Stone Mud Buggy SB1600 Guide

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

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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
I perial Torque Chart ................................................................................................................. 10
Metric Torque Chart .................................................................................................................... 11
Hardware Chart ........................................................................................................................... 12
HEALTH & SAFETY ..................................................................................................................... 13-17
MAINTENANCE............................................................................................................................. 18-28
Tasks ........................................................................................................................................... 18
Know Your Buggy ....................................................................................................................... 19
Engine ......................................................................................................................................... 19
Engine /Battery Policy ................................................................................................................ 20
Power Train/Trans ission .......................................................................................................... 21
Chassis Lube ............................................................................................................................... 22
Brake Adjust ent........................................................................................................................ 22
Tires/Lugnuts and Hardware ....................................................................................................... 23
Changing Dual Wheel to Single Wheel ...................................................................................... 23
Quick Release Wheel Option ......................................................................................................23
Hardware Guidelines .................................................................................................................. 23
Fuel Tank ..................................................................................................................................... 24
Cold Weather Starting ................................................................................................................. 24
Cleaning Machine ....................................................................................................................... 24
Parking/Transporting Buggy ....................................................................................................... 24-25
Lifting Points .............................................................................................................................. 25
Storage ........................................................................................................................................ 25-26
Spring Start-Up ........................................................................................................................... 26
Troubleshooting .......................................................................................................................... 27
Service Record ............................................................................................................................ 28

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Mud Buggy
Table of Contents
EXPLODED DIAGRAM AND PARTS LIST ............................................................................... 29-57
Fra e Asse bly/Cowl, Hopper, Splash Guard ......................................................................... 30-31
Engine and Pu p Asse bly........................................................................................................ 32-35
Wheel otors and Brake Asse bly ............................................................................................. 36-37
Brake Rods and Platfor Lock Asse bly .................................................................................. 38-39
Steering Asse bly and Du p Platfor Asse bly ..................................................................... 40-41
Steering, Hydraulic Tank, Battery Asse blies ........................................................................... 42-43
Parking Brake, Hydraulic Valves and Filter Asse bly ............................................................... 44-45
Captivators, Heat Shield and Cylinder Asse bly ....................................................................... 46-47
Pneu atic Tire with Standard Hubs Asse bly ........................................................................... 48-49
Foa Tires and Quick Change Hubs Asse bly .......................................................................... 50-51
Du p Pedal Asse bly ................................................................................................................ 52-53
Option Steel Bucket Asse bly ................................................................................................... 54-55
Hydraulic Diagra ...................................................................................................................... 56-57
Hydraulic Syste Sche atic ...................................................................................................... 58-59
Wiring Sche atic Recoil Start .................................................................................................... 60
Wiring Sche atic Electric Start .................................................................................................. 61
Decal Identification ..................................................................................................................... 62-63
CALIFORNIA PROPOSITION 65 WARNING ........................................................................... I C

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User Information
These instructions include:
Safety regulations
Operating instructions
Maintenance instructions
These instructions have been prepared for
operation on the construction site and for the
maintenance engineer.
These instructions are intended to simplify
operation of the machine and to avoid
malfunctions through improper operation.
Observing the maintenance instructions will
increase the reliability and service life of the
machine when used on the construction site
and reduce repair costs and downtimes.
Always keep these instructions at the place
of use of the machine.
Only operate the machine as instructed and
follow these instructions.
Observe the safety regulations as well as the
guidelines of the civil engineering trade
association. Observe the safety rules for
operation and the pertinent regulations for
the prevention of accidents.
Stone Construction Equipment, Inc. is not
liable for the function of the machine when
used in an improper manner or for other
than the intended purpose.
Operating errors, improper maintenance
and the use of incorrect operating materials
are not covered by the warranty.
The above information does not extend the
warranty and liability conditions of business
of Stone Construction Equipment, Inc.
Stone Construction Equipment, Inc.
P.O. Box 150, Honeoye, New Yor 14471
Phone: [phone]
Fax: [phone]
Foreword
1. Machine Type: ______________________________
Machine S/N: _______________________________
2. Engine Type: _______________________________
Engine S/N: ________________________________
3. VIN: ______________________________________
4. Purchase Date: ______________________________
. Dealer/Distributor Information:
Name: _____________________________________
Address: ___________________________________
__________________________________________
Phone #: ___________________________________
Fax #: _____________________________________
6. Battery
Manufacturer: ______________________________
Battery Type: _______________________________
Battery S/N: ________________________________
Location of above information:
1. Information on S/N tag.
2. Information on engine tag.
3. Information on S/N tag - if applicable.
4. Date you purchased machine.
. Dealer machine was purchased from.
6. Information on battery and battery warranty
card.

