Operator’s Manual Electric Ultra Buggy Model—Serial Range 68037—400000000 and Up 3440-398A Original Instructions (EN) *3440-398* A
Disclaimers and Regulatory Information WARNING CALIFORNIA Proposition 65 The power cord on this product contains lead, a chemical known to the State of California to cause birth defects or other reproductive harm. Wash hands after handling. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Chapter 2: Safety.................................................................................................................................. 2–1 General Safety .................................................................................................................................. 2–1 Safety Alert Classifications............................................................................................................. 2–1 Safety and Instructional Decals ....................................
Cleaning............................................................................................................................................ 5–13 Removing Debris ........................................................................................................................ 5–13 Washing the Machine ................................................................................................................ 5–13 Chapter 6: Storage............................................................
Chapter 1 Introduction Intended Use This machine is intended to be used by professional, hired operators on indoor and outdoor improved surfaces in commercial applications. It is primarily designed to move concrete, mortar, gravel, dirt, or debris around job sites. Using this product for purposes other than its intended use could prove dangerous to you and bystanders. Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage.
Manual Conventions This manual identifies potential hazards and has safety messages identified by the safetyalert symbol, which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. g000502 This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
Chapter 2 Safety General Safety • Read and understand the contents of this Operator’s Manual before starting the machine. • Do not operate the machine without all guards and other safety protective devices in place and functioning properly on the machine. • Park the machine on a level surface, lower the hopper, shut off the machine, and remove the key (if applicable) before leaving the operating position. • Keep your hands and feet away from moving parts.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. Decal Part: 115-4858 Force from above can cause crushing of fingers, hands, toes, or feet —install the cylinder lock. decal115-4858 Decal Part: 125-4959 Force from above can cause crushing of the whole body—never place your head under the hopper.
Decal Part: 125-6694 Tie-down location decal125-6694 Decal Part: 144-0276 decal144-0276 Explosion hazard—do not expose to fire or open flame. Warning—read the Operator’s Manual. Warning—do not open the battery; do not use a damaged battery. Electric shock hazard—do not perform maintenance on the battery. Decal Part: 144-0277 decal144-0277 Positive terminal Do not dispose improperly. Read the Operator’s Manual. Do not expose to fire. Recycle the battery.
Decal Part: 145-1168 decal145-1168 Warning—read the Operator’s Manual. Warning—all operators should read the Operator’s Manual and be trained before operating the machine. Warning—shut off the machine and remove the key before leaving the operator’s position. Horn Raise the hopper. Warning—keep bystanders away; look behind and down when moving in reverse. Lower the hopper. Warning—stay away from moving parts; keep all guards and shields in place.
Decal Part: 145-1170 Warning—read the Operator’s Manual for charging information; do not operate the machine when the machine is charging; disconnect the charging cord before operating the machine. decal145-1170 Decal Part: 145-1173 Traction drive Read the Operator’s Manual for fuse information. Hopper lift cylinder decal145-1173 Decal Part: 145-1175 Warning—turn the battery disconnect switch to the OFF position before performing maintenance.
Decal Part: 145-1181 Forklift lifting point decal145-1181 145-1174 Decal Part: 145-1174 Read the Operator’s Manual for battery charging information.
Chapter 3 Product Overview Work lights Handle bars Control panel Electrical service disconnect switch Operator platform Steering tires Hopper Drive tires Anti-static strap G380315 Controls Electrical Service Disconnect Switch Off—to de-energize the machine electrically On—to energize the machine electrically G387210 3440-398 A Page 3–1 Product Overview
Drive Controls Drive forward Neutral Drive backward G380320 Dump Controls Dump hopper Lower hopper G380321 Emergency Stop Pull to enable the machine. Note: Turn the key to the OFF then ON position to continue operating the machine. Push to immediately shut off the machine.
Key Switch Turn the machine off. Turn the machine on.
Display Display Icon Descriptions Icon Description Menu access Next Previous Scroll down Enter Increase Decrease Exit menu Check PIN entry Parking brake is engaged. Hour meter Battery voltage Battery charge—each solid bar represents the change in 10% increments. Display Main Menu Menu Item Description Faults A list of the recent machine faults. Refer to the Service Manual or your Authorized Service Dealer for more information on the faults menu.
