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1 apr 2022 — associated parts manual, visit our website at: www.multiquip.com ... PAGE 2 — TB12SE/TB12PE TUFFTRUK POWER BUGGY • OPERATION MANUAL — REV. ... 33.40 (848).
OPERATION MANUAL MODEL TB12SE/TB12PE (EB500) WALK-BEHIND POWER BUGGY (24VDC, 750W ELECTRIC MOTOR) Revision #0 (04/01/22) 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. TB12SE/TB12PE TuffTruk Walk-Behind Power Buggy Safety Information................................................. 3-6 Specifications (Buggy).............................................. 7 Specifications (Electric Motor).................................. 8 Noise And Vibration.................................................. 9 Dimensions............................................................. 10 General Information................................................ 11 Components...................................................... 12-13 Inspection.......................................................... 14-15 Operation .......................................................... 16-19 Maintenance...................................................... 20-26 Error Codes....................................................... 28-29 Troubleshooting...................................................... 30 Electronic Component Locator .............................. 32 Wiring Diagram....................................................... 33 TABLE OF CONTENTS PAGE 2 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) 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 specifically 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 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 Addresses practices not related to personal injury. SAFETY INFORMATION 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 fitting 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 influence of drugs or alcohol. 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. NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older. Whenever necessary, replace nameplate, operation and safety decals when they become difficult read. Manufacturer does not assume responsibility for any accident due to equipment modifications. Unauthorized equipment modification will void all warranties. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 3 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 fire extinguisher. ALWAYS know the location of the nearest first 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 fire department. This information will be invaluable in the case of an emergency. TUFFTRUK SAFETY DANGER NEVER operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fire could result causing severe bodily harm or even death. WARNING 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. SAFETY INFORMATION 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 floor. 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. PAGE 4 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) 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 DO NOT exceed payload capacity of TuffTruk. 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, DO NOT start engine on a sloping surface. Ensure that the speed control levers works freely and returns to the stop position. DO NOT start electric motor unless speed control linkage is working properly. Make sure that the tires are inflated 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 operate or tow the TuffTruk in traffic or on public roads. 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. SAFETY INFORMATION 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. BATTERY SAFETY DANGER DO NOT drop the battery. There is a possibility that the battery will explode. DO NOT expose the battery to open flames, sparks, cigarettes, etc.The battery contains combustible gases and liquids. If these gases and liquids come into contact with a flame 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. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 5 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. 