Tomberlin 2010 E-Merge Manuals

Tomberlin 2010 E-Merge Manuals

Manuals and User Guides for Tomberlin 2010 E-Merge. We have 1 Tomberlin 2010 E-Merge manual available for free PDF download: Maintenance Manual

Tomberlin 2010 E-Merge Maintenance Manual

Tomberlin 2010 E-Merge Maintenance Manual (151 pages)

E-MERGE series electric vehicles

Brand: Tomberlin | Category: Offroad Vehicle | Size: 10 MB

Table of Contents

Table of Contents
4
Chapter 1 Overview

10
- Preparation for Emergency
  10
- Safe Use of Battery
  10
- Safe Use of Lubricating Oil
  10
- Safety Precautions
  10
- Electrical Safety During Maintenance
  11
- Use the Designated Lifting Jack
  14
- Cautions
  15
  - Washing and Cleaning
    15
  - Keep Tidy
    15
  - Tightening Torque
    16
  - Parts Replacement
    16
  - Washer, Grease Fitting and O-Ring
    16
  - Bearing and Oil Seal
    16
  - Recommendations on Disassembly and Assembly
    16
- Use Appropriate Tools
  15
  - Special Tools
    15
  - Instrumentation for Electric Control System
    15
Chapter 2 Regular Inspection and Adjustment

17
Chapter 3 Canopy

32
- Removal of Canopy Rods
  32
  - Install
    33
- Removal of the Canopy
  32
  - Remove
    32
  - Install
    32
- Removal of the Pillar
  33
  - Remove
    33
  - Install
    34
Chapter 4 Body

35
- Removal of the Front Bumper
  35
  - Remove
    35
- Removal of the Rear Bumper
  35
  - Install
    35
- Removal of the Rear Tray
  35
- Removal of the Seat Cushion
  36
  - Remove
    36
  - Install
    36
- Removal of Front Cover
  38
  - Remove
    38
  - Install
    38
- Removal of the Dashboard
  39
  - Remove
    39
  - Install
    40
- Removal of the Rear Cover
  40
  - Remove
    40
  - Install
    41
- Rear Cover
  42
Chapter 5 Front Axle

43
- Front Axle
  43
- Removal of the Front Axle
  44
  - Remove
    44
  - Inspect
    48
  - Install
    49
Chapter 6 Driving Axle

50
- Driving Axle
  50
- Removal of the Driving Axle
  51
  - Remove
    51
  - Inspect and Test
    54
  - Install
    55
- Gearbox
  57
- Removal of the Differential Gear
  58
  - Remove
    58
  - Inspection
    60
  - Install
    60
- Brake Pedal
  62
- Brake System
  62
Chapter 7 Brake System

62
- Parking Brake Handle
  62
- Accelerator Pedal
  65
Chapter 8 Steering System

66
- Steering System
  66
  - Removal of the Steering System
    67
  - Removal of the Steering Gear
    68
  - Disassembly of the Steering Gear
    69
  - Install
    72
Chapter 9 Electric Component

73
- Key Switch Removal
  73
- Key Switch Installation
  73
- Removal of Forward/Reverse Gear Switch
  74
- Installation of Forward/Reverse Gear Switch
  74
- Battery Discharge Meter Installation
  76
- Horn Removal
  76
- Horn Installation
  77
- Combination Switch Removal
  77
- Combination Switch Installation
  78
- Controller Removal
  78
- Controller Installation
  80
- Charger Receptacle Removal
  81
- Charger Receptacle Installation
  81
- Battery Removal
  81
- Battery Installation
  82
- DC Converter Removal
  82
- DC Converter Installation
  83
- Removal of DC Changeover Contactor and Diode Assembly
  83
- Installation of DC Changeover Contactor and Diode Assembly
  84
- Motor Removal
  84
- Motor Installation
  86
- Removal of Bulb of Headlight and Front Turn Signal Light
  86
- Headlight Installation
  86
- Tail Light Removal
  87
- Tail Light Installation
  87
- High Mount Stop Lamp Removal
  87
- High Mount Stop Lamp Disassembly
  88
- High Mount Stop Lamp Installation
  88
- Wiper Removal
  88
Chapter 10 Troubleshooting

91
Chapter 11 Battery and Charger

108
- Overview
  108
- Common Misconceptions about Battery
  109
- Battery Replacement
  110
- Battery Maintenance
  111
- Preventative Maintenance
  111
- Electrolyte Liquid Level
  112
- Self Discharge
  112
- Mineral Content
  113
- Vibration Damage
  113
- AC Power Supply Line
  114
- Battery Charging
  114
- Deep Discharge
  114
- Premature Excessive Discharge
  114
- Alternating Use of Vehicles
  115
- Electric Vehicle and Charger Numbering
  115
- Battery Troubleshooting Diagram
  116
- Charging Voltage Inspection
  117
- Inspection and Test of the Battery
  117
- Inspection and Test of the Battery Charger
  117
- Inspection with Hydrometer
  117
- Calibration of Hydrometer
  118
- Hydrometer Inspection Result Presentation
  118
- Procedures for Inspection with Hydrometer
  118
- Discharge Test
  119
- Discharge Test Result Presentation
  120
- Procedures for Discharge Test
  120
- Battery Troubleshooting Example
  121
- Battery Storage
  122
- Battery Charger
  123
- Conditions to be Noted before Charging
  123
- Overview
  123
- Get to Know the Charger
  124
- Removal of the Charger
  125
- Maintenance of the Battery Charger
  126
- Diode Test Procedure
  128
- Procedures for Component Replacement
  128
- Troubleshooting
  128
- Charger Trouble-Shooting Procedure
  129
- On-Board Charger
  131
- Operating Instructions
  131
- Maintenance Instructions
  132
- Specifications
  132
- Installation Instructions
  133
Chapter 12 Electric Motor

136
- Check Procedure 1－Internal Short Circuit
  136
- Check Procedure 2－Disconnection of Armature Circuit
  136
- Exterior Inspection of the Electric Motor
  136
- Overview
  136
- Check Procedure 3－Open Excitation Circuit
  137
- Removal of the Electric Motor
  138
- Armature Earth Test
  139
- Inspection and Test of the Motor Element
  139
- Inspection of the Armature
  139
- Inspection of the Excitation Winding
  140
- Motor Element
  140
- Bearing Inspection
  141
- Inspection of the Speed Sensor Magnet
  141
- Mounting of the Bearing
  141
- Removal of the Bearing
  141
- Mounting of the Speed Sensor Magnet
  142
- Readjustment of the Electric Motor
  142
- Removal of the Speed Sensor Magnet
  142
- Specifications for the Electric Motor
  143
- Assembly of the Electric Motor
  144
- Mounting of the Electric Motor
  146
- Inspection of the Speed Sensor of the Electric Motor
  149
- Mounting of the Speed Sensor of Electric Motor
  149
- Removal of the Speed Sensor
  149
- Speed Sensor of the Electric Motor
  149

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