TOMCAR TM2 Owner'S Manual Download

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OWNER’S MANUAL

Summary of Contents for TM2

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Page 3: ...ations 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 recommendations outlined in this Owner s Manual This manua...

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Page 5: ...t visible without disassembly Frame VIN under hood on middle frame bar Ignition Key Number stamped on key A ________________________________________ ___________________________________________ Your Supplier Details __________________________________________ __________________________________________ __________________________________________ __________________________________________ Vehicle Deliv...

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Page 7: ...ock Lever 39 Parking Brake 40 OPERATIONS 42 Emission Control System Warranty 42 Guidelines Vehicle Break In Period 45 Pre Ride Inspection 46 Starting the Engine 49 Shutting Off the Engine 51 Braking 51 Driving Procedures 52 MAINTENANCE LUBRICATION 61 Periodic Maintenance Chart 61 Lubrication Fluid Recommendations 65 Engine Maintenance 69 Engine Oil Change 71 Transmission 74 Cooling System 76 Spark...

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Page 9: ... 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 TMX7X Six models are derived from this descriptor 1 TM27CL 2 TM47CL 3 TM57CL 4 TM27BL 5 TM47BL 6 TM57BL C Gasoline Engine B Diesel Engine L High Low Differential Lock Gearbox ...

Page 10: ... 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 reg...

Page 11: ...pecified intervals 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 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 When you see the safety alert CAUTION it is an indication that there is an immediate hazard th...

Page 12: ...storm leave the vehicle and seek appropriate shelter Please follow all instructions and procedures outlined in further detail within your Owner s Manual Failure to do so may result in serious injury or death 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 operat...

Page 13: ...lways follow the proper procedures outlined in this manual before traveling downhill or braking on hills Never travel downhill at excessive speeds avoid going downhill at an angle which would cause the vehicle to lean sharply to one side and travel straight down the hill where possible 19 Always follow the proper procedures outlined in this manual when operating over obstacles and never attempt to...

Page 14: ...f sparks or flame 33 In order to prevent any unauthorized use or accidental start up always remove the ignition key when the vehicle is not in use We recommend that the operator always check all safety components before using TOMCAR in order to ensure that TOMCAR is in excellent operating condition at all times Equipment Modifications Do not make any modifications to your TOMCAR vehicle Operating ...

Page 15: ...n Maintain a steady speed when climbing a hill IF YOU LOSE ALL FORWARD SPEED Apply 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 ...

Page 16: ... 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 on public streets roads or highways Collision with another vehicle Avoid operating this vehicle on public streets roads o...

Page 17: ... 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 have t...

Page 18: ...g characteristics of 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 After any overturn or accident have qualified service personnel inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems CAUTION Always...

Page 19: ...n 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 20: ...ions 18 1 This cab frame is not designed or intended to provide rollover protection VEHICLE ROLLOVER could cause severe injury or death ALWAYS WEAR YOUR SEAT BELT AND HELMET for maximum protection WARNING Location 1 Rear Cross Tube ...

Page 21: ...SAFETY Safety Decals and Locations 19 Location 2 Front Fire Wall 2 3 4 ...

Page 22: ...ocations 20 Fuel tanks are in the cabin beware of fire Smoking is prohibited in cabin WARNING o Location 3 Fuel Tanks Location 4 Transmission To avoid transmission damage shift only when vehicle is stationary and at idle CAUTION ...

Page 23: ...s stored Do not overfill the tank Do not fill the tank neck If the neck is filled heat may cause the fuel to expand and overflow from the tank vent or around the fuel cap If fuel spills on your skin or clothing immediately wash with soap and water and change clothing Engine exhaust fumes contain poisonous carbon monoxide which can cause serious illness and death Never run the engine in an enclosed...

Page 24: ...with special features such as a spare tire second fuel tank etc Not all models come with all features Please refer to the specifications section at the end of this manual 1 Steering Wheel 2 Head Protection Bar 3 Cargo Box 4 Seat Belts 5 Side Hip Protection Bar FEATURES CONTROLS ...

Page 25: ...FEATURES CONTROLS Component Locations 23 6 Cargo Box Latch 7 Handle Bar 8 Shift Lever 9 Seat 10 Fuel Tank Cap ...

