Battery Electrolyte Correction should be number number temperature factor Battery 1 Battery 2 Battery 3 Battery 4 taken Normal 1.275 –.024 1.280 –.024 1.280 –.024 1.280 –.024 20°F (-6.6°C) –.024 battery-fully...
  • Page 120: Procedures For Discharge Test

    Battery and Charger Chapter 11 The discharge test is the most difficult and time-consuming test. Please use battery discharge tester. Procedures for discharge test 1. Ensure that the battery is fully charged and that the liquid level of electrolyte in battery compartment is normal.
  • Page 121: Battery Troubleshooting Example

    Battery and Charger Chapter 11 Battery voltage Battery condition 7.00V 7.00V 7.00V 7.00V 7.00V 7.00V Very good The service life of batter No 4 7.07V 7.07V 7.22V 6.50V 7.07V 7.07V is to expire. The service lives of battery No 7.20V 7.20V 6.67V 7.33V...
  • Page 122: Battery Storage

    Battery and Charger Chapter 11 Hydrometer inspection result: Battery number Battery compartment number Battery 1 (positive terminal) 1.200* 1.265 1.300 1.250 1.280 1.260 Battery 2 1.285 1.275 1.290 1.270 1.295 1.265 Battery 3 (negative terminal) 1.265 1.270 1.275 1.265 1.280 1.275 Battery 4 (negative terminal) 1.275...
  • Page 123: Battery Charger

    Battery and Charger Chapter 11 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 124: Get To Know The Charger

    Battery and Charger Chapter 11 Fig 11-11: Electrical outlet 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.
  • Page 125: Removal Of The Charger

    Battery and Charger Chapter 11 continue till the remaining cycle is completed. 3. In case the storage battery is fully charged in a very short period (less than 2 hours), the charger will shut off. In case the voltage of open circuit storage battery drops down to a point where the recharge is needed, the charger will start and charge the battery till it is fully charged.
  • Page 126: Maintenance Of The Battery Charger

    Battery and Charger Chapter 11 Maintenance of the battery charger The only maintenance the charger requires is the periodic cleaning of the auxiliary contacts of AC connector. To clean the auxiliary contacts, please press down the elastic connector protective sleeve (See Fig 11-13).
  • Page 127 Battery and Charger Chapter 11 MERGE 11-20...
  • Page 128: Troubleshooting

    Battery and Charger Chapter 11 Troubleshooting The simple and effective way to spot the defective battery charger is to follow the troubleshooting procedures (see Fig 11-15). Continuity inspection WARNING To carry out continuity inspection, please see to it to disconnect the battery charger from the AC and DC mains.
  • Page 129: Charger Trouble-Shooting Procedure

    Battery and Charger Chapter 11 Charger trouble-shooting procedure Start-up begins, and the charger shuts off; Connect the DC cable on the vehicle Disconnect the Plug AC wire Transformer AV and DV into the has sound wires electrical outlet Close sound Start the charger of the relay Complete the...
  • Page 130 Battery and Charger Chapter 11 Fig 11-15: Charger trouble-shooting procedure Fig 11-16: diode test procedure Fig 11-17: lester full automatic controllable silicon charger wiring diagram MERGE 11-23...
  • Page 131: On-Board Charger

    Battery and Charger Chapter 11 On-board charger Operating Instructions 1. Always use a grounded outlet. When using an extension cord, avoid excessive voltage drops by using a grounded 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 132: Maintenance Instructions

    Battery and Charger Chapter 11 a problem with the battery pack (voltage not attaining the required level), or that the charger output was reduced due to high ambient temperatures. [4 FLASH] Check Battery: the battery pack could not be trickle charged up to the minimum level required for the charge to be started.
  • Page 133: Installation Instructions

    Battery and Charger Chapter 11 Operation Charger Model:912- Xx0x(10 LED) Xx1x(1 LED) AC ON Solid YELLOW LED Active AC Low Flash YELLOW Flash YELLOW Thermal Cutback Flash Bar graph Flash YELLOW <80% Charge Indicator Short Flash GREEN >80% Charge Indicator Solid YELLOW Long Flash GREEN 100% Charge Indicator...
  • Page 134 Battery and Charger Chapter 11 void the warranty. b) Securely fasten the black ring terminal from the charger to the negative terminal“.”, “NEG”,NEGATIVE”) of the battery pack. c) Check that the correct charge algorithm is being used –refer to section 4).Securely fasten the red ring terminal to the positive terminal (“+”,“POS”, “POSITIVE”) of the battery pack.
  • Page 135 Battery and Charger Chapter 11 Figure 1 4) Check/Change Charging Algorithm: The charger comes pre-loaded with algorithms for batteries as detailed in Table 1. If your specific battery model is not listed, please contact Delta-Q. Each time AC power is applied with the battery pack NOT connected, the charger enters an algorithm select/display mode for approximately 11 second.
  • Page 136: Chapter 12 Electric Motor

