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Stone Mud Buggy SB1600 Service & Parts Manual

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SERVICE/PARTS MANUAL
MODELS: SB1600
Mud Buggy™
A 100% employee-owned American manufacturer
REVISION: C 07/2002
PN 56487

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Summary of Contents for Stone Mud Buggy SB1600

  • Page 1 SERVICE/PARTS MANUAL MODELS: SB1600 Mud Buggy™ A 100% employee-owned American manufacturer REVISION: C 07/2002 PN 56487...

  • Page 3: Table Of Contents

    Table of Contents Mud Buggy FOREWORD ........................... 5 LIMITED WARRANTY ......................... 6 TECHNICAL DATA ........................7-12 Machine Specifications ....................... 7 Engine Specifications........................8 Lubrication Specifications ......................8 Machine Sound Level Test ......................9 Imperial Torque Chart ......................... 10 Metric Torque Chart ........................11 Hardware Chart ...........................
  • Page 4 Table of Contents Mud Buggy EXPLODED DIAGRAM AND PARTS LIST ................29-57 Frame Assembly/Cowl, Hopper, Splash Guard ................. 30-31 Engine and Pump Assembly......................32-35 Wheelmotors and Brake Assembly ..................... 36-37 Brake Rods and Platform Lock Assembly .................. 38-39 Steering Assembly and Dump Platform Assembly ..............40-41 Steering, Hydraulic Tank, Battery Assemblies ................

  • Page 5: Foreword

    Battery Type: _______________________________ operation and the pertinent regulations for the prevention of accidents. Battery S/N: ________________________________ Stone Construction Equipment, Inc. is not Location of above information: liable for the function of the machine when used in an improper manner or for other 1.

  • Page 6: Limited Warranty

    No claim will be allowed for products lost or damaged in transit. Such claims should be filed with the carrier within fifteen days. Effective September 2001. Stone Construction Equipment, Inc. Phone: 1-800-888-9926 • 1-585-229-5141 Bred Tough, Technology Born To Work.

  • Page 7: Technical Data

    TECHNICAL DATA Specifications Stone Mud Buggy – Specifications 0 RGH O 6 % &D SD FLW\ P   &X )W    : H LJKW NJ   /H QJWK FP   : LGWK VLQJOH Z KH H O FP ...

  • Page 8: Engine Specifications

    TECHNICAL DATA Engine & Lubrication Specs (1*,1( 63(&,),&$7,216 (QJLQH 7\SH KS F\FOH 2YHUKHDG 9DOYH  N: (QJLQH 0DNH +RQGD (QJLQH 0RGHO *; 3RZHU #  530  IWOE  1P 2SHUDWLQJ 530  %DWWHU\  DPS )XHO 7\SH 8QOHDGHG *DV )XHO 7DQN &DSDFLW\  JDO  OLWHU )XHO &RQVXPSWLRQ...

  • Page 9: Machine Sound Level Test

    TECHNICAL DATA Sound Level Specs 0DFKLQH 7\SH 0XG %XJJ\ 0DWHULDO +DQGOHU 6RXQG /HYHO 0HWHU &DOLEUDWLRQ 'DWH )HEUXDU\   0HWHU 7\SH 6LPSVRQ 0RGHO  7\SH  7HVW 'DWH 6HSWHPEHU   7HVW &RQGLWLRQV 7HPSHUDWXUH  GHJUHHV )DKUHQKHLW   GHJUHH &HOVLXV $PELHQW 6RXQG GED IDVW PRGH 0RLVWXUH /LPLW...

  • Page 10: Imperial Torque Chart

    TECHNICAL DATA Imperial Torque Chart 6$( *5$'(  6$( *5$'(  &RDUVH 7KUHDG =LQF3ODWHG &RDUVH 7KUHDG =LQF3ODWHG 6,=( 72548( 6,=( 72548( IW OEV IW OEV                             ...