Display (continued) Menu Item Description Diagnostics Displays the state of each machine switch, sensor, and control output. This tells you which machine controls are on and off which assists in troubleshooting. Settings Customize and modify configuration variables on the InfoCenter display. About Lists the model number, serial number, and software version. Display Faults Menu Menu Item Description Current Lists the total number of key-on hours (i.e.
Display (continued) Display Settings Menu Menu Item Description Units Indicates the inputs and outputs for the battery. Inputs include the current battery voltage; outputs include the battery current and percentage state of charge. Language Controls the language used on the InfoCenter. Brightness Controls the brightness of the LCD display. Contrast Controls the contrast of the LCD display. Protected Menus Allows you to access protected menus by inputting a passcode.
Specifications Note: Specifications and design are subject to change without notice. Width (single wheel) 80.65 cm (31.75 inches) Width (dual wheels) 106.7 cm (42 inches) Length (with the platform up) 241.3 cm (95 inches) Length (with the platform down) 282 cm (111 inches) Height 139.7 cm (55 inches) Weight 694 kg (1530 lb) Hopper capacity 0.45 m3 (16 ft3) Maximum load 1136 kg (2500 lb) Wheelbase 104 cm (41 inches) Discharge height 16.5 cm (6.
Chapter 4 Operation Before Operation Before Operation Safety Before Operation General Safety • Never allow children or untrained people to operate the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. • Keep bystanders and children out of the operating area. Allow only people who are responsible, trained, familiar with the instructions, and physically capable to operate the machine.
Before Operation Safety (continued) • Park the machine on a level surface, engage the parking brake (if applicable), and shut off the machine. Wait for all movement to stop and allow the machine to cool before adjusting, servicing, cleaning, or storing the machine. Performing Daily Maintenance Before starting the machine each day, perform the Each Use/Daily procedures listed in the Maintenance Schedule.
During Operation Safety (continued) • Do not overload the hopper and always keep the load level when operating the machine. • Avoid operating the machine on loose terrain. Loose terrain could cause the machine to lose traction, affecting steering, stability, and braking. • Do not operate the vehicle in a dangerous manner, such as stunt driving or horseplay. • Do not deliberately drive the machine over loose objects, potholes, or bumps. • Observe all traffic regulations, including authorized speed limits.
Starting the Machine 1. Ensure that the battery-disconnect switch is in the ON position. 2. Stand on the platform. 3. Insert the key into the key switch and turn it to the ON position. Note: The machine may have difficulty starting under severe cold conditions. When starting a cold machine, keep the machine above -7°C (20°F). Shutting off the Machine 1. Park the machine on a level surface. 2. Put the drive controls in the NEUTRAL position. 3. Turn the key switch to the OFF position and remove the key.
Operator Platform (continued) Raising the Platform Rotate the platform up until it locks into position. G380478 Lowering the Platform 1. Push the platform forward to release pressure on the latch pin. 2. Pull the latch pin out and lower the platform.
Operating the Machine 1. Step onto the machine. CAUTION When mounting the machine, slippery or uneven ground may cause you to fall. Always have 3 out of 4 arms/legs in contact with the machine when you mount or dismount the machine. 2. Turn the key to the ON position. 3. Move the machine in the desired direction: • Forward • Backward switch. —push the top of the switch. —push the bottom of the Note: The more you squeeze the handle, the faster the machine travels. 4.
After Operation After Operation Safety After Operation General Safety • Engage the parking brake (if applicable), shut off the machine, remove the key, and wait for all movement to stop before adjusting, cleaning, or repairing the machine. • Do not touch parts that may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service the machine. • Clean debris from drives and the motor to help prevent fires. • Use care when loading or unloading the machine onto a trailer or truck.
After Operation Safety (continued) • Remove metal items such as rings, bracelets, necklaces, and watches when working with a lithium-ion battery. A lithium-ion battery can produce enough current to cause a severe burn. • Never operate the charger without good visibility or light. • Use an extension cord capable of handling 15 A or more. If you are charging outdoors, use an extension cord rated for outdoor use.
