TOMCAR TM27EL Owner'S Manual Download Page 99

Page: 99 / 101

Troubleshooting

MAINTENANCE

CODE Fault name &

Effect of Fault

Possible cause

Set/Clear Conditions

B+ over Voltage Cutback

Reduced brake torque

Battery disconnected while
regen braking

Cycle KSI

Motor Temp Hot Cutback

Reduced drive torque

Motor temperature too high

Reduce load on vehicle

Sequencing Fault

Shut down throttle

Safety fault. KSI input was
received after direction
selection switch or throttle
pedal command.

Set ‘Direction selection’ switch to

Neutral and release the throttle.
Cycle KSI if error remains.

Stall Detected

Shutdown Motor;

Shutdown Main Contactor;

Shutdown Throttle

;

Full Brake;

Stalled motor

Cycle KSI

Summary of Contents for TM27EL

Page 1: ...es component selection field testing customer recommendations and vehicle manufacturing codes which all lead to this fine utility and recreational vehicle Your safety is our prime concern both while operating and servicing your TOMCAR We have achieved excellent safety records throughout our history In order to maintain this good record we need your cooperation in following the instructions and rec...

Page 2: ...WELCOME 2 TOMCAR Electric Vehicle Variants Two Seater Pickup TM37E Four Seater TM47E Two Seater Pickup TM58E ...

Page 3: ... safe place Should all keys be lost or stolen please contact your TOMCAR supplier for assistance For security purposes the Identification number also appears inside the cabin Not visible without disassembly Frame VIN PIN under hood on middle frame bar Ignition Key Number stamped on key A Your Supplier Details Vehicle Delivery Date Signature of Supplier at delivery Signature of Customer at delivery...

Page 4: ...4 ...

Page 5: ...l descriptor uses the X letter as a wild card relating to several models available The following list elaborates the various models and how they are reflected within this manual TMXXEL Six models are derived from this descriptor 1 TM27EL 2 TM37EL 3 TM47EL 4 TM58EL E Electric Motor L High Low Differential Lock Gearbox ...

Page 6: ...6 ...

Page 7: ...67 Load Compensators 30 Throttle System 74 Seat Belts 31 Brakes 75 Seat Adjustment 32 Steering Wheel 78 Console 33 Drive Belt 79 Driver Controls 37 4 Point Harness 80 Direction Driving modes selection 38 Tires 81 Windshield wiper Lights and Horn Levers 39 Suspension 83 Pedals 40 Hardware 84 Gear Shifter 41 Low Voltage System 85 Differential Lock Lever 42 High Voltage System 89 Parking Brake 43 Cle...

Page 8: ... how are essential for safe operation Age Restrictions Operation of this vehicle is limited to persons who are licensed and have been trained including reading and understanding this Owner s Manual No one under the age of 16 should be allowed to operate a TOMCAR The minimum age recommendation for passengers is 16 years old Young or inexperienced drivers may not be able to control the vehicle Local...

Page 9: ...tervals DANGER When you see the safety alert DANGER it is an indication that there is an immediate hazard that will result in severe personal injury or death WARNING When you see the safety alert WARNING it is an indication that there is an immediate hazard that may result in serious personal injury or death CAUTION When you see the safety alert CAUTION it is an indication that there is an immedia...

Page 10: ... further detail within your Owner s Manual Failure to do so may result in serious injury or death WARNING 1 Please read this manual and all labels carefully and follow the operating procedures described 2 Never allow anyone without a valid driver s license and appropriate TOMCAR training to operate this vehicle 3 Electric vehicles have special features It is important to read the following manual ...

Page 11: ...peeds before attempting to turn at faster speeds Follow procedures for turning as described in this manual Never turn at excessive speeds 15 Should this vehicle be involved in an accident always have it thoroughly checked before continued use 16 Practice operating the TOMCAR on smaller hills before attempting larger hills Never operate TOMCAR on hills that are too steep for the vehicle or your abi...

Page 12: ...en it is safe to do so and avoid turning at sharp angles when in reverse 23 Always use the correct type and size of tires specified in this manual and maintain the correct tire pressure as specified in the maintenance and specification sections of this manual 24 Never modify this vehicle through improper installation or use of accessories 25 When hauling cargo ensure that the cargo is properly dis...

