MQ Multiquip TB11G-TB11E Walk Behind Power Buggy Operation Manual

OPERATION MANUAL

MODEL

TB11G

TB11E

WALK-BEHIND

POWER BUGGY

(HONDA GX200UT2QX4 GASOLINE ENGINE/

24VDC, 1300W ELECTRIC MOTOR)

Revision #1 (09/11/19)

To find the latest revision of this publication or associated parts manual, visit our website at:

www.multiquip.com

THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.

PROPOSITION 65 WARNING

TB11G/TB11E

POWER BUGGY

PAGE 2 — TB11G/E TUFFTRUK • OPERATION MANUAL — REV. #1 (09/11/19)

TB11G/E TuffTruk

Walk-Behind Power Buggy

Proposition 65 Warning ........................................... 2

Table of Contents ..................................................... 3

Safety Information ............................................. 4–10

Specifications (Buggy) ........................................... 11

Specifications (Engine) .......................................... 12

Noise and Vibration Emissions .............................. 13

Dimensions ............................................................ 14

General Information ............................................... 15

Components .................................................... 16–17

Engine Components .............................................. 18

Inspection ........................................................ 19–21

Operation (Gasoline) ...................................... 22–23

Operation (Electric) ........................................ 24–25

Operation (Gas/Electric) ................................. 26–28

Maintenance .......................................................... 29

Maintenance (Gasoline) .................................. 30–36

Maintenance (Electric) ..................................... 37–39

Maintenance (Gas/Electric) ............................. 40–44

Troubleshooting (Engine) ................................. 45–46

Troubleshooting (Gas) ........................................... 47

Troubleshooting (Electric) ...................................... 48

Error Codes ........................................................... 49

Electronic Component Locator ............................. 50

Wiring Diagram ...................................................... 51

TABLE OF CONTENTS

TB11G/E TUFFTRUK• OPERATION MANUAL — REV. #1 (09/11/19) — PAGE 3

DO NOT

operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment.

Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.

SAFETY MESSAGES

The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifi cally address the level of exposure to the operator and are preceded by one of four words:

DANGER, WARNING, CAUTION

or

NOTICE.

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not avoided,

WILL

result in

DEATH

or

SERIOUS INJURY.

WARNING


COULD

result in

DEATH

or

SERIOUS INJURY.

CAUTION


COULD

result in

MINOR

or

MODERATE INJURY.

NOTICE

Addresses practices not related to personal injury.

SAFETY INFORMATION

Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.

Symbol Safety Hazard

Lethal exhaust gas hazards

Explosive fuel hazards

Burn hazards

Rotating parts hazards (V-belt)

Rotating parts hazards (Chain)

Hydraulic fluid hazards


GENERAL SAFETY

CAUTION

NEVER

operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.

Avoid wearing jewelry or loose fi tting clothes that may snag on the controls or moving parts as this can cause serious injury.

NEVER

operate this equipment when not feeling well due to fatigue, illness or when under medication.

NEVER

operate this equipment under the infl uence of drugs or alcohol.


NOTICE

This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.

Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.

Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation will void all warranties.

NEVER

use accessories or attachments that are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.

ALWAYS

know the location of the nearest

fi re extinguisher.

ALWAYS

know the location of the nearest

fi rst aid kit.

ALWAYS

know the location of the nearest phone or

keep a phone on the job site.

Also, know the phone numbers of the nearest

ambulance, doctor

and

fi re department.

This information will be invaluable in the case of an emergency.

ALWAYS

clear the work area of any debris, tools, etc. that would constitute a hazard while the equipment is in operation.

No one other than the operator is to be in the working area when the equipment is in operation.

DO NOT

use the equipment for any purpose other than its intended purposes or applications.


TUFFTRUK SAFETY

DANGER

Engine fuel exhaust gases contain poisonous carbon monoxide. This gas is colorless and odorless, and can cause death if inhaled.

The engine of this equipment requires an adequate free fl ow of cooling air.

NEVER

operate this equipment in any enclosed or narrow area where free fl ow of the air is restricted. If the air fl ow is restricted it will cause injury to people and property and serious damage to the equipment or engine.

DANGEROUS

GAS FUMES

NEVER

operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fi re could result causing severe

bodily harm or even death.

WARNING

NEVER

use your hand to fi nd hydraulic leaks.

Use a piece of wood or cardboard. Hydraulic fl uid injected into the skin must be treated by a knowledgeable physician immediately or severe injury or death can occur.

Accidental starting can cause severe injury or death.

ALWAYS

place the ON/OFF switch in the OFF position.

NEVER

disconnect any

emergency or safety devices.

These devices are intended for operator safety.

Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties.

NEVER

approach power lines with any part of the

TuffTruk unless all local, state/provincial and federal

(OSHA) required safety precautions have been taken.

Use extreme caution when approaching high voltage power lines.


CAUTION

ALWAYS

inspect the surface over which you will travel.

Look for holes, drop-offs and obstacles. Look for rough and weak spots on docks, ramps or fl oor.

ALWAYS

Look for oil spills, wet spots and slippery surfaces. Look for soft soil, deep mud and standing water.

Watch for anything that might make you lose control or cause the TuffTruk to tip over.

ALWAYS

clear away trash and debris. Pick up anything that might puncture the tires.

ALWAYS

make sure aisles, ramps, doorways and passages are clear.

ALWAYS

plan your work. Make sure you know where you will make your pickups, dumps and turns. Before you take a load, know where you will place it.

NEVER

travel down a slope with a

full load

. The possibility exists of tipping.

DO NOT

operate the TuffTruk on unsafe haul roads, load areas, and dump areas.

WARNING

TIPPING OF BUGGY

CAN OCCUR

DO NOT

operate TuffTruk on excessive slopes with a grade higher than 25° (45%), forward and backward.

DO NOT

operate TuffTruk on extremely uneven surfaces.

NEVER

allow people to ride inside the tub/bucket.

DO NOT

operate the TuffTruk at excessive speeds.

Reckless operation may cause accidents and severe injury. Slow down when approaching people, wet areas, and going up and down grades. It is the responsibility of the operator to adjust speed, as necessary, depending on the conditions of the road or path.

Forward travel speed should not exceed 4 mph

(6.44 km/h). Reverse travel speed should not exceed

1.5 mph (2.42 km/h).

ALLOW

extra time to stop when operating the TuffTruk on wet surfaces or loosely graded materials.

DO NOT

dump materials from bucket/tub while the

TuffTruk is moving.


NOTICE

ALWAYS

ensure TuffTruk is

securely

placed on appropriate blocks or jackstands when performing maintenance.

When parking on a slope, position the TuffTruk at a right angle to a slope.

When filling or dumping capacity of TuffTruk.

DO NOT

exceed payload

ALWAYS

be aware of traveling conditions. Reduce load if necessary.

DO NOT

activate dump mechanism (tub/bucket) if

TuffTruk is facing a down hill slope.

DO NOT

stand in front or along side the TuffTruk when discharging a load.

ALWAYS

block the TuffTruk with appropriate blocks when leaving the TuffTruk parked on a slope.

To prevent unexpected loss of control, engine on a sloping surface.

DO NOT

start

Ensure that the speed control levers works freely and returns to the stop position.

DO NOT

start engine unless speed control linkage is working properly.

Make sure that the tires are infl ated to the manufacturer’s recommended tire pressure.

NEVER

operate the TuffTruk with bad or worn tires.

ALWAYS

replace defective tires with new ones.

Avoid sudden stops and starts and changes in direction.

Operate the controls smoothly.

DO NOT

jerk the steering or any other controls.

NEVER

attempt to engage the controls except from the operator’s position.

NEVER

roads.

operate or tow the TuffTruk in traffi c or on public

ALWAYS

keep the machine in proper running condition.

Fix damage to machine and replace any broken parts immediately.


The entire TuffTruk (tub, shroud, wheels, etc.) should be cleaned after every use. Make sure there is no buildup of concrete, grease, oil or debris on the machine.

ALWAYS

store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel.

ALWAYS

place the fuel valve lever in the when the equipment is not in use.

OFF

position

ENGINE SAFETY

WARNING

DO NOT

place hands or fingers inside engine compartment when engine is running.

NEVER

operate the engine with heat shields or guards removed.

Keep fi ngers, hands hair and clothing away from all moving parts to prevent injury.

ALWAYS

shut down the engine before performing service or maintenance.

DO NOT

remove the engine oil drain plug while the engine is hot. Hot oil will gush out and severely scald any persons in the general area of the TuffTruk.

CAUTION

NEVER

touch the hot exhaust manifold, muffl er or cylinder. Allow these parts to cool before servicing equipment.

Make certain the operator knows how to and is capable of turning the engine

OFF

in case of an emergency.

NOTICE

NEVER

run engine without an air fi lter or with a dirty air fi lter. Severe engine damage may occur. Service air fi lter frequently to prevent engine malfunction.

NEVER

tamper with the factory settings of the engine or engine governor. Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable.


FUEL SAFETY

DANGER

DO NOT

start the engine near spilled fuel or combustible fl uids. Fuel is extremely fl ammable and its vapors can cause an explosion if ignited.

ALWAYS

refuel in a well-ventilated area, away from sparks and open fl ames.

ALWAYS

use extreme caution when working with

fl ammable

liquids.

DO NOT

or hot.

fi ll the fuel tank while the engine is running

DO NOT

overfi ll tank and tighten fuel cap until you hear

"clicking", since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system.

Store fuel in appropriate containers, in well-ventilated areas and away from sparks and fl ames.

NEVER

use fuel as a cleaning agent.

DO NOT

smoke around or near the equipment.

Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine.

DO NOT

leave the TuffTruk in the vicinity of ovens, furnaces or radiant heaters. Heat could raise the pressure of the fuel so that vented gas could ignite.

BATTERY SAFETY (ELECTRIC START ONLY)

DANGER

DO NOT

drop the battery. There is a possibility that the battery will explode.

DO NOT

expose the battery to open fl ames, sparks, cigarettes, etc. The battery contains combustible gases and liquids. If these gases and liquids come into contact with a fl ame or spark, an explosion could occur.


WARNING

ALWAYS

wear safety glasses when handling the battery to avoid eye irritation.

The battery contains acids that can cause injury to the eyes and skin.

Use well-insulated gloves when picking up the battery.

ALWAYS

keep the battery charged. If the battery is not charged, combustible gas will build up.

DO NOT

charge battery if frozen. Battery can explode.

When frozen, warm the battery to at least 61°F (16°C).

ALWAYS

recharge the battery in a well-ventilated environment to avoid the risk of a dangerous concentration of combustible gases.

