Truxta BENDI 300G User manual
English
OPERATOR MANUAL
MACHINE MODELS BENDI 300G BENDI 300E
MACHINE MODELS BENDI 450G BENDI 450E
2
INDEX
CONTENTS
General Safety / Health & Safety
3
Warning, Symbols & Decals
4
Operang Instrucons - ELECTRIC
(Electric / Baery Charger )
5-6
Service & Maintenance - ELECTRIC
(Problem Solving / trouble shoong/ wiring diagram)
7-9
Warning, Symbols & Decals PETROL
10
Operang Instrucons; - PETROL
(Pre-Start Checks, Start and Stop Procedures)
10
Service & Maintenance - PETROL
11-14
Warranty Registraon
15
3
GENERAL SAFETY
For your own personal protecon and for the safety of those around you, please read and ensure you fully understand the
following safety informaon. It is the responsibility of the operator to ensure that he/she fully understands how to operate
this equipment safely. If you are unsure about the safe and correct use of the TRUXTA, consult your supervisor or TRUXTA
This equipment is heavy and must not be lied single-handedly, GET HELP and use suitable liing equipment.
• Cordon o the work area and keep members of the public and unauthorized personnel at a safe distance.
• Personal Protecve Equipment (PPE) must be worn by the operator when ever this equipment is being used (see Health & Safety).
• Make sure you know how to safely switch this machine OFF before you switch it ON in case you get into diculty.
• Always switch OFF the engine before transporng, moving it around the site or servicing it.
• During use the engine becomes very hot; allow the engine to cool before touching it. Never leave the engine running and unaended.
• Never remove or tamper with any guards ed, they are there for your protecon.
• Always check guards for condion and Security, if any is damaged or missing, DO NOT USE THE TRUXTA unl the guard has been
replaced or repaired.
• Do not operate the machine when you are ill, feeling red, or when under the inuence of alcohol or drugs.
• Do not stand the machine on end with the engine running.
• Do not use the TRUXTA to transport people.
• Do not release the brake suddenly when travelling forward at speed with a heavy load as the machine may topple forward.
• (Brake o). Close the throle if necessary so that engine braking controls the speed. Always ensure that when moving downwards on
a hill, the machine is travelling in reverse.
• Before refuelling, switch o the engine and allow it to cool.
When refuelling, DO NOT smoke or allow naked ames in the area.
• Spilt fuel must be made safe immediately, by using sand. If fuel is spilt on your clothes, change them.
• Store petrol in an approved, purpose made container away from heat and ignion sources.
• If fuel is spilt when re-fuelling the tank, wipe o the excess and wait 2 minutes before re-starng.
• STEERING THE TRUXTA ON GRADIENTS.
DO NOT steer the TRUXTA le or right when travelling up or down a gradient. Always travel in a straight line. When travelling across a
graduated slope, always travel in a forward direcon, maximum gradient 6 degrees (10%) when travelling across with a TRUXTA.
• ENVIRONMENTAL — Safe Disposal.
Instrucons for the protecon of the environment. The machine contains valuable materials. Take the discarded apparatus and
accessories to the relevant recycling facilies.
VIBRATION
Some vibraon from the operaon is transmied through the handle to the operator’s hands. DO NOT exceed the maximum usage mes.
(See Technical Data secon)
PPE (Personal Protecve Equipment).
Suitable PPE must be worn when using this equipment i.e. Safety Goggles, Gloves, Ear Defenders, Dust Mask and Steel Toe capped.
Footwear. Wear clothing suitable for the work you are doing. Tie back long hair and remove any jewellery which may catch in the
equipment’s moving parts.
Petrol Machines. Do not ingest fuel or inhale fuel vapours and avoid contact with your skin. Wash fuel splashes immediately. If you get
fuel in your eyes, Irrigate with copious amounts of water and seek medical aenon as soon as possible.
Exhaust Fumes Do not operate the PETROLTRUXTA indoors or in a conned space, make sure the work area is adequately venlated.
Electric Do not aempt to charge the electric machine if cable or connectors are damaged.
Do not connect or disconnect the machine with wet hands immediately replace damaged charging parts.
