Columbia Vehicle Group Tomberlin ESCAPE 2018 User manual

ESCAPE
2018
Owner / Operator
Manual
712458-00

Preface
Welcome, and congratulations on your choice of vehicle from Columbia Vehicle
Group, Inc. (CVG)
Columbia Vehicle Group, Inc. proudly manufacturers vehicles for the Columbia and
Tomberlin families. Your vehicle has been designed and manufactured to conform
to applicable sections of ANSI B56.8. Your safe use and operation of your vehicle is
important to us. Any alteration of your vehicle that results in the vehicle being in
noncompliance with applicable ANSI standards is strictly prohibited. Tomberlin is
not responsible or liable for any damage that results from any such alteration, and
all warranties for any such altered vehicles are null and void.
These vehicles are not designed for over-the-road use. They do not conform to
Federal Motor Vehicle Safety Standards or EPA regulations, and are not equipped
for operation on public streets, roads, or highways.
To the best knowledge of Tomberlin, the material contained herein is accurate as
of the date this publication was approved for printing. Tomberlin is not liable for
errors in this manual or for incidental or consequential damages that result from
the use of the material in this manual. Tomberlin reserves the right to change
specifications, equipment or designs at any time without notice and without
incurring obligation.
This manual contains proprietary information that is protected by copyright. All
rights are reserved. No part of this manual may be photocopied, reproduced, or
translated to another language without the written consent of Tomberlin.
Tomberlin products are manufactured under multiple U.S. Patents.
NOTICE: In an effort to streamline product support, please ensure your vehicle is properly registered
with Columbia Vehicle Group. Registration allows for more effective product support including product
updates and warranty processing. Please consult with your authorized dealer to verify or complete the
registration process.
2505 Industrial Street Leesburg, FL 34748
Phone: [phone] • Fax: [phone]
(844)-EMERGE2 (363-7432)Web: www.Tomberlin.net

TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 SAFETY MESSAGES
1.2 VEHICLE DESCRIPTION
1.3 VEHICLE IDENTIFICATION NUMBER (VIN)
1.4 VIN MATRIX
1.5 VEHICLE SPECIFICATIONS
2.0 SAFETY
2.1 GETTING STARTED
2.2 SAFETY VEHICLE STATEMENTS
2.3 SAFETY WARNINGS
2.4 SAFETY CONCERNS
3.0 OPERATIONS AND CONTROLS
3.1 IMPORTANT FIRST STEP
3.2 INSPECTING THE VEHICLE
3.3 VEHICLE CONTROLS
3.3.1.A POWER KEY SWITCH
3.3.1.B DIRECTION SELECTOR
3.3.1.C HIGH/LOW SPEED SWITCH (OPT)
3.3.1.D LIGHT SWITCH
3.3.1.E ACC SWITCH (OPT)
3.3.1.F HOUR METER
3.3.1.G BATTERY STATUS INDICATOR
3.3.1.H SYSTEM STATUS LED
3.3.1.I 12V POWER OUTLET
3.3.1.J WARNINGS/OPERATING
INSTRUCTIONS
3.3.1.K WINCH CONTROL
3.3.2 BRAKE PEDAL/PARKING BRAKE
3.3.3 ACCELERATOR PEDAL
3.3.4 CHARGER RECEPTACLE & REMOTE LED
3.3.5 STEERING WHEEL
3.3.6 HORN BUTTON
3.4 DRIVING THE VEHICLE
3.5 PRE-OPERATION CHECKLIST
4.0 ELECTRIC SYSTEM
4.1 IMPORTANT INFORMATION
4.2 BATTERY INSPECTION & MAINTENANCE
4.3 BATTERY CLEANING
4.4 CONDITIONS WHICH AFFECT CHARGING
4.5 DELTA-Q BATTERY CHARGING
4.5.1 CHARGER OPERATING INSTRUCTIONS
4.5.2 RED LIGHT CHARGER ERROR CODES
4.5.3 CHECK / CHANGE CHARGING
ALGORITHM
4.6 EXCESSIVELY DISCHARGED BATTERIES
4.7 SPECIFIC GRAVITY TEST
4.8 TIPS FOR MAINTAINING YOUR BATTERIES
4.9 SINGLE POINT WATERING SYSTEM
4.10 BATTERY DISCONNECT METHODS
4.11 BATTERY REMOVAL & INSTALLATION
5.0 SERVICING YOUR VEHICLE
5.1 MAINTENANCE GUIDELINES
5.2 MECHANICAL BRAKE SYSTEM
5.3 HYDRAULIC BRAKE SYSTEM
5.4 BRAKE FLUID MAINTENANCE
5.5 TIRE CARE
5.6 WHEEL & TIRE REMOVAL/INSTALLATION
5.7 CLEANING
5.8 LUBRICATION
5.9 MAINTENANCE SCHEDULE -
OWNER/OPERATOR
5.10 MAINTENANCE SCHEDULE –QUALIFIED
TECHNICIAN
5.11 VEHICLE TROUBLESHOOTING
5.12 CONTROLLER TROUBLESHOOTING
6.0 TOWING & TRANSPORTING
6.1 TOWING YOUR VEHICLE
6.2 TRANSPORTING YOUR VEHICLE
7.0 VEHICLE STORAGE
7.1 BATTERY PREPARATION
7.2 VEHICLE PREPARATION
7.3 RETURNING VEHICLE TO SERVICE
8.0 WINCH OPERATON
9.0 VEHICLE LIMITED WARRANTY
CHANGE HISTORY
DATE
DESCRIPTION
BY
DATE
DESCRIPTION
BY
12/2017
Initial Issue
TS