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 unit before transporting. When transporting of the TuffTruk is required, place the TuffTruk on a flat 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 flat (horizontal) position and securely latched. SAFETY INFORMATION 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. 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. 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. PAGE 6 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) SPECIFICATIONS (BUGGY) Table 1. Specifications (TuffTruk) Model TB11SE/TB12PE Maximum Weight Capacity 529 lbs. (239.9 kg) Maximum Payload Weight 1,100 lbs. (498.9 kg.) Bucket/Tub Capacity 12.0 cu. ft. Water Level (.44 cu. yd.) Bucket/Tub Capacity (Option) 7.0 cu. ft. Water Level (.26 cu. yd.) Bucket/Tub Material Steel/Polyethylene Drive 24 VDC Electric Motor Speed Forward Up to 4.0 mph. (6.43 km/h) Speed Reverse Up to 1.5 mph. (2.42 km/h) Steering Radius Outside Dia. 56 in. (1,422 mm) Brake System Dead Man Handle Dump Control Mechanical Dump and Manual Return Discharge Height 2.0 in. (50.8 mm) Gradeability Slope (Up/Down) 25° Gradeability Lateral (Side-Side) 6° Battery Type 12V 27 AGM Deep Cell, 550 CCA @ 0°F 77Ah@5 Hr./89Ah@20 Hr. Capacity@25A 158 minutes Battery (LxWxH) Battery Weight Pneumatic Tires Pneumatic Tire Pressure 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) TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 7 SPECIFICATIONS (ELECTRIC MOTOR) Table 2. Electric Motor Specifications Model AMER Type Permanent Magnet DC Electric Motor 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. Curtis 1228 Controller Electric 2900 24 VDC 750 X 2 (1500W) 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) PAGE 8 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) NOISE AND VIBRATION Table 3. Noise and Vibration Emissions Model TB12SE/TB12PE Guaranteed ISO 11201:2010 Based Sound Pressure Level at Operator Station in dB(A)a 56 Guaranteed ISO 3744:2010 Based Sound Power Level in dB(A)b 76 Hand-Arm Vibration Per ISO 5349-1:2001 in m/s2 A(8) 2.5 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 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/s2 A(8). The daily exposure limit value is 5 m/s2 A(8). TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 9 SIDE VIEW C DIMENSIONS REAR VIEW J A B G TOP VIEW D E F H I N O OUTSIDE DIAMETER TURNING RADIUS K M L Table 4. Dimensions Reference Letter Dimension in. (mm) A 34.20 (869) B 16.50 (419) C 70.30 (1,786) D 41.90 (1,064) E 39.20 (995) F 10.9 (277) G 7.40 (188) H 28.60 (726) I 53.0 (1,340) J 33.40 (848) K 5.50 (140) L 33.40 (848) M 6.37 (162) N 56.0 (1,22) Figure 1. TB12SE/PE Dimensions PAGE 10 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) The Multiquip Walk-Behind TB12SE and TB12PE electric power buggies 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. The maximum forward speed of the electric driven buggy is rated at 4.0 mph. (6.43 km/h). Maximum reverse speed 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. ELECTRIC POWER PLANT The buggy is equiped with two 750 watt permanent magnet 24 VDC electric motors connected in series that produce a total output of 1500 watts. For additional information, reference Table 2. MOTOR CONTROLLER The electric models are 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. GENERAL INFORMATION AUXILIARY CONNECTIONS (OPTIONS) There are two auxiliary connection ports on the unit, they are labeled AUX 1 and AUX 2. If desired they can be used for horn and light additions. DIAGNOSTIC GAUGE Both electric models are 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. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 11 COMPONENTS 45 1 2 3 6 17 9 8 7 18 19 22 16 23 24 10 11 12 13 14 15 21 20 25 Figure 2. TuffTruk Walk-Behind Power Buggy Components PAGE 12 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) 1. Tub or Bucket -- Used for the transportation of material. Tub holds approximately 12.0 cubic feet (0.44 cubic yards) of water. 2. Lifting Point -- Attach a suitable lifting strap to these points when lifting of the buggy is required. 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. Deadman Control Lever -- Red 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. 5. 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 electric models. 