If the battery liquid (dilute sulfuric acid) comes into contact with

clothing or skin

, rinse skin or clothing immediately with plenty of water.

If the battery liquid (dilute sulfuric acid) comes into contact with

eyes

, rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention.

CAUTION

ALWAYS

disconnect the

NEGATIVE battery terminal

before performing service on the equipment.

ALWAYS

keep battery cables in good working condition.

Repair or replace all worn cables.

ALWAYS

use proper lifting procedures when removing the batteries from the machine. Batteries are quite heavy.

Bodily injury may result if proper lifting procedures are not employed.


LIFTING SAFETY

CAUTION

NEVER

allow any person or animal to stand underneath the equipment while lifting.

NOTICE

When lifting of the TuffTruk is required, attach lifting straps or chains to designated lifting points only.

Use lifting straps or chains of adequate lifting capacity.

NEVER

tip the engine to extreme angles during lifting as it may cause oil to gravitate into the cylinder head, making the engine start diffi cult.

DO NOT

lift machine to unnecessary heights.

NEVER

lift the equipment while the engine is running.

ALWAYS

use ramps capable of supporting the weight of the TuffTruk and the operator to load and unload the

TuffTruk.


TRANSPORTING SAFETY

NOTICE

ALWAYS

shutdown engine before transporting.

Tighten fuel tank cap securely and close fuel cock to prevent fuel from spilling.

When transporting of the TuffTruk is required, place the

TuffTruk on a fl at bed truck or equivalent and tie down securely.

ALWAYS

make sure all tie-downs are in place and the tub/bucket is completely lowered in the fl at (horizontal) position and securely latched.

Place

chock blocks

underneath wheel to prevent rolling.

DO NOT

use the TuffTruk to transport people.

When transporting the TuffTruk on a truck or trailer, know the overall height to avoid contacting overhead obstructions such as bridges and power lines. Check the truck and ramp capacities.

ALWAYS

place the fuel valve lever in the before transporting.

OFF

position


ENVIRONMENTAL SAFETY/DECOMMISSIONING

NOTICE

Decommissioning is a controlled process used to safely retire a piece of equipment that is no longer serviceable.

If the equipment poses an unacceptable and unrepairable safety risk due to wear or damage or is no longer cost effective to maintain (beyond life-cycle reliability) and is to be decommissioned (demolition and dismantlement),be sure to follow rules below.

DO NOT

pour waste or oil directly onto the ground, down a drain or into any water source.

Contact your country's Department of

Public Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this equipment.

When the life cycle of this equipment is over, remove battery (if equipped) and bring to appropriate facility for lead reclamation. Use safety precautions when handling batteries that contain sulfuric acid.

When the life cycle of this equipment is over, it is recommended that the unit frame and all other metal parts be sent to a recycling center.

Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.

Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.


EMISSIONS INFORMATION

NOTICE

This equipment conforms with applicable Environmental

Protection Agency (EPA) and California Air Resources

Board (CARB) emission regulations.

The gasoline engine used in this equipment has been designed to reduce harmful levels of carbon monoxide

(CO), hydrocarbons (HC) and nitrogen oxides (NOx) contained in gasoline exhaust emissions.

Mandated Emission Components:

Engine, EPA certifi ed

Fuel cap, EPA certifi ed

Fuel and vapor recovery hoses, EPA certifi ed SAE J30R7 or SAE J30R14T2

Charcoal canister, EPA certifi ed

Miscellaneous Parts Associated with Emission System:

Hose clamps and retainer brackets

Roll over valve vapor recovery valve

Steel fuel tank

Tampering with or altering the emission control system may increase emissions beyond the legal limit. Do not remove or alter any part of the system.

Additionally, modifying the fuel system may adversely affect evaporative emissions, resulting in fi nes or other penalties.

The Emission control system is valid only for the United

States, its territories and commonwealths to include

Canada.

Emission Control Label

The emission control label is an integral part of the emission system and is strictly controlled by regulation(s).

The label must remain with the engine for its entire life.

If a replacement emission label is needed, please contact your authorized engine distributor.


SPECIFICATIONS (BUGGY)

Model

Maximum Weight Capacity

Maximum Payload Weight

Bucket/Tub Capacity

Bucket/Tub Capacity (Option)

Bucket/Tub Material

Drive and Controls

Speed Forward

Speed Reverse

Steering Radius Outside Dia.

Hydraulic Pump Capacity

Hydraulic Oil Tank Capacity

Hydraulic Oil Type

Brake System

Dump Control

Discharge Height

Gradeability Slope (Up/Down)

Gradeability Lateral (Side-Side)

Battery (LxWxH)

Battery Weight

Pneumatic Tires

Pneumatic Tire Pressure

Table 1. Specifications (TuffTruk)

TB11G

374 lbs. (170 kg)

990 lbs. (450 kg.)

10.6 cu. ft. Water Level (.40 cu. yd.)


Steel

Hydrostatic System

Up to 4.0 mph. (6.4 km/h)

Up to 1.5 mph. (2.42 km/h)

58 in. (1,473 mm)

77.23 fl. oz. (2.28 liters)

16.90 fl. oz. (.5 liters)

20W-50 Motor Oil

Hydrostatic/Dead Man Handle

TB11E

561 lbs. (255 kg)

990 lbs. (450 kg.)



Steel

24 VDC Electric Motor Gearbox

Up to 3.5 mph. (5.63 km/h)

Up to 1.5 mph. (2.42 km/h)

58 in. (1,473 mm)

N/A

N/A

N/A

Hydrostatic/Dead Man Handle

Mechanical Dump and Manual Return Mechanical Dump and Manual Return

2.0 in. (50.8 mm) 2.0 in. (50.8 mm)

25°

6°

25°

6°

N/A

N/A

16 x 6.50 x 8

(406 x 165 x 203 mm)

28 PSI (193 kPa)

12V BCI Group 27 550 CCA @ 0°F

12.05 x 6.84 x 9.32 in.

(306 x 174 x 237 mm)

64 lbs (29 kg)

16 x 6.50 x 8

(406 x 165 x 203 mm)

28 PSI (193 Kpa)


SPECIFICATIONS (ENGINE)

Table 2. Gasoline Engine Specifications

Model HONDA GX200UT2QX4

Type

Bore X Stroke

Air-cooled 4 stroke, Single Cylinder,

OHV, Horizontal Shaft Gasoline Engine

2.7 in. X 2.1 in.

(68 mm x 54 mm)

Displacement

Max Output

Fuel Tank Capacity

Fuel

12.0 cu. in. (196 cc)

5.8 H.P./3,600 rpm

0.95 U.S. Gallons (3.6 Liters)

Unleaded Automobile Gasoline

Lube Oil Capacity

Speed Control Method

Starting Method

Dimension Approx.

(L x W x H)

Dry Net Weight

0.63 qt. (0.6 liter)

Centrifugal Fly-Weight Type

Recoil Start

12.6 X 14.8 X 13.6 in.

(321 X 376 X 346 mm)

35.2 lbs. (16.0 Kg)

Model

Table 3. Electric Motor Specifications

AMER

Type

Speed Control Method

Starting Method

Max RPM (No Load)

Input Voltage

Wattage

Poles

Protection Class

Insulation Class

IEC Duty Cycle

Dimension Approx.

(L x W x H)

Dry Net Weight Approx.

Permanent Magnet DC Electric Motor

Curtis 1228 Controller

Electric

2900

24 VDC

1300W

4

IP: 44

F

S3 15%

6.4 X 7.81 X 5.7 in.

(164 X 200 X 145 mm)

22 lbs. (10 kg)


NOISE AND VIBRATION EMISSIONS

Model

Table 4. Noise and Vibration Emissions

TB11G

Guaranteed ISO 11201:2010 Based Sound Pressure Level at Operator Station in dB(A) a

82

Guaranteed ISO 3744:2010 Based Sound Power Level in dB(A) b 96

TB11E

56

69

Hand-Arm Vibration Per ISO 5349-1:2001 in m/s

2

∑

A(8)

4.6

a. With an uncertainty factor K of 2.5 dB (A) included per Note 1 in section 7.2.1 of EN 12649::2008+A1:2011 b. With an uncertainty factor K of 1.5 dB (A) included per Note 1 in section 7.2.1 of EN 12649::2008+A1:2011

2.5

NOTES:

1.

Sound pressure and power levels are “A” weighted measures per ISO 3744:2010. They are measured with the operating condition of the machine which generates the most repeatable but highest values of the sound levels. Under normal circumstances, the sound level will vary depending on the condition of the material being worked upon.

2.

The vibration level indicated is the vector sum of the RMS (root mean Ssquare) values of amplitudes on each axis, standardized to an 8-hour exposure period, and obtained using the operating condition of the machine that generates the most repeatable but highest values in accordance with the applicable standards for the machine.

3.

Per EU Directive 2002/44/EC, the daily exposure action value for hand/arm vibration is 2.5 m/s

2

∑

A(8). The daily exposure limit value is 5 m/s

2

∑

A(8).


C

DIMENSIONS

REAR VIEW

K

L

A B

D

SIDE VIEW

G

P

OUTSIDE DIAMETER

TURNING RADIUS

F

H

J

TOP VIEW

P

E

I

M

N

O

K

L

J

I

G

H

E

F

Table 5. Dimensions

Reference

Letter

Dimension in. (mm)

C

D

A

B

43.34 (1,101)

34.68 (881)

70.98 (1,803)

31.10 (790)

O

P

M

N

16.73 (425)

9.37 (238)

6.18 (157)

29.52 (750)

7.71 (196)

60.11 (1,527)

33.46 (850)

23.62 (600)

5.55 (141)

6.37 (162)

33.46 (850)

57.67 (1,465)

Figure 1. TB11G/E Dimensions


The Multiquip Walk-Behind Series TuffTruk Power Buggies are available in two versions, gas (Model TB11G) or electric

(Model TB11E). Both modes are intended for job site cleanup and material transport.

The buggy is equipped with a 2.0 in. (50.8 mm) dump height which provides clearance and enables the operator to maneuver over any form height.

A low center of gravity has been incorporated into the design which provides added safety when maneuvering the buggy in tight areas.

Maximum

forward

speed for the

gasoline

driven TuffTruk buggy is rated at 4.0 mph. (6.4 km/h). The maximum

forward

speed of the

electric

driven buggy is rated at 3.5 mph. (5.63 km/h). Maximum

reverse

speed for both models is 1.5 mph. (2.42 km/h).

