Tomberlin E-Merge E2 Assembly Manual Download Page 4

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TABLE OF CONTENTS

Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

VIN Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications – General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Lubricant and Maintenance Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assembly Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Torque Conversions Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Crate Opening and Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Steering Column and Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rear Bumper and Bag Well Protector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Canopy Pillar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Windshield/Canopy Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Canopy Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Summary of Contents for E-Merge E2

Page 1: ... ...

Page 2: ...e operator s perspective when seated in a normal operating position This manual includes procedures for assembly operations component identification along with certain specifications for the Emerge E2 unit A table of contents is placed at the beginning of the manual and an alphabetic index is provided at the end of the manual for location of specific page numbers and assembly information Keep this...

Page 3: ...ere injury or death to the operator bystander or person inspecting or servicing the Emerge E2 unit WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator bystander or person inspecting or servicing the Emerge E2 unit CAUTION A CAUTION indicates special precautions that must be taken to avoid personal injury or Emerge and or property damage NOTE A NOTE...

Page 4: ...ue Conversions Table 4 Decimal Equivalent Chart 6 Tap Drill Charts 7 Crate Opening and Unit Inspection 8 Steering Column and Instrument Panel Assembly 12 Rear Bumper and Bag Well Protector Assembly 16 Canopy Pillar Assembly 18 Battery Installation 23 Seat Assembly 28 Windshield Canopy Frame Assembly 30 Windshield Assembly 34 Windshield Wiper Assembly 37 Canopy Assembly 42 Final Assembly 46 ...

Page 5: ... Index 49 User s Guide for On Board Charger 50 On Board Charger Installation 54 ...

Page 6: ... 0 TOMBERLIN Individual Serial No EMERGE Low Speed Vehicle Original Unit Capacity 48 VDC Facility 3 Point Seatbelt System Plant Check Digit Model Year 2010 A This could be either a number or a letter VIN LOCATIONS The VIN can be found in three locations on the unit On the driver s side of dash On the driver s side of the On the frame under the and can be seen through the instrument panel under the...

Page 7: ...5 x 47 25 x 73 25 98 5 x 47 25 x 73 25 98 5 x 49 25 x 73 25 Wheelbase 64 2 1630mm 64 2 1630mm 64 2 1630mm Turning Radius 9 84 3m 9 84 3m 9 84 3m Ground Clearance 3 15 80mm 3 15 80mm 3 15 80mm Dry Weight 1200 lbs 1200 lbs 1200 lbs STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and motor areas A...

Page 8: ...shield Channel WINDEX window cleaner Zep LUBRISIL Silicone Lubricant Release Agent Prod 0058 ASSEMBLY TOOL LIST This tool list is not meant to be all inclusive but is merely given to show the minimum requirements for a unit to be assembled from crate to retail barring any unforeseen problems which may arise Additional tools may be required as circumstances dictate 3 8 in sq drive Flex T handle 3 i...

Page 9: ...lips 3 Philips Common Pliers Slip Joint Duckbilled Diagonal cutting Torque Wrench Head Box End 1 2 12 pt Body preset click type 30 300 in lb range Miscellaneous 8mm Nut driver Small bolt cutters Cobalt rotary rasp 3lb Dead blow hammer ...

Page 10: ...14 84 09 19 14 01 67 49 42 115 84 82 20 14 75 68 50 16 116 85 56 21 15 49 69 50 89 117 86 30 22 16 23 70 51 63 118 87 04 23 16 96 71 52 37 119 87 77 24 17 70 72 53 11 120 88 51 25 18 44 73 53 84 121 89 25 26 19 18 74 54 58 122 89 99 27 19 92 75 55 32 123 90 72 28 20 65 76 56 06 124 91 46 29 21 39 77 56 80 125 92 20 30 22 13 78 57 53 126 92 94 31 22 87 79 58 27 127 93 68 32 23 60 80 59 01 128 94 41...