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L i m i t e d W a r r a n t y
The Manufacturer warrants that products manufactured shall be free from defects in material and
workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric
pumps, one year for Rhino®, Bulldog®, WolfPac Rollers, trowels, Stompers®, saws, forward plates,
engine powered pumps, Lift Jockey, Mortar Buggyand 6 months for all other products from the
dateof shipment. The foregoingshall be the exclusive remedyof the buyer and theexclusive liability of the
Manufacturer. Our warranty excludes normal replaceable wear items, i.e. gaskets, wear plates, seals, O-
rings, V-belts, drive chains, clutches, etc. Any equipment, part or product which is furnished by the
Manufacturer but manufactured by another, bears only the warranty given by such other manufacturer.
(TheManufacturer extendsthe warranty period to “Lifetime” for the drum bearings and seals for the mortar
mixers, and agrees to furnish, free of charge, the bearings and seals only upon receipt of the defective
parts.Thewarrantyis two yearsfor eccentric bearingson the forward plate compactors,mortar and plaster
mixerdrums, trowel gearboxes and five years on the Bulldogtrench rollereccentric bearings.) A Warranty
Evaluation Form must accompany all defective parts. Warranty is voided by product abuse, alterations,
and use of equipment in applications for which it was not intended, use of non-manufacturer parts, or
failuretofollowdocumentedservice instructions. The foregoing warrantyisexclusiveofall other warranties
whether written or oral, expressed or implied. No warranty of merchantability or fitness for a particular
purpose shall apply. The agents, dealer and employees of Manufacturer are not authorized to make
modification to this warranty, or additional warranties binding on Manufacturer. Therefore, additional
statements, whether oral or written, do not constitute warranty and should not be relied upon.
TheManufacturer’ssoleresponsibilityforanybreachof the foregoing provisionofthis contract, with respect
toany product or part not conforming tothe Warranty or thedescription hereincontained, is at its option (a)
to repair, replace or refund such product or parts upon the prepaid return thereof to location designated
specifically by the Manufacturer. Product returns not shipped prepaid or on an economical transportation
basis will be refused (b) as an alternative to the foregoing modes of settlement - the Manufacturer’s dealer
to repair defective units with reimbursement for expenses, except labor, and be reviewed with the
Manufacturer prior to repair. A Warranty Evaluation Form must accompany all warranty claims.
Except as set forth hereinabove and without limitation of the above, there are no warranties or other
affirmations which extends beyond the description of the products and the fact hereof, or as to operational
efficiency, product reliability or maintainability or compatibility with products furnished by others. In no
event whether as a result of breach of contract or warranty or alleged negligence, shall the Manufacturer
beliable for special or consequential damages including but not limited to: Loss ofprofits orrevenues, loss
of use of the product or any associated product, cost of capital, cost of substitute products, facilities or
services or claims of customers.
Noclaim will beallowed forproducts lost ordamaged in transit. Such claims shouldbe filed with the carrier
within fifteen days.
Effective September 2001.
9/01 P/N 51018
Stone Construction Equipment, Inc.
8662 Main Street, P. O. Box 150
Honeoye, NY 14471-0150
Phone: [phone] • 1-585-229-5141
Fax: [phone]
www.stone-equip.com • e-mail: [email protected]
Bred Tough, Technology Born To Work.
The Way It Ought To Be.