6. Reverse Control Lever Signal Cable -- 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. 7. Battery Charger Cable -- Plug battery charger cable plug into a 120 VAC power source. 8. Tires -- Unit uses pneumatic tires. Reference Table 1 for tire size. 9. Tipping Bracket Pivot Bar -- Attach this bar to the buggy frame to tip tub. Be sure to lock in place (locking levers). 10. Deadman Microswitch -- When activated sends a +12 VDC signal (J1-3) to the motor controller to release the brake. Microswitch is located inside handle. 11. Dump Control Lever -- Push the lever forward to place the tub in the dump position (vertical). 12. Free-Wheel Brake Bypass Switch -- Momentary toggle switch. Allows the buggy to be moved with the electric motor brakes disengaged COMPONENTS 13. Battery/Diagnostic Gauge -- Uses a Curtis Model 3100R Gauge Display. Displays battery voltage and fault codes. CAN bus compatible. 14. Emergency Stop Switch -- In the event of an emergency, push this button to shutdown the electric motor. 15. Electric Motor (Front) -- Uses a 24 VDC, 750 watt electric motor. 16. Electric Motor (Rear) -- Uses a 24 VDC, 750 watt electric motor. 17. Ignition/Key -- When activated allows the unit to be started. 18. Contactor -- Heavy duty relay used for the switching of the ON and OFF +12 VDC power required for the Curtis Model 1229 motor controller. Works in conjunction with the contactor solenoid. 19. Fuse Box -- Provides protection for various electrical circuits. Reference wiring diagram in the manual. 20. Contactor Fuse -- 100 amp fuse that provides protection for the electric motor. 21. Contactor Solenoid (Coil) -- When energized (coil), allows +12 VDC power to transfered to the Curtis Model 1229 motor controller via the K1-1and K1-2 contacts. 22. 5K OHM Potentiometer -- Provides signal for speed sensor. 23. Motor Speed Controller -- Unit uses a Curtis Model 1229 Controller. Requires a 24 VDC input. Interfaces with CAN bus applications. 24. Battery Charger (Electric) -- When activated, charges both 12-volt batteries.This feature is only on the TB11E model. 25. Battery -- Uses two 12 volt batteries connected in series (24 volts). Always use gloves and eye protection when handling the batteries. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 13 BEFORE STARTING CAUTION NEVER disable or disconnect the emergency stop switch. It is provided for operator safety. Injury may result if it is disabled, disconnected or improperly maintained. BATTERY 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. INSPECTION Battery Cable Installation ALWAYS be sure the battery cables (Figure 3) are properly connected to the battery terminals as shown below. The batteries are connected in series. 24 VDC TOTAL JUMPER SERIES CONNECTION POSITIVE RED NEGATIVE BA1T2TVEORLYT 1 BLACK BA1T2TVEORLYT 2 Figure 3. Battery Series Connections 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. PAGE 14 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) TIRE CHECK Check for worn or defective tires (Figure 4). Replace any defective or worn tires immediately. Figure 4. Tire Wear 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. INSPECTION 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. 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 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. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 15 STARTING THE BUGGY The following steps outline the procedure for starting the electric power buggy. 1. Located on the control panel of the buggy, is the emergency stop button (Figure 5). Pull this button outward to start the electric motor. EMERGENCY STOP SWITCH 2 OPERATION "DEADMAN" LEVER HOLD DOWN Figure 7. Deadman Lever 4. Slightly squeeze the forward/reverse speed control lever (Figure 8) until the buggy begins to move in a forward direction. 1 230v / 110v 50Hz / 60Hz Figure 5. Emergency Stop Switch (Closed) 2. Place the ignition key (Figure 6) 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. IGNITION SWITCH DIAGNOSTIC GAUGE 2 1 230v / 110v 50Hz / 60Hz FORWARD/REVERSE SPEED CONTROL LEVER Figure 8. Forward/Reverse Speed Control Lever (Electric) 5. 