Flextool TUFFTRUK B450G User manual

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

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B450G/B450E
Mini Dumper
B450G/B450E
Mini Dumper
B450G/B450E
Mini Dumper
PROPOSITION 65 WARNING

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TABLE OF CONTENTS
B450G/E TuffTruk
Walk-Behind Mini Dumper
Proposition 65 Warning ........................................... 2
Table of Contents ..................................................... 3
Safety Information ............................................. 4–10
Specifications (Mini Dumper) ................................ 11
Specifications (Engine) .......................................... 12
Noise and Vibration Emissions .............................. 13
Dimensions ............................................................ 14
General Information ............................................... 15
Components .................................................... 16–17
Engine Components .............................................. 18
Inspection ........................................................ 19–21
Operation (Petrol) ........................................... 22–23
Operation (Electric) ........................................ 24–25
Operation (Petrol/Electric) ............................... 26–28
Maintenance .......................................................... 29
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

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SAFETY INFORMATION
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
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.
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.
Lethal exhaust gas hazards
Explosive fuel hazards
Burn hazards
Rotating parts hazards (V-belt)
Symbol Safety Hazard
Hydraulic fluid hazards
Rotating parts hazards (Chain)

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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 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.
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
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 Flextool 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.

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SAFETY INFORMATION
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.
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
.
levart lliw uoy hcihw revo ecafrus eht tcepsni
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 slipper
y
surfaces. Look for soft soil, deep mud and standing wate
r.
Watch for anything that might make you lose control
or
cause the TuffTruk to tip over.
ALWAYS clear away trash and debris. Pick up an
ything
that might puncture the tires.
ALWAYS make sure aisles, ramps, doorways an
d
passages are clear.
ALWAYS plan your work. Make sure you know
where
you will make your pickups, dumps and turns. Bef
ore
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.
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 seve
re
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 mp
h
(6.44 km/h). Reverse travel speed should not e
xceed
1.5 mph (2.42 km/h).
ALLOW extra time to stop when operating the TuffTr
uk
on wet surfaces or loosely graded materials.
DO NOT dump materials from bucket/tub while th
e
TuffTruk is moving.

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SAFETY INFORMATION
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 engine unless
speed control linkage is working properly.
Make sure that the tyres are infl ated to the manufacturer’s
recommended tire pressure.
NEVER operate the TuffTruk with bad or worn tyres.
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 traffi c 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 o
f
concrete, grease, oil or debris on the machine.
ALWAYS store equipment properly when it is not bein
g
used. Equipment should be stored in a clean, dry locatio
n
out of the reach of children and unauthorized personnel.
ALWAYS place the fuel valve lever in the OFF positio
n
when the equipment is not in use.
ENGINE SAFETY
WARNING
DO NOT place hands or fingers inside
engine compartment when engine is
running.
NEVER operate the engine with heat shields o
r
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 th
e
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 capab
le
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 lte
r
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.

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SAFETY INFORMATION
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
flammable liquids.
DO NOT fi ll the fuel tank while the engine is running
or hot.
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.
DONOT 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.
B
ATTERY 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 batter
y to at least 61°F (16°C).
ALWAYS recharge the battery in a well-ventilate
d
environment to avoid the risk of a dangerous concentratio
n
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 int
o
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 remo
ving
the batteries from the machine. Batteries are quite heavy
.
Bodily injury may result if proper lifting procedures
are
not employed.

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SAFETY INFORMATION
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 do
wn
securely.
ALWAYS make sure all tie-downs are in place and
the
tub/bucket is completely lowered in the fl at (horiz
ontal)
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 ov
erhead
obstructions such as bridges and power lines. Chec
k
the truck and ramp capacities.
ALWAYS place the fuel valve lever in the OFF positio
n
before transporting.

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SAFETY INFORMATION
ENVIRONMENTAL SAFETY/DECOMMISSIONING
NOTICE
Decommissioning
is a controlled process used to safely
.elbaecivres regnol on si taht tnempiuqe fo eceip a erite
r
If
the equipment poses an unacceptable and unrepairable
sa
fety risk due to wear or damage or is no longer cost
ef
fective 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 take to appropriate recycling
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 En
vironmental
Protection Agency (EPA) and California Air Resource
s
Board (CARB) emission regulations.
The gasoline engine used in this equipment has bee
n
designed to reduce harmful levels of carbon monoxid
e
(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 J30R
7
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 ma
y
increase emissions beyond the legal limit. Do not remov
e
or alter any part of the system.
Additionally, modifying the fuel system may adversely affec
t
evaporative emissions, resulting in fi nes or other penalties
.