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TECHNICAL DATA
Stone Mud Buggy – Specifications
Specifications
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TECHNICAL DATA
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Engine & Lubrication Specs
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TECHNICAL DATA Sound Level Specs
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TECHNICAL DATA Imperial Torque Chart
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- 12 -
TECHNICAL DATA Hardware

- 13 -
HEALTH & SAFETY Safety Precautions
Before using this equip ent, study this entire anual to
beco e fa iliar with its operation. Do not allow
untrained or unauthorized personnel, especially children,
to operate this equip ent. Use only factory authorized
parts for service.
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety essages and decals in this anual and on
your achine safety signs. Keep decals in good condition. Replace
issing or da aged decals. Be sure new equip ent co ponents and
repair parts include the current safety signs. Replace ent safety
signs and decals are available through your dealer.
Learn how to operate the achine and how to use controls properly.
Do not let anyone operate without instruction.
Keep your achine in proper working condition. Unauthorized
odifications to the achine ay i pair the function and/or safety
and affect achine life.
If you do not understand any part of this anual and need assistance,
contact your dealer.
This notation appears before warnings in the text. It eans that the
step which follows ust be carried out to avoid the possibility of
personal injury or death. These warnings are intended to help the
technician avoid any potential hazards encountered in the nor al
service procedures. We strongly reco end that the reader takes
advantage of the infor ation provided to prevent personal injury or
injury to others.
UNDERSTAND SIGNAL WORDS
A signal word  DANGER, WARNING, or CAUTION  is used with
the safety-alert sy bol. DANGER identifies the ost serious hazards.
DANGER or WARNING safety signs are located near specific
hazards. General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety essages in this anual.
When warning decals are destroyed or issing, contact
the Manufacturer i ediately at 1-800-888-9926 for
replace ent. For the safety of yourself and others, it is
i perative that the following rules are observed. Failure
to do so ay result in serious injury or death.

- 14 -
HEALTH & SAFETY Safety Precautions
HOT SURFACES
 Avoid contact with hot exhaust syste s and engines.
 Allow all co ponents in the engine co part ent to cool before
perfor ing any service work.
USE COMMON SENSE WHEN HANDLING FUELS
 Transport and handle fuel only when contained in approved safety
container.
 Do not s oke when refueling or during any other fuel handling
operation.
 Do not refuel while the engine is running or while it is still hot.
 If fuel is spilled during refueling, wipe it off fro the engine
i ediately and discard the rag in a safe place.
 Do not operate the equip ent if fuel or oil leaks exist - repair
i ediately.
 Never operate this equip ent in an explosive at osphere.
Always use the proper size grounded extension cord, confor ing to
the National Electric Code and Local Ordinances.
Inspect all extensions and electrical cords for cuts, frayed wire and
broken connectors before use. Do not use cords if not in good
condition.
Do not route extension cords through standing water.
Do not operate the equip ent in standing water.
When cleaning the equip ent, never spray water on the electric
otor.
 Never leave equip ent unattended while running.
 Be certain you can control both speed and direction before oving.
 This is a one-person buggy. Never per it riders.
 Avoid sharp turns at high speed.

- 15 -
HEALTH & SAFETY Safety Precautions
PREPARE FOR EMERGENCIES
 Be prepared if a fire starts.
 Keep a first aid kit and fire extinguisher handy.
 Keep e ergency nu bers for doctors, a bulance service, hospital,
and fire depart ent near your telephone.
 Never perfor any work on the equip ent while it is running.
 Before working on the equip ent, stop the engine and disconnect the
spark plug wire(s) to prevent accidental starting. On electric odels,
disconnect the electric cord at the equip ent.
 Keep cowl closed and latched during the operation, close and latch
cowl i ediately after starting.
 Keep hands, clothing and jewelry away fro all oving parts.
 Keep all guards in place.
WEAR PROTECTIVE CLOTHING
 Wear close fitting clothing and safety equip ent appropriate to the
job.
 Prolonged exposure to loud noise can cause i pair ent or loss of
hearing.
 Wear a suitable hearing protective device such as ear uffs or
earplugs to protect against objectionable or unco fortable loud
noises.
 Operating equip ent safely requires the full attention of the
operator. Do not wear radio or usic headphones while operating
achine.