For ease of dumping, a manual hand lever control is provided. Maximum weight capacity (payload) is 990 lbs.

(450 kg). Multiple lift points have been provided to allow for easy access of a forklift when lifting is required.

POWER PLANT (ELECTRIC)

The electric model (TB11E) is powered by a 24 VDC, 1300 watt permanent magnet DC electric motor. The output shaft of the electric motor is connected to a gearbox reduction unit which drives the front and rear wheels. For additional

information, reference Table 3.

POWER PLANT (GASOLINE)

The gas model (TB11G) is powered by a Honda 5.8 HP,

GX200 air cooled, 4-cycle gasoline engine. Power is transferred from the output shaft of the engine to the V-belt pulley drive system which drives the front and rear wheels.

Reference Table 2 for complete engine specifications. In addition, refer to the engine owner’s manual for instructions regarding the operation and maintenance of your engine.

If the original manual is lost or damaged, please contact your nearest Multiquip dealer for a replacement.

GENERAL INFORMATION

MOTOR CONTROLLER (TB11E MODEL ONLY)

The TB11E is equipped with a sealed heavy-duty permanent motor controller, Curtis Model 1229 Speed

Controller (ECU). This controller provides functional and directional control of the TuffTruk buggy. It allows the buggy to start and stop or move in a forward or reverse direction.

This controller can detect a wide variety of faults or error conditions. Diagnostic information can be obtained by interfacing with the Curtis Model 3100R Gauge Display.

This gauge will display error codes as referenced in the maintenance section of this manual.

In addition, this controller has the capability of interfacing with Controller Area Network (CAN bus) applications.

DIAGNOSTIC GAUGE (TB11E MODEL ONLY)

TB11E is equipped with a diagnostic gauge. This gauge will display system error codes. Reference maintenance section in this manual for further details.

WARNING

All operators must have training before operating the

TuffTruk buggy. For your safety, warnings are on the machine and in this manual. Failure to obey these warnings can cause severe injury or even death.

CAUTION

DO NOT

attempt to operate the TuffTruk buggy until the Safety Information, General

Information, and Inspection sections of this manual have been

read and thoroughly understood.


1

2

8

9

7

3

6

23

GASOLINE

COMPONENTS

10

4

5

13

14

12

11

15

27

26

24

25

22

21

20

16

17

ELECTRIC

19

18

Figure 2. TuffTruk Walk-Behind Power Buggy Components


1.

Deadman Control Lever

—

Yellow

handle lever, when engaged (closed) allows the buggy to travel in either a forward or reverse direction. Works in conjunction with forward and reverse control levers. In addition, this lever when engaged releases the brake.

2.

Reverse Control Lever Signal Cable (TB11E)

— This lever/cable is a 2-wire cable (switch) that when activated sends a +12 VDC signal (J1-10) to the motor controller indicating that the reverse travel function has been selected.

3.

Handle Bar (Steering)

— This handle bar is used to steer the buggy. When steering the buggy, use both hands and hold onto both handle bar grips.

4.

Tub or Bucket

— Used for the transportation of material. Tub holds approximately 10.6 cubic feet

(0.40 cubic yards) of water.

5.

Tires

— Unit uses pneumatic tires. Reference

Table 1 for tire size.

6.

Lifting Point

— Attach a suitable lifting strap to these points when lifting of the buggy is required.

7.

Battery (TB11E)

— Uses two 12 volt batteries connected in series (24 volts). Always use gloves and eye protection when handling the batteries.

8.

Battery Charger Receptacle (TB11E)

— Plug the battery charger cable into this receptacle, then connect the free-end of the cable to a 120 VAC power source.

9.

Forward/Reverse Speed Control Lever

— When fully engaged, the buggy will travel at

FULL

speed in either the forward or reverse direction. When released, the buggy will

STOP

. This feature is only on the

TB11E

model.

10.

Dump Control Lever

— Push the lever forward to place the tub in the dump position (vertical).

11.

Component Fuse (TB11E)

— 10 amp fuse that provides protection for the Curtis Model 3100R

Diagnostic Display and other electronic components.

12.

Ignition/Key (TB11E)

— When activated allows the unit to be started.

13.

Emergency Stop Switch (TB11E)

— In the event of an emergency,

push

this button to shutdown the electric motor.

COMPONENTS

14.

Battery/Diagnostic Gauge (TB11E)

— Uses a Curtis

Model 3100R Gauge Display. Displays battery voltage and fault codes. CAN bus compatible.

15.

Free-Wheel Brake Lever (TB11E)

— Two position lever. When placed in the up position (OFF) and held allows the buggy to be moved with the electric motor disengaged (

OFF

).

16.

Contactor Solenoid (TB11E)

— When energized provides +12 VDC power to motor controller.

17.

5K OHM Potentiometer (TB11E)

— Provides signal for speed sensor.

18.

Deadman Microswitch (TB11E)

— When activated sends a +12 VDC signal (J1-3) to the motor controller to release the brake.

19.

Motor Speed Controller (TB11E)

— Unit uses a

Curtis Model 1229 Controller. Requires a 24 VDC input.

Interfaces with CAN bus applications.

20.

Electric Motor (TB11E)

— Uses a 24 VDC, 1300 watt electric motor.

21.

Contactor Fuse (TB11E)

— 125 amp fuse that provides protection for the electric motor.

22.

Battery Charger (TB11E)

— When activated, charges both 12-volt batteries. This feature is only on the

TB11E

model.

23.

Hydraulic Tank/Cap (TB11G)

— Remove this cap to add hydraulic oil. Tank holds approximately 16.90 fl. oz.

(.5 liters).

DO NOT

over fill. Reference Table 1 for

hydraulic pump oil capacity.

24.

Forward Speed Control Lever (TB11G)


FULL

speed in the forward direction. When released, the buggy will

STOP.

25.

Reverse Speed Control Lever (TB11G)


FULL

speed in the reverse direction. When released, the buggy will

STOP

.

26.

Engine (TB11G Model Only)

— Uses a recoil start

Honda 5.8 HP, GX200 air cooled, 4-cycle gasoline engine.

27.

Free-Wheel Brake Lever (TB11G)

— Two position lever. When placed in the up position (OFF) and held allows the buggy to be moved with the gasoline engine disengaged.


9

8

7

6

10

11

1

2

5

4

3

Figure 3. Engine Components

INITIAL SERVICING

The engine (Figure 3) must be checked for proper

lubrication and filled with fuel prior to operation. Refer to the manufacturer's engine manual for instructions and details of operation and servicing.

1.

Throttle Lever

– Used to adjust engine RPM speed.

2.

Fuel Filler Cap/Fuel Tank

– Remove this cap to add unleaded gasoline to the fuel tank. Fill with unleaded

gasoline. Refer to Table 2 for fuel tank capacity. Make

sure cap is tightened securely.

DO NOT

over fill. For additional information, refer to Honda engine owner's manual.

DANGER

Add fuel to the tank only when the engine is stopped and has had an opportunity to cool down. In the event of a fuel spill,

DO

NOT

attempt to start the engine until the fuel residue has been completely wiped up and the area surrounding the engine is dry.

ENGINE COMPONENTS

3.

Engine On/Off Switch

–

ON

position permits engine starting,

OFF

position stops engine operation.

4.

Recoil Starter (pull rope)

– Manual-starting method.

Pull the starter grip until resistance is felt, then pull briskly and smoothly.

5.

Fuel Valve Lever

–

OPEN

to let fuel flow,

CLOSE

to stop the flow of fuel.

6.

Oil Drain Plug

– Remove this plug to remove oil from the engine's crankcase.

7.

Dipstick/Oil Filler Cap

– Remove this cap to determine if the engine oil is low. Add oil through this filler port as

recommended in Table 6.

8.

Choke Lever

– Used in the starting of a cold engine, or in cold weather conditions. The choke enriches the fuel mixture.

9.

Spark Plug

– Provides spark to the ignition system.

Set spark plug gap according to engine manufacturer's instructions. Clean spark plug once a week.

10.

Muffler

– Used to reduce noise and emissions.

NEVER

touch when

hot!

CAUTION

Engine components can generate extreme heat. To prevent burns,

DO NOT

touch these areas while the engine is running or immediately after operating.

NEVER

operate the engine with the muffler removed.

11.

Air Cleaner

– Prevents dirt and other debris from entering the fuel system. Remove wing-nut on top of air filter canister to gain access to filter element.

NOTICE

Operating the engine without an air filter, with a damaged air filter or a filter in need of replacement, will allow dirt to enter the engine, causing rapid engine wear.


BEFORE STARTING

CAUTION

NEVER

disable or disconnect the

start/stop switch

.

It is provided for operator safety. Injury may result if it is disabled, disconnected or improperly maintained.

1. Read all safety instructions at the beginning of manual.

2. Clean the unit, removing dirt and dust, particularly the engine cooling air inlet, carburetor and air cleaner.

3. Check the air filter for dirt and dust. If air filter is dirty, replace air filter with a new one as required.

4. Check carburetor for external dirt and dust. Clean with dry compressed air.

5. Check fastening nuts and bolts for tightness.

CAUTION

ALWAYS

wear approved eye and hearing protection while operating the buggy.

CAUTION

NEVER

place hands or feet inside the engine guard cover while the engine is running.

ALWAYS

shut the engine down before performing any kind of maintenance service on the buggy.

INSPECTION

ENGINE OIL CHECK

1. To check the engine oil level, place the unit on secure level ground with the engine stopped.

2. Remove the filler dipstick from the engine oil filler hole

(Figure 4) and wipe it clean.

DIPSTICK

Figure 4. Engine Oil Dipstick (Removal)

3. Insert and remove the dipstick without screwing it into the filler neck. Check the oil level shown on the dipstick.

4. If the oil level is low (Figure 5), fill to the edge of the oil filler hole with the recommended oil type (Table 6).

Maximum oil capacity is 0.63 quarts (0.6 liters).

Reference engine manufacturer’s manual for specific servicing instructions.

UPPER LIMIT

LOWER LIMIT

Figure 5. Engine Oil Dipstick (Oil Level)

Season

Summer

Spring/Fall

Winter

Table 6. Engine Oil Type

Temperature

25°C or Higher

25°C ~ 10°C

0°C or Lower

Oil Type

SAE 10W-30

SAE 10W-30/20

SAE 10W-10


FUEL CHECK

DANGER

If your TuffTruk buggy has a gasoline engine, determine if the engine fuel is low. If fuel is low, remove the fuel filler cap and fill it with

unleaded

gasoline.

Motor fuels are

highly flammable

and can be dangerous if mishandled.