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. 6. Squeeze the reverse control lever signal cable (Figure 9) and hold down. BATTERY GAUGE LOW BATTERY LEVEL SIGNAL CABLE Figure 6. Ignition Key (Start) 3. With the electric motor running, fully squeeze the RED deadman lever (Figure 7) 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. REVERSE SPEED CONTROL LEVER Figure 9. Reverse Control Lever Signal Cable 7. Slightly squeeze the forward/reverse speed control lever (Figure 8) until the buggy begins to move in a reverse direction. PAGE 16 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) CAUTION Avoid sudden and quick turns. When steering, turn the handle bar slowly. ALWAYS face the controls when traveling. STEERING To steer the buggy, use the handle bar in front of the unit. 1. To turn left (Figure 10) when traveling in the forward direction, turn the handle bar clockwise. TURN HANDLE BAR CLOCKWISE TO STEER BUGGY TO THE LEFT LEFT Figure 10. Steering the Buggy (CW-Left) 2. To turn right (Figure 11) 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 CAUTION DO NOT steer the buggy left or right when traveling up or down on a grade. Travel in a straight path. 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 12) . DO NOT travel on steeper slopes. To determine the % grade of your path of travel, use the formula and graph in Figure 12. 2. Lateral side to side travel cannot exceed 6°. PERCENT GRADE PERCENT GRADE . 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 45° 357°0% 2455° % MAX 10% 6° 45° 357°0% 10% 6° MAX 0 5 10 15 20 25 30 0 5 10 15 20 25 30 100% 100% 40 35 50 55 60 GRADE 65 70 75 (DEGREES) 80 85 90 DISTANCE (D) 45 DIRECTION OF TRAVEL LEVEL BASE LINE % GRADE = 100 (H¸ D) 50 55 60 GRADE 65 70 75 (DEGREES) 80 85 90 DISTANCE (D) 45 40 35 ODFIRTERCATVIOENL % GRADE = 100 (H¸ D) LEVEL BASE LINE HEIGHT (H) HEIGHT (H) Figure 12. Determining Grade of Slope Figure 11. Steering the Buggy (CCW-Right) TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 17 NOTICE The possibility of tipping (Figure 13A) exist when transporting heavy loads. ALWAYS transport heavy loads as shown in Figure 29B. A OPERATION TUB (BUCKET) DUMPING 1. To place the tub in the dump position (Figure 14) pull back on the dump lever and release. The tub will automatically rotate to the vertical position and dump its contents. DUMP LEVER WARNING TIPPING OF BUGGY CAN OCCUR TuffTruk B 25° MAX. CORRECT DIRECTION FOR TRAVELING UP OR DOWN A SLOPE Figure 13. Slope Travel Direction Figure 14. 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 15) and push down. Figure 15. Tub Horizontal Position PAGE 18 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) NORMAL SHUTDOWN 1. Release the RED 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 1. Push the EMERGENCY STOP switch (Figure 16). EMERGENCY STOP SWITCH 2 1 230v / 110v 50Hz / 60Hz Figure 16. Emergency Stop Switch (Push) OPERATION TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 19 MAINTENANCE Check Item Tub Tub For Cracks/Deformations Tires For Severe Cuts/Wear Fastners Table 5. Power Buggy Maintenance Schedule Periodic Maintenance Interval OPERATION DAILY Every Every 25 Hrs 50 Hrs Every 100-125 Hrs Every 200 Hrs Clean X X Check X Check X Check X PAGE 20 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) BATTERY CHARGER Both buggie models have a built-in 24 VDC battery charger. When charging of the battery is required, perfom the following: NOTICE The battery charger installed 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 17) on the OFF position. OFF ISGWNIITTICOHN Figure 17. Ignition Switch (OFF) 2. Push the EMERGENCY STOP switch (Figure 18). MAINTENANCE 3. Remove the battery charger power cable from the storage compartment as shown in Figure 19. 4. Next, connect the battery charger power cable to a 120 VAC power source. BATTERY CHARGER POWER CABLE STORAGE COMPARTMENT BATTERY CHARGER POWER CABLE CONNECT TO 120 VAC POWER SOURCE Figure 19. Battery Charger Power Cable 5. Charging of the batteries can be observed by viewing the small window (Figure 20) on the left-hand side of the battery box. The charging light is normally ORANGE which changes to GREEN when the batteries are fully charged. PUSH EMERGENCY STOP SWITCH Figure 18. Emergency Stop Switch (Push) CHARGE LAMP 5203H0zv//6101H0zv Figure 20. Charging Light TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 21 MAINTENANCE I 5K OHM POTENTIOMETER E BOLT UNSOLDER (3) F NUT H NUT POTENTIOMETER G THROTTLE ARM B SPRING A CLIP C FWD/REV SPEED CLEVIS D FWD/REV CABLE Figure 21. 