- 16 -
HEALTH & SAFETY Safety Precautions
 Starting fluid (ether) is highly fla able, do not use or an
explosion or fire ay result.
 Never operate unit in a poorly ventilated or enclosed area.
 Avoid prolonged breathing of exhaust gases.
 Engine exhaust fu es can cause sickness or death.
Warning-Eye Protection
•Always wear splash goggles when operating equip ent.

- 17 -
HEALTH & SAFETY Safety Precautions
PRACTICE SAFE MAINTENANCE
 Understand service procedure before doing work. Keep area clean
and dry.
 Never lubricate, service or adjust achine while it is oving. Keep
hands, feet, and clothing fro power-driven parts. Disengage all
power and operate controls to relieve pressure. Lower equip ent to
the ground. Stop the engine. Re ove the key. Allow achine to
cool.
 Securely support any achine ele ents that ust be raised for
service work.
 Keep all parts in good condition and properly installed. Repair
da age i ediately. Replace worn or broken parts. Re ove any
buildup of grease, oil, or debris.
 Disconnect battery ground cable (-) before aking adjust ents on
electrical syste s or welding on achine.
DISPOSE OF WASTE PROPERLY
 I properly disposing of waste can threaten the environ ent and
ecology. Potentially har ful waste used with equip ent include
such ite s as oil, fuel, coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use food or
beverage containers that ay islead so eone into drinking fro
the .
 Do not pour waste onto the ground, down a drain, or into any water
source.
 Air conditioning refrigerants escaping into the air can da age the
Earths at osphere. Govern ent regulations ay require a certified
air conditioning service center to recover and recycle used air
conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste fro your
local environ ental or recycling center.
DECALS - FOR THE SAFETY OF YOURSELF AND OTHERS REPLACE ANY DAMAGED
OR MISSING SAFETY DECALS. SEE DECAL IDENTIFICATION SECTION.

- 18 -
MAINTENANCE
FIMPORTANT
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.
Tasks

- 19 -
MAINTENANCE Know Your Buggy/Engine
Know Your uggy
Read and understand the owners anual before
starting the unit. Make sure you understand the
purpose of every control. When operating the unit,
re e ber the capacity it can carry and adjust speed
and load for changing conditions.
Inspect Machinery--A daily inspection of the unit
is reco ended to insure all syste s are in proper
working orders.
Check Travel Path--Inspect the surface on which
the unit is going to travel. Avoid soft soil, slippery
spots, and water spots. Look for anything that will
ake you lose control.
Machine Cleanliness--Keep unit clean of all debris.
Make sure foot stand stays clean to prevent acci-
dents.
ENGINE
Refer to engine anual for specific engine infor a-
tion.
Oil Fill Location--checking and filling oil is acco -
plished through the opening on side of engine. Fill
oil until level with filler opening.
Oil Grade and Capacity--Engine requires 1.16
quarts/1.1 liter.
 Over 40 Degrees Fahrenheit/13 Degrees
Celsius SAE 30
 Below 40 Degrees Fahrenheit/13 Degrees
Celsius SAE 20
Air Filter--Check air filter before each use and
clean after every 50 hours of service.
Clean pri ary (outer) ele ent at 40 hours (after
break-in period) then every 500 hours or 12 onths.
Service air cleaner ore frequently in dusty
conditions.
IMPORTANT: DO NOT operate engine without the
filter cover.
1. Re ove air cleaner cover.
2. Re ove pri ary (outer) ele ent only.
3. Thoroughly clean all dirt fro inside filter
housing. Insert the cleaning gun into
ele ent, hold air nozzle about 1 (25.4 )
fro perforated etal retainer. Force air
through filter fro inside to outside and
ove air gun up and down pleats to re ove
as uch dirt as possible.
IMPORTANT: Only a special air cleaning gun
should be used. Concentrated air pressure fro an
ordinary nozzle ay severely da age filter ele ent.
DO NOT exceed 30 PSI (2.1 bar) when cleaning
filter ele ent.
4. Inspect filter to deter ine if it is practical to
clean or for da age after cleaning filter. If
necessary, repeat step one to re ove
additional dirt.
a. Hold a bright light inside ele ent
and check carefully for holes.
Discard any ele ent that shows the
s allest hole or rupture.
b. Be sure outer screen is not dented.
Vibration would quickly wear a hole
in filter.
c. Be sure filter gasket is in good
condition. If gasket is da aged or
issing, replace ele ent.
5. Gently pat sides of ele ent with pal of
hand to loosen dirt. DO NOT tap ele ent
against a hard surface.
Electric Start Option--Inspect battery connections
daily for cleanliness and tightness. Replace worn or
frayed wires.