Page 11: ...7 260 191 78 165 121 70 213 157 11 261 192 51 166 122 44 214 157 85 262 193 25 167 123 18 215 158 58 263 193 99 168 123 92 216 159 32 264 194 73 169 124 65 217 160 06 265 195 46 170 125 39 218 160 80 266 196 20 171 126 13 219 161 53 267 196 94 172 126 87 220 162 27 268 197 68 173 127 60 221 163 01 269 198 41 174 128 34 222 163 75 270 199 15 175 129 08 223 164 48 271 199 89 176 129 82 224 165 22 27...

Page 12: ...mm 3937 13 32 4063 27 64 4219 11 mm 4331 7 16 4375 29 64 4531 15 32 4688 12 mm 4724 31 64 4844 1 2 5000 13 mm 5118 33 64 5156 17 32 5313 35 64 5469 14 mm 5512 9 16 5625 37 64 5781 15 mm 5906 19 32 5938 39 64 6094 5 8 6250 16 mm 6299 41 64 6406 21 32 6563 17 mm 6693 43 64 6719 11 16 6875 45 64 7031 18 mm 7087 23 32 7188 47 64 7344 19 mm 7480 3 4 7500 49 64 7656 25 32 7813 20 mm 7874 51 64 7969 13 1...

Page 13: ...1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 METRIC TAP DRILL SIZES Tap Size Drill Size Decimal Equivalent Nearest Fraction 3 x 50 39 0 0995 3 32 3 x 60 3 32 0 0937 3 32 4 x 70 30 0 1285 1 8 4 x 75 1 8 0 125 1 8 5 x 80 19 0 166 11 64 5 x 90 20 0 1...

Page 14: ...TE OPENING AND UNIT INSPECTION CAUTION Always insure the end of the forks extend beyond the cradle openings on the shipping crate whenever a crated unit is lifted and or moved Begin by placing crated unit in an open area ...

Page 15: ...portion of the shipping crate section Use a pair of small bolt cutters to remove any wire used to secure the unit to the lower half of the shipping crate Carefully insert the forks under the chassis of the unit and above the cradle of the shipping crate Lift the unit only high enough to safely remove the lower portion of the shipping crate ...

Page 16: ...t Lower the unit to the floor Roll the unit into position to continue the assembly process If necessary a floor jack may be placed under the bumper mounting bracket of the frame to aid in steering the unit during movement Stage batteries in a readily accessible location for ease during the assembly process ...

Page 17: ... or workmanship from the manufacturer needs to be noted as soon as possible during the assembly process and photographed whenever feasible Be sure to inspect for completeness of packaged components while carefully completing the initial unpacking of the unit Ample component storage racks will help to facilitate the unpacking inventory and inspection process Remove and open the bag well protector s...

Page 18: ...hardware Raise the steering column into its mounting bracket while simultaneously inserting the splined lower portion of the compound steering joint into the upper portion NOTE This process takes patience and practice but can be mastered over time Reinstall the upper mounting hardware in the steering column base and its mounting bracket Tighten the steering column mounting hardware using a 13mm so...

Page 19: ...e are fully tightened by checking for free play Remove the hardware for the instrument panel from the floorboard Slide the steering column through the steering column boot on the instrument panel Use a 2 Phillips screwdriver to remove the turn signal stalk mounting hardware ...

Page 20: ... finish while completing the final assembly of the instrument panel paying close attention to the condition of the plastic panel NOTE Any deficiencies in material or workmanship from manufacturer found now will save in time and aggravation later Reinstall the hardware for the instrument panel into the floorboard Tighten the hardware using a 5mm Hex bit socket on an extension and a 13mm box wrench ...

Page 21: ...t panel using a soft faced dead blow hammer Apply a thin coat of Anti Seize Lubricant to the splines of steering column before loose fitting the steering wheel Loose fit the steering wheel and the nut Push the protective sleeve for the steering column wiring harness unto the steering column ...