Page 13: ...hose specifically designed for TOMCAR may result in failure of critical machine components especially those which increase speed or power TOMCAR may become aerodynamically unstable at speeds higher than those for which it is designed and loss of control may occur at higher speeds Such modifications may also create a safety hazard which could lead to bodily injury The warranty on your TOMCAR is ter...

Page 14: ...pply the brakes Lock the parking brake when fully stopped IF YOU BEGIN ROLLING BACKWARD Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service supplier check the complete vehicle for possible damage Operating this vehicle on public streets roads or highways Collision with another vehicle Avoid operating this veh...

Page 15: ...and perception Could result in an accident Driving a TOMCAR requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your alertness and slow your reaction time In most states and provinces it is prohibited by law to drive while intoxicated or under the influence of drugs Operating this vehicle at excessive speeds Loss of control acciden...

Page 16: ...ns when operating the vehicle You may come upon hidden rocks bumps or holes suddenly without enough time to react Failure to follow the minimum age recommendations for this vehicle Serious injury or death to the child or others Only persons with a valid driver s license should operate a TOMCAR Even though a child may be within the age group for which some vehicles are recommended he or she may not...

Page 17: ...tra fuel tank etc may change the handling characteristics of the vehicle WARNING Leaving the key in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use After any overturn or accident have qualified service personnel inspect the entire vehicle for possible damage including but not limited to brak...

Page 18: ... this manual differ from the decals on your TOMCAR always read and follow the instructions of the decals on the TOMCAR If any decal becomes illegible or comes off contact your TOMCAR supplier to obtain a replacement Replacement safety decals are provided by TOMCAR at no charge The part number is printed on the decal This general purpose off road utility vehicle does not meet federal motor vehicle ...

Page 19: ...19 Safety Decals and Locations SAFETY Location 1 Rear Cross Tube 1 ...

Page 20: ...20 Safety Decals and Locations SAFETY Location 2 Front Firewall ...

Page 21: ...21 Electric Components safety SAFETY Electric Components Safety TM37E 1 Electric Motor 2 Motor Controller 3 Traction Battery 4 Safety Disconnect 5 Charger Socket 6 12 volt battery ...

Page 22: ...22 Electric Components safety SAFETY TM47E 1 Electric Motor 2 Motor Controller 3 Traction Battery 4 Safety Disconnect 5 Charger Socket 6 12 volt battery ...

Page 23: ...23 Electric Components safety SAFETY TM58E 1 Electric Motor 2 Motor Controller 3 Traction Battery 4 Safety Disconnect 5 Charger Socket 6 12 volt battery 7 24 volt battery optional ...

Page 24: ...ularly recharged The traction battery is equipped with a manual safety disconnect switch to cut the battery power in case of an emergency or prior to system maintenance 12 volt Battery The second battery on your vehicle is a 12v battery This battery supplies the energy to operate vehicle equipment lights audio etc and to start up the system It is charged while the vehicle is powered on from the tr...

Page 25: ... power components have the vehicle checked by an authorized dealer Never touch the high power components or cables which are exposed and visible inside or outside the vehicle In the event of fire In the event of fire evacuate everyone from the vehicle immediately and contact the emergency services informing them that this is an electric vehicle Disconnect the safety switch on the battery box Only ...

Page 26: ...e equipped with special features such as a spare tire winch etc Not all models come with all features Please refer to the specifications section at the end of this manual 1 Handle bar 2 Head protection bar 3 Side Hip protection bar 4 Seat belts 5 Cargo box 6 Cargo box latch 1 2 5 4 3 6 ...

Page 27: ...27 Components Location FEATURES CONTROLS 7 Side mirror 8 Signal Parking lights 9 Head lights 10 Hood rubber strap 7 8 9 10 ...

Page 28: ...28 Components Location FEATURES CONTROLS 11 Rear view mirror 12 Registration plate bracket 13 LED Tail lights 14 Tow ball receiver 12 11 13 14 ...

Page 29: ...l This vehicle is equipped with a receiver for a trailer hitch Trailer towing equipment is not supplied see your supplier for availability To avoid injury and property damage always heed the warnings and towing capacities outlined in this manual ...

Page 30: ...s inflate both load compensators to 150 psi 10 bar using an air compressor If when fully loaded the rear of the vehicle sits too high release equal amounts of air from both compensators until the vehicle is level To release air from the compensators depress the center pin of the Schrader valve with a pointed object An indication of proper use of the compensators is to ensure that the vehicle heigh...

