Extol Craft Cordless Wheelbarrow 402600

Assembly Instructions

CZ / ASSEMBLY OF THE BATTERY WHEELBARROW
SK / ASSEMBLY OF THE BATTERY WHEELBARROW
HU / ASSEMBLY OF THE BATTERY WHEELBARROW
DE / ASSEMBLY OF THE BATTERY WHEELBARROW
EN / ASSEMBLING THE BATTERY-POWERED WHEELBARROW

Included hardware:

• 7x bolts with a curved head (for attaching the tray - step 4, Fig. 1)
• 4x bolts (for attaching the metal battery compartment - step 4, Fig. 1)
• Other bolts are pre-installed.

Follow steps 1-5 for assembly. Except for attaching the wheel (step 1), do not fully tighten bolts in subsequent steps to allow for flexibility. Tighten all threaded connections at the end.

Step 1: Attaching the Wheel

Diagram Description: Shows the wheel being attached to the axle using nuts and washers. Emphasizes tire tread direction.

The fastening nut with washers is screwed onto the thread. The tire tread must point in the direction as shown in the figure, i.e., in the direction of forward travel.

Step 2: Attaching Frame Components

Diagram Description: Illustrates attaching frame parts with bolts, washers, and nuts, noting not to fully tighten yet.

Parts:

• 1. Washer
• 2. Spring washer
• 3. Nut

The bolt with washers is screwed into the hole. Do not fully tighten the threaded connection.

Step 3: Attaching Handles

Diagram Description: Depicts connecting the handles to the main frame.

Step 4: Attaching Tray and Battery Compartment

Diagram Description: Shows how the tray and battery compartment are bolted to the frame, recommending initial loose fitting.

We recommend first bolting on the tray using the four bolts on the bottom of the tray (whilst not fully tightening the bolts). Subsequently, lean the battery-powered wheelbarrow by the tray against a wall and then gradually, bolt by bolt, bolt in the battery storage compartment to the bolt mounts by means of which the tray is bolted to the frame.

Step 5: Adjusting Control Unit Position

Diagram Description: Illustrates adjusting the position of the handlebar control unit.

EN / CHANGING THE POSITION OF THE CONTROL UNIT

Connecting Cables

Diagram Description: Shows connecting cables from the wheel and control unit to the battery compartment sockets.

EN / CONNECTING CABLES INTO SOCKETS

Insert the plugs of the cables from the wheel and from the control unit into the sockets as shown in the figure. Insert the plug horizontally and all the way into the socket, then fully screw in the collars. Otherwise, a proper conductive connection will not be made, and the wheelbarrow will not function correctly or some functions will not work.

Cable Management

Diagram Description: Shows cables being secured to the frame tubes using cable ties.

EN / ATTACHING CABLES TO TUBES USING CABLE TIES

Attach the cables to the frame tubes as shown in the figure so that the cables do not hang loosely. Loose cables could snag on objects during travel, leading to damage and detachment from connectors.

Battery Compartment and Controls

Diagram Description: Shows the battery compartment with numbered parts (1, 2, 3).

EN / PARTS AND CONTROL ELEMENTS ON THE BATTERY COMPARTMENT

• 1. Power switch for turning on/off power supply from the battery
• 2. Charger connector
• 3. Compartment with two batteries connected in series

Control Unit Description

Diagram Description: Shows the control unit on the handlebar, detailing buttons for speed control, forward/reverse, brake, and battery level indicators (LEDs).

EN / DESCRIPTION OF THE CONTROL UNIT

• 1. Travel speed control button
• 2. Button “D” for activating forward travel
• 3. Button “R” for activating reverse travel
• 4. Button “P” for activating/deactivating the brake for immediate stopping
• 5. Battery charge level indicator (LEDs)
• 6. Indicator light for reverse travel
• 7. Indicator light for forward travel
• 8. Indicator is lit green when the brake “P” is not activated; lit red when the brake is activated.

Load and Slope Limits

Diagram Description: A graphic illustrating maximum load capacity and permissible slopes, showing different load limits for various slope percentages.

EN / MAX. PERMITTED LOAD ON SLOPED TERRAIN AND MAX. SLOPE OF TERRAIN

• Max. Load Capacity: 150 kg
• Max. Slope: 20%
• Load at 10%-20% slope: 75 kg
• Load at 0%-10% slope: 150 kg
• Max. Side Slope: 5°

Technical Drawings

Wheelbarrow Exploded View

Diagram Description: A technical drawing showing all parts of the wheelbarrow disassembled for identification.