1.0 INTRODUCTION
This manual provides important safety information, operating instructions, model specifications and
maintenance instructions for the Tomberlin Escape.
The information in this manual is limited to care and maintenance information only. Information covering
repairs and technical service is provided in detailed service manuals available to authorized dealers. These
activities may require the attention of a skilled technician and the use of special tools and equipment.
Your authorized dealer has the facilities, experience and genuine Tomberlin parts and accessories to
properly service your vehicle.
1.1 SAFETY MESSAGES
Safety messages and other information in this manual are preceded by the words DANGER, WARNING,
CAUTION or NOTICE. They are printed in bold face, and are very important. We recommend you take
special notice of this information.
Danger indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury.
Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE: Notices are messages not related to personal injury. They will provide key information to prevent
property damage and to assure procedures are more easily understood or implemented.
1.2 VEHICLE DESCRIPTION
This vehicle is built to carry 2 people and cargo, or 4 passengers if equipped with factory rear seat. It is
not designed to be driven on public highways.
The vehicle is designed to conform to requirements for Type E vehicles as described in O.S.H.A. Standard
Section 1910.178 (Powered Industrial Trucks) and with all applicable portions of the American National
Standard for Personnel and Burden Carriers (ANSI B56.8 1993 Part III).
1.3 VEHICLE IDENTIFICATION NUMBER (VIN)
Do not remove any nameplate, warnings, or instructions affixed to your Tomberlin vehicle. Promptly replace
any that become damaged or removed.
Each vehicle is assigned a unique Vehicle Identification Number (VIN). The VIN describes facts and features
of the vehicle and contains fourteen (14) digits.
The nameplate has important information such as model, vehicle weights and rated capacity (load,
operator and passenger). Do not exceed this rated capacity. Read carefully.
To ensure prompt service when repairs or adjustments are required, your Tomberlin dealer must have
the VIN.
For your own personal reference, note your VIN in the space provided below:

The VIN can be found in two locations: On a label placed under the steering wheel cover (Figure 1.3.1)
and on a vehicle nameplate (Figure 1.3.2) located in the driver side glove box.
1.4 VIN MATRIX
Digit 1-3 (Model)
UE1 (Escape)
Digit 7 (Amps)
4=400 Amps
5=500 Amps
Digit 4 (Power
System)
E=Sep Ex w/Regen Std Duty
F=Sep Ex w/Regen Hvy Duty
Digit 8 (Brakes)
Z=Rear Mechanical
Digit 5 (Voltage)
4=48V (8 6V Batteries)
Digit 9 (Year)
S=2018
T=2019
U=2020
Digit 6 (Type)
-=Standard Product
# =Special Product
Digit 10-13
(Sequence)
0001…1234…9999
1.5 VEHICLE SPECIFICATIONS
TOMBERLIN ESCAPE
Max. Speed FWD
15 mph
Maximum Occupants
2
Max. Range
Up to 40 Miles
Seats
Marine Grade Vinyl
Dimensions (L x W x H)
102” x 48” x 53”
Lighting
Front Halogen
Rear LED
Wheelbase
66”
Storage
Front Tray / (2) Glove Box
Ground Clearance
6.88” @ Differential
7.88” @ Front Center
11.75” @ Mid Chassis
Operator Accessories
Key Switch, Headlight Switch,
Battery Status Indicator,
Horn, 12V Power Port
Weight
# 1,258
Body
Front Rhino-Tuff Polymer
Rear 14 Gauge Steel
Capacity
# 800 Total, Limited to:
# 300 Rear Cargo Area
# 100 Front Tray
Winch
Rated #3000, 50’ 3/16” wired
rope
Motor
DC Direct Drive
Hitch Receiver 2”
Front / Rear Prewired
Horsepower
15.3 Peak
Frame
Tubular Steel
Batteries
(8) 6 Volt
Steering
Rack & Pinion
Charger
On Board 110-240V AC
Brakes
Rear Mechanical Drum
Controller
Programmable w/LED
Suspension, Front
Multi-Leaf Spring, Dual
Shocks
Motor Braking
Regenerative
Suspension, Rear
Dual Coil Springs, Dual
Shocks
Differential
Direct Drive 16.99:1
Tires, Turf/ Multi-
Terrain
Tires, Traction/Multi-
Terrain
23 x 8.5-12 @ 22-25 psi
24 x 9.0-12 @ 22-25 psi
(Never exceed sidewall
rating)
Figure 1.3.1
Figure 1.3.2

