Truxta BENDI 300G User manual

OPERATOR MANUAL & PARTS LIST
MACHINE MODELS
BENDI 300G BENDI 300D BENDI 300E
BENDI 450G BENDI 450D BENDI 450E
SERIAL Numbers After B151040

Page 2
TABLE OF CONTENTS
Declaration of Conformity ...............................................................................3-7
Warning, Symbols & Decals …………………………………………………..………………..8
Machine Specification ………................................................................................9
General Safety / Health & Safety .................................................................10-11
Operating Instructions; - Petrol Diesel ........................................................12-13
(Pre-Start Checks, Start and Stop Procedures)
Service & Maintenance - Petrol & Diesel ....................................................... 14
Service - Pump Control Settings & Adjustment…..……………..……..…..……….. 15
Operating Instructions - Electric …………………………….…….……….....…….…….. 16
Operating Instructions - Battery Charger …………………...…….……..…..……….. 16
Warning, Symbols & Decals ............................................................................ 17
Service & Maintenance - Electric Problem Solving ……………..……..………..18-21
Parts Lists & Assembly
All Machines - Top Frame - Parts List …………………..…....……….….……..…. 22-23
All Machines - Front Chassis - Parts Lists ………………………...………...……...24-25
Petrol & Diesel - Rear Assembly - Parts Lists ………………...….....…...….....26-27
Electric - Rear Assembly - Parts List ………………………..….……..…..….…….28-29
Attachments - Flat Bed - Tow-Ball - Parts List ………………………….……….……...30
Warranty Registration ........................................................................................31

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We, Tufftruk Ltd, Sheen, nr. Buxton, Derbyshire, SK17 0EU, GB, hereby certify
that if the product described within this certificate is bought from an authorised
Tufftruk dealer within the EEC, it conforms to the following EEC directives:
2006/42/CE (This directive replaces directive 98/37/EC), Electromagnetic
Compatibility Directive 2004/108/CE (as amended by 89/336/EEC, 92/31/EEC
& 93/68 EEC).
The Waste Electrical and Electronic Equipment (WEEE) 2002/96/CE, the low
voltage directive 2006/95/CE, BS EN ISO 12100-1:2003 Safety of machinery and
associated harmonised standards, where applicable.
Noise emissions conform to directive 2000/14/EC Annex VI, for machines under
article 12 the notified body is AV Technology Limited, AVTECH House, Birdhall
Lane, Cheadle Heath, Stockport, Cheshire, SK3 0XU, GB.
Noise Technical Files are held at the Tufftruk Head Office address stated above.
DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
We
TUFFTRUK Ltd
The Croft, Sheen, Buxton, Derbyshire, SK170EU
Declare that the following equipment conforms to the Directive: -
2000/14/EC (as amended) of the European Parliament and of the council on the
approximation of the laws of the Member States relating to the Noise Emission in
the Environment by Equipment for Use Outdoors.
Equipment Category: Pedestrian Power Barrow
Product Name/Model: TRUXTA
Type/Serial No: B300D & B450D & R300D
The technical documentation is held by: TUFFTRUK Ltd Address above
The conformity assessment procedure followed was in according with annex VI
of the Directive.
Notified Body: AV Technology Ltd SK9 3RW
Measured Sound Power Level: 97 dB (LWA)
Guaranteed Sound Power Level: 100 dB (LWA)
A copy of this certificate has been submitted to the European Commission and to
EU Member State, United Kingdom
Place of Declaration: TUFFTRUK Ltd SK17 0EU
Date: 29/09/2014
Signed by: Ronald Blackhurst
Position in Company:. Managing Director
Name and address of manufacturer or Authorised representative: Tufftruk Ltd SK17 0EU

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DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
We
TUFFTRUK Ltd
The Croft, Sheen,Buxton,Derbyshire,SK170EU
Declare that the following equipment conforms to the Directive: 2000/14/EC (as
amended) of the European Parliament and of the council on the approximation
of the laws of the Member States relating to the Noise Emission in the
Environment by Equipment for Use Outdoors.
Equipment Category: Pedestrian Power Barrow
Product Name/Model: TRUXTA
Type/Serial No: B300G & R300G
The technical documentation is held by: TUFFTRUK Ltd Address above
The conformity assessment procedure followed was in according with annex VI
of the Directive.
Notified Body: AV Technology Ltd SK9 3RW
Measured Sound Power Level: 91 dB (LWA)
Guaranteed Sound Power Level: 94 dB (LWA)
A copy of this certificate has been submitted to the European Commission and to
EU Member State, United Kingdom
Place of Declaration: TUFFTRUK Ltd SK17 0EU
Date: 29/09/2014
Signed by: Ronald Blackhurst
Position in Company:. Managing Director
Name and address of manufacturer or Authorised representative: Tufftruk Ltd SK17 0EU

