Tomberlin E-MERGE 2007 User Manual

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volta gethatcanresultinshock,fireandinjuryifnot
performedbyaprofessional.Damagetothevehiclecanalsooccur.Someproceduresrequir e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.

Tomberlin E-MERGE 2007 Specifications

General

Brand	Tomberlin
Model	E-MERGE 2007
Category	Offroad Vehicle
Language	English

Summary

INTRODUCTION

Symbols

Explains warning, danger, and caution symbols used in the manual for safety.

Chapter 1 Overview

Safety Precautions

Critical safety guidelines for vehicle maintenance and operation.

Appropriate Tools and Cautions

Emphasizes using correct tools and following cautions for maintenance tasks.

Maintenance Procedures Overview

Covers parts replacement, bearing, oil seals, and disassembly/assembly recommendations.

Chapter 4 Body

Body Component Removal

Details procedures for removing front bumper, seat cushion, front cover, dashboard, and rear cover.

Chapter 5 Front Axle

Front Axle Removal and Inspection

Outlines procedures for removing and inspecting the front axle assembly.

Chapter 6 Driving Axle

Driving Axle Removal and Gearbox Procedures

Explains driving axle removal and differential gear disassembly.

Chapter 7 Brake System

Brake Pedal and Parking Brake Inspection

Covers inspection and measurement of brake pedal and parking brake.

Brake Drum and Shoe Inspection

Describes inspection of brake drums and shoes for wear.

Chapter 8 Steering System

Steering System Removal and Inspection

Covers removal of the steering system and inspection of linkage/gear.

Chapter 9 Electric Component

Key Switch and Controller Maintenance

Details removal, installation, and checks for key switch and controller.

Motor and Related Component Maintenance

Covers motor removal, installation, and related electrical components.

Lighting, Wiper, and Other Component Maintenance

Explains maintenance for headlights, tail lights, wipers, and other electrical parts.

Chapter 10 Troubleshooting

Troubleshooting Instructions Part 1

Lists symptoms and correction actions for common electrical and mechanical problems.

Troubleshooting Instructions Part 2 (Controller Failures)

Provides diagnostic codes and solutions for controller-related failures.

CHAPTER 11 BATTERY AND CHARGER

Battery Overview, Maintenance, and Testing

Covers battery overview, misconceptions, maintenance, testing, and troubleshooting.

Battery Charger Operation and Troubleshooting

Explains charger operation, installation, maintenance, and troubleshooting procedures.

Chapter 12 Electric Motor

Electric Motor Overview and Exterior Inspection

Covers overview, exterior inspection, and basic checks of the electric motor.

Motor Element Inspection and Testing

Details inspection of armature, excitation winding, and motor elements.

Motor Bearing and Speed Sensor Maintenance

Covers bearing inspection, removal, mounting, and speed sensor maintenance.

Electric Motor Assembly and Specifications

Provides steps for assembling, readjusting, and specifications for the electric motor.

Chapter 2 Regular Inspection and Adjustment

Regular Maintenance Schedule

Details normal maintenance schedules and procedures for optimal vehicle performance.

Periodic Lubrication Plan

Outlines a schedule for lubricating various points on the vehicle.

Chapter 3 Canopy

Canopy and Pillar Removal/Installation

Covers procedures for removing and installing the canopy, rods, and pillars.