EN / TECHNICAL DETAILED DRAWING OF THE BATTERY-POWERED WHEELBARROW

Battery Compartment Exploded View

Diagram Description: A technical drawing of the battery compartment components.

EN / TECHNICAL DETAILED DRAWING OF THE BATTERY COMPARTMENT

General Description

Diagram Description: A diagram of the assembled wheelbarrow with numbered parts corresponding to a list.

EN / GENERAL DESCRIPTION OF THE BATTERY-POWERED WHEELBARROW

• 1. Tray
• 2. Control unit
• 3. Handle
• 4. Compartment with two batteries connected in series
• 5. Wheel with an electric drive

Product Labels

Diagram Description: Close-up images or diagrams of the product and charger labels, highlighting key information like model number, certifications, and specifications.

EN / LABEL ON THE BATTERY-POWERED WHEELBARROW AND CHARGER

Key information on labels includes:

• Model: 402600
• Battery: GelPb | Rated: 24 V (2×12 V) | 8.6 kg (2×4.3 kg)
• Rated Voltage 24 V | 12 Ah | 288 Wh
• Max. 500 W | Max. 150 kg
• Max. 6 km/h | 33 kg
• IP64 rating
• CE marking
• Charger Input: 230 V ~ 50 Hz | 0.3 A
• Charger Output: Max. 29.6 V | Max. 1.8 A
• Compatibility note for charger and battery.
• Manufacturer details.

Important Notices

ATTENTION TO SCRATCHING (DAMAGE) OF THE SURFACE PAINT COAT

Scratches may occur during transport, which cannot be entirely prevented. The paint coat is primarily for aesthetic purposes and does not protect against surface corrosion. Surface corrosion is normal and will not cause the tray material to rust through. The paint will naturally scratch and wear over time.

Introduction

Dear customer, thank you for purchasing this Extol® product. The product has undergone reliability, safety, and quality tests according to European Union standards and regulations. For any questions, please contact our customer and consulting center.

Manufacturer: Madal Bal a. s., Průmyslová zóna Příluky 244, 76001 Zlín, Czech Republic

Date of issue: 22. 10. 2024

Contact: www.extol.cz | info@madalbal.cz | Tel.: +420 577 599 777

I. Description – Purpose of Use

The battery-powered wheelbarrow features an auxiliary electric drive with continuously adjustable speed control for forward and reverse motion. Powered by two high-capacity 12 V/12 Ah lead AGM batteries, it is designed for transporting solid, powdery, or dense materials in demanding terrain. The batteries are connected in series within the battery compartment and do not need to be removed for charging. The charger connects directly to the compartment socket. The electric drive significantly speeds up material transport and reduces operator fatigue, thereby increasing work productivity.

• ✔️ The cordless wheelbarrow can be used even in rainy weather.
• ✔️ BRUSHLESS MOTOR (without carbon brushes) offers higher power output with lower energy consumption, leading to longer battery life and increased motor lifespan.
• ✔️ The control panel on the right handle allows for continuous speed adjustment, direction selection (forward/reverse), activation of the electronic brake for immediate stopping, and displays the battery charge level.

When the power is turned off or the battery is depleted, the wheelbarrow can be manually pushed like a conventional wheelbarrow.

Diagram Description: Shows the control panel with LED indicators for battery level (100%, 50%, 20%) and buttons for speed control, forward (D), reverse (R), and brake (P).

II. Technical Specifications

Battery Specifications

Charger Specifications

1) Adhere to the pressure value indicated on the tyre. This value may vary due to production changes.

2) The maximum terminal voltage of two series-connected batteries without load is 28.8 V. The batteries are connected in series within the compartment and are not removed for charging.

III. Parts and Control Elements

Fig. 5: Battery Compartment Components

• 1. Power switch (On/Off)
• 2. Charger connector
• 3. Compartment with two series-connected batteries

Fig. 6: Control Unit Components

• 1. Speed control lever
• 2. Button “D” for forward travel
• 3. Button “R” for reverse travel
• 4. Button “P” for brake (immediate stop)
• 5. Battery charge level indicator (LEDs)
• 6. Reverse travel indicator light
• 7. Forward travel indicator light
• 8. Brake status indicator (Green: Brake OFF, Red: Brake ON)

IV. Preparing the Battery-Powered Wheelbarrow for Use

Assembly

Assemble the wheelbarrow according to steps 1-5 (Fig. 1). Do not fully tighten bolts in subsequent steps (except for wheel attachment in step 1) to allow for flexibility. Tighten all threaded connections at the end. Adjust the control unit position as shown in Fig. 2.