5K Ohm Potentiometer Replacement 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. Reference Figure 21. 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. Unhook the clip attached to the FWD/REV speed clevis (Figure 21Figure 21A). Position the clip downward. 5. Next, remove the spring (Figure 21B) from the FWD/REV speed clevis. 6. Remove the FWD/REV speed clevis (Figure 21C) from the throttle arm. 7. Position the FWD/REV cable (Figure 21D) away from throttle bracket. 8. Remove the two bolts (Figure 21E) that secure the throttle bracket to the frame. 9. Loosen the nut (Figure 21F) that secures the potentiometer to the throttle arm. 10. Slide the throttle arm (Figure 21G) off the output shaft of the potentiometer. 11. Remove the nut that secures the potentiometer to the throttle bracket (Figure 21H). 12. Next, unsolder the WHITE, BLACK and BLUE wires connected to the potentiometer (Figure 21I). Mark orientation. 13. Solder the WHITE, BLACK and BLUE wires removed in step 12 back onto the 5K ohm replacement potentiometer in the same orientation. 14. Install new 5K ohm potentiometer back onto throttle bracket and secure with retaining nut. 15. Reinstall throttle arm back onto output shaft of potentiometer. Do not tighten retaining nut at this time. 16. Reconnect the FWD/REV speed cable and associated hardware back onto throttle bracket. PAGE 22 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) THROTTLE ADJUSTMENT 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 (Figure 22) 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 21H) 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 BRACKET MAINTENANCE FREE-WHEELING NOTICE Battery must be sufficiently charged in order for the brake bypass switch to operate. In the event the buggy needs to be moved with the electric motors OFF or not working, please follow the procedure below: 1. Turn ignition key to the ON position (Figure 23). 2. Push upwards and hold the brake bypass momentary switch (Figure 23). ELECTRONIC BRAKE MOMENTARY OVERRIDE SWITCH 2 1 230v / 110v 50Hz / 60Hz STOP SCREW THROTTLE ARM Figure 23. Brake Bypass Momentary Switch 3. The buggy can now be moved. 4 MM GAP Figure 22. Throttle Arm Gap (4 MM) TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 23 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 24) used on the power buggy are pnuematic. Proper inflation is 28 PSI (193 kPa). In addition, inspect the tires for cuts, wear and deformity. MAINTENANCE 3. After first road use, retorque all lug nuts in sequence Check all wheel lug nuts periodically. 1 4 3 2 4-LUG NUTS 1 4 3 2 5 5-LUG NUTS 1 6 3 4 5 2 1 6 3 8 7 4 5 2 6-LUG NUTS 8-LUG NUTS LUG NUT TORQUE WRENCH PNEUMATIC AIRGUN Figure 24. Tire Inspection 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 25) 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 6. Table 6. Tire Torque Requirements Wheel Size First Pass FT-LBS Second Pass Third Pass FT-LBS FT-LBS 480 x 8 in. 20-25 35-40 50-65 Figure 25. Lug Nut Torque Sequence TUB REMOVAL/PLACEMENT 1. Place both locking levers in the unlock position (Figure 26). LOCKING LEVERS Figure 26. Locking Levers (Unlock) 2. With two people, lift and remove the tub (Figure 27). Place the tub onto its side away from the unit. PAGE 24 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) CAUTION DO NOT attempt to lift or move the tub by yourself. MAINTENANCE 4. With two people, lift the tub and tipping bracket onto the chassis (Figure 29). Make sure the tipping bracket pivot bar rests within the tipping slots. CAUTION DO NOT attempt to lift or move the tub by yourself. Figure 27. Tub Removal 3. Orient the tub tipping bracket to the base of the tub as shown in Figure 28. TIPPING BRACKET TIPPING LOCATION SLOTS TIPPING BRACKET PIVOT BAR TUB TIPPING BRACKET Figure 28. Tipping Bracket Orientation Figure 29. Tub Placement 5. Tilt the tub