4
WARNING SYMBOLS & DECALS
SAFETY DECALS
1DIRECTION OF TRAVEL
2LIFTING POINTS UN-LADEN
3BRAKE OVERRIDE, SKIP RETAINER CATCH
4PPE
5VOLTAGE WARNING
6HYDROSTATIC OVER-RIDE (PETROL ONLY)
7CRUSH ZONE WARNING
8PAYLOAD
5
6
7
8
1
2
3
4
5
ELECTRIC TRUXTA - WARNING SYMBOLS & DECALS
OPERATING INSTRUCTIONS
Check Baery Condion - Orange light charging Green light charged
11. E Stop out
ignion on
2 & 3 Forward & Reverse Controls
4 & 5. Stopping and Park brake
ON
INCLINES
Do not use TRUXTA on inclines / ramps above 25°
Do Not travel forwards down inclines.
TO MOVE
TRUXTA
Press yellow dead-man handle on right handle
down for any movement.
Right handle lower lever for forward moon.
RH & LH lower lever together for reverse moon.
TO STOP /
PARK
Release dead-man handle to stop.
Release lower forward / reverse levers.
Ideally Park on at surface.
6
Check mains lead is stored correctly and is secured to the machine.
Check mains lead is not damaged in any way and replace as necessary.
OPERATING THE TRUXTA
Pull out large red buon. (DEADMAN KILL SWITCH)
Turn ignion key on.
Depress dead man lever (yellow) on right hand controls.
To Move Forward — squeeze right hand lever to move forward.
To Reverse — squeeze and hold le hand lever, then squeeze the right hand lever to move the machine in reverse.
STOPPING THE TRUXTA
Release the right hand lever to stop the machine
Release the dead man yellow lever to engage the parking brake
In emergencies hit the large red buon (DEADMAN KILL SWITCH)
When machine is not in use, always push in the large red buon.
PARKING BRAKE
The Parking Brake operates automacally when the dead man lever (yellow) is in the upright posion.
The brake is on unl the dead-man (yellow) lever is compressed to release it.
MOVING the TRUXTA with NO POWER
For manual brake release when the machine has no power
Push brake release lever forward and hold the dead-man lever down, the TRUXTA can now be moved manually.
CHARGING THE ELECTRIC TRUXTA
1. TRUXTA has a built-in 24v charger
2. Turn o ignion switch.
3. Push in the large red buon.
4. Connect the cable provided to a mains supply 110-230 v. Charger is dual voltage.
5. Check baeries are charging by observing small window on le hand side of baery box.
6. The CHARGING light is normally ORANGE which changes to GREEN when the baery is fully charged.
7. The charger is a Smart Charger, it can be le connected to the baeries aer full charge (green light) without harming
baeries. The charger uses minimum power in this stand-by mode (aer baery is fully charged), maintains the baeries at
full charge and extends baery life.
OPERATING INSTRUCTIONS & CHARGING - ELECTRIC TRUXTA
7
SERVICE & MAINTENANCE - ELECTRIC TRUXTA
Machine Cleaning
Clean the machine aer it has been used to prevent the collecon of hardened debris. Hardened debris is very dicult to
remove. To clean it use an old brush or hand brush with water. Never pressure wash or hose down the electric motor
housing. Clean only with a cloth or compressed air.
Transmission Drive Chains and Centre Drive Pivot
Clean and lubricate the 3 transmission drive chains TWICE a year.
Lubricate the single grease nipple on the centre drive universal joint once a year
Tyre Pressure
Truxta tyre pressure should be regularly checked and maintained at 25PSI (otaon and turf tyres)
Adjustment of Centre Steering Damper
The Hydraulic damper is maintenance free device, it is adjusted on assembly to provide a medium damping force of
approx. 1500N.
The damping force can be adjusted if required to provide lighter or heavier feeling to the steering. Specic details for the
adjustment of the damper can be seen in the Truxta workshop manual.
8
ELECTRIC TRUXTA - DIAGNOSTICS & TROUBLESHOOTING
ELECTRIC TRUXTA - DIAGNOSTICS & TROUBLESHOOTING
The machine controller detects a wide variety of faults or errors. Diagnosc informaon can be obtained on the 3100R fuel gauge display
where an error code in the format ''Err ##''.