Page 31: ...eps 1 Loosen shoulder straps 1 2 Place arms through the shoulder straps 1 3 Insert the latch plate into the buckle until it clicks 3 4 Tighten straps 2 followed by shoulder straps 1 5 Make sure the harness is tightened securely Falling from a moving vehicle could result in serious injury or death Always fasten your harness securely before operating or riding in the TOMCAR Small passengers require ...

Page 32: ...stable driver and front passenger seats only To adjust the seat locate the lever 1 underneath the seat Pull up on the lever and slide the seat to the desired position Once the desired position is reached try to slide the seat forward and backward to make sure the lever is locked in place ...

Page 33: ...33 Console FEATURES CONTROLS Console 1 Steering Wheel 2 Instrument panel All in one display 3 Instrument panel EV display 4 12v Accessory plug 5 Glove box 2 5 4 1 3 ...

Page 34: ...ES CONTROLS Instrument Panel All in One Display 1 Speedometer 6 Hazard warning lights marker 2 Odometer 7 12v Battery Low voltage warning 3 LH turn signal marker 4 RH turn signal marker 5 High beam marker 2 1 3 5 7 4 6 ...

Page 35: ...ate traction battery state of charge in percentage from 0 to 100 2 Selected driving mode at standstill 3 The present error number if an error is present The EV display unit is used for SOC display error messages and warnings from the main computer on your electric TOMCAR Driver must pay attention to the display in all times for range control and system awareness 5 LED SOC Display Displays the trac...

Page 36: ...vehicle ON while exiting the vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 2 1 Steering wheel adjustment lever 1 is used to position the steering wheel s height Turn the lever counterclockwise to release the column and adjust the height Lock the steering wheel s...

Page 37: ...iver seat are hidden for clarity 1 Direction selection switch 2 Driving mode selection switch 3 Maximum regeneration switch 4 Windshield wiper lever 5 Lights Signal Horn lever 6 Throttle pedal 7 Brake pedal 8 Gear shifter 9 Rear Differential Lock lever 10 Parking brake lever ...

Page 38: ...in forward or reverse position while existing the vehicle Driving Mode Selection Switch Your electric TOMCAR has 3 driving modes to select from Each mode influences driving range and performance Refer to page 44 for further details a Switch up MAX PERFORMANCE Fast acceleration and maximum top speed Minimum range b Switch centered NORMAL PERFORMANCE Moderate acceleration and maximum top speed c Swi...

Page 39: ...ltifunctional handle controls the following a Shift handle up right signal blinks 2 b Shift handle down left signal blinks 2 c Turn handle forward once to switch on side lights 6 d Turn handle forward twice to switch on headlights 5 e Pull handle backward switches to high beam 4 f Push handle toward steering wheel activates horn 1 NOTE The ignition switch key must be in the ON position to operate ...

Page 40: ...sult in energy recovery by using the motor braking torque Brake Pedal Press the brake pedal to slow or stop the vehicle Throttle Pedal Press the pedal down to increase requested motor torque Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the vehicle WARNING Always check free pedal movement Never place items...

Page 41: ...gear Maintaining proper shift linkage adjustment is important for the shifter function See your supplier if you experience any shifting problems CAUTION Do not attempt to shift gears while the vehicle is moving or damage to the transmission could result Make sure the lever is in the proper position and the gear is fully engaged WARNING When parking the vehicle always switch OFF the ignition and re...

Page 42: ...the reversal of the engagement procedure Slight changes in direction of travel while operating the lever may assist in the engagement and disengagement of the differential lock Damage to the differential can occur if the differential lock is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning without traction CAUTION Using the differential lock feature requi...

Page 43: ...ft the handle to a horizontal position 2 Parking Brake Engagement 1 Engage the parking brake when parking the vehicle to prevent the vehicle from rolling To apply the parking brake pull up the lever with your hand Parking Brake Release 2 To release the parking brake slightly pull the lever up to disengage the lock position press the thumb button and push the lever down all the way Make sure the pa...

Page 44: ...hter driving style Drive at a constant speed Adapt your driving to avoid excessive energy consumption Anticipate traffic changes by lifting your foot off the accelerator pedal to recover energy Road type Do not try to maintain the same speed up a hill Accelerate no more than you would on a level ground Tires An under inflated tire increases energy consumption Comply with the specified tire pressur...

Page 45: ...that the neutral braking torque is greater when using the LOW gear in the transmission Using the neutral braking by anticipating traffic and road conditions ahead will increase your mileage however it is forbidden to use the neutral braking or the maximum regen function instead of the brake pedal Always be ready to use the brake pedal Important Note After a maximum charge of the battery and during...

