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Flextool TUFFTRUK B450G Operating Instructions Manual

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OPERATING INSTRUCTIONS
FLEXTOOL
TUFFTRUK
®
™
PETROL B450G & ELECTRIC B450E
Version 1.0 (July 2021)
FOR MORE INFORMATION
CONTACT US ON
1300 353 986
OR VISIT
flextool.com.au

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Summary of Contents for Flextool TUFFTRUK B450G

  • Page 1 OPERATING INSTRUCTIONS FLEXTOOL TUFFTRUK ® ™ PETROL B450G & ELECTRIC B450E Version 1.0 (July 2021) FOR MORE INFORMATION CONTACT US ON 1300 353 986 OR VISIT flextool.com.au...

  • Page 2: Proposition 65 Warning

    PROPOSITION 65 WARNING B450G/B450E B450G/B450E B450G/B450E Mini Dumper Mini Dumper Mini Dumper 1300 353 986 flextool.com.au...

  • Page 3: Table Of Contents

    Maintenance (Petrol) ........30–36 Maintenance (Electric) ........37–39 Maintenance (Petrol/Electric) ......40–44 Troubleshooting (Engine) ......... 45–46 Troubleshooting (Petrol) ........47 Troubleshooting (Electric) ........48 Error Codes ............49 Electronic Component Locator ......50 Wiring Diagram ............. 51 1300 353 986 flextool.com.au...

  • Page 4: Safety Information

    COULD result in DEATH or SERIOUS INJURY. CAUTION Rotating parts hazards (Chain) Indicates a hazardous situation which, if not avoided, COULD result in MINOR or MODERATE INJURY. NOTICE Hydraulic fluid hazards Addresses practices not related to personal injury. 1300 353 986 flextool.com.au...
  • Page 5 NEVER use accessories or attachments that are not Avoid wearing jewelry or loose fi tting clothes that may recommended by Flextool for this equipment. Damage snag on the controls or moving parts as this can cause to the equipment and/or injury to user may result.
  • Page 6 Use extreme caution when approaching high voltage ALLOW extra time to stop when operating the TuffTruk power lines. on wet surfaces or loosely graded materials. DO NOT dump materials from bucket/tub while the TuffTruk is moving. 1300 353 986 flextool.com.au...
  • Page 7 NEVER tamper with the factory settings of the engine or engine governor. Damage Fix damage to machine and replace any broken parts to the engine or equipment can result immediately. if operating in speed ranges above the maximum allowable. 1300 353 986 flextool.com.au...
  • Page 8 DO NOT expose the battery to open fl ames, not employed. 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. 1300 353 986 flextool.com.au...
  • Page 9 TuffTruk and the operator to load and unload the obstructions such as bridges and power lines. Check TuffTruk. the truck and ramp capacities. ALWAYS place the fuel valve lever in the OFF position before transporting. 1300 353 986 flextool.com.au...
  • Page 10 fi nes or other penalties. Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings. 1300 353 986 flextool.com.au...

  • Page 11: Specifications (Mini Dumper)

    64 lbs (29 kg) 16 x 6.50 x 8 16 x 6.50 x 8 Pneumatic Tires (406 x 165 x 203 mm) (406 x 165 x 203 mm) Pneumatic Tire Pressure 28 PSI (193 kPa) 28 PSI (193 Kpa) 1300 353 986 flextool.com.au...

  • Page 12: Specifications (Engine)

    IP: 44 Insulation Class IEC Duty Cycle S3 15% Dimension Approx. 6.4 X 7.81 X 5.7 in. (L x W x H) (164 X 200 X 145 mm) Dry Net Weight Approx. 22 lbs. (10 kg) 1300 353 986 flextool.com.au...

  • Page 13: Noise And Vibration Emissions

    Per EU Directive 2002/44/EC, the daily exposure action value for hand/arm vibration is 2.5 m/s A(8). The daily exposure limit value is 5 m/s A(8). 1300 353 986 flextool.com.au...

  • Page 14: Dimensions

    43.34 (1,101) 34.68 (881) 70.98 (1,803) 31.10 (790) 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. B450G/E Dimensions 1300 353 986 flextool.com.au...

  • Page 15: General Information

    GENERAL INFORMATION MOTOR CONTROLLER (B450E MODEL ONLY) The Flextool Walk-Behind Series TuffTruk Power Buggies are available in two versions, petrol (Model B450G) or The B450E is equipped with a sealed heavy-duty permanent electric (Model B450E). Both modes are intended for motor controller, Curtis Model 1229 Speed Controller (ECU).