2.0 SAFETY
2.1 GETTING STARTED
For personal safety, before operating the vehicle, it is the operator’s responsibility to read, understand
and follow the basic rules of operation and maintenance instructions in this manual. If you are responsible
for the use of the vehicle, it is your responsibility to inform the person or persons using the vehicle about
the following basic rules of operation for their personal safety.
It is Tomberlin’s specific recommendation that the following warnings must be observed at all times. Not
all are repeated throughout this manual, but the recommendations included must be observed whenever
these subjects (vehicle operation hazards, battery hazards, etc.) are encountered. Section 4.0 ELECTRIC
SYSTEM contains important safety and other system information.
2.2 SAFETY VEHICLE STATEMENTS
Any modifications or changes to the vehicle that affect the stability, steering or that results in increased speed
beyond factory specifications could result in vehicle damage, severe personal injury or death.
Only trained service professionals should repair or service this vehicle. Persons doing even simple repairs or
maintenance should have a working knowledge and experience in general electrical and mechanical repair.
Follow all procedures exactly and observe all safety messages stated in this manual. Working on vehicles without
following proper procedures and using proper equipment may result in vehicle damage or personal injury. See
Section 2.3 OPERATOR SAFETY INSTRUCTIONS.
Moving parts hazard! When operating any vehicle in a stationary position, avoid tires and wheels which could
snag clothing or cause severe injury to body parts. A running vehicle must be worked on with the greatest care.
Failure to maintain vehicle properly could result in decreased vehicle performance, reliability or cause severe
personal injury.
Always wear safety glasses or approved eye protection while performing vehicle maintenance.
This vehicle is not Federal or State DOT approved and is not equipped to be operated on public roads or highways.
Do not exceed the rated vehicle speed. Exceeding this speed may result in steering difficulty, motor damage,
and/or loss of control and injury.
When replacement parts are required, use only genuine Tomberlin parts.
No modifications or additions, which affect the mechanical or electrical integrity and the safe operation of the
vehicle, shall be made without the written approval of the manufacturer. If such modifications are approved,
the capacity, operation, and maintenance instruction markings shall be changed accordingly. If in doubt about
any modification, contact your local Tomberlin authorized dealer or Tomberlin Client Care. Do not overload the
vehicle. Never exceed maximum payload as specified on the Vehicle Nameplate. Your safety and the safety of
others depend on your safe operation and maintenance of this vehicle.

2.3 SAFETY WARNINGS
For personal safety and to maintain stability and control, operate this vehicle under these conditions only. Failure
to comply with these warnings may result in bodily injury and property damage.
Do not drive this vehicle unless you are a qualified and trained operator and familiar with the vehicle
operational controls.
All vehicles should be operated from the driver’s side.
Never exceed the capacity ratings of the vehicle. Exceeding these limits may endanger occupants.
Personal injury may result if body parts (arms, head, and legs) are not kept inside vehicle while moving.
Allow only one occupant per seat. Do not start moving until all occupants are seated with seat belts
fastened, if equipped. Remain seated and hold on while vehicle is in motion.
Before leaving your seat, completely stop vehicle and lock parking brake. If vehicle is to be left unattended,
turn key switch to “OFF” and remove key.
Do not use accelerator to hold vehicle on an incline. Use brake.
Make sure directional key switch is in position for the desired direction of travel before depressing the
accelerator. Do not change the directional key switch while vehicle is moving.
Drive slowly in turns and up and down grades. Do not make turns on steep hills or inclines.
Do not operate while under the influence of alcohol or drugs.
To avoid the risk of injury or vehicle damage, operate at maximum speed only on smooth flat surfaces.
Allow additional stopping distance when traveling at higher speeds.
Do not drive this vehicle in hazardous areas unless this vehicle is approved and labeled for such operation.
Keep a safe distance when following other vehicles and from the edge of ramps and platforms.
2.4 SAFETY CONCERNS
It is recommended that the operator and owner or renter of this vehicle comply with applicable vehicle
safety standards.
As a minimum every operator should, in addition to the above requirements found in the standards noted
above:
Demonstrate a working knowledge of each control.
Understand all safety rules and guidelines as presented in this manual.
Know how to properly load and unload cargo.
Know how to properly park the vehicle.
Recognize an improperly maintained vehicle.
Demonstrate ability to handle the vehicle in all conditions.
Every owner or renter of this vehicle must, at a minimum:
Define where the vehicles should and should not be driven and utilized.
Ensure all warnings as to driving hazards are displayed and visible.
Install safety signage concerning hills, speed bumps, ramps, turns, blind crossings, intersections, etc.
Define who should and who should not drive the vehicles.
Enforce safe driving and operating rules.
Provide driver training for first time operators and review safe operating recommendations regularly.
Maintain vehicles in a safe operating condition and maintain a schedule for daily, weekly, monthly,
quarterly, semi-annually and annual vehicle inspections.
Determine who, when, and how should pre-operation inspections be conducted.
Notify operators what should be done if an unsafe condition or operating problem is discovered.

3.0 OPERATIONS AND CONTROLS
3.1 IMPORTANT FIRST STEP
Upon initial delivery, it is very important that the battery pack is properly charged. This is required
whether the vehicle is to be stored for later use or is to be used immediately.
Check that the batteries are not damaged or leaking and that connections are secure.
For non-sealed batteries only, remove the battery vent caps and inspect each cell for proper
electrolyte level. The battery manifold assemblies on vehicles with a single point watering system
will require a ¼ counterclockwise turn to be removed for this inspection.
If the electrolyte level is below the plates add only enough water to cover the plates. See Section 4.2.
NOTICE: Do not overfill a cell. Electrolyte expands and can overflow during charging.
For vehicles with a single point watering system, replace the manifold assemblies with a ¼ clockwise
turn.
With the electrolyte level correct, use the on board charger to charge the batteries as described in
Section 4.5.1.
Charging is complete when the charger green 100% charge LED is steadily lit.
For vehicles without a single point watering system, refill cells to below the bottom of the each cell
vents. See Figure 4.2.1.
Vehicles with a single point watering system will require completion of 4 to 5 charge cycles before
watering.
NOTICE: If the vehicle is not going to be used the on-board charger can remain connected to an AC source. It has
the capability to test and recharge the battery pack during storage.