DO NOT

smoke while refueling.

DO NOT

attempt to refuel the mixer if the engine is

hot

or

running.

1. Remove the fuel cap (Figure 6) located on top of fuel

tank.

2. Visually inspect to see if fuel level is low. If fuel is low, replenish with unleaded fuel.

INSPECTION

TIRES

Check for

worn

or

defective

tires (Figure 7). Replace any

defective or worn tires immediately.

FUEL

CAP

V-BELT CHECK

Figure 7. Tire Wear

Visually examine the V-belt (Figure 8) and determine if it

is full of tiny cracks, frayed, has pieces of rubber missing, is peeling or otherwise damaged.

Also, examine the belt and determine if it is

oil soaked

or

"

glazed

" (hard shiny appearance on the sides of the belt).

Either of these two conditions can cause the belt to run hot, which can weaken it and increase the danger of it breaking.

If the V-belt exhibits any of the above wear conditions replace the V-belt immediately.

OIL SOAKED

Figure 6. Fuel Check

3. When refueling, be sure to use a strainer for filtration.

DO NOT

top-off fuel. Wipe up any spilled fuel immediately.

GLAZED

CORD FAILURE

WORN BACK

COVER

BROKEN

MISSING RUBBER

CRACKS

SIDEWALL

WEAR

Figure 8. V-Belt Inspection


BATTERY (ELECTRIC MODEL ONLY)

This unit is of negative ground

DO NOT

connect in reverse.

ALWAYS

maintain battery fluid level between the specified marks. Battery life will be shortened, if the fluid levels are not properly maintained. Add only distilled water when replenishment is necessary.

DO NOT

over fill. Check to see whether the battery cables are loose. Poor contact may result in poor starting or malfunctions.

ALWAYS

keep the terminals firmly tightened and coat the terminals with an approved battery terminal treatment compound. Replace battery with only recommended type battery. The battery type used in this power buggy is BCI

Group 27.

The battery is sufficiently charged if the specific gravity of the battery fluid is 1.28 (at 68° F). If the specific gravity should fall to 1.245 or lower, it indicates that the battery is dead and needs to be recharged or replaced.

Before charging the battery with an external electric source, be sure to disconnect the battery cables.

CAUTION

ALWAYS

disconnect the negative terminal

FIRST

and reconnect the negative terminal

LAST

.

Battery Cable Installation

ALWAYS

be sure the battery cables (Figure 9) are properly

connected to the battery terminals as shown below. The batteries are connected in series.

JUMPER

24 VDC TOTAL

SERIES CONNECTION

POSITIVE

NEGATIVE

RED

BLACK

Y 1

T

INSPECTION

When connecting battery do the following:

1.

NEVER

connect the battery cables to the battery terminals when the ignition is in the

ON

position (start).

2. Place a small amount of battery terminal treatment compound around both battery terminals. This will ensure a good connection and will help prevent corrosion around the battery terminals.

NOTICE

If the battery cable is connected incorrectly, electrical damage to the power buggy will occur. Pay close attention to the polarity of the battery when connecting the battery.

CAUTION

Inadequate battery connections may cause poor starting of the TuffTruk buggy, and create other malfunctions.

TIRE PRESSURE CHECK

The wheels and tires of the power buggy are very important in its effective operation.

1. Check the tires regularly to make certain the lug nuts are tight.

2. Make sure tires are inflated to manufacturer's suggested tire pressure.

DO NOT

operate the buggy with bad or worn tires.

LINKAGE CHECK

Check and make sure that

all

linkages within the TuffTruk buggy are functioning correctly.

STEERING CHECK

1. Check and make sure that the power buggy's steering turns freely and that there is no binding.

BA

TTER

12 VOL

Y 2

T

Figure 9. Battery Series Connections


OPERATION (GASOLINE)

This section is intended to assist the operator with the initial start-up of the unit. It is extremely important that this section be read carefully before attempting to use the TuffTruk walk-behind power buggy in the field.

DO NOT

use your buggy until the

General Information, and Inspection sections of this manual have been

read and thoroughly understood

.

WARNING

Failure to understand the operation of the buggy could result in severe damage to the buggy or personal injury.

Reference Figure 2 and Figure 3 for the location of any

components referenced in this manual.

CAUTION

NEVER

operate the TuffTruk walk-behind power buggy in a confined area or enclosed area structure that does not provide ample free flow of air. Gasoline models only.

STARTING THE BUGGY (GASOLINE MODEL)

The following steps outline the procedure for starting the gasoline TuffTruk buggy.

1. Place the fuel shut-off lever (Figure 10) in the

ON

position.

CHOKE LEVER

CLOSE

OPEN

Figure 11. Choke Lever (Closed)

NOTICE

The

CLOSED

position of the choke lever enriches the fuel mixture for starting a cold engine. The

OPEN

position provides the correct fuel mixture for normal operation after starting, and for restarting a warm engine.

3. If starting a warm engine or the temperature is warm, move the

choke lever (Figure 12) to the

OPEN

position.

CHOKE LEVER

FUEL VALVE

LEVER

OFF

ON

Figure 10. Fuel Shut-Off Lever (ON)

2. To start a cold engine, move the choke lever (Figure 11)

to the

CLOSED

position.

CLOSE

OPEN

Figure 12. Choke Lever (Open)

4. Move the throttle lever (Figure 13) away from the slow

position, about 1/3 of the way toward the fast position.

THROTTLE

LEVER

FAST SLOW

Figure 13. Throttle Lever


OPERATION (GASOLINE)

5. Place the engine ON/OFF switch (Figure 14) in the

ON

position.

PUSH

DOWN

OFF

ON

TRANSMISSION

BYPASS LEVER

(SET/ENGAGED)

ENGINE SWITCH

Figure 14. Engine On/Off Switch (ON)

6. Pull the

starter grip

(Figure 15) lightly until you feel

resistance, then pull briskly. Return the starter grip gently.

Figure 16. Transmission Bypass Lever (Engaged)

NOTICE

NEVER

activate (pull upwards) the transmission bypass lever with the engine running. Serious damage to the unit could occur.

2. With the engine running, fully squeeze the

YELLOW

deadman lever (Figure 16) and hold down. Transmission

is now active (unlocked).

NOTICE

The transmission bypass lever when

pushed down

works in conjunction with the deadman lever. With the deadman lever in the upright position, the transmission is

locked

. When the

YELLOW

deadman lever is engaged (fully squeezed), the transmission will automatically be unlocked.

STARTER GRIP

Figure 15. Starter Grip

NOTICE

DO NOT

pull the starter rope all the way to the end.

DO NOT

release the starter rope after pulling. Allow it to rewind as soon as possible.

TRAVELING

1. Make sure the transmission bypass lever (Figure 16)

is engaged (down position). To engage, push lever downward and move to the left.

NOTICE

If the transmission bypass lever is placed in the

UP

position (free-wheel) the buggy will not move when the forward or reverse speed control levers are activated.

For normal operation this lever should always be placed in the down position.

“DEADMAN” LEVER

HOLD DOWN

Figure 17. Deadman Lever (Gas)


3. Located underneath the

YELLOW

deadman lever is the forward speed control lever.

4. Slightly squeeze the

forward

speed control lever

(Figure 18) until the buggy begins to move in a forward

direction.

OPERATION (ELECTRIC)

STARTING THE BUGGY (ELECTRIC MODEL)

NOTICE

The travel function (forward/reverse) for the electric model is different from the gasoline version.

The following steps outline the procedure for starting the electric model power buggy.

1. Located on the control panel of the buggy, is the

start/ stop

button (Figure 20). Pull this button outward to start

the electric motor.

EMERGENCY

STOP SWITCH

FORWARD SPEED

CONTROL LEVER

Figure 18. Forward Speed Control Lever (Gas)

5. Walk slowly behind the buggy to get a feel for the buggy.

For maximum speed,

fully squeeze

the forward speed control lever.

6. To stop, release the forward speed control lever.

7. On the opposite side of the handle bar is the

reverse

speed control lever (Figure 19). Repeat the above steps

for traveling in the reverse direction.

PULL

Figure 20. Emergency Stop Switch (Closed)

2. Place the ignition key (Figure 21) in the

START

position.

Verify that all segments of the diagnostic gauge illuminate for 1 second and then turn off. In addition, check battery voltage level. If low, recharge batteries.

DIAGNOSTIC

GAUGE

IGNITION

SWITCH

BATTERY

GAUGE

START

REVERSE SPEED

CONTROL LEVER

Figure 19. Reverse Speed Control Lever (Gas)

NOTICE

NEVER

squeeze both speed control levers at the same time, as this will cause damage to the unit.

LOW

BATTERY

LEVEL

Figure 21. Ignition Key (Start)


TRAVELING

1. Place the brake bypass lever (Figure 22) in the

AUTO

position. If the lever is left in the

ON

(free-wheel) position, the buggy will not move when the forward/ reverse speed control lever is activated.

NOTICE

The brake bypass lever when placed in the

AUTO

position works inconjunction with the deadman lever.

With the deadman lever in the upright position, the brake is set (engaged). When the

YELLOW

deadman lever is engaged (fully squeezed), the brake will automaticlly be released (disengaged).

BRAKE BYPASS

LEVER (

AUTO

)

OFF

AUTO

OPERATION (ELECTRIC)


forward/reverse

speed control

lever (Figure 24) until the buggy begins to move in a

forward

direction.

FORWARD/REVERSE

SPEED CONTROL LEVER

Figure 24. Forward/Reverse Speed

Control Lever (Electric)

4. On the opposite side of the handle bar is the

reverse

control lever

signal cable

. This cable is a 2-wire cable that sends a signal via a switch to the motor controller

(J1-10) indicating that the

reverse

travel function has been selected.

5. Squeeze the

reverse

control lever signal cable

(Figure 25) and hold down.

Figure 22. Brake Bypass Lever (Auto)

2. With the electric motor running, fully squeeze the

YELLOW

deadman lever (Figure 23) and hold down.

When the lever is held down, a signal is sent via a microswitch to the motor controller (J1-3) to release the brake.

“DEADMAN” LEVER

SIGNAL

CABLE

Avoid sudden and quick turns. When steering, turn the handle bar slowly.

ALWAYS

face the controls when traveling.

REVERSE SPEED

CONTROL LEVER

Figure 25. Reverse Control Lever Signal Cable


forward/reverse

speed control

lever (Figure 24) until the buggy begins to move in a

reverse

direction.

CAUTION

HOLD DOWN

Figure 23. Deadman Lever (Electric)


STEERING (GAS/ELECTRIC)

To steer the buggy, use the handle bar in front of the unit.