Lowering the Hopper without Power (continued) 4. Disconnect the hose fittings in the manifold block and allow the fluid to drain into the pan. Note: Dispose of the used fluid at a certified recycling center. 5. Connect the hose fittings. 6. Use a hoist or have 2 people hold up the hopper and remove the cylinder lock. 7. Carefully lower the hopper. 8. After making repairs, install the hoses to the manifold block fittings. 9. Raise the hopper, secure with the cylinder lock, and add hydraulic fluid.
Raising the Hopper without Power 1. Remove any material from the hopper. 2. Raise the machine and support it using jack stands rated for the weight of the machine. 3. Place a large drain pan under the lift cylinder. 4. Remove the access panel. 5. Disconnect the hose fittings in the manifold block and allow the fluid to drain into the pan. Note: Dispose of the used fluid at a certified recycling center. 6. Use a hoist or have 2 people hold up the hopper and install the cylinder lock. 7.
Haul the Machine Use a heavy-duty trailer or truck to haul the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
Haul the Machine (continued) Loading the Machine WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Load and unload the machine with the heavy end up the ramp. • Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a tip-over situation.
Haul the Machine (continued) 7. Use the metal tie-down loops to securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Refer to local regulations for tie-down requirements. IMPORTANT Do not use the tie-down loops to lift the machine.
Haul the Machine (continued) Unloading the Machine 1. Lower the ramp(s). 2. Lower the operator platform. 3. Drive the machine forward down the ramp.
Chapter 5 Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • Park the machine on a level surface, engage the parking brake (if applicable), shut off the machine, and remove the key. Wait for all movement to stop and allow the machine to cool before adjusting, servicing, cleaning, or storing the machine. • Do not make repairs or adjustments on the machine unless you are specifically trained and authorized to do so.
• Inspect and maintain the battery, motor, controllers, switches, safety protective devices, electrical wiring, and connections according to the instructions. • Keep the machine clean to minimize hazards and make inspecting the machine for servicing easier. • Ensure that the extension cord plugs are in good condition and are not hot from operation. Do not use a damaged or worn extension cord.
Pre-Maintenance Procedures Retrieving a Machine In an emergency, you can push or tow the machine. Note: Do not tow the machine on a slope; the wheels will spin freely once the gear is removed. 1. Remove the gearbox cover. G388719 2. Remove the gear from the gearbox. 3. Tow the machine as required using the tie down locations. 4. Clean and install the gear in the gearbox and install the gearbox cover to resume normal operation.
Lifting the Machine Lifting the Machine with a Forklift IMPORTANT Ensure that the hopper is empty before lifting the machine. 1. Place the platform in the raised position. 2. Lift the machine using the side or rear pockets. G380480 Lifting the Machine with a Hoist IMPORTANT Ensure that the hopper is empty before lifting the machine. 1. Place the platform in the raised position. 2. Place the hopper in the dump position. 3. Install the cylinder lock. 4. Attach a chain or straps to each of the lift points.
Using the Cylinder Lock Installing the Cylinder Lock 1. Park the machine on a level surface, move the motion-control levers to the NEUTRAL-LOCK position, and fully raise the hopper. 2. Remove the 2 cotterless pins securing the cylinder lock to the machine. G380311 3. Slide the cylinder lock over the lift-cylinder rod and secure with the cotterless pins.
Lubrication Greasing the Machine Grease Type: General-purpose grease. Note: Remove the blue protection caps, if applicable, before greasing and replace when finished. 1. Park the machine on a level surface. 2. Shut off the machine. 3. Clean the grease fittings with a rag. 4. Connect a grease gun to each fitting. G387212 5. Pump grease into the fittings until grease begins to ooze out of the fittings (approximately 3 pumps). 6. Wipe up any excess grease.
Electrical System Maintenance Checking the Anti-Static Strap 1. Park the machine on a level surface, lower the hopper, shut off the machine, and remove the key. 2. Check the anti-static strap and replace it if it is worn or missing. G388771 Battery Service Note: The machine is equipped with 3 lithium-ion batteries. Dispose of or recycle lithium-ion batteries in accordance with local and federal regulations. If a battery requires service, contact your Authorized Service Dealer for assistance.