into its discharge position and place both locking levers in the lock position (Figure 30). TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 25 MAINTENANCE TUB LATCH LOCKING LEVER Figure 30. Locking Levers (Lock) 6. Place the tub in the forward position and make sure it is secured firmly under the tub catch (Figure 31). Adjust the tub catch if necessary. Figure 31. Tub Latch TUFFTRUK BUGGY STORAGE For storage of the buggy for over 30 days, the following is recommended: Clean the entire buggy. Clean tub of all debris and foreign matter. Cover the buggy with a plastic sheet in a moisture and dust-free location out of direct sunlight. PAGE 26 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) AGM BATTERY CHARGING To maximize the life of your AGM battery (), it is important that it is properly charged. As with all lead-acid batteries, both over- and under-charging an AGM battery will result in shortened service life. The AGM batteries are sealed for life units and do not require any fluid top up. 24 VDC TOTAL JUMPER SERIES CONNECTION POSITIVE RED NEGATIVE BA1T2TVEORLYT 1 BLACK BA1T2TVEORLYT 2 Figure 32. Battery Series Connections The TB12SE and TB12PE power buggies are equipped with an on-board SMART charger (Figure 33) which maintains the battery full charge condition without resulting in over charging. Figure 33. Battery Charger MAINTENANCE Charging System Inspection The charger's AC power cord should be free of breaks or cuts and the wall plug socket should be clean and free from debris. The cable connectors from the on-board charger should be clean and properly mate with the battery terminals to ensure a sound connection. Battery Inspection Check battery cables are not damaged. Connectors should be free of corrosion. Make sure battery cable post or eyelet connectors are tight to avoid arcing. Charging Guidelines When the batteries have been discharged to ¼ full as indicated on the battery gauge it is time to have the batteries fully charged. Plug the on-board battery charger power cord into a 120 VAC power outlet. Allow batteries to complete a full charge and do not disconnect until fully charged. Once fully charged, the on-board SMART battery charger will indicate a GREEN status light indicating that the batteries are fully charged. NOTICE The charging light is normally ORANGE which changes to GREEN when the batteries are fully charged. DO NOT charge batteries i.e. if the batteries have only discharged to ¾ full as indicated on the battery gauge. There is no need to connect the battery charger power cable to the AC power outlet. It is recommended to use the buggy until the batteries have discharged to ¼ full as indicated on the battery gauge, then place the batteries into a full charge cycle. ALWAYS charge batteries in a well ventilated area as gasses (fumes) may be released through the pressure relief valve if the batteries are excessively over-charged. NEVER charge a frozen battery. Ideal charging temperatures: 32°F to 104°F (0°C to 40°C) TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 27 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. The Curtis1229 controller detects a wide variety of faults or error conditions. Diagnostic information will be shown on the Curtis 3100R diagnostic display (Figure 34). Error or faults will be displayed in the format "Er ##". The error code shown in Figure 34 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. ERROR CODE Figure 34. 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 29 Supervisor SW 4 Fault 76 Driver 5 Overcurrent 2 PLD Clock Fail 30 Supervisor SW 5 Fault 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 33 Supervisor Dir Check Fault 80 HPD Sequencing 12 EMR Redundancy 34 External Supply Fault 81 Parameter Change 13 EEPROM Failure 36 EM Brake Driver Open Drain 82 NV Memory Fault 15 Main Contactor Dropped 37 EM Brake Driver On 90 Motor Temp Hot Cutback 16 Current Sensor 41 Pot 1 92 Motor Open 17 Main Contactor Welded 42 Pot 2 93 Controller Overcurrent 18 Encoder 43 Pot 3 94 VBAT Too High 19 PDO Timeout 50 Severe Undervoltage 95 Controller Undertemp Cutback 20 Supervisor Comms 52 Controller Severe Undertemp 96 Stall Detected 21 Supervisor Watchdog 53 