1. To turn left (Figure 26) when traveling in the forward

direction, turn the handle bar clockwise.

TURN HANDLE BAR

CLOCKWISE TO STEER

BUGGY TO THE LEFT

LEFT

Figure 26. Steering the Buggy (CW-Left)

2. To turn right (Figure 27) when traveling in the forward

direction, turn the handle bar in the counterclockwise direction.

RIGHT

TURN HANDLE BAR

COUNTERCLOCKWISE TO STEER

BUGGY TO THE RIGHT

OPERATION (GAS/ELECTRIC)

TRAVELING ON A SLOPE

1. When traveling on a slope, it is necessary to determine the grade of the path. The TB11G/E buggies can travel

up or down slopes not exceeding 25° (Figure 28) .

DO

NOT

travel on steeper slopes.

To determine the % grade of your path of travel, use

the formula and graph in Figure 28.

.

2. Lateral side to side travel cannot exceed 6°.

100

95

90

85

80

75

70

65

60

40

35

30

25

20

15

10

5

0

55

50

45

100

95

90

85

80

75

70

65

60

35

30

25

20

15

10

5

0

55

50

45

40

100%

45°

70%

35°

45%

25°

MAX

10%

6°

10

15

20

25

30

35

40

45

50

55

60

65

70

GRADE (DEGREES)

75

80

85 90

DIRECTION OF TRAVEL

DISTANCE (D)

% GRADE = 100 (H ¸ D)

LEVEL BASE LINE

10%

6°

MAX

70%

35°

100%

45°

15

35

30

20

25

OF TRAVEL

40

45

50

55

60

65

70

GRADE (DEGREES)

75

80

10

85 90

DISTANCE (D)

% GRADE = 100 (H ¸ D)

LEVEL BASE LINE

HEIGHT (H)

HEIGHT (H)

Figure 28. Determining Grade of Slope

Figure 27. Steering the Buggy (CCW-Right)

CAUTION

DO NOT

steer the buggy left or right when traveling up or down on a grade. Travel in a straight path.


NOTICE

The possibility of

tipping

(Figure 29

A

) exist when transporting heavy loads.

ALWAYS

transport heavy loads as shown in Figure 29

B

.


A

DUMP

LEVER

WARNING

TIPPING OF BUGGY

CAN OCCUR

B

CORRECT DIRECTION

FOR TRAVELING UP OR

DOWN A SLOPE

25° MAX.

Figure 29. Slope Travel Direction

TUB (BUCKET) DUMPING

1. To place the tub in the dump position (Figure 30)

pull back on the dump lever and release. The tub will automatically rotate to the vertical position and dump its contents.

Figure 30. Tub Vertical Position

NOTICE

If the buggy is on a incline, it might be necessary to slightly push the tub upward in a forward direction so the tub can be placed in the dump position.

2. To return the tub back to the horizontal position, grab

hold of the tub (Figure 31) and push down.

Figure 31. Tub Horizontal Position


NORMAL SHUTDOWN (GASOLINE)

Correct shutdown is important for safe operation. Follow these general steps:

1. Release the

YELLOW

deadman lever and come to a complete stop. Brake is now set.

2. Let the engine idle for 3-5 minutes for gradual cooling.

3. Place the engine ON/OFF switch in the

OFF

position.

4. Place the fuel valve lever in the

OFF

position.

5. Block wheels if on a slope or incline.

EMERGENCY SHUTDOWN (GASOLINE)

1. Place the engine ON/OFF switch (Figure 32) in the

OFF

position.


NORMAL SHUTDOWN (ELECTRIC)

1. Release the

YELLOW

deadman lever and come to a complete stop. Brake is now set.

2. Place the ignition switch in the

OFF

position.

3. Block wheels if on a slope or incline.

EMERGENCY SHUTDOWN (ELECTRIC)

1. Push the

EMERGENCY STOP

switch (Figure 33).

EMERGENCY

STOP SWITCH

START

OFF

ON

ENGINE SWITCH

Figure 32. Engine ON/OFF Switch (OFF)

PUSH

Figure 33. Emergency Stop Switch (Push)


MAINTENANCE

DESCRIPTION

(3)

OPERATION

Table 7. Engine Maintenance Schedule

BEFORE

EACH

USE

FIRST

MONTH OR

25 HRS.

EVERY 6

MONTHS

OR 100

HRS.

X

Engine Oil

Check

Change

Engine Oil Filter Replace

Check

Air Cleaner Clean

Change

X

X

X (1)

X

Every 100 Hrs.

X

Spark Plugs

Check/Adjust

Cooling Fins

Fuel Filter

Fuel Tube

Replace

Clean

Replace

Check

* - Replace the paper filter element only.

(1) Service more frequently when used in

DUSTY

areas.

X

EVERY

YEAR

OR 300

HRS.

X

X

X (2)

Every 2 years (replace if necessary) (2)

EVERY 2

YEARS OR

500 HRS.

X (*)

(2) These items should be serviced by your service dealer, unless you have the proper tools and are mechanically proficient.

Refer to the Briggs & Stratton, Vanguard Shop Manual for service procedures.

(3) For commercial use, log hours of operation to determine proper maintenance intervals.

Check Item

Tub

Tub For Cracks/Deformations

Tires For Severe Cuts/Wear

Hydraulic Oil Level (TB11G)

Hydraulic Oil (TB11G)

Hydraulic Oil System (TB11G)

Drive Chains

V-Belt (TB11G)

Bearing (TB11E)

Fastners

Table 8. Power Buggy Maintenance Schedule

OPERATION DAILY

X

Every

25 Hrs

Periodic Maintenance Interval

Every

50 Hrs

Every

100-125

Hrs

X

Every 200 Hrs

X

Clean

Check

Check

Check

Replace

Check

Clean/Lube

Check

Lube

Check

X

X

X

X

X

X

1st time

X

X

X

Once a Year


MAINTENANCE (GASOLINE)

MAINTENANCE

When performing any maintenance on the power buggy engine or electric motor, follow all safety messages and rules for safe operation stated at the beginning of this manual.

WARNING

Accidental starts can cause severe injury or death.

ALWAYS

place the ON/OFF switch in the

OFF position.

Disconnect and ground spark plug leads and disconnect negative battery cable from battery before servicing.

WARNING

Some maintenance operations may require the engine to be run. Ensure that the maintenance area is well ventilated. Exhaust contains poisonous carbon monoxide gas that can cause unconsciousness and may result in

DEATH

CAUTION

ALWAYS

allow the engine to cool before servicing.

NEVER

attempt any maintenance work on a hot engine.

NOTICE

See the engine manual supplied with your machine for appropriate engine maintenance schedule and troubleshooting guide for problems.

Perform the scheduled maintenance procedures as defined

by Table 7 and below:

DAILY

Thoroughly remove dirt and oil from the engine and control area. Clean or replace the air cleaner elements as necessary. Check and retighten all fasteners as necessary.

WIRING

Inspect the entire buggy for bad or worn electrical wiring or connections. If any wiring or connections are exposed

(insulation missing) replace wiring immediately.

PIPING AND HOSE CONNECTION

Inspect all piping, oil hose, hydraulic hose and fuel hose connections for wear and tightness. Tighten all hose clamps and check for leaks. If any hose lines are defective replace them immediately.

FUEL STRAINER (IF EQUIPPED)

1. Thoroughly clean the area around the fuel cap.

2. Remove the fuel cap from the fuel tank.

3. Next, remove, inspect and clean the fuel filter

(Figure 34) with solvent.

FUEL

CAP

GASKET

FUEL

FILTER

DANGER

DO NOT

use gasoline as a cleaning solvent to avoid creating the risk of fire or an explosion.

NOTICE

Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure to the engine. In addition, plugged cooling fins, and/or cooling shrouds removed will cause engine damage due to overheating.

FUEL

TANK

Figure 34. Fuel Strainer


SPARK PLUG

1. Remove and clean the spark plug (Figure 35), then

adjust the spark gap to 0.024~0.028 inch (0.6~0.7 mm).

This unit has electronic ignition, which requires no adjustments.


ENGINE AIR CLEANER

1. Remove the air cleaner cover and foam filter element

as shown in (Figure 37).

2. Tap the paper filter element (Figure 37) several times

on a hard surface to remove dirt, or blow compressed air [not exceeding 30 psi (207 kPa, 2.1 kgf/cm2)] through the filter element from the air cleaner case side.

NEVER

brush off dirt. Brushing will force dirt into the fibers. Replace the paper filter element if it is excessively dirty.

3. Clean foam element in warm, soapy water or nonflammable solvent. Rinse and dry thoroughly. Dip the element in clean engine oil and completely squeeze out the excess oil from the element before installing.

DANGER

DO NOT

use gasoline as a cleaning solvent to avoid creating the risk of fire or an explosion.

GAP

:

0.024 - 0.028 in.

(0.6 - 0.7 mm.)

Figure 35. Spark Plug Gap

ENGINE OIL

1. Drain the engine oil when the oil is warm as shown in

(Figure 36).

2. Unscrew the oil filler dipstick from its holder.

3. Next, remove oil drain bolt and sealing washer and allow the oil to drain into a suitable container.

4. Replace engine oil with recommended type oil as

listed in Table 6. For engine oil capacity, see Table 2

(Engine Specifications).

DO NOT

overfill.

5. Install drain bolt with sealing washer and tighten securely.

OIL FILLER

DIPSTICK

WING NUT

AIR CLEANER

COVER

FOAM FILTER

ELEMENT

BLOW COMPRESSED

AIR FROM THE

INSIDE OUT

PAPER FILTER

ELEMENT

GASKET

Figure 37. Engine Air Cleaner

DRAIN

BOLT

SEALING

WASHER

Figure 36. Draining Engine Oil


SPARK ARRESTER CLEANING (OPTIONAL)

Clean the spark arrester (Figure 38) every 6 months or

100 hours.

1. Remove the 4 mm screw (3) from the exhaust deflector

(Figure 38), then remove the deflector.

4 MM

SCREW

PROTECTOR

4 MM

SCREW

5 MM

SCREW


ADDING HYDRAULIC OIL

1. Replace hydraulic oil after every 200 hours of operation.

The reservoir tank capacity is 16.90 fl. oz. (.5 liters).

2. Visually inspect the hydraulic oil level by reading the

hydraulic oil level (Figure 40) indicated on the hydraulic

oil tank.