Page 26: ...FEATURES CONTROLS Component Locations 24 11 Side Mirror 12 Signal Parking Lights 13 Headlights 14 Hood Rubber Strap ...

Page 27: ...FEATURES CONTROLS Component Locations 25 15 Registration Plate Holder 16 Rearview Mirror 17 Towing Ball 18 Tail Lights ...

Page 28: ...ped with a 2 inch 50 8 mm towing ball 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 Towing Ball TM5 model shown ...

Page 29: ...l tanks are found under both seats In a TM4 the fuel tanks are located under the rear seats A fuel gauge indicator is located on the console When refueling always use appropriate fuel for your engine Models TMXXC Unleaded gasoline with a minimum pump octane number of 87 Models TMXXB Diesel fuel where fitted Fuel Tank Fuel Cap 2 2 ...

Page 30: ...rear fire wall panel between the seats To change from the left or right fuel tank rotate the selector valve to the desired tank IMPORTANT The fuel gauge is only connected to the right fuel tank The fuel gauge will not show the fuel level of the left fuel tank When using dual tanks it is suggested to begin use with the left tank selected Dual Tank Mounted on Left Hand Side Dual Tank Selector Valve ...

Page 31: ... 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 height once loaded is the same as the vehicle heigh...

Page 32: ... safety when using the 4 point harness please perform the following steps 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 secur...

Page 33: ...k refuel at the earliest opportunity 12 Volt Accessory Plug 8 The 12 volt receptacle is a standard automotive 12 volt auxiliary socket Master Switch 9 When you must stop the operation of the vehicle in emergency situations use of the master switch will disconnect battery power from the vehicle Master Switch Operation 1 The L shaped key points left for regular operation 2 In order to cut off power ...

Page 34: ...ROLS Indicator Lights The indicator lights on the console display 1 Blue High Beam On 2 Yellow Green Signal Lights On 3 Red Low Oil Pressure and or High Temperature 4 Red Low Brake Fluid 5 Amber Red Glow Plug diesel Check Engine gasoline 1 2 3 5 4 ...

Page 35: ...The heater value is located on the left side of the rear fire wall To operate the heater move the heater valve to the ON position Once the engine has reached operating temperature turn the heater fan knob to the desired fan speed Heater Valve Shown in ON Position Indicator Light Heater Fan Knob Heater Operation FEATURES CONTROLS Heater Operation ...

Page 36: ... 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 The 4 seat TOMCAR has a lock pin 2 allowing the operator passenger to lock the seat 2 1 FEATURES CONTROLS 34 ...

Page 37: ...ate the wipers Ignition Switch The ignition switch is a four position key operated switch The key can be removed from the switch when it is in the OFF position b The normal off positon is position b OFF a ACCESSORIES Engine is off All electrical circuits are on Cooling fan runs b OFF Engine is off all electrical circuits are off except 12V plug on console c ON Engine circuits are on All electrical...

Page 38: ...own left signal blinks 2 3 Turn handle forward once to switch on side lights 6 4 Turn handle forward twice to switch on headlights 5 5 Pull handle backward switches to high beam 4 6 Push handle toward steering wheel activates horn 1 NOTE The ignition switch key must be in the ON position to operate the headlights The multifunctional handle will not return automatically to its original position on ...

Page 39: ... 1 Depress the brake pedal to slow or stop the vehicle Throttle Pedal 2 Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine 37 ...

Page 40: ...r with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important for proper transmission function See your supplier if you experience any shifting problems Shifting into reverse should be with one swift motion without stopping in the neutral position Do not attempt to shift the transmission while the vehicle is moving or damage to the transm...

Page 41: ... Disengagement is simply 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 Using the differential l...

Page 42: ...e parking brake when parking the vehicle to prevent the vehicle from rolling To apply the parking brake push in the thumb button and pull up the lever with your hand releasing the thumb button to lock the position Parking Brake Release 2 To release the parking brake pull the lever to allow the operation of the thumb button and while holding in the thumb button push the lever to the lower position ...