3.2 INSPECTING THE VEHICLE
After battery charging, perform a pre-delivery inspection of the vehicle. Also, before using the vehicle,
there are checks that must be performed to ensure that it is in safe proper working order.
NOTICE: Vehicle should be inspected immediately after delivery. Use the following guidelines to make sure there
are no obvious problems.
Examine the contents of all packages and accessories that may have come in separate packages with this
vehicle. Make sure everything listed on the packing slip is there. Items should not be broken or damaged.
Examine any visible wiring for obvious signs of damage. Check that all connections are secure.
Inspect the tires for obvious wear or damage. Check for proper tire inflation (Section 1.5). Make sure that
all wheel lugs are secure.
Check the body, seats, trim and other external parts for obvious damage. Look for body damage, jagged
edges etc. that may cause personal injury.
Operate each of the following controls before turning on the power key switch:
Accelerator Pedal should perform with smooth operation and fully raise when foot is removed from
pedal.
Braking Pedal when pressed should feel firm with minimal travel.
Steering should rotate smoothly with less than 1” play in steering wheel.
The power key should only be removable when key switch in “OFF” position.
NOTICE: Each control should operate smoothly and easily without sticking or requiring excessive effort.
Check that the directional selector operates properly, that the horn works and that the warning buzzer
sounds in reverse.
If vehicle has just been delivered, report any physical damage or missing items to the shipping company
and your local Tomerblin dealer.
Report any battery or service issue problems to the individual(s) responsible for correction and/or repair
or contact your local Tomberlin dealer for service.
If any problems are found, do not operate vehicle until repairs are made. Failure to make necessary repairs could
result in fire, severe personal injury, property damage or death. Consult your local Tomberlin Dealer for
professional service.

3.3 VEHICLE CONTROLS
This section describes the operating controls of the vehicle. Figure 3.3.1 identifies many of these controls.
Your vehicle may not be equipped with each of these controls.
3.3.1.A POWER KEY SWITCH
With the power key switch in “OFF” position, the traction system is powered down. This conserves battery
energy by reducing the power draw when vehicle is not in use. Turning the power key switch to OFF is
highly recommended whenever vehicle is not in use. Always remove the key from the key switch when
leaving the vehicle to prevent unauthorized use. When the direction selector is in the vertical position,
the vehicle’s drive system is turned OFF or in neutral. If accelerator is pressed with selector in neutral (N),
the System LED (I) will flash twice indicating the unit can not move until a direction is selected. If this
occurs, release accelerator pedal and select either forward (F) or reverse (R).
3.3.1.B DIRECTION SELECTOR
Turn direction selector to the right from vertical position to move the vehicle in forward direction. Turn
direction selector to the left from vertical position to move the vehicle in reverse direction. A warning
alarm sounds when in reverse.
3.3.1.C HIGH / LOW SPEED SWITCH (OPTIONAL)
This switch is a two-position toggle switch. The up position (rabbit) is for high speed and allows the vehicle
to reach full speed. The down position (turtle) is a lower maximum speed and is recommended for
inexperienced operators or for steep grades and/or off road in rough terrain. This switch is not in
operation when the vehicle is in reverse.
3.3.1.D LIGHT SWITCH
Move switch up to activate headlights and taillights, down to turn off.
Figure 3.3.1

3.3.1.E AUXILIARY EQUIPMENT SWITCH (OPTIONAL)
A switch for auxiliary equipment will be located in this position.
3.3.1.F HOUR METER INDICATOR (OPTIONAL)
The hour meter indicates the total number of hours the vehicle has been operating. It would be located
immediately below the Battery State of Charge meter.
3.3.1.G BATTERY STATE OF CHARGE METER
This meter will display the battery state of charge. As shown, it is an analog gauge with an indicating
needle and a colored background. It is a continuously reading meter. At rest with fully charged batteries
the meter should read in the white region.
When accelerating quickly, the needle will move to the green region nearest the red region. This is normal
and will recover once vehicle achieves constant speed. If the needle continues past the green region into
the very far left red region, it indicates that the batteries are 80% discharged or basically empty (only 20%
charge remaining). Recharge as soon as possible to avoid a shut-down of the vehicle. When decreasing
speed, the needle will move slightly to the right as electrical energy is being “regenerated” back into the
batteries.
NOTICE: At 80% discharge, you must immediately charge batteries or vehicle operation will cease and permanent
battery damage could occur.
3.3.1.H SYSTEM STATUS LIGHT
With the power key switch in the “ON” position, the controller is powered and this light should display a
steady green light. If this green status light is not lit or is flashing refer to Section 5.12 CONTROLLER
TROUBLESHOOTING.
3.3.1.I AUXILIARY 12V POWER PORT
Provides a 12 volt power source accessory connection.
3.3.1.J WARNINGS & OPERATING INSTRUCTIONS
Read this information carefully before operating the vehicle. Promptly replace if removed or damaged.
Contact your Tomberlin dealer for replacements if needed.
3.3.1.K WINCH CONTROL
With winch properly secured and fastened, pressing the IN switch will draw winch cable into spool.
Pressing the OUT switch will release the cable. (See section 8.0 for further winch details).