Cable Management

Attach cables to the frame tubes using cable ties (Fig. 4) to prevent them from snagging on objects during operation.

Connecting Connectors

Insert cable plugs from the wheel and control unit into the sockets (Fig. 3). Ensure plugs are fully inserted and collars are screwed in for a proper connection. Incorrect connection will prevent operation or specific functions.

Charging the Batteries

Use only the specified charger (Part No. 402600A). Using an incorrect charger may cause fire or explosion. Inspect the charger, power cord, and plug for damage before use. Do not use a damaged charger.

• First, connect the charger plug to the wheelbarrow socket (Fig. 5, pos. 2), then connect the charger to the mains power.
• Charge the battery within an ambient temperature range of 0°C to +40°C.
• Charging is indicated by a red light on the charger; a green light indicates a full charge. (Note: Light signals may change due to manufacturing updates).
• After charging, disconnect the charger from the mains, then from the wheelbarrow.
• Replace the socket cover (Fig. 5, pos. 2) to protect against water and dirt.
• Check tyre pressure with a gauge before use.

V. Turning On / Speed Travel / Brake / Battery Charge Level / Turning Off

Turning On

1. Set the power switch (Fig. 5, pos. 1) to position “I” to enable operation. Functions cannot be activated if the switch is in position “0”.
2. Press button “D” (Fig. 6, pos. 2) for forward travel, or button “R” (Fig. 6, pos. 3) for reverse travel. The corresponding indicator light will illuminate.

Putting into Motion, Travel Speed, Turning Off the Drive

Push the lever (Fig. 6, pos. 1) to move the wheelbarrow. The degree of lever pressure controls the travel speed. Releasing the lever turns off the electric drive.

With the power switch ON (Fig. 5, pos. 1), the electric brake engages, making manual movement difficult but providing auxiliary braking on inclines. To move freely without electric drive or brake resistance, set the power switch (Fig. 5, pos. 1) to “0”.

Brake

Press the brake button “P” (Fig. 6, pos. 4) for immediate stopping. Indicator light (Fig. 6, pos. 8) is green when the brake is OFF and red when ON.

Battery Power Level

Check the battery level via the LED indicators on the control panel (Fig. 6, pos. 5):

• All 3 LEDs lit: 100% - 50% charged
• 2 LEDs lit: 50% - 20% charged
• Red LED lit: Battery is flat

Electric Protection Against Full Discharge

The battery has electronic protection against deep discharge. This protection will suddenly cut off motor power to prevent damage. It does not prevent natural self-discharge.

⚠️ WARNING: Adhere to load and incline limits shown in Fig. 7 and instructions in Chapters V and VI.

Turning Off / Putting Out of Operation

When not in use, set the power switch (Fig. 5, pos. 1) to “0” and fully charge the battery. Batteries self-discharge; recharge regularly. Storing a discharged battery causes irreparable damage, similar to a car battery, and requires replacement.

VI. General Safety Instructions

⚠️ WARNING! Read all safety instructions, the user manual, images, and regulations provided with this tool. Failure to follow these instructions may result in electric shock, fire, and/or serious personal injury. Keep all instructions and the manual for future reference.

1) Safety in the Work Area

• Keep the work area clean and well-lit.
• Do not use in explosive environments (flammable liquids, gases, dust). Sparks can ignite dust or vapors.
• Prevent access by children and unauthorized persons. Distractions can lead to loss of control.

2) Electrical Safety

• Ensure the power plug matches the socket. Do not modify plugs. Do not use adapters with grounded tools.
• Avoid contact with grounded objects (pipes, radiators, etc.).
• Do not expose to rain, moisture, or wetness. Water ingress increases shock risk.
• Do not use the power cord for other purposes (carrying, pulling). Protect cord from heat, grease, sharp edges, and moving parts. Damaged cords increase shock risk.
• Use outdoor-rated extension cords for outdoor use.
• Use an RCD (Residual Current Device) in damp areas.