MOT

20W

MUFFLER

5 MM

SCREW

HYDRAULIC OIL

RESERVOIR TANK

SPARK

ARRESTOR

Figure 38. Spark Arrester

2. Remove the 5 mm screw (4) from the muffler protector, then remove the muffler protector.

3. Carefully remove carbon deposits from the spark

arrester screen (Figure 39) with a wire brush

WIRE BRUSH

FULL

COLD

Figure 40. Hydraulic Oil Reservoir Tank

3. If the hydraulic oil level is low, fill to the proper level with

20W-50 motor oil or equivalent as indicated on the tank.

4. Start the engine and read the oil level on the tank again.

If oil level is still low, add motor oil as required.

NOTICE

If adding oil to an

empty

hydraulic drive pump, oil capacity is 77.23 fl. oz. (2.28 liters)

SPARK ARRESTOR

SCREEN

Figure 39. Cleaning The Spark Arrester

4. If the spark arrester is damaged and has breaks or holes, replace with a new one.

5. Reinstall the spark arrester and muffler protector in reverse order of disassembly.


DEADMAN CONTROL CABLE ADJUSTMENT

The

deadman

cable may require adjustment at some point in time. This cable is responsible for the dis-engagement of the safety pin, the setting and releasing of the brake. To gain access to the safety pin, the access panel

must

be removed.

1. Remove the four screws (Figure 41) that secure the

rear access panel to the frame.


3. Verify that the safety pin (Figure 43) has been released

from the

pump direction bracket slot

.

PUMP

DIRECTION

BRACKET

SAFETY PIN

(RELEASED)

SLOT

1

REMOVE (2)

ACCESS P

ANEL

REMOVE (2)

Figure 41. Rear Access Panel Removal

2. With the engine

OFF

, push down on the

YELLOW

deadman lever (Figure 42) about 10~20°.

Figure 43. Safety Pin Released

4. If the safety pin has not been released from the pump

direction bracket slot, adjust the nut (Figure 44) on the

deadman lever until the safety pin clears the pump direction bracket slot.

DEADMAN LEVER

ADJUSTMENT NUT

10°~20°

DEADMAN

LEVER

10°~20°

Figure 44. Deadman Lever Adjustment Nut

Figure 42. Deadman Lever Engaged (10°~20°)


5. Release the deadman lever (Figure 45).

DEADMAN

LEVER

RELEASED


DIRECTION CONTROL CABLE ADJUSTMENTS

After some use, it may become necessary to adjust the tension on the forward and reverse control cables. Please use the following procedure to make the adjustments.

Forward/Reverse Control Cables Adjustment

1. Fully engage the deadman control lever (Figure 47).

Secure lever with a cable-tie in the closed position.

DEADMAN

LEVER

Figure 45. Deadman Lever Released (Disengaged)

6. Verify that the safety pin (Figure 46) has been properly

seated back into the pump direction bracket slot.

PUMP

DIRECTION

BRACKET

SAFETY PIN

(SET/LOCKED)

CABLE TIE

Figure 47. Securing Deadman Lever

2. Verify that the safety pin (Figure 43) has cleared the

pump direction bracket slot.

3. Fully squeeze the

forward

control lever and verify

that a 0.12~0.20 inch (3~5 mm) gap (Figure 48) exists

between the control lever and the handle bar/hand grip.

Figure 46. Safety Pin Engaged (Locked)

HAND

GRIP

0.12~0.20 IN.

(3~5 MM) GAP

FORWARD

CONTROL LEVER

Figure 48. Forward Control Lever Gap

4. If the correct gap has not been achieved, adjust the

nut (Figure 49) on the cable of the

forward lever

until the correct gap has been achieved.



5° CW

PUMP

DIRECTION

BRACKET

FORWARD CONTROL

LEVER ADJUSTMENT NUT

Figure 49. Forward Control Lever Adj. Nut

5. Once the correct gap has been established and the forward control lever is fully engaged, verify that the

pump direction bracket

(Figure 50) rotates about

15° CCW.

PUMP

DIRECTION

BRACKET

15° CCW

FORWARD

CONTROL

CABLE

REVERSE

CONTROL

CABLE

Figure 51. Pump Direction Bracket (CW 5°)

PUMP NEUTRAL SETTING

NOTICE

Lifting of the buggy will be required when making the pump neutral setting adjustments. Use two people to lift the TuffTruk buggy.

If the unit tends to creep while in the

neutral

position, adjustment of the pump neutral setting will be required.

The pump neutral setting requires that the buggy be placed on wooden blocks.

1. Lift the buggy and place wooden blocks (Figure 52) at

the front and rear of the buggy. Place blocks so that the front and rear wheels can rotate freely just above the ground.

Figure 50. Pump Direction Bracket (CCW15°)

6. If the correct bracket rotation (15°) has not been

achieved, adjust the nut (Figure 49) on the cable of

the

forward control lever

until the correct rotation has been achieved.

7. Recheck forward lever control lever gap (0.12~0.20 inch/3~5 mm).

8. Repeat the same procedure for the

reverse control lever

using 5° rotation for the pump direction bracket

(Figure 51).

FRONT

REAR

WOODEN

BLOCK

Figure 52. Wood Block Placement


NOTICE

Disconnection of the forward and reverse control cables from the cable support bracket may not be required. If the cables have

sufficient slack

, then disconnection will not be required. Disconnect these cables only if necessary.

2. If necessary, disconnect both the forward and reverse control cables from the cable support bracket as shown

in Figure 53.


5. Using a 3/16-inch allen wrench, loosen the pump

neutral setting screw (Figure 54).

PUMP DIRECTION

CONTROL BRACKET

PUMP

NEUTRAL

SCREW

(LOOSEN)

CCW CW

JAM NUT

(LOOSEN)

CABLE

SUPPORT

BRACKET

JAM NUT

(LOOSEN)

Figure 53. FWD/REV Cable Support Bracket

3. Start the engine and let idle.

4. Next, fully engage the

YELLOW

deadman control lever

(Figure 47). Secure lever with tape or rubber band in

the

closed

position.

CAUTION

When loosening the pump neutral screw or rotating the pump direction control bracket, be sure to keep

hands clear

of the V-belt and pulley. Possibility exists of entaglement.

Figure 54. Pump Neutral Setting Screw

6. Slightly move the

pump direction control bracket

(Figure 54) either CW or CCW. Tighten pump neutral

setting screw.

7. Verify if the front or rear wheels are rotating (creeping).

If buggy still creeps, repeat steps 5 and 6.

8. If the forward and reverse control cables were disconnected, reconnect to the cables to the support bracket.

9. Fully engage the forward control lever and verify that the wheels rotate between 74~78 rpm's in the forward direction.

10. Fully engage the reverse control lever and verify that the wheels rotate between 28~32 rpm's in the reverse direction.

11. Turn off engine.


FREE-WHEEL

In the event the buggy loses power a free-wheel feature has been built into the buggy so that the unit can be moved due to loss of power.

Gas Version

1.

Pull up

on the transmission bypass lever (Figure 55).

GAS

PULL

UP

MAINTENANCE (ELECTRIC)

BATTERY CHARGER

The TB11E buggy has a built-in 24 VDC battery charger.

When charging of the battery is required, perfom the following:

NOTICE

The battery charger installed on the TB11E is a Smart

Charger, it can be left connected to the batteries after full charge (green light on) without harming batteries.

The charger uses minimum power in this stand-by mode

(battery fully charged) and maintains the batteries at full charge and extends battery life.

1. Place the ignition switch key (Figure 57) on the

OFF

position.

OFF

IGNITION

SWITCH

TRANSMISSION

BYPASS LEVER

(FREE-WHEEL)

Figure 55. Transmission Bypass

Lever (Free-Wheel)

2. Next, fully squeeze the

YELLOW

deadman lever.

3. The buggy can now be moved.

Electric Version

1.

Push

and

hold

the brake bypass lever (Figure 56).

BRAKE BYPASS

LEVER (OFF)

FREE-WHEEL

PUSH AND

HOLD

OFF

AUTO

ELECTRIC

Figure 57. Ignition Switch (OFF)

2. Push the

EMERGENCY STOP

switch (Figure 58).

PUSH

EMERGENCY

STOP SWITCH

Figure 58. Emergency Stop Switch (Push)

Figure 56. Brake Bypass Lever

2. The buggy can now be moved.


3. Insert the 3-pronged blue and white battery charger power cable plug into the battery charger receptacle

as shown in Figure 59.

BATTERY CHARGER

RECEPTACLE

BATTERY CHARGER

3-PRONGED PLUG

CONNECT TO

120 VAC POWER

SOURCE

BATTERY CHARGER

POWER CABLE

Figure 59. Battery Charger Power Cable

4. Next, connect the other end of the battery charger power cable to a 120 VAC voltage source.

5. Charging of the batteries can be observed by viewing

the small window (Figure 60) on the left-hand side of

the battery box.

CHARGE

LAMP

Figure 60. Charging Light

6. The charging light is normally

orange

which changes to

green

when the battery is fully charged.


5K OHM POTENTIOMETER REPLACEMENT

The speed on the the electric buggy is controlled by a 5K ohm potentiometer. This potentiometer provides a 0~5 VDC input signal to the motor controller via pin-13. Reference wiring diagram.

Use the following procedure when installing a replacement

potentiometer. ReferenceFigure 61.

1. Lift the buggy and place wooden blocks at the front and rear of the buggy. Place blocks so that the front and rear wheels can rotate freely just above the ground

2. Remove the four screws that secure the control panel to the frame.

3. Carefully set control panel down.

4. Loosen the nut on the

deadman clevis

(Figure 61

A

) that secures the deadman cable to the throttle bracket upper spring.

5. Remove bolt, black rubber spacer and

upper

spring

(Figure 61

B

) from the deadman clevis.

6. Position deadman cable (Figure 61

C

) away from throttle bracket.

7. Unhook the clip attached to the FWD/REV clevis

(Figure 61

D

). Position the clip downward.

8. Next, remove the

lower

spring (Figure 61

E

) from the

FWD/REV clevis.

9. Remove the FWD/REV clevis (Figure 61

F

) from the throttle arm.

10. Position the FWD/REV cable (Figure 61

G

) away from throttle bracket.

11. Remove the four bolts (Figure 61

H

) that secure the throttle bracket to the frame.

12. Loosen the nut (Figure 61

I

) that secures the potentiometer to the throttle arm.

13. Slide the throttle arm (Figure 61

J

) off the output shaft of the potentiometer.

14. Remove the nut that secures the potentiometer to the

throttle bracket (Figure 61

K)

.

15. Next, unsolder the

WHITE

,

BLACK

and

BLUE

wires

connected to the potentiometer (Figure 61

L

). Mark orientation.