  • Page 11: Metric Torque Chart

    TECHNICAL DATA Metric Torque Chart 3URSHUW\ &ODVV  &RDUVH 7KUHDG )LQH 7KUHDG =,1&3/$7(' 6,=( IW OEV IW OEV 3URSHUW\ &ODVV  &RDUVH 7KUHDG )LQH 7KUHDG =,1&3/$7(' 6,=( IW OEV IW OEV  3URSHUW\ &ODVV  &RDUVH 7KUHDG )LQH 7KUHDG =,1&3/$7(' 6,=( IW OEV IW OEV...

  • Page 12: Hardware Chart

    TECHNICAL DATA Hardware - 12 -...

  • Page 13: Health & Safety

    HEALTH & SAFETY Safety Precautions Before using this equipment, study this entire manual to When warning decals are destroyed or missing, contact become familiar with its operation. Do not allow the Manufacturer immediately at 1-800-888-9926 for untrained or unauthorized personnel, especially children, replacement.
  • Page 14 HEALTH & SAFETY Safety Precautions USE COMMON SENSE WHEN HANDLING FUELS • Transport and handle fuel only when contained in approved safety container. • Do not smoke when refueling or during any other fuel handling operation. • Do not refuel while the engine is running or while it is still hot. •...
  • Page 15 HEALTH & SAFETY Safety Precautions • Never perform any work on the equipment while it is running. • Before working on the equipment, stop the engine and disconnect the spark plug wire(s) to prevent accidental starting. On electric models, disconnect the electric cord at the equipment. •...
  • Page 16 HEALTH & SAFETY Safety Precautions Warning-Eye Protection Always wear splash goggles when operating equipment. • • Starting fluid (ether) is highly flammable, do not use or an explosion or fire may result. • Never operate unit in a poorly ventilated or enclosed area. •...
  • Page 17 HEALTH & SAFETY Safety Precautions PRACTICE SAFE MAINTENANCE • Understand service procedure before doing work. Keep area clean and dry. • Never lubricate, service or adjust machine while it is moving. Keep hands, feet, and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure.

  • Page 18: Maintenance

    MAINTENANCE Tasks IMPORTANT The person attempting any of the following maintenance tasks must be authorized to do so and have read and understood all sections within this manual. - 18 -...

  • Page 19: Know Your Buggy

    MAINTENANCE Know Your Buggy/Engine Know Your Buggy IMPORTANT: DO NOT operate engine without the filter cover. Read and understand the owner’s manual before starting the unit. Make sure you understand the 1. Remove air cleaner cover. purpose of every control. When operating the unit, remember the capacity it can carry and adjust speed 2.

  • Page 20: Engine/Battery Policy

    Drink large amounts of water or milk. Then drink milk of magnesia, beaten Battery warranty begins when equipment is sold eggs, or vegetable oil. from Stone Construction Equipment, Inc. or a Stone Get medical attention immediately. dealer to a customer. •...

  • Page 21: Power Train/Transmission

    MAINTENANCE Power Train/Transmission CAUTION: This breather is designed to pressurize Power Train the reservoir to 5 PSI. Loosen cap slowly to avoid injury whenever adding oil or working on the See Lubrication Specifications Section. Check hydraulic system. Use a wrench on the hex directly hydraulic oil level daily using the sight gauge under the cap.

  • Page 22: Chassis Lube

    MAINTENANCE Chassis Lube/Brake Adjust Grease weekly using a grease gun. Remove the blue protection caps before greasing and replace when finished. Moving Joints, Hinges, Throttle, Controls, Cables--Lubricate with oil every 500 hours. Brake Adjustments Brakes are adjusted at factory and will need to be adjusted as brake shoes wear.

  • Page 23: Tires/Lugnuts And Hardware

    Tires, Lugnuts and Hard- MAINTENANCE ware/Changing Dual Wheel Tires, Lugnuts and Hardware Proper Care--Inspect tires for cuts, slashes, or bulges. Tires with defects need to be replaced or DO NOT exceed rated pressure. To ensure long tire repaired for proper handling and safety. life and safe handling check tire pressure daily.