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SPECIFICATIONS (MINI DUMPER)
Table 1. Specifications (TuffTruk)
Model B450G (Petrol) B450E (Electric)
Maximum Weight Capacity 374 lbs. (170 kg) 561 lbs. (255 kg)
Maximum Payload Weight 990 lbs. (450 kg.) 990 lbs. (450 kg.)
Bucket/Tub Capacity (Poly) 10.6 cu. ft. Water Level (.40 cu. yd.) 10.6 cu. ft. Water Level (.40 cu. yd.)
Bucket/Tub Capacity (Steel) 7.0 cu. ft. Water Level (.26 cu. yd.) 7.0 cu. ft. Water Level (.26 cu. yd.)
Drive and Controls Hydrostatic System 24 VDC Electric Motor Gearbox
Speed Forward Up to 4.0 mph. (6.4 km/h) Up to 3.5 mph. (5.63 km/h)
Speed Reverse Up to 1.5 mph. (2.42 km/h) Up to 1.5 mph. (2.42 km/h)
Steering Radius Outside Dia. 58 in. (1,473 mm) 58 in. (1,473 mm)
Hydraulic Pump Capacity 77.23 fl. oz. (2.28 liters) N/A
Hydraulic Oil Tank Capacity 16.90 fl. oz. (.5 liters) N/A
Hydraulic Oil Type 20W-50 Motor Oil N/A
Brake System Hydrostatic/Dead Man Handle Hydrostatic/Dead Man Handle
Dump Control Mechanical Dump and Manual Return Mechanical Dump and Manual Return
Discharge Height 2.0 in. (50.8 mm) 2.0 in. (50.8 mm)
Gradeability Slope (Up/Down) 25° 25°
Gradeability Lateral (Side-Side) 6° 6°
Battery (LxWxH) N/A
12V BCI Group 27 550 CCA @ 0°F
12.05 x 6.84 x 9.32 in.
(306 x 174 x 237 mm)
Battery Weight N/A 64 lbs (29 kg)
Pneumatic Tires 16 x 6.50 x 8
(406 x 165 x 203 mm)
16 x 6.50 x 8
(406 x 165 x 203 mm)
Pneumatic Tire Pressure 28 PSI (193 kPa) 28 PSI (193 Kpa)

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SPECIFICATIONS (ENGINE)
Table 2. Petrol Engine Specifications
Model HONDA GX200UT2QX4
Type Air-cooled 4 stroke, Single Cylinder,
OHV, Horizontal Shaft Gasoline Engine
Bore X Stroke 2.7 in. X 2.1 in.
(68 mm x 54 mm)
Displacement 12.0 cu. in. (196 cc)
Max Output 6.5 H.P./3,600 rpm
Fuel Tank Capacity 0.95 U.S. Gallons (3.6 Liters)
Fuel Unleaded Automobile Gasoline
Lube Oil Capacity 0.63 qt. (0.6 liter)
Speed Control Method Centrifugal Fly-Weight Type
Starting Method Recoil Start
Dimension Approx.
(L x W x H)
12.6 X 14.8 X 13.6 in.
(321 X 376 X 346 mm)
Dry Net Weight 35.2 lbs. (16.0 Kg)
Table 3. Electric Motor Specifications
Model AMER
Type Permanent Magnet DC Electric Motor
Speed Control Method Curtis 1228 Controller
Starting Method Electric
Max RPM (No Load) 2900
Input Voltage 24 VDC
Wattage 1300W
Poles 4
Protection Class IP: 44
Insulation Class F
IEC Duty Cycle S3 15%
Dimension Approx.
(L x W x H)
6.4 X 7.81 X 5.7 in.
(164 X 200 X 145 mm)
Dry Net Weight Approx. 22 lbs. (10 kg)

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NOISE AND VIBRATION EMISSIONS
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/s2A(8). The daily exposure limit value
is 5 m/s2 A(8).
Table 4. Noise and Vibration Emissions
Model B450G B450E
Guaranteed ISO 11201:2010 Based Sound Pressure Level
at Operator Station in dB(A)a82 56
Guaranteed ISO 3744:2010 Based Sound Power Level in dB(A)b96 69
Hand-Arm Vibration Per ISO 5349-1:2001 in m/s2 A(8) 4.6 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

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DIMENSIONS
Figure 1. B450G/E Dimensions
Table 5. Dimensions
Reference
Letter
Dimension
in. (mm)
A 43.34 (1,101)
B 34.68 (881)
C 70.98 (1,803)
D 31.10 (790)
E 16.73 (425)
F 9.37 (238)
G 6.18 (157)
H 29.52 (750)
I 7.71 (196)
J 60.11 (1,527)
K 33.46 (850)
L 23.62 (600)
M 5.55 (141)
N 6.37 (162)
O 33.46 (850)
P 57.67 (1,465)

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The Flextool Walk-Behind Series TuffTruk Power Buggies
are available in two versions, petrol (Model B450G) or
electric (Model B450E). Both modes are intended for
job site cleanup and material transport.
The Mini Dumper 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 Mini Dumper in tight areas.
Maximum forward speed for the petrol driven TuffTruk
Mini Dumper is rated at 4.0 mph. (6.4 km/h). The maximum
forward speed of the electric driven Mini Dumper is rated
at 3.5mph. (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 (B450E) 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 (PETROL)
The gas model (B450G) is powered by a Honda 6.5 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 Flextool dealer for a replacement.
MOTOR CONTROLLER (B450E MODEL ONLY)
The B450E 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 Mini Dumper. It allows the Mini Dumper 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 (B450E MODEL ONLY)
B450E 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 Mini Dumper. 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
Mini Dumper until the Safety Information,
General Information, and Inspection sections
of this manual have been read and
thoroughly understood.
GENERAL INFORMATION