  • Page 16: Components

    COMPONENTS ELECTRIC GASOLINE Figure 2. TuffTruk Walk-Behind Mini Dumper Components 1300 353 986 flextool.com.au...
  • Page 17 27. Free-Wheel Brake Lever (B450G) — Two position electric motor. lever. When placed in the up position (OFF) and held allows the Mini Dumper to be moved with the gasoline engine disengaged. 1300 353 986 flextool.com.au...

  • Page 18: Engine Components

    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. 1300 353 986 flextool.com.au...

  • Page 19: Inspection

    LOWER LIMIT Figure 5. Engine Oil Dipstick (Oil Level) Table 6. Engine Oil Type Season Temperature Oil Type Summer 25°C or Higher SAE 10W-30 Spring/Fall 25°C ~ 10°C SAE 10W-30/20 Winter 0°C or Lower SAE 10W-10 1300 353 986 flextool.com.au...
  • Page 20 3. When refueling, be sure to use a strainer for filtration. DO NOT top-off fuel. Wipe up any spilled fuel CORD FAILURE GLAZED immediately. WORN BACK COVER BROKEN MISSING RUBBER CRACKS SIDEWALL WEAR Figure 8. V-Belt Inspection 1300 353 986 flextool.com.au...
  • Page 21 Check and make sure that all linkages within the TuffTruk batteries are connected in series. Mini Dumper are functioning correctly. STEERING CHECK 1. Check and make sure that the Mini Dumper's steering turns freely and that there is no binding. Figure 9. Battery Series Connections 1300 353 986 flextool.com.au...

  • Page 22: Operation (Petrol)

    1/3 of the way toward the fast position. Figure 10. Fuel Shut-Off Lever (ON) 2. To start a cold engine, move the choke lever (Figure 11) to the CLOSED position. THROTTLE LEVER FAST SLOW Figure 13. Throttle Lever 1300 353 986 flextool.com.au...
  • Page 23 (free-wheel) the Mini Dumper will not move when the forward or reverse speed control levers are activated. Figure 17. Deadman Lever (Petrol) For normal operation this lever should always be placed in the down position. 1300 353 986 flextool.com.au...

  • Page 24: Operation (Electric)

    If low, recharge batteries. Figure 19. Reverse Speed Control Lever (Petrol) NOTICE NEVER squeeze both speed control levers at the same time, as this will cause damage to the unit. Figure 21. Ignition Key (Start) 1300 353 986 flextool.com.au...
  • Page 25 (Figure 24) until the Mini Dumper begins to move in a reverse direction. CAUTION Avoid sudden and quick turns. When steering, turn the handle bar slowly. ALWAYS face the controls when Figure 23. Deadman Lever (Electric) traveling. 1300 353 986 flextool.com.au...

  • Page 26: Operation (Petrol/Electric)

    Figure 28. Determining Grade of Slope Figure 27. Steering the Mini Dumper (CCW-Right) CAUTION DO NOT steer the Mini Dumper left or right when traveling up or down on a grade. Travel in a straight path. 1300 353 986 flextool.com.au...
  • Page 27 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 31. Tub Horizontal Position 1300 353 986 flextool.com.au...
  • Page 28 5. Block wheels if on a slope or incline. EMERGENCY SHUTDOWN (PETROL) 1. Place the engine ON/OFF switch (Figure 32) in the OFF position. Figure 33. Emergency Stop Switch (Push) ENGINE SWITCH Figure 32. Engine ON/OFF Switch (OFF) 1300 353 986 flextool.com.au...

  • Page 29: Maintenance

    Check Tires For Severe Cuts/Wear Check Hydraulic Oil Level (B450G) Check Hydraulic Oil (B450G) Replace Hydraulic Oil System (B450G) Check 1st time Drive Chains Clean/Lube Once a Year V-Belt (B450G) Check Bearing (B450E) Lube Fastners Check 1300 353 986 flextool.com.au...

  • Page 30: Maintenance (Petrol)