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DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
We
TUFFTRUK Ltd
The Croft, Sheen, Buxton, Derbyshire, SK170EU
Declare that the following equipment conforms to the Directive: -
2000/14/EC (as amended) of the European Parliament and of the council on the
approximation of the laws of the Member States relating to the Noise Emission in
the Environment by Equipment for Use Outdoors.
Equipment Category: Pedestrian Power Barrow
Product Name/Model: TRUXTA
Type/Serial No: B450G
The technical documentation is held by: TUFFTRUK Ltd Address above
The conformity assessment procedure followed was in according with annex VI
of the Directive.
Notified Body: AV Technology Ltd SK9 3RW
Measured Sound Power Level: 93 dB (LWA)
Guaranteed Sound Power Level: 96 dB (LWA)
A copy of this certificate has been submitted to the European Commission and to
EU Member State, United Kingdom
Place of Declaration: TUFFTRUK Ltd SK17 0EU
Date: 29/09/2014
Signed by: Ronald Blackhurst
Position in Company:. Managing Director
Name and address of manufacturer or Authorised representative: Tufftruk Ltd SK17 0EU

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DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
We
TUFFTRUK Ltd
The Croft, Sheen, Buxton, Derbyshire, SK170EU
Declare that the following equipment
conforms to the Directive: -
2000/14/EC (as amended)
of the European Parliament and of the council on the approximation of the laws of the Member States
relating to the Noise Emission in the Environment by Equipment for Use Outdoors.
Equipment Category: Pedestrian Power Barrow
Product Name/Model: TRUXTA
Type/Serial No: B300E / B450E - ELECTRIC OPTIONS
The technical documentation is held by: TUFFTRUK Ltd Address above
The conformity assessment procedure followed was in according with annex VI of the Directive.
Notified Body: AV Technology Ltd SK9 3RW
Measured Sound Power Level: 69 dB
Guaranteed Sound Power Level: 69 dB
A copy of this certificate has been submitted to the European Commission and to EU Member State, United
Kingdom
Place of Declaration: TUFFTRUK Ltd SK17 0EU
Date: 29/09/2014
Signed by: Ronald Blackhurst
Position in Company:. Managing Director
Name and address of manufacturer or Authorised representative: Tufftruk Ltd SK17 0EU

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WARNING SYMBOLS & DECALS
TRUXTA BENDI - MACHINE SPECIFICATIONS
Model
Petrol B300G
(Petrol B450G)
Diesel B300D
(Diesel B450D)
Electric B300E
(Electric B450E)
Engine/Motor/Power
(kW)/hp
Honda GX 160 3.6 / 4.8
Honda GX200 4.1 / 5.5
Yanmar L48 3.5/ 4.7
Yanmar L48 3.5 / 4.7
DC Brushless
Motor 1000W /24v
Motor 1300W / 24v
Fuel Type Unleaded Petrol (4 stroke) Diesel 2 x 12v Batteries
Fuel Capacity 3.1 litres 2.5 litres
Max Payload (kg) 300kg / 7ft³ / 0.2m³
(450kg / 10.6ft³/ 0.3m³)
300kg /7ft³/ 0.2m³
(450kg / 10.6ft³/ 0.3m³)
300kg / 7ft³/ 0.2m³
(450kg / 10.6ft³ / 0.3m³)
Unladen Weight (kg) 170 (180) 201 (219) 224 (255)
Working Gradient 25° 25° 25°
Drive & Controls Hydrostatic System 24v Motor Gearbox
Brake System Fail-safe dead-man handle (International patents pending)
Standard Fitment Tyres Flotation with option for turf tyres
Travel Speed
Fwd/Reverse
0-4 mph forward
0-1.5 mph reverse
0-3.5 mph forward
0-1.5 mph reverse
Noise Level (db.) < 94 < 100 < 69
Hand Arm
Vibration
3.6 m/s²
4.6 m/s²
3.8 m/s²
3.8 m/s²
2.5 m/s²
2.5 m/s²
All dimensions unless otherwise stated are in mm.
We reserve the right to change specification without prior notice.
A 12 month warranty is applicable on all TRUXTA machines.