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COMPONENTS
Figure 2. TuffTruk Walk-Behind Mini Dumper Components
123
4
10
11
12
13
14
5
6
7
8
9
15
16
17
18
19
20
21
22
23
24
25
26
GASOLINE
ELECTRIC
27

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COMPONENTS
1. Deadman Control Lever — Yellow handle lever, when
engaged (closed) allows the Mini Dumper 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 (B450E) — 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 Mini Dumper. When steering the Mini Dumper,
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. Tyres — 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 Mini Dumper is required.
7. Battery (B450E) — Uses two 12 volt batteries
connected in series (24 volts). Always use gloves and
eye protection when handling the batteries.
8. Battery Charger Receptacle (B450E) — Plug the
battery charger cable into this receptacle, then connect
the free-end of the cable to a 240 VAC power source.
9. Forward/Reverse Speed Control Lever — When fully
engaged, the Mini Dumper will travel at FULL speed in
either the forward or reverse direction. When released,
the Mini Dumper will STOP. This feature is only on
the B450E model.
10. Dump Control Lever ot drawrof revel eht hsuP —
place the tub in the dump position (vertical).
11. Component Fuse (B450E) — 10 amp fuse that
provides protection for the Curtis Model 3100R
Diagnostic Display and other electronic components.
12. Ignition/Key (B450E) — When activated allows the
unit to be started.
13. Emergency Stop Switch (B450E) — In the event
of an emergency, push this button to shutdown the
electric motor.
14. Battery/Diagnostic Gauge (B450E) — Uses a Curtis
Model 3100R Gauge Display. Displays battery voltage
and fault codes. CAN bus compatible.
15. Free-Wheel Brake Lever (B450E) — Two position
lever. When placed in the up position (OFF) and held
allows the Mini Dumper to be moved with the electric
motor disengaged (OFF).
16. Contactor Solenoid (B450E) — When energized
provides +12 VDC power to motor controller.
17. 5K OHM Potentiometer (B450E) — Provides signal
for speed sensor.
18. Deadman Microswitch (B450E) — When activated
sends a +12 VDC signal (J1-3) to the motor controller
to release the brake.
19. Motor Speed Controller (B450E) — Unit uses a
Curtis Model 1229 Controller. Requires a 24 VDC input.
Interfaces with CAN bus applications.
20. Electric Motor (B450E) — Uses a 24 VDC, 1300 watt
electric motor.
21. Contactor Fuse (B450E) — 125 amp fuse that
provides protection for the electric motor.
22. Battery Charger (B450E) — When activated, charges
both 12-volt batteries. This feature is only on the B450E
model.
23. Hydraulic Tank/Cap (B450G) — 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 (B450G) — When fully
engaged, the Mini Dumper will travel at FULL speed in
the forward direction. When released, the Mini Dumper
will STOP.
25. Reverse Speed Control Lever (B450G) — When fully
engaged, the Mini Dumper will travel at FULL speed in
will STOP.
the reverse direction. When released, the Mini Dumper
26. Engine (B450G Model Only)— Uses a recoil start
Honda 6.5 HP, GX200 air cooled, 4-cycle gasoline
engine.
27. Free-Wheel Brake Lever (B450G) — Two position
lever. When placed in the up position (OFF) and held
allows the Mini Dumper to be moved with the gasoline
engine disengaged.

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ENGINE COMPONENTS
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.
2
11
10 1
3
9
8
7
6
54
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.
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!
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.
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.
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.

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INSPECTION
BEFORE STARTING
1. Read all safety instructions at the beginning of manual.
2. eht ylralucitrap ,tsud dna trid gnivomer ,tinu eht naelC
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
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.
CAUTION
ALWAYS wear approved eye and hearing
protection while operating the Mini Dumper.
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 Mini Dumper.
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.
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).
5. I
Figure 5. Engine Oil Dipstick (Oil Level)
DIPSTICK
NOTICE
Reference engine manufacturer’s manual for specific
servicing instructions.
UPPER LIMIT
LOWER LIMIT
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

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FUEL CHECK
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.
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.
DANGER
If your TuffTruk Mini Dumper has a petrol
engine, determine if the engine fuel is
low. If fuel is low, remove the fuel filler
cap and fill it with unleaded fuel.
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.
FUEL
CAP
INSPECTION
TIRES
Check for worn or defective tires (Figure 7). Replace any
defective or worn tires immediately.
Figure 7. Tyre Wear
V-BELT CHECK
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.
Figure 8. V-Belt Inspection
GLAZED
OIL SOAKED
BROKEN
CORD FAILURE
CRACKS
MISSING RUBBER
SIDEWALL
WEAR
WORN BACK
COVER