    In addition, plugged cooling fins, and/or cooling shrouds Figure 34. Fuel Strainer removed will cause engine damage due to overheating. 1300 353 986 flextool.com.au...
  • Page 31 (Engine Specifications). DO NOT overfill. PAPER FILTER COVER ELEMENT 5. Install drain bolt with sealing washer and tighten FOAM FILTER securely. ELEMENT OIL FILLER DIPSTICK GASKET Figure 37. Engine Air Cleaner DRAIN SEALING BOLT WASHER Figure 36. Draining Engine Oil 1300 353 986 flextool.com.au...
  • Page 32 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. 1300 353 986 flextool.com.au...
  • Page 33 Figure 41. Rear Access Panel Removal 2. With the engine OFF, push down on the YELLOW deadman lever (Figure 42) about 10~20°. DEADMAN LEVER 10°~20° Figure 44. Deadman Lever Adjustment Nut Figure 42. Deadman Lever Engaged (10°~20°) 1300 353 986 flextool.com.au...
  • Page 34 Figure 46. Safety Pin Engaged (Locked) 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. 1300 353 986 flextool.com.au...
  • Page 35 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). Figure 52. Wood Block Placement 1300 353 986 flextool.com.au...
  • Page 36 10. Fully engage the reverse control lever and verify that the pump direction control bracket, be sure to keep the wheels rotate between 28~32 rpm's in the reverse hands clear of the V-belt and pulley. Possibility exists direction. of entaglement. 11. Turn off engine. 1300 353 986 flextool.com.au...

  • Page 37: Maintenance (Electric)

    1. Push and hold the brake bypass lever (Figure 56). 2. Push the EMERGENCY STOP switch (Figure 58). Figure 58. Emergency Stop Switch (Push) Figure 56. Brake Bypass Lever 2. The Mini Dumper can now be moved. 1300 353 986 flextool.com.au...
  • Page 38 (Figure 61L). 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. 1300 353 986 flextool.com.au...
  • Page 39 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 Figure 62. Throttle Arm Gap (4 MM) 1300 353 986 flextool.com.au...

  • Page 40: Maintenance (Petrol/Electric)

    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 1300 353 986 flextool.com.au...
  • Page 41 Zerk Fitting Lubrication 1. Lubricate the zerk fitting as shown in Figure 66 using Figure 67. Tyre Inspection lithium base grease, grade N0.1 once a year. Apply two shots. of grease Figure 66. Zerk Fitting Lubrication 1300 353 986 flextool.com.au...
  • Page 42 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. Figure 68. Lug Nut Torque Sequence Figure 70. Tub Removal 1300 353 986 flextool.com.au...
  • Page 43 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. LATCH Figure 74. Tub Latch Figure 72. Tub Placement 1300 353 986 flextool.com.au...
  • Page 44 Clean the entire Mini Dumper and engine compartment. Clean drum of all debris and foreign matter. Cover the Mini Dumper with a plastic sheet in a moisture and dust-free location out of direct sunlight. 1300 353 986 flextool.com.au...

  • Page 45: Troubleshooting (Engine)

    Fuel cock does not open properly? replace if necessary. No fuel present at carburetor. Fuel fi lter/lines clogged? Replace fuel fi lter. Fuel tank cap breather hole clogged? Clean or replace fuel tank cap. Air in fuel line? Bleed fuel line. 1300 353 986 flextool.com.au...
  • Page 46 ON/OFF device not activated ON? Turn on ON/OFF device. Check cable connections. Charge or replace Will not start, no power with key "ON". (if Battery disconnected or discharged? applicable) battery Ignition switch/wiring defective? Replace ignition switch. Check wiring. 1300 353 986 flextool.com.au...

  • Page 47: Troubleshooting (Petrol)

    Adjust pump neutral setting. Low on fuel or fuel tank empty? Add fuel. Engine will not start. Engine ON/OFF switch in OFF position? Set engine ON/OFF switch to ON position. Fuel Shut-off valve CLOSED? Open Fuel shut-off valve. 1300 353 986 flextool.com.au...

  • Page 48: Troubleshooting (Electric)

    Check or replace fuse. Electric motor will not start. Emergency Stop Switch open? Close switch. Pull to close. Defective batteries? Check or replace batteries. Defective contactor? Check or replace contactor. Defective ignition switch? Check or replace ignition switch. 1300 353 986 flextool.com.au...

  • Page 49: Error Codes

    (Er 18). Reference the error code table shown below for necessary and reinsert. If that does not correct the problem, additional codes. please contact your nearest Flextool Authorized Service Center (ASC) for repair or replacement. Some errors may be corrected by simply turning the ignition key off, then back on and see if the fault clears.

  • Page 50: Electronic Component Locator

    ELECTRONIC COMPONENT LOCATOR 1300 353 986 flextool.com.au...

  • Page 51: Wiring Diagram

    WIRING DIAGRAM CONNECT TO 240 VAC POWER SOURCE 1300 353 986 flextool.com.au...
  • Page 52 Design and technical specifications may be subject to changes. © This publication is copyright. All rights are reserved. Flextool is a registered trade mark and TuffTruk is a trade mark of Parchem Construction Supplies Pty Ltd. FOR MORE INFORMATION...

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