Page 46: ...ock buckle b Tighten bottom horizontal straps c Tighten shoulder straps 5 Change gears only when the vehicle is stationary 6 Ignition ensure direction selection switch in Neutral center position 7 While driving avoid applying the throttle and brake pedal simultaneously 8 Read and understand safety instructions 9 Driver must have a valid driver s license 10 Reverse operation can be dangerous even a...

Page 47: ... each use to ensure it is in proper operating condition Safety instructions 1 Make sure the ignition key is in the OFF position 2 Make sure the vehicle is on a flat surface 3 Make sure the gear lever is in neutral 4 Make sure the parking brake is engaged locked 5 Make sure the battery disconnect switch is in the OFF position 6 Make sure you read and follow the instructions carefully ...

Page 48: ...vehicle startup check vacuum pump operation 2 Steering System Check for free play by turning the steering wheel left and right 3 12v Electrical System Check the light system front rear parking lights headlights high low indicators left right brake lights and registration plate light 4 Throttle Travel Check that the throttle has full movement and springs back when released 5 Wheels Check for free p...

Page 49: ...roll 14 Oil Leaks Check for large oil leaks from the transmission box and final drive Slight oil moisture is not problematic Vehicle operation can result in oil drips from the breathers 15 Rear Suspension Check shock absorbers by pressing the vehicle hard downward The vehicle should spring back slowly and symmetrically Check that all fasteners are in place and tight 16 Load Compensators If carryin...

Page 50: ... carefully Failure to follow these instructions may lead to risk of fire serious injury or death Never use a non TOMCAR approved charger Do not alter or damage the charge connector If damage to the charger or charge connector is noticeable contact your dealer TM47E Charge Connector TM37E Charge Connector ...

Page 51: ...ging cord or socket do not charge the vehicle 3 Do not attempt to touch the cord contacts 4 Avoid charging your vehicle in extreme temperatures hot or cold At temperatures below 5O C or above 55O C the battery cannot be charged Charging 1 Switch the ignition off 2 Make sure the manual battery disconnect switch is in the ON position 3 Connect the charger to the wall socket 4 Remove charge connector...

Page 52: ...e display is not working refer to section diagnostics trouble shooting Gear Shifting This vehicle is equipped with a 2 speed transmission Select the proper gear ratio as described in page 41 The transmission was designed for increased durability with a mechanical gear engagement mechanism This mechanism will lock the gears and block the shifting in the event torque is present in the system such as...

Page 53: ...ving In case the direction is reversed while driving the motor will increase regenerative braking till the vehicle comes to a complete stop Only then the system will allow for a change of direction Vehicle Shutdown 1 Release the throttle pedal completely 2 Brake to a complete stop 3 Change direction selection switch to the Neutral center position 4 Shift vehicle s transmission to Neutral 5 Engage ...

Page 54: ...ete stop safely Driving Safely 1 Sit in the driver s seat and fasten the seat belt as described earlier 2 press the brake pedal and shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Disengage the parking brake 5 Keeping both hands on the steering wheel with thumbs on the outside take your foot off the brake pedal and slowly press the throttle with your ...

Page 55: ... or ice be alert for the possibility of skidding and sliding Under these conditions follow these precautions 1 Slow down 2 Read the trail and avoid quick sharp turns which can cause skids Keep alert at all times 3 In the event of skidding correct a skid by turning the steering wheel in the direction of the skid WARNING Failure to exercise care when operating on slippery surfaces can result in the ...

Page 56: ...oper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in this Owner s Manual Use caution when climbing hills with excessively slippery or loose surfaces Never go over the crest of a hill at a high speed an obstacle could be on the ...

Page 57: ...um regeneration switch b Avoid turning the maximum regeneration switch after starting the descent It could result an unexpected braking torque 6 Apply the brakes slightly and softly to aid in slowing if required WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessi...

Page 58: ...an occur Your TOMCAR can operate through water up to a maximum recommended depth equal to your TOMCAR s floor level 1 Always determine water depths and current before entering 2 Deeper water levels than recommended can result is critical electric powertrain damage and may result in electric shock 3 Choose a crossing where both banks have inclines that are as gradual as possible 4 Proceed slowly av...