3.3.2 BRAKE PEDAL/PARKING BRAKE
Figure 3.3.2 shows the brake pedal (B) and the parking brake lock (C). The parking brake lock (C) is a bar
located at the top of the brake pedal. To lock foot brake for parking, depress brake pedal and bar at the
same time. Always apply parking brake when leaving the vehicle. It remains applied until automatically
released by depressing the accelerator pedal (N). Parking brake can also be released by momentarily
depressing the brake pedal, and then releasing it.
NOTICE: Never rest your foot on brake pedal while operating the vehicle. This wears brake pads, creates drag and
causes excess battery discharge.
3.3.3 ACCELERATOR PEDAL
Figure 3.3.2 shows the accelerator pedal (A) which controls the speed of the vehicle in the same manner
as a conventional automobile. The pedal should be fully released when changing directions.
To avoid injury, speed in reverse should always be kept at a minimum.
3.3.4 CHARGER RECEPTACLE & REMOTE LED
The charger receptacle (Figure 3.3.4) is located on the panel by the driver’s left leg. The AC
cord will be connected here for battery charging.
The charger is inter-locked with the traction control system which powers down the
vehicle during charging so that the vehicle can not be driven while connected to AC, to
prevent possible damage to the vehicle or the AC receptacle.
Near the receptacle is a remote multicolored LED which will indicate the on-board battery
charging status. See Section 4.5.1 for information on the remote LED.
Always apply the parking brake when charging.
NOTICE: Before removing the AC cord, be sure to check the charging status lights. The light should be steady
green, indicating charge cycle is complete.
3.3.5 STEERING WHEEL –NOT SHOWN
The steering wheel controls the path of the vehicle exactly the same as a conventional automobile
steering wheel.
3.3.6 HORN BUTTON –NOT SHOWN (OPTIONAL)
The horn button, if equipped, is located on the left side of the steering wheel column. Press button to
sound the horn.
Figure 3.3.4
Figure 3.3.2

3.4 DRIVING THE VEHICLE
Complete the following PRE-OPERATION CHECKLIST.
Fasten seat belts (if vehicle is so equipped).
Insert key in power key switch, press brake pedal firmly, and turn key to "ON" position.
Switch the direction selector to the direction of desired travel.
Release the parking brake and brake pedal.
Slowly press accelerator pedal to obtain desired vehicle speed.
To slow or stop vehicle, remove foot from accelerator and press brake pedal.
3.5 PRE-OPERATION CHECKLIST
Should any item malfunction or need adjustment. Do not operate vehicle until the problem has been corrected.
ITEM
PROCEDURE
Batteries
Fully charged and AC cord is disconnected from the vehicle
Electrolyte level covers the top of cell plates. (See Section 4.10 if equipped with
Single Point Battery Watering System.)
Batteries secure, free of corrosion, all terminals and connections tight.
Tire Pressure
Inflated to recommendation per Section 1.5 Do not exceed maximum stated on
tire sidewall.
Lights, Horn and
Reverse Buzzer
When equipped, make sure lights, horn and reverse buzzer operate correctly.
Brakes
Brake pedal has firm pedal pressure with minimal travel.
Parking brake has proper engagement and release.
Steering
Responsiveness and the absence of excessive free play.
Cargo
Load is secure, balanced and not top heavy.
Obstacles
Path of intended travel is free from obstructions.
Seat Belts
If equipped, driver and passenger are secured by seatbelts before moving vehicle.
Labels
All warning and operation labels in place.
Accelerator
Check for smooth operation.

4.0 ELECTRIC SYSTEM
4.1 IMPORTANT INFORMATION
The type of battery used in a Tomberlin vehicle has a service requirement which is quite different from
that of an automotive battery.
The electric vehicle battery supplies all of the power to drive the vehicle. During operation the power
stored in the batteries is expended. Be aware that the amperage drain rate can vary greatly depending on
the type of service, the duration of use and the number of "starts" and "stops" made during a day. During
use the batteries will progress through each duty cycle from "fully charged" to an almost depleted state.
This type of service is known as "deep cycle" service and electric vehicle batteries are specifically designed
to handle this type of service. Proper performance of your Tomberlin vehicle can only be obtained from
specified deep cycle, electric vehicle batteries.
PLEASE REVIEW IMPORTANT DANGER AND WARNING STATEMENTS WHEN WORKING AROUND
BATTERIES AND CHARGING SYSTEMS
Always remove key and disconnect battery pack before servicing or repairing the vehicle. See Section 2.5.
Always wear full-face shield when working on or near batteries.
All batteries used in electric vehicles can explode! Batteries produce explosive hydrogen gas at all times,
especially during charging or discharging. Ventilate area when charging batteries.
Do not attempt to charge a battery if it is frozen, or if the case is bulged excessively. Frozen batteries can
explode! Properly dispose of any battery by recycling at auto parts store, battery vendor or salvage yard.
Do not smoke around batteries. Keep sparks and flames away from batteries and the charging area. Use care
to prevent an accidental arc which could cause an explosion. Use only approved insulated tools, remove
jewelry such as rings, watches, chains etc. and place an insulating material (wood, plastic, rubber etc.) over
all battery connections.
Never add acid to a battery.
Battery acid is poisonous and can cause severe burns. Avoid contact with skin, eyes, or clothing.
ANTIDOTES:
EXTERNAL: Flush with water. Call a physician immediately.
INTERNAL: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable oil. Call a
physician immediately.
EYES: Flush with water for fifteen minutes. Call physician immediately.
To reduce the risk of electrical shock or injury:
Do not use an ungrounded two to three-prong adapter to connect the charger to a two-prong outlet or
extension cord. The battery charger must be properly grounded.
Use a three prong No. 12 AWG heavy duty power cord no more than 50 feet long.
Locate all cords so that they will not be stepped on, tripped on, or otherwise damaged. Immediately replace
worn, cut, or damaged power cords or wires.
Do not connect the power cord near fuels, grain dust, solvents, thinners, or other flammables. The spark can
ignite flammable materials and vapors.