Page 43: ...ed in the above illustration the brakes are unlocked To lock the brakes shift the handle to a horizontal position 2 Parking Brake Engagement 2 Engage the parking brake when parking the vehicle to prevent the vehicle from rolling To apply the parking brake push down the lever with your hand Parking Brake Lever 1 To release the parking brake pull the lever up Make sure the parking brake lever is fun...

Page 44: ...ntain a record of all maintenance performed on your vehicle and retain all receipts covering maintenance on your vehicle You may not be denied a warranty claim solely because of your failure to ensure the performance of all scheduled maintenance or lack of maintenance records or receipts You are responsible for presenting your vehicle to an authorized dealer at the first sign of a problem The warr...

Page 45: ...warranted part or an authorized dealer is not reasonably available to the owner repairs may be performed at any available service establishment or by the owner using any replacement part The distributor shall reimburse the owner for the expenses including diagnostic charges not to exceed the distributor s suggested retail price for all warranted parts replaced and labor charges based on the distri...

Page 46: ...ntal consequential or special damages of any description whether arising out of express or implied warranty or any other contract negligence or other tort or otherwise No express Emission Control System Warranty is given by the distributor except as specifically set forth herein Any Emission Control System Warranty implied by law including any warranty of merchantability or fitness for a particula...

Page 47: ...e operation can be dangerous even at low speeds Steering becomes difficult To prevent rollover avoid sharp turns 11 The parking brake can be used in an emergency in case of primary brake system failure Vehicle Break In Period The break in period for your new TOMCAR is 65 miles and or 50 hours It is vital that you take care of your new engine Following the recommended break in period will result in...

Page 48: ... Always inspect the vehicle before each use to ensure it is in proper operating condition Safety instructions 1 Make sure the vehicle is on a flat surface 2 Make sure the gear lever is in neutral 3 Make sure the parking brake is engaged locked 4 Make sure you read and follow the instructions carefully Be sure the ignition key is in the OFF position 46 ...

Page 49: ...parking lights headlights high low indicators left right brake lights and registration plate light Check indicator lights on the dashboard yellow blue red 5 Throttle Travel Check that the throttle has full movement and springs back when released 6 Front Wheel Check for free play by grabbing the top of the tire firmly and pulling it back and forth 7 Front Suspension Check shock absorbers by pressin...

Page 50: ...ngine Oil Check engine oil Add if needed 17 Oil Leaks Check for large oil leaks from the engine the transmission box and final drive Slight oil moisture is not problematic Vehicle operation can result in oil drips from the breathers 18 Cooling System Check that the radiator and fans are free of debris Check coolant level 19 Air Filter Hose Check that all air hoses are connected properly 20 Rear Ai...

Page 51: ... engine damage Allow the engine to warm up before operating the vehicle Never press the throttle pedal down all the way when in neutral it may cause severe damage to the transmission Do not operate the starter continuously for more than five seconds or the starter will overheat and the battery power will drop temporarily Wait at least five seconds between each operation of the starter to allow it ...

Page 52: ...ry master switch has been turned to the off position the E C M will need to be re calibrated To re calibrate the E C M 1 Turn the ignition switch to the ON position for two seconds and return switch to OFF 2 Wait for 15 seconds before attempting to start engine 3 Go to back to step 1 in Starting the Gasoline Engine and follow the normal starting procedure Starting the Diesel Engine In order to sta...

Page 53: ...il you are familiar with the controls A rolling vehicle can cause property damage and serious injury Always apply the parking brake when the vehicle is parked Failure to allow for increased braking distance when hauling cargo towing a trailer or in inclement weather may result in accident and injury Always slow down and allow additional braking distance when towing hauling cargo or in inclement we...

Page 54: ...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 right foot and begin driving Vehicle speed is controlled by the amount the pedal is pressed 6 Practice maneuvering and using the throttle and brakes on level surfaces 7 Never operate at speeds too fast for your skills or the conditions at hand NOTE The hi...

Page 55: ...oid 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 Failure to exercise care when operating on slippery surfaces can result in the loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively ...

Page 56: ...lways check the terrain carefully before climbing a hill When operating on hilly terrain braking and handling are greatly affected Improper 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 cl...

Page 57: ...scent 2 Keep in a straight line and proceed directly downhill 3 Maintain a safe speed in accordance with the conditions 4 Apply the brakes slightly and softly to aid in slowing 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 Excessive speed may result in the loss of vehicle ...