Page 59: ...ined below 1 Apply the brakes 2 Put direction selection switch in the reverse position down 3 Always look around you before reversing 4 Slowly release brake pedal and gently apply the throttle pedal for movement 5 Reverse slowly 6 Apply the brakes lightly for stopping 7 Avoid turning at sharp angles 8 Be gentle and minded when applying throttle pressure WARNING Failure to use caution when operatin...

Page 60: ...damage and serious injury Always apply the parking brake after turning off the vehicle Always block he downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position instead Operating the vehicle while the hand brake is engaged is not energy efficient and could cause loss of control and result in serious injury or death Always disengage the parking brake b...

Page 61: ...re when hauling or towing loads Slow down The TOMCAR has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels Driving with passengers in the cargo box can result in severe injury or death Hauling excessive weight will reduce your driving range Always be aware of your traction battery state of charge and plan your d...

Page 62: ... exceeds 100 kg or 220 lbs Operate the vehicle slower than usual and take into consideration the terrain and the slope Do not tow more than the recommended weight for the vehicle Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Driving Range Towing loads will reduce...

Page 63: ... bumper and in the front towing hitch receiver Always use jack stands after lifting the vehicle Never work on the vehicle while charging the traction battery Always ensure power is OFF Place an electric fire fire extinguisher nearby Lifting points and wheel chock location example WARNING To reduce the possibility of severe injury or death always follow the guidelines of this manual Never perform a...

Page 64: ... reveals the need for replacement parts please use genuine TOMCAR parts available from your TOMCAR supplier NOTE Service and adjustments are critical If you are not familiar with safe service and adjustment procedures have a qualified person perform these operations Maintenance intervals in the following chart are based upon average riding conditions Vehicles subjected to severe use must be inspec...

Page 65: ... 70 83 3 Tires I 81 Max tire air pressure 7 psi Front 15 psi Rear 4 Brake Pedal Travel I 75 5 Brake Fluid Level I 75 76 6 Wheel Nuts I A Torque to 165 Nm 7 Frame Hardware I 84 Frame nuts bolts and fasteners 8 Headlights Tail Lights I C Check proper operation 9 Parking Brake Operation I 77 10 Drive Belt I 79 Tension and wear I Inspect C Clean A Adjust ...

Page 66: ...d ends Check shock mounts 5 Inspect shock absorbers for any kind of damage 6 Inspect brake disc and pads 7 Check for free play in rear end Final drives Shock mounts 8 Change transmission oil 9 Change final drives oil 10 Inspect timing belt for cracks and proper tension 11 Adjust parking brake 12 Check for leaks 13 Check low voltage electrical system Lights Horn Wipers 14 Clean auxiliary battery te...

Page 67: ...shafts 22 Check steering system for free play 23 Test drive the vehicle Lubrication and Fluid Recommendations Item Lubricant Capacity Procedure Transmission case oil BG 80 90w Extra duty 2 4 L Maintain as recommended Final drive oil 90w Gear oil 0 75 L per side Maintain as recommended Brake fluid DOT 4 By tank markings Maintain level according to tank markings Front ball joints multipurpose grease...

Page 68: ...68 Lubrication MAINTENANCE Front Suspension Lubrication Grease fitting locations 1 Shock Absorber 2 Upper Ball Joint 3 Lower Ball Joint Image of right hand side Lubrication of left side is the same ...

Page 69: ...69 Lubrication MAINTENANCE Steering Box Grease Fitting ...

Page 70: ... Area Lubrication Grease fitting locations 1 LHS drive axle exterior joint 2 LHS drive axle inner joint 3 RHS drive axle exterior joint 4 RHS drive axle inner joint 5 LHS shock absorber pivots RHS is similar Motor removed for clarity ...

Page 71: ...outlined in the periodic maintenance chart Checking lubrication level Position the vehicle on a level surface Clean the area around the check plug and remove the plug The correct lubrication level is just below the bottom of the threaded hole 1 Transmission fill plug 2 Oil level check plug 3 Drain Plug ...

Page 72: ...ain plug and drain the oil into a drain pan 4 Wipe the magnetic end of the drain plug and remove accumulated metallic filings 5 After the oil drain is complete install a new sealing washer and reinstall drain plug Tighten to 25 Nm 6 Add 2 4 liters of oil per the lubrication fluid table 7 Reinstall the fill plug and tighten to 20 Nm ...