3) Safety of People

• Be attentive, use common sense, and concentrate. Do not use when tired, under the influence of drugs, alcohol, or medication.
• Wear appropriate Personal Protective Equipment (PPE), including eye protection, respirators, safety footwear, hard hats, and hearing protection.
• Prevent accidental starting: Ensure the switch is OFF before connecting power or battery, or when carrying the tool.
• Remove all adjustment tools and spanners before turning on the tool.
• Maintain a stable stance and balance for better control.
• Dress appropriately. Avoid loose clothing and jewelry. Keep hair and clothing away from moving parts.
• Use dust extraction/collection equipment if available.
• Do not become complacent due to routine; unsafe practices can lead to serious injury.

VII. Safety Instructions for the Battery-Powered Wheelbarrow

Loading Loads

1. Do not overload the machine. Adhere to load limits.
2. Secure loads firmly with fastening belts.
3. Avoid loads protruding from the tray to prevent accidents.
4. Keep loads below eye level to maintain visibility and balance.
5. Load loads evenly. Uneven loads can cause tipping.
6. Load heavier items first for better balance.
7. Ensure front and side protective frames are not extended beyond their limit position.
8. Load and unload on a level surface.

Maintenance

Before maintenance, park the machine on a level surface and engage the brake.

Safety Instructions for Using the Battery-Powered Wheelbarrow

• Always wear anti-slip footwear and protective clothing.
• Check the route before moving materials. Ensure it is wide enough for safe passage.
• Be cautious on slippery, unpaved, or unstable terrain.
• Do not use on excessively steep slopes.
• Maintain a stable stance when working on slopes. Work across slopes, not up or down.
• Use level surfaces for stopping, loading, and unloading. Never leave unattended on a slope.
• When stopping on a slope, turn the machine uphill or downhill and engage the electronic brake.
• If leaving the machine unattended, engage the brake in a safe stopping location.
• Ensure ramps are clean, rigid, and safe. Use ramps wide enough for stable transport.
• Avoid extending ramps over open spaces without bracing or handrails.
• Ensure all bolts are tightly secured before use.
• Do not overload the machine. Ensure sufficient load capacity.
• Do not stack material too high or allow it to overhang the sides.
• Use containers and fasteners to secure loads.
• Maintain a firm grip on the handles.
• Turn off the power switch and remove the battery when not in use to prevent accidental activation.
• This machine must not be operated on public roads.
• Use rigid boards with non-slip surfaces for loading/unloading on inclines (max. 12° slope). Operate slowly and carefully.
• Do not repair or modify the machine.

Operation

1. Stand behind the machine and hold the handles firmly.
2. Do not operate while riding on the machine.
3. Do not permit others to ride.
4. Look behind when reversing to avoid slips or trips.
5. Avoid use in poor visibility conditions to prevent collisions.
6. Reduce speed and be careful on uneven surfaces.
7. Avoid soft surfaces to prevent tipping.
8. Do not operate on slopes greater than 20°.
9. If a problem occurs, stop on a level surface and engage the brake.
10. Ensure cables do not snag on loads or obstacles.

Use on Slopes

• Work perpendicular to the slope (along the contour).
• Reduce speed and be very careful.
• Be cautious when starting or stopping on a slope.
• Secure loads firmly with ropes as they are less stable on slopes.
• Limit load to a minimum on unstable terrain.
• Limit load height due to reduced visibility on slopes.
• Do not park on steep slopes. Park on a level surface and turn off power.
• Do not change direction or speed mode on steep slopes.
• Do not release the start switch on ascending slopes, as the machine could reverse.
• Ensure the battery is sufficiently charged before working on slopes.

⚠️ Electromagnetic Field Warning: The machine generates an electromagnetic field that may affect medical implants (e.g., pacemakers). Consult a doctor or implant manufacturer before use.

Safety Instructions for the Battery Charger

• Read the manual before charging.
• Use charger indoors only. Protect from rain, humidity, and temperatures above 40°C.
• Use only with specified battery model (402600B).
• Keep away from children. Ensure adequate ventilation during charging.
• Charge between 0°C and 40°C.
• Protect charger from impacts and water damage.

Safety Instructions for the Battery

• Protect battery from elements, heat, and mechanical damage. Do not open, burn, or short circuit.
• Store fully charged and recharge regularly. Storing discharged batteries causes irreparable damage.
• Do not store in freezing temperatures. Cover terminals during transport.
• Check battery for damage before installation. Use only original replacement parts.
• AGM battery type. Use specified charger (402600A). Terminal voltage must not exceed 14.4V. Overcharging can cause fire or explosion.