  • Page 24: Fuel Tank

    Fuel Tank/Cold Weather Starting/ MAINTENANCE Parking & Transporting Buggy Hoses, Fittings and Leakage--Check weekly for Fasteners should be replaced with the same or higher loose hose fittings, damage, and leakage--it is grade. If higher grade fasteners are used, these important to check entire machine periodically. should only be tightened to the strength of the original.

  • Page 25: Lifting Points

    Lifting Points/ MAINTENANCE Transporting/Storage middle position. The transmission is also provided contact with buggy during mounting and dismount- with a bypass valve. ing. Always face the buggy whether mounting or dismounting. Transporting Machine--When transporting unit, observe overall height for proper clearance of Starting Instructions--Before starting engine, refer to obstacles overhead.

  • Page 26: Spring Start-Up

    MAINTENANCE Storage/Spring Start Up Storage (cont’d) 5. Operate the engine for a short period in order to circulate the lubricating oil. 6. Disconnect the battery. Then put the battery into safe storage in a fully charged condi- tion. Before the battery is put into storage, protect its terminals against corrosion.

  • Page 27: Troubleshooting

    MAINTENANCE Troubleshooting 7URXEOHVKRRWLQJ <RXU %XJJ\ (QJLQH /DFNV 3RZHU )XHO OLQH SOXJJHG &OHDQ RU UHSODFH 'LUW\ IXHO ILOWHU &OHDQ RU UHSODFH $LU ILOWHU GLUW\ &OHDQ RU UHSODFH :RUQ F\OLQGHU DQG SLVWRQ 5HSODFH ULQJV 7RR PXFK RLO LQ FUDQNFDVH 'UDLQ WR SURSHU OHYHO 2LO &RQVXPSWLRQ :RUQ YDOYH JXLGHV 5HSODFH...

  • Page 28: Service Record

    MAINTENANCE Service Record 0RGHO 1R 0DFKLQH 61 (QJLQH 61 5HFRUG +RXUV DQG 'DWHV RI 0DLQWHQDQFH %HORZ (QJLQH 2LO )LOWHU +\GUDXOLF 2LO )LOWHU %UHDWKHU $LU &OHDQHU *UHDVH )LWWLQJV %DWWHU\ %UDNHV 9DOYH &OHDUDQFH (QJLQH 530V )XHO 7DQN )XHO /LQHV +\GUDXOLF +RVHV&RQQHFWLRQV )RUZDUG5HYHUVH &RQWURO &DEOHV &KDUJH 6\VWHP +DUGZDUH /XJQXWV...

  • Page 29: Exploded Diagram And Parts List

    PARTS LIST Exploded Views with Parts EXPLODED DIAGRAM AND PARTS LIST ................ 29-57 Frame Assembly/Cowl, Hopper, Splash Guard ................. 30-31 Engine and Pump Assembly......................32-35 Wheelmotors and Brake Assembly ..................... 36-37 Brake Rods and Platform Lock Assembly .................. 38-39 Steering Assembly and Dump Platform Assembly ..............40-41 Steering, Hydraulic Tank, Battery Assemblies ................

  • Page 30: Frame Assembly/Cowl, Hopper, Splash Guard

    Frame Assembly PARTS LIST Cowl, Hopper, Splash Guard - 30 -...
  • Page 31 Frame Assembly PARTS LIST Cowl, Hopper, Splash Guard - 31 -...

  • Page 32: Engine And Pump Assembly

    PARTS LIST Engine and Pump Assembly - 32 -...
  • Page 33 PARTS LIST Engine and Pump Assembly - 33 -...
  • Page 34 PARTS LIST Engine and Pump Assembly - 34 -...
  • Page 35 PARTS LIST Engine and Pump Assembly - 35 -...

  • Page 36: Wheelmotors And Brake Assembly

    PARTS LIST Wheelmotors and Brake Assembly - 36 -...
  • Page 37 PARTS LIST Wheelmotors and Brake Assembly - 37 -...