- 20 -
MAINTENANCE
attery--Battery replace ent is a Crown U1-12 or
equal 165 CCA battery. See Engine Specifications
Section for battery require ents.
Battery vapors can explode. Keep sparks and fla es
away fro batteries. Use a flashlight to check
battery electrolyte level. Never check battery charge
by placing a etal object across the posts. Use a
volt eter or hydro eter. Sulfuric acid in battery
electrolyte is poisonous. It is strong enough to burn
skin, eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
- Filling batteries in a well-ventilated area.
- Wearing eye protection and rubber
gloves.
- Avoid breathing fu es when electrolyte
is added.
- Avoid spilling or dripping electrolyte.
- Use proper ju p start procedures.
If you spill acid on yourself:
- Flush your skin with water.
- Apply baking soda or li e to help
neutralize the acid.
- Flush your eyes with water for 10 - 15
inutes. Get edical attention
i ediately.
If acid is swallowed:
- Drink large a ounts of water or ilk.
- Then drink ilk of agnesia, beaten
eggs, or vegetable oil.
- Get edical attention i ediately.
 Once a onth check the battery condition.
With engine off, check the battery for 12.5
volts with a volt eter or check the specific
gravity of the electrolyte fluid in each cell.
 Check for proper electrolyte fluid level. Use
distilled water when adding and run 30
inutes to ix. Clean battery, posts, and
ter inals. Disconnect battery cables before
charging to avoid da age to the electrical
syste .
 Once a onth, check the charging syste
with the engine running at full speed for 13 -
14 volts with a volt eter to ensure engine
volt eter readings are correct.
 Keep batteries clean by wiping the with a
da p cloth. Keep all connections clean and
tight. Re ove any corrosion and wash
ter inals with a solution of 1 part baking
soda and 4 parts water. Tighten all
connections and check that the battery is
securely fastened with properly installed
hold downs.
NOTE: Coat battery ter inals and connectors with
a ixture of petroleu jelly and baking soda to
retard corrosion.
 Keep battery fully charged, especially
during cold weather. If a battery charger is
used, turn charger off before connecting
charger to battery. Attach POSITIVE (+)
battery charger lead to POSITIVE (+)
battery post. Then attach NEGATIVE (-)
battery charger lead to a good ground.
attery Policy
Battery warranty begins when equip ent is sold
fro Stone Construction Equip ent, Inc. or a Stone
dealer to a custo er.
Battery warranty clai s ust include the units
purchase receipt with date. Clai s without purchase
receipt will be based on the battery identification
nu bers.
Battery returns and/or adjust ents are ade through
battery distributors.
For nearest Crown distributor call: 1-800-237-6126.
Engine/Battery Policy