Page 22: ... the hardware into the bag well protector Place the bag well protector next to the unit Remove the rear bumper mounting hardware from the unit and place in the bag well protector Align the rear bumper on the unit checking for fit and finish Loosely install and hand start both sides of the rear bumper mounting hardware ...

Page 23: ...ing a 15mm socket and a 13mm box wrench Install clip nuts on the rear bumper Insert the bag well protector Use a 2 Phillips screwdriver to install the bag well protector mounting screws Use a dead blow hammer to install the bag well protector rubber push screws ...

Page 24: ...e rear seat and all the assembly components that were stored in the battery compartment during shipment if it has not already been done Place the canopy pillar supports in the bag well Remove canopy pillars from packaging Inspect seat belts for flaws ...

Page 25: ... Page 20 200909 Loose fit right canopy pillar on pillar base Insert end of canopy wire harness into pillar base Loose fit left canopy pillar on pillar base Select left canopy pillar support ...

Page 26: ...e the rear body grommets up the canopy pillar and canopy pillar support to insure pillars fully seat on the pillar bases Complete the process on the right side Slide all the rear body grommets back into position Find the end of the canopy wiring harness and carefully route the harness along the unit frame ...

Page 27: ... harness insuring wire color codes match Carefully remove any canopy wiring harness slack Place the canopy pillar and pillar support hardware in the bag well protector Insert the seatbelt clip into its buckle to insure proper belt alignment during pillar final assembly ...

Page 28: ...ocket and a 17mm box wrench Secure the canopy pillar support to its base as shown with the bolt being inserted from the front of the unit going to the rear Tighten the pillar support hardware using a 14mm socket and a 13mm box wrench The canopy pillar and pillar support are secured together in the same manner with the bolt going through from the underside of the canopy pillar support upwards Units...

Page 29: ... avoid risk of danger and injury observe these precautions when handling or working with a lead acid battery Wear ANSI approved safety glasses or goggles and a face shield Wear proper clothing to protect your face hands and body Make sure the work area is well ventilated Never lean over a battery while boosting testing or charging Cigarettes flames or sparks could cause a battery to explode Keep a...

Page 30: ...from the right side of the unit starting with the front bank Place the batteries in the front bank with the terminal post side of the battery toward the front of the unit NOTE Use carrying strap provided by the battery manufacturer when handling batteries Once a battery is placed in the battery compartment use the lift strap to help slide the battery into place ...

Page 31: ...he batteries apart just enough to insert the battery baseboards can help to simplify this process Place the small terminal boots 1 red and 1 black on the ends of each of the battery cables Starting from the left side of the unit begin installing the battery cables beginning with the main harness Positive cable terminals then proceed to the main harness Negative cable terminals Only hand tighten th...

Page 32: ...m socket Tighten the battery terminal hardware using a 13mm socket WARNING When tightening the battery terminals be sure to check them using a torque wrench set at 100 in lbs The example shown is a Snap on Torque Wrench Body Preset Click type U S 30 300 in lb Range Stock QC1P300 with the Torque Head Box End 1 2 12 pt Stock QJX16A Coat the battery terminal connections and battery baseboard hardware...

Page 33: ... pair of slip joint pliers to carefully pull the boots into place can help to simplify this process Carefully prepare the main terminal connector boots by splitting the underside of each Hold the terminal boot in place using two nylon Ty Wraps Cut the excess Ty Wrap off using a pair of diagonal cutters ...

Page 34: ...wered into place SEAT ASSEMBLY Remove the hardware from the armrest then begin attaching the armrest by hand starting the hardware into the armrest from the underside of the seat bottom insuring that the curve of the arm rest faces to the front of the unit Tighten the armrest hardware using a 10mm socket ...

Page 35: ...y in the mounting bracket on the other canopy pillar It may be necessary to use a ratcheting strap placed between the tops of the canopy pillars to in order to align the seat back assembly holes with the holes on the mounting brackets on the canopy pillars so that the assembly hardware can be loose fitted Once all of the mounting hardware has been loose fitted tighten the seat back assembly using ...