The troubleshoong chart below describes the Error code faults and their possible causes. Whenever a fault is encountered the rst
acon should be to turn o the ignion and push in the E stop buon. Then pull out the E stop buon and turn the ignion back on to
see if the fault clears.
This is the RESET procedure.: If the Error code does not clear aer the machine RESET, turn o the ignion switch and remove the 35-pin
connector. Check the connector for correcon or damage, clean it if necessary, and reinsert it.. If the Error is sll seen then the wiring and
connecons on the machine should be checked for breakages or loose connecons. The table below should be used as a reference once
the above checks have been carried out.
Erro
r
code
Descripon
of Error Possible Cause /
Reason for Error Check points Technical
Bullen
(see website)
1HW
Fail-safe Motor fault voltage (hardware failure) 1. Motor voltage does not correspond to throle request.
2. Short in motor or In motor wiring.
15 Main
Current
dropped Main contractor failed open. 1. Clean the contactor switch TB10001
17 Main
Contactor
Welded Main contractor on fault 1. Main contactor failed closed, replace contactor.
33 Supervisor
DIR Check
Fault
If fault is on an external signal, check that
signal rst. If no problem with the external
signal, likely indicates an internal controller
fault.
Early controllers were re-programmed
34 External
Supply
Fault Under voltage 1. Check control wiring circuit, potenometer wiring in
parcular. TB10010
36
EM-Brake
Driver
Open
Drain
Hold voltage is set at 90% 1. Check bullet connectors to brake, check connuity. Or
2. the motor brake has failed.
54 Pre-
charged
Failed Pre-charge fault 1. Low baery voltage - 25V (11/12V) is good condion,
22V (9/10V) or lower is bad baeries condion.
2. Short circuit on tracon motor outputs. TB10008
80 HPD
Sequencin
g HPD fault present > 10 seconds 1. Misadjusted throle
2. Broken throle potenometer or throle mechanism. TB10004
92 Motor
Open Tracon motor not connected. Controller can not see the motor. Could be a short circuit
in the motor.
1. Check the resistance across the motor leads.
99 Under-
voltage
Cutback Baery voltage too low Baery voltage < undervoltage threshold. 1. Bad
connecon at baery or controller. 2. Check no corrosion
on the baery terminals.
Quick checks if no reading on fuel gauge and machine does not operate:
1. Check 10A fuse in the control panel. Fuse holder is located to the right hand side of the main control panel, turn CCW to release the
fuse holder.
2. Check main fuse located behind the rear motor housing cover, 125A fuse (450 models) & 100A fuse (300 models). Remove the rear
cover which is xed in posion with 4 x M6 screws, ensure the cover is supported during this process. Main fuse is located on the le
hand side of the baery housing.
When changing the 100 or 125 amp fuses, ensure that the posive baery lead is fully dis-connected. Electrical maintenance should be
carried out by a qualied person.
9
TRUXTA ELECTRIC—WIRING DIAGRAM
10
Always read the manual before use. Wear appropriate PPE
OPERATING INSTRUCTIONS
1. Always check oil level before starng.
2. Choke controls starng.
3. Pull to start
4. Adjust choke controls when engine running.
5. Engine rpm control lever.
TO MOVE TRUXTA
6/7. Press yellow dead-man handle on right
handle down for any movement.
Right handle lower lever for forward moon .
Le handle lower lever for reverse moon.
TO STOP / PARK
8. Release dead-man handle to stop.
Release lower forward / reverse levers
9. Ideally park on at surface.
10. Engine OFF switch & close fuel tap when transporng to
prevent carbureor ooding.
ON INCLINES
Do not use on inclines / ramps above 25°
Do Not travel forwards down inclines.
SKIP TIPPING
When Tipping always posion on a at.
Use skip p handle to release the skip.
The skip has a 2-stage p acon to fully empty.
PETROL - OPERATING INSTRUCTIONS
11
PRE START UP INSPECTION
The following pre-start-up inspecon must be performed before the start of each work session or aer every EIGHT hours of
use, whichever is rst.
Please refer to the service secon for detailed guidance.