Page 73: ...drain plug and drain the oil into a drain pan 5 Wipe the magnetic end of the drain plug and remove accumulated metallic filings 6 After the oil drain is complete install a new sealing washer and reinstall drain plug Tighten to 35 Nm 7 Add 0 75 liters of oil per the lubrication fluid table 8 Reinstall the fill plug and tighten to 30 Nm 1 Fill plug 2 Drain plug ...

Page 74: ...starting the vehicle and occasionally during operation Throttle Free Play If the throttle pedal has excessive play due to cable stretch or miss adjustment it will cause a delay in throttle response In addition the throttle may not open fully If the throttle pedal has no free play the throttle may be hard to control Check the throttle pedal free play at the intervals outlined in the Periodic Mainte...

Page 75: ...r death if the brake pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating brake pedal Immediately contact your qualified TOMCAR service representative if brake problems arise Always check proper functionality of the brake system before and occasionally during driving Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brak...

Page 76: ...at the reservoir under the hood 1 The level should be about 1 2 in 12 5 mm from the top of the reservoir 3 If the fluid level is lower check for leakage in the system and add brake fluid 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle of...

Page 77: ...tion 2 Once the lever is locked check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Parking Brake Adjustment 1 Position the vehicle on a level surface 2 Use wheel chocks to prevent the vehicle from rolling 3 Loosen or tighten the nuts on both sides of the cabin side cable ...

Page 78: ...tact your qualified TOMCAR service representative if steering system problems arise Always check proper functionality of the steering system before driving While driving ensure that your thumbs remain outside of the steering wheel Inspection 1 Position the vehicle on level ground 2 Check slack in the steering wheel by moving it left and right 3 There should be no free play 4 If there is free play ...

Page 79: ...eved tighten the motor housing bolts 2 and recheck alignment Recheck belt tension Belt Replacement If noticeable wear is present the belt must be replaced Place the gear box in neutral Turn OFF the vehicle The belt can be replaced in the field by loosening the top tensioner 4 securing nuts and rotating the center section counter clockwise to move the motor closer to the gear box Install the new be...

Page 80: ...elt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked and or replaced by a TOMCAR supplier 4 Check that the harness is attached firmly to the hooks on the frame four locations The TOMCAR 4 point harness is adjustable and should be adjusted for all occupants before driving Make sure the 4 point harness is adjusted before riding WARNING Failure to foll...

Page 81: ...e or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Low tire pressure also consumes more energy from the system which in turn reduces your mileage Always maintain proper tire pressure Tire Tread Depth Always replace tires when the tread depth is worn to 5 16 in 8 mm or less on both front and rear wheels This value applies to the original...

Page 82: ...essures are Front 7 psi Rear 15 psi WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always use TOMCAR recommended tires and ensure that all wheel nuts are tightened to specification Rear wheel and tire ...

Page 83: ...und Remove the valve cap from the shock air valve Attach the air chuck to the shock air valve and hold in place for five seconds Reinstall the valve cap Important Due to the size of the air chamber in the shock the volume of air is small Do not try to check the air pressure with a pressure gauge Attempting to check the shock air pressure will release a significant amount of air resulting in poor s...

Page 84: ...steners in the vehicle Oiled threads are to be tightened by 20 less torque This torque is indicated in brackets Description Thread Tightening torque Nm Shock absorbers M12 x 1 5 85 Air compensators M12 x 1 5 85 Steering ball joint M14 x 1 5 100 Upright ball joint king pin M16 x 1 5 200 Trailing arm pivot nut M24 x 2 400 Trailing arm fill plug M16 x 1 5 30 24 Trailing arm drain plug M16 x 1 5 35 28...

Page 85: ...in an enclosed space Always wear eye protection and gloves when handling the battery KEEP OUT OF REACH OF CHILDREN Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Battery Removal 1 Remove the hood 2 Disconnect the black negative battery cable 3 Remove the bracket on the battery 4 Disconnect the red positive battery cable n...

Page 86: ...cables are properly routed NOTE When installing a new battery make sure it is fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool...

Page 87: ...87 Low Voltage System MAINTENANCE Low Voltage Fuse Panel ...

Page 88: ...t relay 16 Main switch fuse 7 ACC 21 Horn 8 Flasher 22 Parking and license plate lights 23 All in one display back light 24 Low beam 25 High beam 26 ACC 31 Turn signals 34 Switch input to traction battery fuse panel 35 All in one display KSI 36 All in one display memory 41 Reverse light 42 Air compressor pressure switch input 43 Wipers 46 Cabin power socket interior light 51 Switch input to Remote...