  • Page 38: Brake Rods And Platform Lock Assembly

    Brake Rods and PARTS LIST Platform Lock Assembly - 38 -...

  • Page 39: Brake Rods And Platform Lock Assembly

    Brake Rods and PARTS LIST Platform Lock Assembly - 39 -...

  • Page 40: Steering Assembly And Dump Platform Assembly

    Steering Assembly PARTS LIST Dump Platform Assembly - 40 -...
  • Page 41 Steering Assembly PARTS LIST Dump Platform Assembly - 41 -...

  • Page 42: Steering, Hydraulic Tank, Battery Assemblies

    Steering, Hydraulic Tank, PARTS LIST Battery Assemblies - 42 -...
  • Page 43 Steering, Hydraulic Tank, PARTS LIST Battery Assemblies - 43 -...

  • Page 44: Parking Brake, Hydraulic Valves And Filter Assembly

    Parking Brake, Hydraulic Valves PARTS LIST and Filter Assembly - 44 -...
  • Page 45 Parking Brake, Hydraulic Valves PARTS LIST and Filter Assembly - 45 -...

  • Page 46: Captivators, Heat Shield And Cylinder Assembly

    Captivators, Heat Shield PARTS LIST and Cylinder Assembly - 46 -...
  • Page 47 Captivators, Heat Shield PARTS LIST and Cylinder Assembly - 47 -...
  • Page 48 Pneumatic Tire with PARTS LIST Standard Hubs Assembly - 48 -...

  • Page 49: Pneumatic Tire With Standard Hubs Assembly

    Pneumatic Tire with PARTS LIST Standard Hubs Assembly - 49 -...

  • Page 50: Foam Tires And Quick Change Hubs Assembly

    Foam Tires & Quick PARTS LIST Change Hubs Assembly - 50 -...
  • Page 51 Foam Tires & Quick PARTS LIST Change Hubs Assembly - 51 -...

  • Page 52: Dump Pedal Assembly

    PARTS LIST Dump Pedal Assembly - 52 -...
  • Page 53 PARTS LIST Dump Pedal Assembly - 53 -...

  • Page 54: Option Steel Bucket Assembly

    PARTS LIST Option Steel Bucket Assembly - 54 -...
  • Page 55 PARTS LIST Option Steel Bucket Assembly - 55 -...

  • Page 56: Hydraulic Diagram

    PARTS LIST Hydraulic Diagram - 56 -...
  • Page 57 PARTS LIST Hydraulic Diagram - 57 -...

  • Page 58: Hydraulic System Schematic

    PARTS LIST Hydraulic System Schematic - 58 -...
  • Page 59 PARTS LIST Hydraulic System Schematic - 59 -...

  • Page 60: Wiring Schematic Recoil Start

    PARTS LIST Wiring Schematic Recoil Start - 60 -...

  • Page 61: Wiring Schematic Electric Start

    PARTS LIST Wiring Schematic Electric Start - 61 -...

  • Page 62: Decal Identification

    PARTS LIST Decal Identification 45927 55200 55398 55485  - 62 -...
  • Page 63 PARTS LIST Decal Identification 45927 Decal Control Fwd/Rev Tilt 55200 Decal Lift Here 55215 Decal Warning Pinch Point 55398 Decal Warning Hot Surfaces 55422 Decal Hydraulic Fluid Mobil 424 55482 Decal Emissions Honda 55486 Decal Push Start 55485 Tag Switch Stop Fuel - 63 -...

  • Page 67: California Proposition 65 Warning

    CALIFORNIA PROPOSITION 65 WARNING Operation of this equipment and/or engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
  • Page 68 The Way It Ought To Be. Stone Construction Equipment, Inc. P.O. Box 150, Honeoye, New York 14471 Phone: (800) 888-9926 Fax: 585-229-2363 e-mail: sceny@mcimail.com www: stone-equip.com A 100% employee-owned American manufacturer © 1995 Stone Construction Equipment, Inc. Printed in U.S.A. GP1M...

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