If any fault is discovered, the TRUXTA must not be used unl the fault is reced.
1. Thoroughly inspect the TRUXTA for signs of damage.
2. Check components are present and secure.
3. Check uid lines, hoses ller openings, drain plugs and any other areas for signs of leakage. Fix any leaks before operang.
4. Check the engine oil and fuel levels and top up as necessary.
5. Check the tyre pressures and top up as necessary.
6. Check for fuel and oil leaks.
OPERATING THE TRUXTA BENDI
1. Start the engine by pung the throle to the run posion and turning the ignion on. (use choke if cold)
2. Grip the dead man lever and hold it down.
3. Use the forward and reverse levers to control direcon of travel and speed.
4. Never press both levers at once or whilst the dead man is released as this will cause unnecessary strain on the operaon
cables
EMPTYING THE SKIP
1. Stop the machine by releasing the Drive Lever followed by releasing the
dead man Brake Lever.
2. Once the machine has become staonary, pull the Skip Release Lever and the Skip will p forwards disposing of its
contents.
3. When the Skip is empty, push back to its original posion. The Skip will lock into place automacally.
4. Do not use the skip as a levelling blade as this could result in damage to the pping under carriage.
TRANSMISSION BY-PASS FREEWHEEL FACILITY
This allows the Truxta to be moved without the engine running.
In the event of engine or drive belt failure it is possible to manually move the Truxta by liing the by-pass lever and locang
to the le, then depress the yellow Deadman brake lever and the Truxta will now freewheel.
The By-pass lever is located next to the oil reservoir under the steering column. THE BY-PASS LEVER MUST NOT BE LIFTED
WITH THE ENGINE RUNNING.
OPERATING INSTRUCTIONS - PETROL
CAUTION IF IT IS NECESSARY TO TRAVEL DOWN A SLOPE OF M ORE THAN 15° WHEN FULLY LADEN,
ENSURE THAT THE MACHINE IS TURNED ROUND AND REVERSE DOWN A SLOPE
!
12
SERVICE & MAINTENANCE - PETROL
Hydrostac Oil Top up if oil is below minimum level when machine is cold. If there are any signs of leakage, stop using
the machine and contact your local dealer or Turuk Ltd. Rell with motor oil - 20W50
Machine Cleaning - Clean the machine aer it has been used to prevent the collecon of hardened debris. Hardened
debris is very dicult to remove. To clean it use an old brush or hand brush with water. Never pressure wash or hose
down the engine or electric motor housing. Clean only with a cloth or compressed air.
Air Filter - If it is dirty, proceed as follows:-
Foam Element - Wash the element in a soluon of washing-up liquid and water. Allow the element to dry, then soak in
clean engine oil and squeeze out the excess oil. If the engine smokes during start-up then too much oil has been le on
the foam.
Paper Element - Tap the element on a hard surface or blow from inside using compressed air to remove any excess dust
within the lter. Replace every 200 hours or if it is extremely dirty.
Transmission Drive Chains and Centre Drive Pivot—Clean and lubricate the 3 transmission drive chains TWICE a year.
Lubricate the single grease nipple on the centre drive universal joint once a year
Tyre Pressure - Truxta tyre pressure should be regularly checked and maintained at 25PSI (otaon and turf tyres)
Adjustment of Centre Steering Damper
The Hydraulic damper is maintenance free device, it is adjusted on assembly to provide a medium damping force of
approx. 1500N. The damping force can be adjusted if required to provide lighter or heavier feeling to the steering.
Specic details for the adjustment of the damper are in the Truxta workshop manual.
13
REGULAR SERVICE - HONDA
(Perform at every indicated month or
operang hour interval, whichever comes rst)
Each
Use
First month
or 20 hrs
3 month or 50
hrs
6 month or
100 hrs
Every Year
or 300 hrs
ENGINE OIL Check level o
Change oo
AIR FILTER Clean o * o *
Replace o**
SEDIMENT CUP Clean o
SPARK PLUG Check-adjust o
Replace o
IDLE SPEED Check-adjust o
VALVE CLEARANCE Check-adjust o
COMBUSTION
CHAMBER Clean aer every 500 hours
FUEL TANK & FILTER Clean o
FUEL TUBE Clean Every 2 years (replace if necessary)
SERVICE & MAINTENANCE - PETROL
PUMP NEUTRAL SETTING
1: Adjust pump neutral seng if required if machine creeps forwards/backwards when in neutral,
• disconnect forward and rearward control cables
• fully press Deadman lever to disengage the direcon safety pin
Check oil level daily as shown above, running the engine with a
low oil level can cause engine damage.