16. Solder the

WHITE

,

BLACK

and

BLUE

wires removed in step 15 back onto the 5K ohm replacement potentiometer in the same orientation.



5K OHM

L

POTENTIOMETER

UNSOLDER (3)

C

DEADMAN

CABLE

C

NUT

G

FWD/REV

CABLE

CLIP

D

I

NUT

CLEVIS

DEADMAN

A

UPPER

SPRING

B

THROTTLE

BRACKET

BOLT

H

NUT

THROTTLE

ARM

LOWER

SPRING

E

K

POTENTIOMETER

J

FWD/REV

CLEVIS

F

THROTTLE ADJUSTMENT

Figure 61. 5K Ohm Potentiometer Replacement

17. Install new 5K ohm potentiometer back onto throttle bracket and secure with retaining nut.

18. Reinstall throttle arm back onto output shaft of potentiometer. Do not tighten retaining nut at this time.

19. Reconnect deadman and FWD/REV cables and associated hardware back onto throttle bracket.

1. Using a small flat blade screw driver, rotate the shaft on the potentiometer

fully

counterclockwise.

2. Fully engage the deadman control lever, then fully squeeze the forward speed control lever.

3. Verify that a 4mm gap () exist between the throttle arm and the stop screw. Adjust if necessary.

4. With the deadman lever held down and the forward speed lever still fully engaged, turn the potentiometer adjustment screw slowly clockwise until the motor

clicks

. Verify that the wheels rotate forward. slowly

5. Tighten the nut (Figure 61

I

) that secures the output shaft of the potentiometer to the throttle arm.

6. Remove support blocks, and reinstall control panel.

NOTICE

Ensure when the forward speed lever is released the motor dis-engages the drive before the potentiometer arm makes contact with the stop screw.

THROTTLE

ARM

THROTTLE

BRACKET

STOP

SCREW

4 MM

GAP

Figure 62. Throttle Arm Gap (4 MM)


DRIVE CHAIN LUBRICATION

There are

three

drive chains that require lubrication at least once a year. Follow the procedure below when lubrication of the drive chains are required.

Drive Chains Lubrication

NOTICE

Lifting of the buggy will be required when lubrication of the three drive chains is required. Use two people to lift the TuffTruk buggy.

1. Pull back on the dump lever and place the tub in the dump position.

2. Next, remove the

six

bolts that secure the front drive

chain access panel (Figure 63) to the frame. Set the

bolts aside and remove access panel.

MAINTENANCE (GAS/ELECTRIC)

3. Next, remove the

four

bolts that secure the rear drive chains access panel to the frame. Set the bolts aside and remove access panel.

GAS

REAR ACCESS

PANEL

ELECTRIC

FRONT ACCESS

PANEL

Figure 64. Rear Access Panel Removal

4. Lift the buggy and place wooden blocks at the front and

rear of the buggy as shown in Figure 52. Place blocks

so that the front and rear wheels can rotate freely just above the ground.

5. Start the engine and let idle.

6. Fully squeeze the

YELLOW

deadman lever and hold down.

7. Next, slightly squeeze the

forward

speed control lever and verify that all three chains are rotating.

8. Using chain lube lubricant (Figure 65), lubricate each

rotating chain.

Figure 63. Front Access Panel Removal


FRONT

REAR


TIRES/WHEELS/LUG NUTS

Tires and wheels are very important and critical components of the buggy. When specifying or replacing the wheels, it is important that the wheels, tires, and axle are properly matched.

CAUTION

DO NOT

attempt to repair or modify a wheel. If the rim is cracked, replace the rim immediately and inspect the tire for cuts, wear, and deformations.

TIRE WEAR

The tires (Figure 67) used on the power buggy are

pnuematic. Proper inflation is 28 PSI (193 kPa). In addition, inspect the tires for cuts, wear and deformity.

CHAIN

LUBRICANT

Figure 65. Lubricating Drive Chains

9. Reinstall

all

access panels. Tighen bolts securely.

Zerk Fitting Lubrication

1. Lubricate the zerk fitting as shown in Figure 66 using

lithium base grease, grade N0.1 once a year. Apply two shots. of grease

Figure 67. Tire Inspection

2 SHOTS

Figure 66. Zerk Fitting Lubrication


LUG NUT TORQUE REQUIREMENTS

It is extremely important to apply and maintain proper wheel mounting torque on the TuffTruk. Be sure to use only the fasteners matched to the cone angle of the wheel. Proper procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts (Figure 68) in sequence.

DO NOT

torque the wheel lug nuts all the way down. Tighten

each lug nut in 3 separate passes as defined by Table 9.

Table 9. Tire Torque Requirements

480 x 8 in.

20-25

Second Pass

FT-LBS

35-40

Third Pass

FT-LBS

50-65


TUB REMOVAL/PLACEMENT

1. Place both locking levers in the

unlock

position

(Figure 69).

LOCKING LEVERS

3. After first road use, retorque all lug nuts in sequence

Check all wheel lug nuts periodically.

4

1

2

3

4

2

1

5

3

Figure 69. Locking Levers (Unlock)

2. With

two people

, lift and remove the tub (Figure 70).

Place the tub onto its side away from the unit.

CAUTION

DO NOT

attempt to lift or move the tub by yourself.

4-LUG NUTS 5-LUG NUTS

6

4

1

2

3

5

8

6

4

1

2

3

5

7

6-LUG NUTS 8-LUG NUTS

LUG NUT

TORQUE

WRENCH

PNEUMATIC

AIRGUN

Figure 68. Lug Nut Torque Sequence

Figure 70. Tub Removal



3. Orient the tub tipping bracket to the base of the tub as

shown in Figure 71.

5. Tilt the tub into its discharge position and place both locking levers in the

lock

position (Figure 73).

TUB TIPPING

BRACKET

Figure 71. Tipping Bracket Orientation

4. With

two people

, lift the tub and tipping bracket onto

the chassis (Figure 72). Make sure the tipping bracket

pivot bar rests within the tipping slots.

CAUTION

DO NOT

attempt to lift or move the tub by yourself.

LOCKING

LEVER

Figure 73. Locking Levers (Lock)

6. Place the tub in the forward position and make sure it is

secured firmly under the tub catch (Figure 74). Adjust

the tub catch if necessary.

TUB

LATCH

TIPPING BRACKET

PIVOT BAR

TIPPING

BRACKET

TIPPING SLOTS

Figure 72. Tub Placement

Figure 74. Tub Latch


TUFFTRUK BUGGY STORAGE

CAUTION

NEVER

store the power buggy with fuel in the tank for any extended period of time.

ALWAYS

clean up spilled fuel immediately.


For storage of the buggy for over 30 days, the following is recommended:

Run the engine until the gasoline in the carburetor is completely consumed.

Drain the fuel tank completely, or add STA-BIL to the fuel.

Completely drain the oil from the crankcase and refill with fresh oil.

Remove the spark plug, pour 2 or 3 cc of SAE 30 oil into the cylinder and crank slowly to distribute the oil.

Slowly rotate the engine a few times with the starter rope and install a new plug.

Pull out the starter rope slowly and stop at the compression point.

Clean the entire buggy and engine compartment.

Clean drum of all debris and foreign matter.

Cover the buggy with a plastic sheet in a moisture and dust-free location out of direct sunlight.


TROUBLESHOOTING (ENGINE)

Symptom

Diffi cult to start, fuel is available, but no spark at spark plug.

Diffi cult to start, fuel is available, and spark is present at the spark plug.

Diffi cult to start, fuel is available, spark is present and compression is normal.

Diffi cult to start, fuel is available, spark is present and compression is low.

No fuel present at carburetor.

Troubleshooting (Engine)

Possible Problem

Spark plug bridging?

Carbon deposit on spark plug?

Short circuit due to defi cient spark plug insulation?

Improper spark plug gap?

Spark plug is red?

Solution

Check gap, insulation or replace spark plug.

Clean or replace spark plug.

Check spark plug insulation, replace if worn.

Spark plug is bluish white?

No spark present at tip of spark plug?

No oil?

Oil pressure alarm lamp blinks upon starting? (if applicable)

If insuffi cient compression, repair or replace engine. If injected air leaking, correct leak. If carburetor jets clogged, clean carburetor.

Check if transistor ignition unit is broken, and replace defective unit. Check if voltage cord cracked or broken and replace. Check if spark plug if fouled and replace.

Add oil as required.

Check automatic shutdown circuit, "oil sensor".

(if applicable)

ON/OFF switch is shorted?

Ignition coil defective?

Improper spark gap, points dirty?

Set correct spark gap and clean points.

Condenser insulation worn or short circuiting?

Replace condenser.

Spark plug wire broken or short circuiting?

Check switch wiring, replace switch.

Replace ignition coil.

Wrong fuel type?

Replace defective spark plug wiring.

Flush fuel system, replace with correct type of fuel.

Water or dust in fuel system?

Air cleaner dirty?

Choke open?

Suction/exhaust valve stuck or protruded?

Piston ring and/or cylinder worn?

Cylinder head and/or spark plug not tightened properly?

Head gasket and/or spark plug gasket damaged?

No fuel in fuel tank?

Set to proper gap.

Check transistor ignition unit.

Flush fuel system.

Clean or replace air cleaner.

Close choke.

Reseat valves.

Replace piston rings and/or piston.

Torque cylinder head bolts and spark plug.

Fuel cock does not open properly?

Fuel fi lter/lines clogged?

Fuel tank cap breather hole clogged?

Air in fuel line?

Replace head and spark plug gaskets.

Fill with correct type of fuel.

Apply lubricant to loosen fuel cock lever, replace if necessary.

Replace fuel fi lter.

Clean or replace fuel tank cap.

Bleed fuel line.


TROUBLESHOOTING (ENGINE)

Weak in power, compression is proper but misfi res.

Engine overheats

Will not start, no power with key "ON". (if applicable)

Symptom

Weak in power, compression is proper and does not misfi re.

Rotational speed fl uctuates.

Recoil starter malfunctions. (if applicable)

Starter malfunctions.

Burns too much fuel.

Exhaust color is continuously "white".

Exhaust color is continuously "black".

Troubleshooting (Engine) - continued


Air cleaner dirty?

Improper level in carburetor?

Defective spark plug?

Improper spark plug?

Water in fuel system?

Solution


Check fl oat adjustment, rebuild carburetor.


Set to proper gap.

Flush fuel system and replace with correct type of fuel.


Dirty spark plug?

Ignition coil defective?

Wrong type of fuel?