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GENERAL SAFETY
For your own personal protection and for the safety of those around you, please read and
ensure you fully understand the following safety information.
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 lifted single-handedly, GET HELP and use suitable lifting
equipment.
 Cordon off the work area and keep members of the public and unauthorized personnel at a safe distance.
 Personal Protective 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
difficulty.
 Always switch OFF the engine before transporting, 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 unattended.
 Never remove or tamper with any guards fitted, they are there for your protection.
 Always check guards for condition and Security, if any is damaged or missing, DO NOT USE THE
TRUXTA until the guard has been replaced or repaired.
 Do not operate the machine when you are ill, feeling tired, or when under the influence 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 off). Close the throttle 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 off the engine and allow it to cool.
When refuelling, DO NOT smoke or allow naked flames in the area.
 Spilt fuel must be made safe immediately, by using sand. If fuel is spilt on your clothes, change them.

VIBRATION
Some vibration from the operation is transmitted through the handle to the operator’s hands. DO NOT
exceed the maximum usage times. (See Technical Data section)
PPE (Personal Protective 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 And Diesel 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 attention as soon as possible.
Exhaust Fumes
Do not operate the TRUXTA indoors or in a confined space, make sure the work area is adequately
ventilated.
Electric
Do not attempt 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
HEALTH AND SAFETY
Safe Disposal.
Instructions for the protection of the environment.
The machine contains valuable materials.
Take the discarded apparatus and accessories to the relevant recycling facilities.
ENVIRONMENT
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OPERATING THE TRUXTA BENDI
1. Start the engine by putting the throttle to the run position and turning the ignition on.
(use choke if cold)
2. Grip the dead man lever and hold it down.
3. Use the forward and reverse levers to control direction of travel and speed.
Never press both levers at once or whilst the dead man is released as this will cause unnecessary
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 stationary, pull the Skip Release Lever and the Skip will tip forwards
disposing of its contents.
3. When the Skip is empty, push back to its original position. The Skip will lock into place
PRE START UP INSPECTION
The following pre-start-up inspection must be performed before the start of each work session or after every
four hours of use, whichever is first.
Please refer to the service section for detailed guidance.
If any fault is discovered, the TRUXTA must not be used until the fault is rectified.
1. Thoroughly inspect the TRUXTA for signs of damage.
2. Check components are present and secure.
3. Check fluid lines, hoses filler openings, drain plugs and any other areas for signs of leakage.
Fix any leaks before operating.
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.
Electric models
1. Check mains lead is stored correctly and is secured to the machine.
2. Check mains lead is not damaged in any way and replace as necessary.
OPERATING INSTRUCTIONS - PETROL AND DIESEL

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OPERATING THE PETROL TRUXTA B300G / B450G
Start the engine by putting the throttle to the run position and turning the ignition on.
(use choke if cold)
Grip the dead man lever and hold it down.
Use the forward and reverse levers to control direction of travel and speed. (Never press both
levers at once or whilst the dead man is released as this will cause unnecessary damage to the
machine.
Release the dead man to stop.
PETROL AND DIESEL - OPERATING INSTRUCTIONS
OPERATING THE L48 ELECTRIC START DIESEL TRUXTA B300D / B450D
Start the engine by turning the ignition key on. Move throttle to desired speed
Grip the dead man lever and hold it down.
Use the forward and reverse levers to control direction of travel and speed.
Never press both levers at once or whilst the dead man is released as this will cause
unnecessary damage to the machine.
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 lifting the by-pass
lever and locating to the left, then depress the yellow Deadman brake lever and the Truxta will now free-
wheel.
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.