NOTICE: Automotive batteries should never be used for "deep cycle" application, as their useful life will be very
short.
Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical/electronic
components in the charger and vehicle from all but direct or “close proximity” lightning strikes.
Damaged or corroded battery terminals should be replaced or cleaned as necessary. Failure to do so may cause
overheating during operation.
Do not attempt to recharge batteries with a charger not designed for your vehicle.
Only trained technicians should service the on-board charging system. Contact your Tomberlin Dealer for
assistance.
4.2 BATTERY INSPECTION & MAINTENANCE
Check the electrolyte level on new batteries before they are put into service, and, at a minimum, once a
week thereafter. Water use increases as batteries age. (See Section 4.10 if vehicle is equipped with a
Single Point Battery Watering System.)
See Figure 4.2.1. Never allow the electrolyte level (A) to fall below the top of the plates (C). If the plates
are exposed, add only enough to cover the plates before charging. After batteries are fully charged, fill
cells to just below the bottom of the cell vents (B), approximately 1/8” to 1/4”. Electrolyte level should
not touch the bottom of the cell vents.
Do not overfill batteries. Electrolyte expands and can overflow during charging. Water added to replace
the spillage dilutes the electrolyte and reduces its specific gravity. Use only distilled water. Vehicle
batteries may use up to 16 quarts of water during their useful life and non-distilled water may contain
harmful minerals which will have a cumulative adverse effect on battery performance and life.
Be sure battery hold downs are properly tightened. A loose hold down may allow the battery to become
damaged from vibration or jarring. A hold down that is too tight may buckle or crack the battery case.
On a weekly schedule inspect battery posts, clamps and cables for breakage, loose connections and
corrosion. Replace any that are damaged. Check to see that battery cap vent holes are clear. Plugged vent
holes will not permit gas to escape from the cell and could result in battery damage. Batteries and
connections must be clean and dry. See Section 4.3.
Weekly an equalization charge is to be applied to the battery pack. This process balances the electrical
charge in each battery and the battery pack as a whole, which will help to extend battery life.
The following procedure is used to complete this.
Charge the battery pack allowing the on-board charger to go to green 100% charge.
Once the green LED’s light unplug the power cord.
Wait approximately 30 seconds. Reconnect the power cord and allow the charger to complete a
second charge cycle.
If the vehicle is not to be used, leave power cord connected. The charger can test and recharge as
needed.
Figure 4.2.1

4.3 BATTERY CLEANING
Acid-soaked debris on the battery terminal connections will cause current leakage, reducing battery
efficiency and battery life.
Check that all vent caps are tightly in place. Hose wash battery terminal connections periodically with
clean low-pressure water to keep them free of acid spillage, dirt, and other debris. Do not hose wash
electronic controllers, switches, solenoids and other electrical control devices. Cover these as necessary
to prevent splashing.
Clean battery terminal connections with baking soda (sodium bicarbonate) and water solution. Mix 5
teaspoons baking soda per quart of water. Use a stiff bristle brush, rinse with clean water and dry with a
clean cloth. Do not allow solution to enter cap vent holes. Steam cleaning is not recommended as steam
could disperse vapors.
4.4 CONDITIONS WHICH AFFECT CHARGING
Always schedule enough charging time so the on-board charger attains the 100% level. Charging time is
affected by age and battery condition, state of discharge, electrolyte temperature, AC line voltage, and
other variables. Correct charging methods extend battery life and vehicle range between charges.
New batteries need up to four hours more charging than “mature” batteries. Before the first use,
completely charge new batteries. Charging time will vary based on conditions noted.
If vehicle is used only occasionally, a refresher charge should be given prior to using.
Battery efficiency is affected by temperature. If the temperature of the outside air and/or batteries is
below 60º F, battery capacity is reduced. Batteries will require more frequent and longer charge periods
in early spring, fall and winter.
As batteries age, they finish charge at progressively higher charge rates and tend to use more distilled
water. At this point in battery age, charger will automatically begin reducing charge time.
Batteries found defective must be replaced. All batteries in a vehicle should be matched according to age,
capacity and brand.
4.5 BATTERY CHARGING
All vehicles are manufactured and equipped with a fully automatic on-board battery charger. The battery
charge status can be found in two locations: on the charger face and on a remote multicolored LED (Figure
4-5B). This LED and descriptive label will located near the AC connection receptacle.
NOTICE: Follow local ordinances and codes for proper disposal of battery cleaning waste.
Figure 4.5A
Figure 4.5B