Page 36: ...ASSEMBLY Remove the packing material and inspect the windshield instrument panel Place the instrument panel on the hood After removing the packing material inspect the windshield frame and both rear canopy brackets Use a 3 Philips screwdriver to remove the screw from the insertion end of both canopy bracket connectors ...

Page 37: ...o the windshield frame NOTE Insure the rubber bushing on the canopy bracket is facing away from the windshield when the canopy bracket connector has been inserted Reinstall both bracket connector screws Use a 2 Philips screwdriver to remove the inner mirror hardware from the windshield frame Remove the packaging and inspect the lighted inner mirror With the windshield laying facedown and the inner...

Page 38: ...lars Temporarily secure the canopy brackets to the canopy pillars with Ty wraps Fit the windshield instrument panel onto the lower cross member of the windshield frame NOTE Insure the instrument cluster wiring coming through the hood is placed to the REAR of the lower cross member of the windshield frame in order to facilitate the removal of the instrument cluster if the need arises Hand start the...

Page 39: ...RDWARE Cross threading or breaking a bolt off in a windshield standoff will render the entire unit frame unserviceable Loose fit all canopy bracket to canopy pillar hardware Use a 13mm socket and a 14mm box wrench to tighten the canopy bracket to canopy pillar hardware Use Ty wraps to attach the canopy wiring harness to the canopy bracket ...

Page 40: ...Y When using a glass windshield begin by removing all edge tape from off the windshield When using a Lexan windshield begin by beveling the edge on both sides of the windshield using a 1 2 inch cobalt rotary rasp WARNING Always use proper Personal Protective Equipment when using the rotary rasp ...

Page 41: ...windshield instrument panel Before continuing with the windshield assembly process insure the windshield itself is centered and fully seated in the slot of the windshield instrument panel Begin attaching the windshield channels by pushing the top channels onto the top edge of the windshield If necessary a dead blow hammer can be used to help seat the channels in place ...

Page 42: ... lower end of each windshield channel onto the edge of the windshield while simultaneously tipping the windshield away from the windshield frame Lower end of a driver s side channel Working BOTH sides of the windshield at the same time slowly push the windshield channels into place while simultaneously begin to seat the windshield channels onto the windshield frame Insure that the lower end of bot...

Page 43: ...ases an audible CLICK can be heard when this occurs WINDSHIELD WIPER ASSEMBLY Take the wiper motor from the packing material Route motor wires under the mounting bracket Remove the hardware from the motor shaft Use a 2 Philips screwdriver to remove the wiper motor housing hardware Separate the motor case halves ...

Page 44: ... Insert mounting hardware nut in housing half Place wiper motor in housing half Replace other housing half and secure with case hardware Insert second mounting hardware nut under rubber bushing on motor mounting plate ...

Page 45: ...through hole on wiper motor bracket Loose fit the main rubber bushing washer and nut on motor shaft Connect canopy wiring harness to inner mirror dome light and wiper motor Check to insure both the dome light and the wiper motor are functional ...

Page 46: ...909 Loose fit wiper motor mounting hardware Use an 8mm nut driver and 19mm box wrench to tighten the wiper motor hardware Place the wiper arm bushing on the wiper motor shaft Attach the wiper blade to the wiper arm ...

Page 47: ...and nut Use a 10mm box wrench to tighten the wiper arm hardware Use the adhesive backed harness clips to secure the dome light wiring to the windshield frame Stow the remaining wiring harness excess at wiper motor using Ty wrap Use diagonal cutters to remove the excess Ty wrap material ...

Page 48: ...ket around the base of the plastic housing Insert the brake light connector through large hole in canopy Place high mount brake light assembly on canopy Insure the housing remains fully nested within the gasket while aligning the holes of the brake light assembly with those on the canopy ...

Page 49: ...d pressure when inserting the screws that attach the brake light assembly to insure a tight gasket seal between the high mount brake light assembly housing and the canopy Carefully place the canopy onto canopy frame assembly while standing in the bag well While raising the canopy slightly insert a canopy bolt through a flat washer rubber bushing and the canopy ...