Page 89: ...h high voltage cables wires and components If it is required to turn the vehicle ON for maintenance rear wheels must be lifted and supported Always use isolated tools and clothing Remove all jewelry If you recognize any wear in the high voltage system components stop using the vehicle and contact your Tomcar dealer Always have an electric fire fire extinguisher nearby ...

Page 90: ...y involves high voltage maintenance and should be performed only by authorized personal Fuse Panel Cover Removal Turn OFF the key switch Disconnect the charger from the vehicle if connected Turn OFF the Safety Switch 1 located on the traction battery box Open the fuse panel cover 2 securing bolts TM58E Battery Box ...

Page 91: ...tor BMS Battery Box 10A 11 1A 21 Controller Drive Mode Cooling Fan BMS Drive KSI OBD POWER KSI KSI 5A 12 5A 22 Batt Box Fan 1 2 3 5A 13 23 BMS Charge KSI DC DC DC DC Pre Charge 5A 14 24 Power On Power ON 72V DC DC Input Drive Mode Charge Mode 10A 15 25 Pre Charge 4 5 6 5A 16 26 DANGER Hi voltage system ...

Page 92: ... system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes headlights and warning labels The safest way to clean your vehicle is by using a hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent...

Page 93: ...es will self discharge over time The rate of discharge varies depending on the ambient temperature and battery age and condition b Traction battery is to be stored above 0o and below 40o Celsius c For long durations more than a month it is best to store the traction battery at around 50 SOC d It is important to check battery SOC every 4 weeks and recharge if SOC drops below 10 e A special storing ...

Page 94: ...xiliary battery as described on pg 86 2 Recharge the traction battery as described on pgs 50 51 3 Perform a pre ride inspection as described om pg 65 4 Lubricate at the intervals outlined in the periodic maintenance chart on pgs 66 67 5 Turn on the vehicle and check the traction battery SOC ...

Page 95: ...ake sure charge plug is properly connected 2 Damaged charge cable or connector Visually inspect the cable plug and socket for wear and tear Contact manufacturer for replacement if necessary 3 BMS charge power failure Check fuse 14 in traction battery fuse panel Replace if necessary 4 Main BMS power failure Check fuse 21 in traction battery fuse panel Replace if necessary 5 DC DC converter power up...

Page 96: ...ring wheel Tighten steering linkage joints Shifter Shifter lever is stuck in gear Try releasing the lever while driving at low speed with low traction Shifter lever pops out of gear Ensure proper engagement by driving at low speed while engaging the shifter Differential Lock Diff lock does not engage Engagement should be performed while driving with minimum load Diff lock does not release Try chan...

Page 97: ...Failed Shutdown Motor Shutdown Main Contactor Shutdown Throttle Full Brake Open circuit in external pre charge resistor or associated wiring Check safety switch located by the charge socket is ON Check fuse 16 in traction battery fuse panel Cycle KSI 15 Controller Severe Under temp Shutdown Motor Shutdown Main Contactor Shutdown Throttle Full Brake Controller is operating in an extreme environment...

Page 98: ...vere B Over Voltage Shutdown Motor Shutdown Main Contactor Shutdown Throttle Full Brake 1 Battery charger fault Battery was charged to excessive voltage 2 Battery disconnected while regen braking Cycle KSI 18 Severe KSI Over Voltage Shutdown Motor Shutdown Main Contactor Shutdown Throttle Full Brake 1 Auxiliary battery voltage too high 2 Auxiliary battery polarity is reversed Check auxiliary volta...

Page 99: ...Cutback Reduced drive torque Motor temperature too high Reduce load on vehicle 47 Sequencing Fault Shut down throttle Safety fault KSI input was received after direction selection switch or throttle pedal command Set Direction selection switch to Neutral and release the throttle Cycle KSI if error remains 73 Stall Detected Shutdown Motor Shutdown Main Contactor Shutdown Throttle Full Brake Stalled...

Page 100: ...s below allowed value Recharge the battery 56 BMS in Charge Mode Charger is connected while KSI is switched ON Disconnect Charger and Cycle KSI 57 Traction Battery Over Voltage Shutdown Motor 1 Battery charger fault 2 Battery disconnected while regen braking Cycle KSI 59 Traction Battery Internal BMS Over Temp Shutdown Motor Charge cycle was interrupted during modules balancing at final stage Wait...

Page 101: ...101 NOTES ...

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