SERVICE & MAINTENANCE - PETROL & DIESEL
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Hydrostatic 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 Tufftruk ltd.
Machine Cleaning
Clean the machine after it has been used to prevent the collection of hardened debris. Hardened debris is very
difficult 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 solution 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
left 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 filter. Replace every 200 hours or if it is extremely dirty.
Transmission Drive Chains
Clean and lubricate the 3 transmission drive chains once a year.
Every 20
hours
Every 50
hours
Every 200
hours
ROUTINE MAINTENANCE
ENGINE OIL CHANGE
AIR FILTER CHECK CONDITION
CLEAN / REPLACE
SPARK PLUG CHANGE
SPARK PLUG AND OIL DATA
Engine Oil
Type
Quantity
(gals) Fuel Type Capacity (gals)
Spark
Plug
Electrode Gap
(mm)
Hydrostatic
Transmission Oil
PETROL
HONDA
S.A.E
10W30 0.17 UNLEADED 0.53 BPR5ES 0.07-0.8 20W50
YANMAR DIE-
SEL l48
SAE
5W-30 0.18 DIESEL 0.55 N/A N/A 20W50
POWER CIRCUIT—Diesel Electric Start

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SERVICE & MAINTENANCE - PETROL & DIESEL
PUMP CONTROL SETTINGS & ADJUSTMENT
FORWARD CONTROL CABLE
REARWARD CONTROL CABLE
DIRECTION SAFETY PIN
(SHOWN IN LOCKED POSITION)
CABLE ADJUSTMENT NUTS
PUMP NEU-
TRAL SETTING
SCREW
DEPRESS DEADMAN LEVER
TO DISENGAGE PIN
PUMP DIREC-
TION BRACKET
1: Adjust Deadman lever cable tension if required, see engage angle. Adjust cable adjustment nuts. With Deadman
lever in fully pressed position ensure the direction safety pin is clear of control plate (see above)
2: Adjust forward/reverse direction 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
direction bracket turns
15 degree forward direction 75 rpm @ wheels
4: Ensure that with rearward lever fully pressed the pump
direction bracket turns
5 degree rearward direction 30 rpm @ wheels
PUMP NEUTRAL SETTING
1: Adjust pump neutral setting if required if machine creeps
forwards/backwards when in neutral,
 disconnect forward and rearward control cables
 fully press Deadman lever to disengage the direction safety
pin
 loosen pump neutral setting screw
 adjust angle of pump control bracket by rotating forward/
backward until no creep
 re tighten pump neutral setting screw when wheel rotation is
0 rpm
CABLE
ADJUSTMENT
NUTS
DEADMAN LEVER
ENGAGE ANGLE
10-
20 degree
DEADMAN LEVER
FULLY PRESSED
POSITION
DIRECTION LEVERS
GAP TO HANDLE 5MM
WHEN FULLY
PRESSED

CHARGING THE ELECTRIC TRUXTA
 TRUXTA has a built-in 24v charger
 Turn off ignition switch.
 Push in the large red button.
 Connect the cable provided to a mains supply 110-230 v. Charger is dual voltage.
 Check batteries are charging by observing small window on left hand side of battery box.
 The CHARGING light is normally ORANGE which changes to GREEN when the battery is fully charged.
 The charger is a Smart Charger, it can be left connected to the batteries after full charge (green light) without
harming batteries. The charger uses minimum power in this stand-by mode (after battery is fully charged),
maintains the batteries at full charge and extends battery life.

MACHINE CLEANING
Clean the machine after it has been used to prevent the collection of hardened debris. Hardened debris is very
difficult 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
Clean and lubricate the 3 transmission drive chains once a year.
OPERATING INSTRUCTIONS & CHARGING - ELECTRIC TRUXTA
OPERATING THE TRUXTA
Pull out large red button. (DEADMAN KILL SWITCH)
Turn ignition 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 left 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 button (DEADMAN KILL SWITCH)
When machine is not in use, always push in the large red button.
PARKING BRAKE
The Parking Brake operates automatically when the dead man lever (yellow)
is in the upright position.
The brake is on until 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
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ELECTRIC TRUXTA - WARNING SYMBOLS & DECALS
Page 17

Page 18
ELECTRIC TRUXTA - WIRING DIAGRAM - DIAGNOSTICS & TROUBLESHOOTING

ELECTRIC TRUXTA - DIAGNOSTICS & TROUBLESHOOTING
TRUXTA Electric Service Diagnostics
The 1229 controller detects a wide variety of faults or error conditions.
Diagnostic information can be obtained through the 3100R fuel gauge display where an error code in the
format “Err ##”; the codes are listed in Table 4.
The troubleshooting chart (Table 5) describes the faults and their possible causes; the faults are listed in
alphabetical order.
Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI and turn it back
on to see if the fault clears. If it does not, shut off KSI and remove the 35-pin connector. Check the
connector for corrosion or damage, clean it if necessary, and re-insert it.
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DIAGNOSTICS & TROUBLESHOOTING - TRUXTA ELECTRIC
Page 20