Controller Severe Overtemp 97 Controller Overtemp Cutback 22 Supervisor Pot 1 Fault 54 Precharge Failed 98 Overvoltage Cutback 23 Supervisor Pot 2 Fault 70 Driver Shorted 99 Undervoltage Cutback 24 Supervisor Pot 3 Fault 71 Driver 3 Fault 101 User Fault Estop 25 Supervisor Pot H Fault 72 Driver 3 Overcurrent 102 User Fault Severe 26 Supervisor SW1 Fault 73 Driver 4 Fault 27 Supervisor SW2 Fault 74 Driver 4 Overcurrent 28 Supervisor SW3 Fault 75 Driver 5 Fault PAGE 28 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) ERROR CODES Troubleshooting (Error Codes) The machine controller detects a wide variety of faults or errors. Diagnostic information can be obtained on the 3100R fuel gauge display where an error code in the format "Err ##". The troubleshooting chart below describes the error code faults and their possible causes. Whenever a fault is encountered the first action should be to turn off the ignition and push in the E-stop button. Then pull out the E-stop button and turn the ignition back on to see if the fault clears. This is the RESET procedure: If the error code does not clear after the machine RESET, turn off the ignition switch and remove the 35-pin connector. Check the connector for correction or damage, clean it if necessary, and reinsert it. If the error is still seen then the wiring and connections on the machine should be checked for breakages or loose connections. The table below should be used as a reference once the above checks have been carried out. Error Code Symptom Possible Problem Solution 1 HW fail-safe Motor fault voltage (hardware failure) Motor voltage does not correspond to throttle request? Check for short in motor or motor wiring. 10 Main brake driver over current. Short circuit or overloaded controller driver? Check brake controller driver. Reference Curtis controller owner's manual. 15 Main current dropped. Main contactor failed to open? Clean the contactor switch. 17 Main contactor welded. Main contactor fault / failed to close? Replace contactor. 33 Supervisor DIR check fault. Program issue? If fault is on an external signal, check that signal first. If no problem with the external signal, likely indicates an internal controller fault. Reference Curtis controller owner's manual 34 External supply fault. Under voltage? Check control wiring circuit, potentiometer wiring in particular. 36 EM-brake driver open drain. Hold voltage set at 90%? Check brake electrical connectors. Check continuity. Replace motor brake if failed. 54 Pre-charge failed/fault. Low battery voltage? Check battery voltage. 25V (11/12V per battery) is good condition, 22V (9/10V per battery) or lower is bad battery condition. Short circuit on traction motor outputs? 80 HPD sequencing HPD fault present > 10 seconds. Misadjusted throttle? Broken throttle potentiometer or throttle mechanism? Adjust. See maintenance section. Replace. 92 Traction motor open / not connected. Controller cannot see the motor. Short circuit in the motor? Check the resistance across the motor leads. 99 Undervoltage cutback. Battery voltage < undervoltage threshold? Check connection at battery or controller. Check no corrosion on the battery terminals. Quick checks if no reading on the fuel gauge and the machine does not operate: 1. Check 10-amp ignition fuse located on the backside of the control panel. Reference 'Electronic Component Locator" drawing. 2. Check 100-amp main fuse*located on the backside of the control panel. Reference 'Electronic Component Locator" drawing. 2. When changing the 100-amp fuse, ensure that the positive battery cable is fully disconnected. Electrical maintenance should be carried out by a qualified person. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 29 TROUBLESHOOTING Symptom Loss of Power. Loss of Travel Speed. System jerky when started. Difficult to steer. Parking brake will not hold. Difficulty in stopping. Electric motor will not start. Troubleshooting Possible Problem Defective motor controller? 100A main fuse blown? 