VIII. Service and Maintenance

• Before service, switch off the power and disconnect the battery.
• The machine requires no special maintenance during its lifetime.
• Check tyre pressure regularly and inflate as needed.
• Fully charge the battery before storage and check charge periodically. Storing discharged batteries causes irreparable damage.
• If any part of the wheelbarrow, charger, or battery is damaged, do not use it and arrange for replacement with original manufacturer parts.

Standard Spare Parts Available for Purchase

Refer to Fig. 8 and Fig. 9 for technical drawings with numbered parts if ordering other components.

IX. Meaning of Markings on Labels (Fig. 11)

Diagram Description: Icons and symbols found on product labels are explained.

• CE: Product conforms to relevant EU harmonisation legislation.
• Read Manual: Read the user's manual before use.
• Safety Footwear: Wear solid anti-slip footwear when operating.
• No Direction Change on Slope: Do not change travel direction on a slope.
• Load on Level Ground: Load loads on level ground.
• Distribute Load Evenly: Unevenly loaded cargo can shift, affecting stability and control.
• Not for Road Use: The machine must not be operated on roads.
• Not for Transporting People: The machine is not intended for transporting people.
• Max. Load Capacity: 150 kg
• Max. Forward Travel Speed: Max. 6 km/h
• Maximum Upward Slope: 20%
• Maximum Downward Slope: 10%
• Max. Load Capacity on Slope: 75 kg (at 10%-20% slope)
• IP64: Ingress Protection rating.
• Rain Symbol: Can be used in rainy weather.
• Warning (⚠️): Indicates a hazard or important safety information.
• SMPS: Switch Mode Power Supply.
• Polarity Symbol: Indicates polarity of the DC connector for battery charging.
• Indoor Use Only: Use charger indoors only. Protect from rain and water ingress.
• Class II Device: Double insulated.
• End-of-Life Symbol: Indicates machine and battery at the end of their lifetime.
• Battery Capacity: XX mAh / XX Wh
• Serial Number (SN): Includes year, month of manufacture, and production series designation.

X. Storage

Store the machine in a dry location, out of reach of children, and at temperatures below 40°C. Protect from direct sunlight, heat sources, humidity, water, and rodents.

Refer to relevant sections for battery storage instructions.

XI. Waste Disposal

Packaging Materials

Dispose of packaging materials in the appropriate recycling bins.

Electrical Equipment and Batteries at the End of Their Lifetime

According to EU Directive 2012/19, unusable electrical equipment must not be disposed of with household waste. It must be handed over for ecological disposal at designated collection points due to hazardous components. Batteries must be removed before disposal and taken to separate battery collection points for ecological disposal and metal recycling. Information on collection points can be obtained from local authorities or retailers.

XII. Warranty Period

A 2-year warranty (liability for defects) applies from the date of sale. Written warranty conditions will be provided upon request.

Warranty and After-Sales Service

For warranty repairs, contact the retailer where the product was purchased. For after-sales service, contact an authorized service center. Service locations can be found at www.extol.cz. For inquiries, call the service line at 222 745 130 or email servis@madalbal.cz.

EU Declaration of Conformity

Manufacturer: Madal Bal a.s., Bartošova 40/3, 760 01 Zlín, Czech Republic

Product: Extol® Craft 402600 Battery-powered wheelbarrow

Madal Bal a.s. hereby declares that the product described above conforms to all relevant stipulations of the European Union's harmonisation legal regulations (2006/42 EC; (EU) 2011/65; (EU) 2014/30).

This declaration is issued under the sole responsibility of the manufacturer.

Harmonised norms used for conformity assessment include EN 62841-1:2015, EN 1175:2020, EN 1757:2022, EN ISO 12100:2010, EN IEC 55014-1:2021, EN IEC 55014-2:2021, EN IEC 63000:2018.

Technical documentation compiled by Martin Šenkýř at Madal Bal a.s., Průmyslová zóna Příluky 244, 760 01 Zlín, Czech Republic. Documentation is available at the manufacturer's address.

Place and date of issue: Zlín, 23.09.2024

On behalf of Madal Bal, a.s.:

Martin Šenkýř
Member of the Company's Board of Directors