Flextool TUFFTRUK EB500 User manual

FOR MORE INFORMATION
CONTACT US ON 1300 353 986 OR VISIT flextool.com.au
Version 1.0 (November 2022)
OPERATING INSTRUCTIONS
FLEXTOOL TUFFTRUK™
EB500

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TABLE OF CONTENTS
EB500
TuffTruk Walk-Behind
Mini Dumper
Safety Information ................................................ 4-7
Specifications (Mini Dumper) ................................... 8
Specifications (Electric Motor) ................................. 9
Noise And Vibration
................................................. 10
Dimensions ............................................................ 11
General Information ............................................... 12
Components ..................................................... 13-14
Inspection ......................................................... 15-16
Operation ......................................................... 17-20
Maintenance ..................................................... 21-27
Error Codes ...................................................... 29-30
Troubleshooting ..................................................... 31
Electronic Component Locator ............................. 33
Wiring Diagram ...................................................... 34

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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.
F
ailure to read and understand the safety
m
essages and operating instructions could
result in inju
ry to yourself and others.
SAFETY MESS
AGES
T
he four safety messages shown below will inform you
about
potential hazards that could injure you or others. The
s
afety messages specifi cally address the level of exposure
to
the operator and are preceded by one of four words:
D
ANGER, 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.
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protectiv
e
clothing, shatterproof glasses, respiratory protection
,
hearing protection, steel-toed boots and other protectiv
e
devices required by the job or city and state regulations.
Avoid wearing jewelry or loose fi tting clothes that ma
y
snag on the controls or moving parts as this can caus
e
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 wor
king
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 an
d
safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for an
y
accident due to equipment modifi cations. Unauthoriz
ed
equipment modifi cation will void all warranties.

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SAFETY INFORMATION
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.
TUFFT
RUK SAFETY
DANGER
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
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 electric motor
unless speed control linkage is working properly.
Make sure that the tires are infl ated to the manufacturer’s
recommended tire pressure.
NEVER operate the TuffTruk with bad or worn tires.
ALWAYS replace defective tires with new ones.
Avoid sudden stops and starts and changes in direction.
Operate the controls smoothly. DO NOT jerk the steering
or any other controls.
NEVER attempt to engage the controls except from the
operator’s position.
NEVER 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 of
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
.
BATTERY SAFETY
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.

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SAFETY INFORMATION
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.
TRANSPO
RTING SAFETY
NOTICE
ALWAYS shutdown unit before transporting.
When transporting of the TuffTruk is required, place the
TuffTruk on a fl at bed truck or equivalent and tie down
securely.
ALWAYS make sure all tie-downs are in place and the
tub/bucket is completely lowered in the fl at (horizontal)
position and securely latched.
Place
chock blocks
underneath wheel to prevent rolling
.
DO NOT use the TuffTruk to transport people.
When transporting the TuffTruk on a truck or trailer
,
know the overall height to avoid contacting ov
erhead
obstructions such as bridges and power lines. Chec
k
the truck and ramp capacities.
ENVIRONMENTAL SAFETY/DECOMMISSIONING
NOTICE
Decommissioning is a controlled process used to saf
ely
.
elbaecivres regnol on si taht tnempiuqe fo eceip a eriter
If the equipment poses an unacceptable and unrepairab
le
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, remov
e
battery (if equipped) and bring to appropriate facility f
or
lead reclamation. Use safety precautions when handlin
g
batteries that contain sulfuric acid.
When the life cycle of this equipment is over, it i
s
recommended that the unit frame and all other
metal
parts be sent to a recycling center.
Metal recycling involves the collection of metal fro
m
discarded products and its transformation into ra
w
materials to use in manufacturing a new product
.
Recyclers and manufacturers alike promote the proces
s
of recycling metal. Using a metal recycling cente
r
promotes energy cost savings.

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SPECIFICATIONS (MINI DUMPER)
Table 1. Specifications (TuffTruk)
Model EB500
Maximum Weight Capacity 529 lbs. (239.9 kg)
Maximum Payload Weight 1,100 lbs. (500 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 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. (1422 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°C
77Ah@5 Hr./89Ah@20 Hr.
Capacity@25A 158 minutes
Battery (LxWxH) 12.05 x 6.84 x 9.32 in.
(306 x 174 x 237 mm)
Battery Weight 64 lbs (29 kg)
Pneumatic Tires 16 x 6.50 x 8
(406 x 165 x 203 mm)
Pneumatic Tire Pressure 28 PSI (193 Kpa)

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SPECIFICATIONS (ELECTRIC MOTOR)
Table 2. 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 750 X 2 (1500W)
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
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 3. Noise and Vibration Emissions
Model EB500
Guaranteed ISO 11201:2010 Based Sound Pressure Level
at Operator Station in dB(A)a56
Guaranteed ISO 3744:2010 Based Sound Power Level in dB(A)b76
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