10A ignition fuse blown? Emergency Stop Switch open? Low electric motor RPM? Defective batteries? Defective contactor? FWD/REV speed cable signal not present? REV speed switch signal not present? Defective motor controller? FWD/REV speed signal intermittent? Low tire pressure? Defective damper or steering rod? Defective electric motor? Defective motor controller? Defective deadman microswitch? Defective brake motor? Defective motor controller? Defective motor controller? 100A main fuse blown? 10A ignition fuse blown? Emergency Stop Switch open? Defective batteries? Defective contactor? Defective ignition switch? Solution Check or replace motor controller. Check or replace fuse. Check or replace fuse. CLOSE switch. Pull to close. Check electric motor voltage. Check or replace batteries. Check or replace contactor. Check or replace 5K ohm potentiometer. Check or replace switch inside reverse lever. Check or replace motor controller/software. Check or replace 5K ohm potentiometer. Check tire pressure. Check or replace damper or steering rod. Check or replace electric motor. Check or replace motor controller/software. Check or replace microswitch. Check or replace electric motor. Check or replace motor controller/software. Check or replace motor controller. Check or replace fuse. Check or replace fuse. Close switch. Pull to close. Check or replace batteries. Check or replace contactor. Check or replace ignition switch. PAGE 30 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) NOTES TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 31 ELECTRONIC COMPONENT LOCATOR O G C B AD 2 1 X 230v / 110v 50Hz / 60Hz K N A1 Z S I E QH M U R B1 C1 W F L T V P J Y PAGE 32 -- TB12SE/TB12PE TUFFTRUK POWER BUGGY · OPERATION MANUAL -- REV. #0 (04/01/22) WIRING DIAGRAM Q 2-PIN MOLEX CONNECTOR 1 1 BLK AUX #1 2 2 RED/BLK MF R 2-PIN MOLEX CONNECTOR 1 AUX #2 2 1 BLK 2 RED/GRN MF S 4-PIN MOLEX CONNECTOR 3 PTO 1 4 RED BLK 2 D GND. 1 I SPEED CONTROLLER CONNECTOR (J1) T A DIAGNOSTIC GAUGE D GND. 1 B RED F2 12 VDC PWR 2 1 GND. EMERGENCY STOP SWITCH 10A 4 3 CAN HIGH U F3 10A V F1 E 20A J1 1 BRN CAN LO 2 PURPLE 3 GRAY 4 ORANGE 5 GRN FC 6 WHT 8 RED 10 BLK/WHT RED RED B RED/YEL A2 E CONTACTOR K1 COIL A1 12 VDC SPLICE 12 VDC PWR PINK (COIL RETURN) A1 W F4 10A C2 IGNITION SWITCH RED 30 75 15 RED/YEL RED/YEL J1 I 11 RED/BLUE YEL/PURPLE 9 12 YEL BLUE/YEL 16 2 1 17 4 3 GRN/YEL NC COM NO D MOMENTARY BYPASS SWITCH X SERIAL PORT CABLE (PROG) BLK 13 B C1 18 CONTACTOR 20 SOLENOID RED K1-1 E RED K1-2 H B+ D BLK/YEL GND. 1 B- M1 M2 J1 I CURTIS 1229 MOTOR CONTROLLER J 24 VDC ELECTRIC RED REAR BLK MOTOR 750W 24 VDC ELECTRIC FRONT MOTOR N 750W WHT BLK BLUE WHT RED GRAY SPLICE 12 VDC SPLICE A L FUSE 100A 2-PIN MOLEX K CONNECTOR ORANGE BLUE 11 FRONT MOTOR BRAKE RED 2 2 BROWN MF Y 2-PIN MOLEX CONNECTOR ORANGE BLUE 11 REAR MOTOR BRAKE RED 2 2 BROWN MF RED BLK/WHT 2-PIN Z MOLEX CONNECTOR 11 22 BLUE BROWN O REVERSE SWITCH NC NO COM MF 2-PIN A1 MOLEX CONNECTOR 11 RED/YEL 2 2 G DEADMAN BRAKE NC MICROSWITCH NO COM MF MF ANALOG GND. WHT 11 1 0~5V IN BLK 22 2 5V OUT 33 BLUE 3 BLK C GND M 3-PIN MOLEX B1 CONNECTOR F 3-WIRE 5K OHM POTENTIOMETER BLK RED BLK GRN M BATTERY POS NEG P 12V BATTERY #1 POS NEG SERIES CONNECTION P 12V BATTERY #2 CHARGER CONNECT NOTES: TO 120 VAC POWER SOURCE 1 BLUE SQUARE WHITE LETTERING DENOTES INTER-CONNECTIONS POINTS BLACK CIRCLE WHITE LETTERING DENOTES COMPONENT LOCATION. 2 REFERENCE COMPONENT LOCATOR OPPOSITE PAGE. TB12SE/TB12PE TUFFTRUK POWER BUGGY· OPERATION MANUAL -- REV. #0 (04/01/22) -- PAGE 33 OPERATION MANUAL HERE'S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON-HAND WHEN CALLING UNITED STATES Multiquip Inc. (310) 537- 3700 6141 Katella Avenue Suite 200 Cypress, CA 90630 E-MAIL: mq@multiquip.com WEBSITE: www.multiquip.com CANADA Multiquip (450) 625-2244 4110 Industriel Boul. Laval, Quebec, Canada H7L 6V3 E-MAIL: infocanada@multiquip.com UNITED KINGDOM Multiquip (UK) Limited Head Office 0161 339 2223 Unit 2, Northpoint Industrial Estate, Globe Lane, Dukinfield, Cheshire SK16 4UJ E-MAIL: sales@multiquip.co.uk © COPYRIGHT 2022, 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 specifications 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 specifications, design or the information published in this publication at any time without notice and without incurring any obligations.Adobe PDF Library 16.0.5 Adobe InDesign 17.1 (Windows)