Page 58: ...l to your TOMCAR s floor level 1 Always determine water depths and current before entering 2 Choose a crossing where both banks have inclines that are as gradual as possible 3 Proceed slowly avoiding rocks and any other obstacles that might be in your way NOTE After running your vehicle in water it is critical that you perform the services outlined in the Periodic Maintenance Chart beginning on pa...

Page 59: ...se When driving in reverse please follow the guidelines outlined below 1 Apply the brakes 2 Put shift lever in the reverse position 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 Never open the throttle suddenly while in reverse Failure...

Page 60: ...l or park the vehicle in a side hill position instead Operating the vehicle while the hand brake is engaged could cause loss of control and result in serious injury or death Always disengage the parking brake before operating the vehicle Fuel is extremely flammable and can be explosive under certain conditions Once parked inside a garage or other structure be sure that the structure is well ventil...

Page 61: ...box with the load as far forward as possible Always operate the vehicle with extreme care 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 Never allow passengers to ride in the car...

Page 62: ...ations section beginning on pg 101 2 Make sure the vertical load on the trailer hitch never exceeds 100 kg or 220 lbs 3 Operate the vehicle slower than usual and take into consideration the terrain and the slope 4 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 th...

Page 63: ...s 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 inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Operating at high engine speeds Prolonge...

Page 64: ...Tires I 9 Max Tire Air Pressure 7 psi Front 15 psi Rear 4 Brake Fluid Level I 1 5 Brake Pedal Travel I 1 6 Wheel Nuts I 8 Torque to 80 Nm 7 Frame Hardware I Frame Nuts Bolt and Fasteners 8 Engine Oil Level I 16 9 Front Air Filter I C 3 10 Rear Air Filter I C 20 11 Coolant Level I 18 12 Headlights Tail Lights I 4 13 Parking Brake Operation I 14 14 CVT Belt I 21 NOTE Refer to the Engine Maintenance ...

Page 65: ...r boots as needed Check Steering Rod Ends Check Shock Mounts 5 Fill Shock Air Chambers maximum air pressure 200 psi 6 Remove Drums Inspect Brake Shoes and Drums 7 Check for Free Play in Rear End Final Drives Shock Mounts 8 Change Engine Oil and Filter refer to Engine Maintenance Chart 9 Change Fuel Filters 10 Check Rear Air Filter Inspect Air Intake Hoses 11 Check Spark Plugs refer to Engine Maint...

Page 66: ...Proper Tension 18 Install Wheels 19 Adjust Parking Brake 20 Check for Leaks 21 Check Electrical System Lights Horn Warning Lights Windshield Wipers 22 Check Wiper Blades 23 Check Front Air Filter clean replace as needed 24 Check Brake Fluid DOT4 25 Clean Battery Terminals 26 Inspect Fuses 27 Grease Steering Box and Check Steering System for Free Play 28 Check Windshield Washer Fluid 29 Inspect Thr...

Page 67: ...neral Lubrication interval Item Lubricant procedure Item Lubricant Capacity Procedure Engine Oil TMx7C Gas SAE 5W 30 Below 20C SAE 15W 40 Above 20C Engine Oil SAE 15W 40 Oil dipstick should indicate safe range TMx7B Diesel Transmission Case Oil SAE 80W 90 2 4 l Maintain as recommended Final Drive Oil SAE 80W 90 0 75 l Per Side Maintain as recommended Brake Fluid DOT 4 0 5 l Maintain level between ...

Page 68: ...tion Recommendations MAINTENANCE LUBRICATION Lubrication Recommendations Front Suspension Lubrication 1 Upper Ball Joint Bolt 2 Lower Ball Joint Bolt Front Ball Joint Bolts RHS 1 2 Lubrication Recommendations MAINTENANCE LUBRICATION 66 ...

Page 69: ...MAINTENANCE LUBRICATION 67 Lubrication Recommendations Lubrication Recommendations MAINTENANCE LUBRICATION Steering Box Lubrication Point Steering Box Lubricate at 1 67 ...