Rell with Engine Oil type — SAE 10W30
Internal vent carbureor with dual element type only.
Replace paper element type only.
14
SERVICE & MAINTENANCE - PETROL / PUMP CONTROL SETTINGS & ADJUSTMENT
3
4
5
1
6
2
7
1. DIRECTION LEVERS GAP TO HANDLE 5MM
WHEN FULLY PRESSED
2. DEADMAN LEVER FULLY PRESSED POSITION
3. DEADMAN LEVER ENGAGE ANGLE
4. CABLE ADJUSTMENT NUTS
4
3
2
1
10-20 °
1: Adjust Deadman lever cable tension if required, see engage angle. Adjust cable adjustment nuts. With
Deadman lever in fully pressed posion ensure the direcon safety pin is clear of control plate (see above)
2: Adjust forward/reverse direcon levers cable tension if required, ensure 3mm - 5mm gap when fully
pressed. Adjust cable adjustment nuts.
3: Ensure that with forward lever fully pressed the pump direcon bracket turns 15 degree forward
direcon 75 rpm @ wheels
4: Ensure that with rearward lever fully pressed the pump direcon bracket turns 5 degree rearward
direcon 30 rpm @ wheels
PUMP CONTROL SETTINGS & ADJUSTMENT
1. PUMP NEUTRAL SETTING SCREW
2. PUMP DIRECTION BRACKET
3. FORWARD CONTROL CABLE
4. REARWARD CONTROL CABLE
5. DIRECTION SAFETY PIN (SHOWN IN LOCKED
POSITION)
6. DEPRESS DEADMAN LEVER TO DISENGAGE PIN
7. CABLE ADJUSTMENT NUTS
15
GUARANTEE AND WARRANTY CARD
Your new TRUXTA is warranted to the original purchaser for a period of one-year
(12 months) from the original date of purchase. The TRUXTA warranty is against defects in design, materials
and workmanship.
The following are not covered under the TRUXTA warranty:
1. Damage caused by abuse, misuse, dropping or other similar damage caused by or as a result of failure to
follow assembly, operaon or user maintenance instrucons.
2. Alteraons, addions or repairs carried out by persons other than Turuk or their recognised agents.
3. Transportaon or shipment costs to and from TRUXTA or their recognised agents, for repair or
assessment against a warranty claim, on any machine.
4. Materials and /or labour costs to renew repair or replace components due to fair wear and tear the
following components are not covered by warranty: ·
Drive belt · Engine air lter · Engine spark plug
TRUXTA and/or their recognised agents, directors, employees or insurers will not be held liable for
consequenal or other damages, losses or expenses in connecon with or by reason of or the inability to
use the machine for any purpose.
Warranty Claims All warranty claims should rstly be directed to the point of purchase: your TRUXTA
reseller / distributor. Keep a record of the warranty form for your records
Any warranty issues please do contact your place of purchase.
For warranty claims: Tel +44 (0) 1298 84687or Email; sales@turuk.co.uk
For your records, please complete this warranty registraon form
To Register your Warranty please complete the warranty form and post to
Turuk Limited, Unit 5, Prince Street Business Park, Prince Street, Leek, Staordshire ST13 6DB
Alternavely visit the website
www.truxta.com/service and register warranty online.
Alternavely email the completed warranty form sales@turuk.co.uk
WARRANTY REGISTRATION FORM
DATE OF PURCHASE:
PLACE OF PURCHASE/ COMPANY:
CUSTOMER NAME:
ADDRESS:
MACHINE MODEL NO:
SERIAL NO OF MACHINE:
SPARE PARTS details can be found on Truxta website www.truxta.com
Once you have the part no. and descripon of required item please contact your TRUXTA retailer
Turuk direct to sales@turuk.co.uk
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