Battery Service (continued) temperature exceeds the range specified in the Battery Storage Requirements, page 6– 1. IMPORTANT Temperatures outside of this range will damage your batteries. High temperatures during storage, especially at a high state of charge, reduces the life of the batteries. • When storing the machine for more than 10 days, ensure that the machine is in a cool and dry location, out of sunlight, rain, and wet conditions.
Battery Service (continued) IMPORTANT Charge the machine in temperatures 0° to 45°C (32° to 113°F). The onboard charger will not function in temperatures exceeding this range. 1. Park the machine in the designated location for charging. 2. Shut off the machine and remove the key. 3. Ensure that the electrical service disconnect switch is in the OFF position. 4. Open the cover for the charger cord storage. 5. Insert the charger plug into a grounded electrical outlet. 6.
Battery Service (continued) Charger Maintenance IMPORTANT All electrical repairs should be performed by an Authorized Service Dealer only. The charger requires little maintenance other than protecting it from damage and weather. • Clean the charger cord with a slightly damp cloth after each use. • Coil the cord when not in use. • Periodically examine the cord for damage, and replace it when necessary with Toroapproved parts.
Changing the Drive-Motor Gear Oil 1. Start the machine and drive it for 5 minutes. Note: This warms the gear oil so that it drains better. 2. Park the machine on a level surface so that a drain plug on the front motor is in the 6 o’clock position. 3. Shut off the machine and remove the key. 4. Place a drain pan under the drive motor. 5. Remove both plugs and allow the gear oil to drain. 6. Install the lower plug. G387302 7.
Hydraulic System Maintenance Hydraulic Fluid Specifications Hydraulic-Fluid type Toro Multipurpose ATF Hydraulic fluid capacity 3.03 L (3.2 US qt) The machine hydraulic tank is filled at the factory with approximately 3.03 L (3.2 US qt) of hydraulic fluid. Checking the Hydraulic Lines Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, and deterioration. Make necessary repairs before operating. Changing the Hydraulic Fluid 1.
Changing the Hydraulic Fluid (continued) 12. Install the cap. Cleaning Removing Debris 1. Park the machine on a level surface, shut off the machine, and remove the key. 2. Clean any debris from the machine. IMPORTANT Blow the dirt out rather than wash it out. If you use water, keep it away from electrical items and hydraulic valves. Clean electrical connectors using compressed air; do not use contact cleaner.
Chapter 6 Storage Storage Safety Park the machine on a level surface, engage the parking brake (if applicable), shut off the machine, and remove the key. Wait for all movement to stop and allow the machine to cool before adjusting, servicing, cleaning, or storing the machine. Preparing the Machine for Storage Over 30 Days IMPORTANT Do not store the machine outdoors. 1. Park the machine on a level surface and lower the hopper. 2. Shut off the machine and remove the key. 3.
IMPORTANT Storing the machine outside these temperature ranges will damage the batteries or reduce their lifespan. • Before you store the machine, charge or discharge the batteries to between 40% and 60% (54.3V and 57.3V). Note: A 50% charge is optimal to ensure a maximum battery life. When the batteries are charged to 100% before storage, the battery life shortens. If you anticipate that the machine will be stored for a longer period of time, charge the batteries to around 60%.
Chapter 7 Troubleshooting The machine does not start. Possible Cause Corrective Action The batteries need to be charged. 1. Check the InfoCenter for the battery status. 2. Charge the machine. The electrical service disconnect switch is in Turn the electrical service disconnect switch the OFF position. to the ON position. The emergency stop switch is engaged. Disengage the emergency stop switch. The machine does not drive.
Possible Cause Corrective Action The hydraulic system is damaged. Contact your Authorized Service Dealer. The sensor is not working. 1. Adjust the sensor to 3/4 inch above the mounting bracket. 2. Check if the sensor has gone bad. The throttle is not working properly. Possible Cause Corrective Action The throttle needs to be calibrated. Calibrate the throttle. The steering is not working properly. Possible Cause Corrective Action The steering wheel needs to be calibrated.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