Cooling fi ns dirty?

Intake air restricted?

Oil level too low or too high?

Governor adjusted incorrectly?

Governor spring defective?

Over-accumulation of exhaust products?

Wrong spark plug?

Replace ignition coil.

Replace with correct type of fuel.

Clean cooling fi ns.

Clear intake of dirt and debris. Replace air cleaner elements as necessary.

Fuel fl ow restricted?

Check entire fuel system for leaks or clogs.

Recoil mechanism clogged with dust and dirt?

Clean recoil assembly with soap and water.

Spiral spring loose?

Loose, damaged wiring?

Battery insuffi ciently charged?

Starter damaged or internally shorted?

Replace spiral spring.

Ensure tight, clean connections on battery and starter.

Recharge or replace battery.

Replace starter.

Lubricating oil is wrong viscosity?

Worn rings?

Air cleaner clogged?

Choke valve set to incorrect position?

Adjust oil to proper level.

Adjust governor.

Replace governor spring.

Check and clean valves. Check muffl er and replace if necessary.

Replace spark plug with manufacturer's suggested type.

Replace lubricating oil with correct viscosity.

Replace rings.


Adjust choke valve to correct position.

Carburetor defective, seal on carburetor broken?

Poor carburetor adjustment, engine runs too rich?

ON/OFF device not activated ON?

Replace carburetor or seal.

Adjust carburetor.

Battery disconnected or discharged?

Ignition switch/wiring defective?

Turn on ON/OFF device.

Check cable connections. Charge or replace battery

Replace ignition switch. Check wiring.


TROUBLESHOOTING (GAS)

Symptom

Loss of Power.

Troubleshooting (Power Buggy Gas)


FWD/REV speed cables out of adjustment?

Solution

Adjust FWD/REV speed control cables. Replace cables if necessary

Hydraulic drive pump defective?

Hydraulic oil level low?

Low engine RPM?

Defective V-belt?

Check or replace hydraulic drive pump.

Check hydraulic oil level. Add oil if necessary.

Check engine speed.

Check or replace V-belt.


Adjust FWD/REV speed control cables.

Loss of Travel Speed.

Parking brake in free-wheel position?

Hydraulic drive pump defective?

Place parking brake lever in set (down) position

Check or replace hydraulic drive pump.

System Operating Hot.

Hydraulic oil level low?

System jerky when started.

Diffi cult to steer.

Defective hydraulic drive pump?

Low tire pressure?

Parking brake will not hold. Pump neutral setting incorrect?

Check hydraulic oil level add hydraulic oil if necessary.

Defective cooling fan?

Inspect cooling fan, replace if necessary.


Adjust FWD/REV speed control cables.

Check drive pump, replace if necessary.

Check tire pressure.

Adjust pump neutral setting.

Diffi culty in stopping

Engine will not start.

.

Deadman lever out of adjustment?

Pump neutral setting incorrect?

Low on fuel or fuel tank empty?

Engine ON/OFF switch in OFF position?

Fuel Shut-off valve CLOSED?

Adjust deadman lever.

Adjust pump neutral setting.

Add fuel.

Set engine ON/OFF switch to ON position.

Open Fuel shut-off valve.


TROUBLESHOOTING (ELECTRIC)

Symptom

Loss of Power.

Loss of Travel Speed.

System jerky when started.

Diffi cult to steer.

Parking brake will not hold.

Diffi culty in stopping

.

Electric motor will not start.

Troubleshooting (Power Buggy Electric)


Defective motor controller?

Solution

Check or replace motor controller.

125A main fuse blown?

Check or replace fuse.

10A ignition fuse blown?

Emergency Stop Switch open?

Low electric motor RPM?

Defective batteries?


CLOSE

switch. Pull to close.

Check electric motor voltage.

Defective contactor?

FWD/REV speed cable signal not present?

REV speed switch signal not present?

Parking brake in free-wheel position?


Check or replace batteries.

Check or replace contactor.

Check or replace 5K ohm potentiometer.

Check or replace switch inside reverse lever.

Place parking brake lever in set (AUTO) position.

Check or replace motor controller/software.

FWD/REV speed signal intermittent?

Low tire pressure?

Defective damper or steering rod?

Defective electric motor?


Defective deadman microswitch?

Defective brake motor?


Check or replace 5K ohm potentiometer.

Check tire pressure.

Check or replace damper or steering rod.

Check or replace electric motor.


Check or replace microswitch.

Check or replace electric motor.



125A main fuse blown?

10A ignition fuse blown?

Emergency Stop Switch open?

Defective batteries?

Defective contactor?

Defective ignition switch?

Check or replace motor controller.



Close switch. Pull to close.

Check or replace batteries.

Check or replace contactor.

Check or replace ignition switch.


ERROR CODES

DIAGNOSTICS

NOTICE

The Curtis 1229 controller is not repairable in the field.

Please contact your nearest Multiquip Authorized

Service Center (ASC) for repair or replacement.

ERROR

CODE

The Curtis1229 controller detects a wide variety of faults or error conditions. Diagnostic information will be shown

on the Curtis 3100R diagnostic display (Figure 75). Error

or faults will be displayed in the format “Er ##”.

The error code shown in Figure 75 is an

encoder

failure

(Er 18). Reference the error code table shown below for additional codes.

Some errors may be corrected by simply turning the ignition key off, then back on and see if the fault clears. If that does not work turn the ignition to the off position and remove the

35-pin connector from the controller.

Figure 75. Curtis 3100 Diagnostic Gauge

Check the connector for corresion or damage, clean if necessary and reinsert. If that does not correct the problem, please contact your nearest Multiquip Authorized Service

Center (ASC) for repair or replacement.

Error Codes

1 HW Failsafe

2 PLD Clock Fail

29 Supervisor SW 4 Fault

30 Supervisor SW 5 Fault

76 Driver 5 Overcurrent

77 Driver 6 Fault

9 Calibration Reset 31 Supervisor KSI Voltage Fault 78 Driver 6 Overcurrent

10 Main Brake Driver Overcurrent 32 Supervisor Motor Speed Fault 79 Correlation Fault

11 Main Driver Open Drain

12 EMR Redundancy

13 EEPROM Failure

15 Main Contactor Dropped

16 Current Sensor

17 Main Contactor Welded

33 Supervisor Dir Check Fault

34 External Supply Fault

36 EM Brake Driver Open Drain

37 EM Brake Driver On

41 Pot 1

42 Pot 2

80 HPD Sequencing

81 Parameter Change

82 NV Memory Fault

90 Motor Temp Hot Cutback

92 Motor Open

93 Controller Overcurrent

18 Encoder

19 PDO Timeout

20 Supervisor Comms

21 Supervisor Watchdog

22 Supervisor Pot 1 Fault



25 Supervisor Pot H Fault

26 Supervisor SW1 Fault

43 Pot 3

50 Severe Undervoltage

54 Precharge Failed

70 Driver Shorted

71 Driver 3 Fault


73 Driver 4 Fault

94 VBAT Too High

95 Controller Undertemp Cutback

52 Controller Severe Undertemp 96 Stall Detected

53 Controller Severe Overtemp 97 Controller Overtemp Cutback

98 Overvoltage Cutback

99 Undervoltage Cutback

101 User Fault Estop

102 User Fault Severe




75 Driver 5 Fault


A

B

C D

ELECTRONIC COMPONENT LOCATOR

TB11E

ELECTRIC BUGGY

O

M

L

K

J

E

F

J1

N

H

G

I

P


WIRING DIAGRAM

12 VDC PWR

DIAGNOSTIC

GAUGE

2

4

A

1

3

GND.

D

EMERGENCY

STOP SWITCH

RED

A

1

10A FUSE

RED

IGNITION

SWITCH

C

30

75

15

B

D

2

RED

CAN LO

RED/YEL

9

SPEED CONTROLLER

CONNECTOR J1

YEL/PURPLE

1

12

YEL

2

16

17

BLUE/YEL

2

4

GRN/YEL

1

3

3

4

5

SERIAL

PORT

CABLE

6

8

10

B

13

18

20

CONTACTOR

SOLENOID

RED

K1-1

RED

K1-2

RED

I

GRN

BRN

PURPLE

GRAY

ORANGE

WHT

F

RED

BLK/WHT

BLK

C

RED

B

12 VDC PWR

CONTACTOR

COIL

K1

12 VDC

SPLICE

E

PINK (COIL RETURN)

ORANGE

M

RED

M

BLK/WHT

F

RED

F

A2

A1

F

F

BLUE

MOTOR

BRAKE

K

B+

M1

B-

M2

D

BLK/YEL

6-PIN

MOLEX

CONNECTOR

BLK

M

1

F

1

N

BLUE

2 2

WHT

NC

GRAY

3

5

4

6

3

4

5

6

NC

GRAY

F

BROWN

REVERSE

SWITCH

NC

O

BLUE

M

NO COM

M

BROWN

DEADMAN

BRAKE MICROSWITCH

NC

G

COM

NO

RED

J1

J

24 VDC

ELECTRIC

MOTOR

1300W

I

CURTIS 1229 MOTOR

CONTROLLER

POS

WHT

NEG

P

12V BATTERY #1

H

BLK

BLK

A

FUSE

125A

BLK

L

SERIES

CONNECTION

POS

NEG

P

12V BATTERY #2

RED/YEL

F

ANALOG GND.

WHT

3-WIRE 5K OHM

POTENTIOMETER

1

F

0~5V IN

BLK

2

5V OUT BLUE

3

BLK

GND

M

C

CONNECT

TO 120 VAC

POWER SOURCE

GRN

BATTERY

CHARGER

M

NOTES:

1

BLUE SQUARE

WHITE LETTERING DENOTES INTER-CONNECTIONS POINTS

2

BLACK CIRCLE

WHITE LETTERING DENOTES COMPONENT LOCATION.

REFERENCE COMPONENT LOCATOR OPPOSITE PAGE.


OPERATION MANUAL

UNITED STATES

Multiquip Inc.

(310) 537- 3700

6141 Katella Avenue Suite 200

Cypress, CA 90630

E-MAIL: [email protected]

WEBSITE: www.multiquip.com

HERE’S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL

NUMBER ON-HAND WHEN CALLING

CANADA

Multiquip

(450) 625-2244

4110 Industriel Boul.

Laval, Quebec, Canada H7L 6V3

E-MAIL : [email protected]

© COPYRIGHT 2019, MULTIQUIP INC.

Multiquip Inc , the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.

This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.

The information and specifi cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published in this publication at any time without notice and without incurring any obligations.

Your Local Dealer is:

No results