4.5.1 CHARGER OPERATING INSTRUCTIONS
Connect the supplied power cord to the vehicle charger receptacle and to a properly grounded wall outlet.
Charger start and charge time is automatic. The yellow AC power LED (Fig. 4.5A No. 1) should remain
illuminated while the charger is plugged into an AC source. The remote LED will be flashing short green. If
these LED’s are not lit, before replacing charger, recheck the AC connection and the AC source fuse or
breaker. If this fails to correct the problem, contact your Tomberlin dealer for assistance.
Charger will automatically turn on and conduct a short self-test and battery pack test. All charger LED’s
will flash in sequence and then a trickle current will be applied to batteries until a minimum voltage is
reached. In Figure 4.5A No. 3 indicates the bar graph and No. 2 indicates the lowest LED. Three (3) amperes
is displayed as the lowest LED on the bar graph.
If the batteries meet the minimum voltage requirements of the charger program, signifying they are
serviceable (chargeable), the charger enters the bulk charging stage (higher amperage-constant current).
The bar graph LED’s indicate the electrical current being delivered to the batteries as the charger moves
through its automatic charge program. The length of charge time at each level will vary based on battery
size and battery charge depletion. The remote LED will be flashing short green.
NOTICE: If the batteries are excessively discharged, the on-board charger will not be able to charge the complete
set of batteries. The charger red fault LED (Fig. 4.5A No. 6) will flash and the remote LED will also be flashing red.
(See Section 4.5.2 Red Light Charger Error Codes). It will then be necessary to follow the Special Charging for
Excessively Discharged Batteries, Section 4.6.
When the yellow 80% LED (Fig 4.5A No. 4) is lit, the charger has completed the bulk stage and the batteries
are at approximately 80% state of charge. The 80% LED remains on as the last 20% of charge is returned
to the batteries in the second phase (constant voltage phase). At this time the remote LED will flash long
green.
NOTICE: You can terminate charging at this point if necessary. The vehicle can be used, but completing the charge
cycle at the next available opportunity is highly recommended.
Charge completion is when the 100% green LED is lit (Fig. 4.5A No. 5). The remote LED will also be green.
Repeated “short charging” (leaving the charge short of 100%) will shorten operating distance and
significantly reduce overall battery life.
A low current “finish-charge” phase returns and maintains batteries to maximum capacity. The 100%
green LED’s will blink until “finish charge” phase is complete.
A 100% green LED continuously lit indicates the batteries are completely charged. The charger may now
be disconnected from the AC source.
If the vehicle will not be used for a length of time, check monthly for the charge level. It is also acceptable
to leave the on-board charger plugged in, as it has the capability to test and recharge if necessary.
A fault occurring while charging causes the red fault LED and the remote LED to flash with a code relaying
the error. Some errors may require repair by a qualified technician and others may be simply transient
and will automatically recover when the fault condition is eliminated and the charger cycled by
disconnecting the AC source for a minimum of 20 seconds.
NOTICE: A yellow (amber) flashing LED in the upper bar graph (Fig. 4.5A No. 3) and a flashing yellow remote LED
indicates the thermostatic control has limited the charger output due to ambient temperature conditions. It is
still charging, but at a reduced rate which will increase charging time.

4.5.2 RED LIGHT CHARGER ERROR CODES
1 FLASH = Battery Voltage High: Auto-recover. May be temporary condition, or wrong charger installed,
i.e. 36 volt charger on 48 volt battery pack.
2 FLASH = Battery Voltage Low: Auto-recover. Confirm each individual battery’s minimum voltage with a
voltmeter. If two or more 6 volt batteries measure less than 5.85 volts, or accumulative total pack voltage
has been discharged to less than 20% remaining, vehicle operation will cease until batteries are recharged.
See EXCESSIVELY DISCHARGED BATTERIES Section 4.6.
3 FLASH = Charge Timeout: The charging did not complete in allowed time, up to 24 hours. This may
indicate a battery problem, or that the charger output was reduced due to high ambient temperatures.
Disconnect AC supply, confirm sufficient ventilation, allow cool down time, and restart charger.
NOTICE: If the on-board charger is exhibiting a 3 flash fault and it has been determined that the cause was not
due to ventilation or high ambient temperature, the following checks and services may restore the battery pack
to normal operation.
Battery posts and terminals must be clean and free of corrosion.
Check that electrolyte level just covers plates.
Plug in charger for at least a 16 hour charge.
Check and fill electrolyte.
Drive the vehicle for less than half the distance normally driven.
Repeat the above steps until the charger LED goes green, 100% charge on a 16 hour charge.
If repeated cycles (5-7) do not result in a 100% charge as indicated by a steady green LED, the batteries are beyond
useful life and will need replacement.
4 FLASH = Check battery pack: The batteries could not be trickle charged up to a minimum level to start
charger. This may be the result of badly discharged batteries, or one (or more) damaged cells. See
EXCESSIVELY DISCHARGED BATTERIES Section 4.6.
5 FLASH = Over-Temperature: The charger shutdown due to high internal temperature. May require reset
(AC unplugged) and cool down to restart charging cycle. This fault may indicate inadequate cooling airflow
or high ambient air temperatures. Check for debris or blockage at cooling fins. Move the vehicle to a
cooler, well ventilated area, or adjust time of day when charging.
6 FLASH = On-board charger fault: A fault was detected either in the batteries or in the charger. The
batteries must be tested to ensure there is no damage to one or more cells. If the batteries are found to
be good, the charger may need to be replaced by a qualified technician.
A STEADY RED FAULT LED confirms an internal electrical fault of the on-board charger and requires
charger replacement. There are no serviceable parts internal to the charger. Do NOT disassemble.