Page 70: ...ANCE LUBRICATION Rear Area Rear Axle RHS Rear Axle CVT LHS 1 Rear Right Drive Axle Lubricating Point 1 Rear Left Drive Axle Lubricating Point 2 Rear Right Drive Axle Lubricating Point 2 Rear Left Drive Axle Lubricating Point 3 CVT Lubricating Point Engine removed from picture for clarity 68 ...

Page 71: ...place Replace Replace Coolant Check Add Check Add Check Add Replace 2 Years Cooling System Hoses Check Tighten Check Tighten Replace 4 Years Spark Plugs Check Replace Check Replace Replace Spark Plug Wires Check Replace Check Replace Replace Air Filter Clean Clean Replace Clean Replace Replace Fuel Filter Check Replace Check Replace Replace Replace Crankcase Breather Check Check Check Valve Cover ...

Page 72: ... 2 Years Oil Filter Replace Replace Replace Engine Oil Replace Check Replace Replace Air Filter Clean Clean Replace Clean Replace Replace Fuel Filter Replace Replace Coolant Check Add Check Add Check Add Replace Cooling System Hoses Check Tighten Check Tighten Check Tighten Valve Adjustment Check Adjust Fuel Injector Pressure Check Adjust Preliminary Fuel Filter Replace Replace Replace Replace Rep...

Page 73: ...ated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Check Please find the relevant dipstick location depending on which engine you have in your TOMCAR vehicle Follow these steps when performing the above check 1 1 Position the vehicle on a level s...

Page 74: ... temperature to which the engine will be subjected to in the winter and the highest functioning temperature during the summer Single degree oils are normally used when the running temperature varies scarcely Multi degree oil is less sensitive to temperature changes Gasoline Engine Oil SAE Classification Diesel Engine Oil SAE Classification Mineral Base Semi Synthetic Base Synthetic Base 72 ...

Page 75: ...er counterclockwise to remove 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the O ring on the new filter with a film of engine oil 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional 1 2 turn 12 Fill oil through the oil cap opening Bring the level to the upper mark on the dipstick 13 Plac...

Page 76: ...e the transmission oil at the intervals outlined in the Periodic Maintenance Chart Maintain the oil level even with the bottom of the check plug hole 1 Transmission Fill Plug 2 Oil Level Indicator Bolt 3 Drain Plug Transmission with High Low Selection and Differential Lock 74 ...

Page 77: ...hange 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Remove the drain plug and drain the oil into a drain pan 4 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 5 After the oil has drained completely install a new sealing washer and reinstall the drain plug 6 Add 2 4 l of oil per Lubrication and Fluid Recommendations table pg 65 7 Reinstall t...

Page 78: ...elf of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added TOMCAR recommends the use of high quality aluminum compatible anti freeze ...

Page 79: ...flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Exercise caution if a high pressure system is used for washing the...

Page 80: ...ol 1 Position the vehicle on level ground 2 View the coolant level in the overflow bottle 3 If the coolant level is below the safe operating range lift the cargo box and locate the overflow bottle lid Remove the lid and use a funnel to add coolant through the filler opening Reinstall the cap NOTE If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in th...

Page 81: ...edure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected Use of a non standard pressure cap will not allow the recovery system to function properly See your supplier for the correct replacement part Service should only be performed once the engine has reached the surrounding...

Page 82: ...r type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by the use of an improper spark plug or incorrect carburetion adjustments 2 The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are...

Page 83: ...so may cause imbalance severe vibration and may reduce its strength so failure can occur at a high speed and can result in severe injury or death The CVT system has been engineered and tested to ensure utmost safety as the system rotates at high speeds creating large amounts of force on transmission components For ultimate safety always follow all recommended maintenance procedures 81 ...

Page 84: ...tom the gap between them should be between 2 2 75 in 5 7 cm 3 If the belt is loosened contact your qualified TOMCAR service representative to tighten the belt CVT Belt Tension CVT Drying When you cross deep water the belt may get wet which can cause it to lose the majority of its grip and it can slip When leaving water drive normally The belt will dry and get normal grip back on its own During the...

Page 85: ...ge 1 and check its condition 3 Wash with warm water and drain 4 Add about five tablespoons of oil and spread evenly over the sponge Applying too much oil can prevent air from going through the filter 5 Reinstall air filter sponge NOTE Service the air filter frequently if the vehicle is operated in wet and dusty conditions or at high throttle openings for extended periods Service to the engine shou...