Page 50: ...inserting the bolt into the canopy frame and adding the final hardware CAUTION A fiber nut will need to be used in lieu of the lock washer if the unit is to be transported in the open Use a 3 Philips screwdriver and a 10mm socket to tighten the canopy hardware Connect the high mount brake light wiring to the canopy wiring harness ...

Page 51: ... the high mount lamp glows Insert the connectors and excess wiring harness through canopy wiring hole Use a 1 4 inch common blade screwdriver to insert the rubber grommet into the canopy wiring hole Attach the canopy wiring harness to the side of the canopy gutter using the adhesive wiring clips ...

Page 52: ...pring clips provided NOTE To ease the attachment of the gutter spouts insert a pair of duck billed pliers into the end of the spout and slightly stretch the spout prior to sliding it onto the canopy gutter port FINAL ASSEMBLY Apply unit decals using templates for proper alignment ...

Page 53: ... the slots of the bag well protector Attach the trunk lid lanyards to the metal buttons on the sides of the bag well Units to be shipped or stored should have the side mirrors front bumper and owners packet placed in the bag well Close the trunk by securing the lock ...

Page 54: ...e unit has been assembled the steering wheel can be set and the nut tightened using a breaker bar and a 17mm socket Torque nut to 35 40 ft lbs After the steering has been set the steering wheel cover can be snapped into place ...

Page 55: ...7 19 Wiring 16 18 Crate Moving 5 Opening 6 G Gutter spouts 43 H High Mount Stop Light 39 40 Wiring 41 42 I Instrument Panel 10 11 S Seat assembly Arm rests 25 Back rest 26 Steering Column 9 Compound joint 9 Steering Wheel 12 T Turn signal stalk 10 U Unit Crate removal 5 7 Moving 7 Inspecting 8 V VIN description 1 VIN Locations 1 W Windshield Channels 33 34 Frame 29 31 Installation 31 34 Lexan prep...

Page 56: ...es pourraient éclater et causer des blessures ou dommages Les batteries peuvent produire des gaz explosives en service normal Ne jamais fumer près de la batterie et éviter toute étincelle ou flame nue à proximité de ces derniers Fournisser la bonne ventilation lors du chargement Ne jamais charger une batterie gelée Prendre connaissance des mesures de précaution spécifiées par le fabricant de la ba...

Page 57: ...Instructions If a fault occurs count the number of red flashes between pauses and refer to the table below Red Flashes Causes Solution Battery High Voltage Check battery size and condition and reset charger interrupt AC power for 15 seconds Battery Low Voltage Check battery size and condition and reset charger interrupt AC power for 15 seconds Charge Timeout caused by battery pack not reaching req...

Page 58: ...g wire must be attached from the stud located on the charger see Figure 1 to the vehicle frame 5 Install such that risk of human contact with hot surfaces is reduced 6 The chargerʼs AC plug must be located at least 18 above the ground and the display visible to the user DC Battery Connection Procedure 1 The green wire outputs battery voltage when the charger is not plugged into AC to provide an in...

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Page 61: ... Page 56 200909 ON BOARD CHARGER INSTALLATION Inspect unit for damage prior to installation Carefully insert charger Loose fit installation hardware ...

Page 62: ... 10mm socket and a 10mm box wrench to tighten the on board charger hardware Route charger wiring Place a piece of shrink tubing on the main wiring harness lead and then connect the charger ground to the main wiring harness ...

Page 63: ...r the main negative battery terminal cable the on board charger cable and main wiring harness together Insert wire bundle into plastic corrugated loom and wrap with electrical tape Use a Ty Wrap to secure the wiring harness to the on board charger mounting bracket ...

Page 64: ... Page 59 200909 Attach the harness to the batteries as specified in the assembly manual NOTES ...

Page 65: ... Page 60 200909 ...

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