    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 137: Check Procedure 3-Open Excitation Circuit

    Electric Motor Chapter 12 of wrong reading, the cause may be the off contact or poor contact of brush set and/or disconnection of armature winding. The electric motor should be removed from the vehicle and be repaired by professionals. Please refer to Chapter 9 "Removal of Motor". Check Procedure 3-open excitation circuit Please refer to Chapter 1 "Safety Protection Measures".
  • Page 138: Removal Of The Electric Motor

    Electric Motor Chapter 12 Removal of the electric motor Remove the electric motor from the electric vehicle. Please refer to Chapter 9 "Removal of Motor". 1. 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 139: Inspection And Test Of The Motor Element

    Electric Motor Chapter 12 Inspection and test of the motor element Inspection of the armature Disassemble the electric motor and carefully inspect the armature for any of the following characteristics: • The insulating material is charred, carbonized or ruptured; • The paint coating is abnormally hardened; •...
  • Page 140: Inspection Of The Excitation Winding

    Electric Motor Chapter 12 Commutator Commutato core Fig 12-4: Armature inspection and test Fig 12-5: Brush spring elasticity test 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 141: Bearing Inspection

    Electric Motor Chapter 12 CAUTION • To inspect the elasticity of the brush spring, it is strictly prohibited to excessively extend the spring. Excessive force may damage the spring. NOTE: 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.
  • Page 142: Removal Of The Speed Sensor Magnet

    Electric Motor Chapter 12 Removal of the speed sensor magnet ○ ○ 18 (see Fig 12-7). Remove the bolts 19 , and take down the speed sensor magnet Mounting of the speed sensor magnet ○ ○ 18 to the shaft with bolts 19 , and tighten the torque of the bolts with Mount the speed sensor magnet 22 inch pound(2.5N·m)。...
  • Page 143: Specifications For The Electric Motor

    Electric Motor Chapter 12 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: Electric motor MERGE 12-8...
  • Page 144: Assembly Of The Electric Motor

    Electric Motor Chapter 12 Items Adjustment limits Commutator diameter(min) 2.265inch(66.675mm) Commutator 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 0.002inch(0.00508mm) exceed: In case the undercut of the commutator segment insulator is smaller than 0.16 inch(0.406mm), the 0.031inch(0.8mm)...
  • Page 145 Electric Motor Chapter 12 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.
  • Page 146: Mounting Of The Electric Motor

    Electric Motor Chapter 12 Terminal contacts Fig 12-9: Mounting of the brush Fig 12-10: Mounting of the end shield Mounting of the electric motor 1. Clean the input shaft of the driving axle. 1.1. Spray detergent over the input shaft. 1.2.
  • Page 147 Electric Motor Chapter 12 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 148 Electric Motor Chapter 12 1/16inch (1.6MM) Chamfer Shaft end Fig 12-13: Clean the chamfer and input shaft end Fig 12-14: Clearance of electric motor and driving axle 4.4. Tighten the bolts ②, ③, ④, ⑤ and ⑥ in turn with a torque of 6.3 foot-pound(9N·m).(see Fig 12-15)...
  • Page 149: Speed Sensor Of The Electric Motor

    Electric Motor Chapter 12 Speed sensor of the electric motor 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 "Protection for Electrical Safety".
  • Page 150 Electric Motor Chapter 12 4. Turn the TOW/RUN switch to the TOW position. To connect the battery, first connect the positive electrode(+)cable,then tighten it with a torque of 110 inch pound(12.4N·m). Apply the antirust oil on all connecting terminals to minimize future corrosion. Fig 12-16: E-merge electric motor speed sensor MERGE 12-15...
  • Page 151 TOMBERLIN AUTOMOTIVE GROUP, INC. 3123 WASHINGTON ROAD AUGUSTA, GA 30907 WWW.TOMBERLIN.NET (706) 860-8880...

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