4.5.3 CHECK / CHANGE CHARGING ALGORITHM
The on-board charger has been programmed for use with the vehicle’s supplied batteries and contains up
to ten algorithms for use with different batteries. The table below details these battery models:
TABLE A
ALGORITHM #
BATTERY TYPE
126
Full River or Equivalent 85ah-145Ah AGM (DC115-12)
125
Full River or Equivalent 160ah-220ah AGM (DC180-6/DC224-6)
72
US Battery or Equivalent 250ah-335Ah Flooded Constant Power dv/dt (USB
305HC)
43
Discover or Equivalent 200ah-400ah AGM (EVL16A/EVGC6A/EV185A)
42
Discover or Equivalent 80ah-150ah AGM (EV31A)
11
US Battery or Equivalent 200ah-255ah flooded Constant Power dv/dt
(USB2200/USB145)
5
Trojan or Equivalent 85ah-150ah Group 31 12v Flooded
1
Trojan or Equivalent 150ah-260ah 6v/8v/12v Flooded (T105)
NOTICE: For maximum battery life the correct algorithm must be used.
NOTICE: If your battery model is not listed in Table A, contact your dealer for further information.
Each time AC power is applied with the battery pack NOT connected, the charger enters an algorithm
select/display mode for approximately 11 seconds. This will also be displayed on the remote LED.
During this time, the current algorithm # is indicated on the 80% LED light. A single digit algorithm # is
indicated by the number of blinks separated by a pause. A two digit algorithm # is indicated by the number
of blinks for the first digit followed by a short pause, then the number of blinks for the second digit
followed by a longer pause.
To check/change the charging algorithm:
Disconnect the charger Battery Positive (red wire) connector from battery pack. Apply AC power and
after the LED test, the algorithm # will be displayed for 11 seconds.
To change the algorithm, touch the positive connector during the 11 second display period to the
battery pack’s positive terminal for 3 seconds and then remove. The algorithm # will advance after 3
seconds. Repeat until the desired algorithm # is displayed. A 30 second timeout is extended for every
increment. Incrementing beyond the last algorithm moves back to the first algorithm. After the desired
algorithm # is displayed touch the charger connector to the battery positive until the output relay is
heard to click (~ 10 seconds). The algorithm is now in permanent memory.
Remove AC power from the charger and reconnect the charger positive connector to the battery pack.
It is highly recommended to check a newly changed algorithm by repeating the above steps.
NOTICE: Do not cover the charger cabinet or cooling fins with clothing, blankets, or other material. Fins provide
ventilation and prevent overheating.
Do NOT disassemble the charger. There are no serviceable components.

4.6 EXCESSIVELY DISCHARGED BATTERIES
NOTICE: Your Tomberlin dealer will have the equipment and experience to perform the following battery
inspections.
The on-board charger will not charge dead batteries. First establish that none of the batteries have an
internal fault or bad cell. If a battery has remained too long in a discharged state (i.e. 2-4 volts each), it
may be internally damaged and not capable of accepting a charge and must be replaced.
If the electrolyte specific gravity is low (less than 1.1098 SG) or individual battery voltage is less than 5.25
volts for three cells (10.5 volts for six cells), recharge each battery with an ordinary 6 volt external trickle
charger at a rate of 3 to 6 amps.
It is not necessary to disconnect the battery cables, as the alligator style clips can be connected to each
positive and negative battery post. Follow specific charger instructions.
To prevent a spark from igniting the gas emitted from the batteries, always disconnect the Charger AC power
cord first when moving the positive/negative alligator clips.
Be sure to charge all of the batteries in the set. Each battery may require two to three hours of charging
to bring it back to serviceable condition. After all batteries have been individually charged, remove the
external charger and restart charging with the on-board charger (Section 4.5.1). It may require several 8-
12 hour cycles to restore severely discharged batteries back to 100% charged condition. If again the on-
board charger has the RED FAULT LED (Fig. 4.5A No. 6) flashing there is a problem with one or more of the
batteries.
4.7 SPECIFIC GRAVITY TEST
It is possible to determine a battery's ability to perform by measuring the specific gravity (sp. gr.) of each
cell with a hydrometer. This is the best method to determine a defective battery.
The hydrometer readings indicate two things:
State of Charge - The amount of electrical power stored in the battery.
Condition - The ability of battery to store and deliver power.
NOTICE: Batteries should be fully charged before performing specific gravity tests to determine battery condition.
Hydrometer tests of batteries not fully charged are misleading and inconclusive.
There are different type hydrometers. Carefully read and follow the instructions supplied with your
hydrometer.
NOTICE: Specific gravity readings are at 800F. Values need adjustment for electrolyte temperature. Reduce .004
for every 100F below 800F. Increase by that amount for every 100F above.