Page 86: ...ace the air filter after after its second cleaning To clean the cartridge gently tap on the end with the handle of a screw driver replace cartridge if it is very dirty or damaged Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart CAUTION Do not use pressurized air or solvents to clean the filter Pressurized air and solvents may damage the filter Oper...

Page 87: ...during operation Throttle Free Play If the throttle pedal has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed In addition the throttle may not open fully If the throttle pedal has no free play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal free play at the intervals outlin...

Page 88: ...ry or 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 ...

Page 89: ...rake fluid level 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 Brake Fluid Container After opening a bottle of brake fluid always discard any unused portion Never s...

Page 90: ...nt is necessary 1 Push the parking brake lever down with your hand 2 Once the lever is in a full horizontal position check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Parking Brake Inspection Parking Brake Inspection Parking Brake Adjustment 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Loosen or t...

Page 91: ...ntact 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 92: ...eck the belt 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 Failure to fol...

Page 93: ...ways replace tires when the tread depth measures 5 16 in 8 mm or less Improper tire inflation or the use of a non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury 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 Tir...

Page 94: ... pressures are Front 7 psi Rear 15 psi 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 92 ...

Page 95: ... wheel nuts slightly 4 Elevate the side of the vehicle by placing a suitable jack under the frame 5 Remove the wheel nuts Remove the wheel Wheel Installation 1 With the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten 3 C...

Page 96: ...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 shock...

Page 97: ...th Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they have cooled sufficiently Headlight Lamp Replacement 1 Unscrew the screw at the bottom of headlight 1 2 Install the new lamp 3 Screw back in the main screw at the bottom of headlight ...

Page 98: ...the housing Rear Lights 1 Brake Light 2 Parking Lights 3 Signal Light Rear Light Inspection 1 Turn the ignition switch to the ON position 2 Depress the brake pedal and check the light 3 Turn on headlights via the lights control to the left of the steering wheel The parking light 2 should come on 4 Shift light control up turn right The signal light 3 should come on periodically Rear Light RHS Signa...

Page 99: ...losed 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 next 5 Lif...

Page 100: ...nd tighten the black negative cable 6 Verify that 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...

Page 101: ...ng so your TOMCAR will not only improve in appearance but it can also extend the life of various components With a few precautions your vehicle can be cleaned much like an automobile NOTE If warning labels are damaged contact your TOMCAR supplier for a replacement If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission sea...

Page 102: ...moisture or small animals from entering 8 Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation for the vehicle Remove Your TOMCAR From Storage Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the spark plug is tight Fill the fuel tank with fuel Perform a Pre Ride Inspection as des...

Page 103: ...Injected 4 Cylinder Liquid Cooled Diesel 1400 cc Naturally Aspirated 4 Cylinder Liquid Cooled Engine Oil Gas Diesel SAE 5W 30 Below 20C SAE 15W 40 Above 20C SAE 15W 40 Transmission Automatic V Belt CVT Rear Wheel Drive Final Drive Oil Bathed Double Chains High Low Reverse Transfer Case Differential lock Cargo Box inside rails 47 8 x 26 2 in 1 214 x 666 mm 66 3 x 52 9 in 1 684 x 1 343 mm Cargo Box ...

Page 104: ...5 in Ground Clearance Steering Rack and Pinion 1 6 Turn Lock to Lock Brakes Power Assisted Hydraulic Brakes Mechanical Parking Brake Fuel Tank Capacity 7 gal 27 l Electrical 12V Battery 40 70AAlternator Horn 12V Power Socket Halogen Headlights Tail Turn and Brake Lights Instrumentation Speedometer with Odometer Voltmeter Fuel Gauge Temperature Gauge Seating Adjustable Front Row Bucket Style with I...

Page 105: ...or omissions or inaccuracies TOMCAR reserves the right to make changes in the design and specifications and to make additions or improvements to it s products without incurring any obligation to install them on products previously manufactured 2009 TOMCAR USA Inc All rights reserved May not be reproduced or translated in whole or in part without the expressed written consent of TOMCAR USA Inc Prin...

Page 106: ...WWW TOMCAR COM ...

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