Stone Champion 855PM Building instructions

SERVICE/PARTS MANUAL
MODELS: 655PM, 755PM, 855PM
REVISION: C 02/2001 P/N 56360
CHAMPION®
PLASTER MORTAR MIXER
A 100% employee-owned American manufacturer

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Table of Contents 655PM, 755PM, 855PM
TABLE OF CONTENTS ................................................................................................................. 3-4
USER INFORMATION ................................................................................................................... 5
LIMITED WARRANTY .................................................................................................................. 6
TECHNICAL DATA ........................................................................................................................ 7-12
655PM, 755PM, 855PM S ecifications ........................................................................................... 7
Machine Sound and Vibration Measurements ................................................................................. 8
Hardware .......................................................................................................................................... 9
Torque Chart - Im erial .................................................................................................................... 10
Torque Chart - Metric....................................................................................................................... 11
Location and Use of Controls .......................................................................................................... 12
HEALTH & SAFETY ...................................................................................................................... 13-16
Safety Training ................................................................................................................................. 13
Safety Precautions ............................................................................................................................ 14-16
MAINTENANCE............................................................................................................................. 16-24
Maintenance Tasks ........................................................................................................................... 16
Wheel Bearing Lubrication/Wheel Bearing Adjustment/Torque Chart/Towing.............................. 17
Towing .............................................................................................................................................. 18
Bull Gear Assembly ......................................................................................................................... 19
Bearing and Seal Installation ........................................................................................................... 20
Trailer Lights O tion ........................................................................................................................ 21
Electric Wiring ................................................................................................................................. 22
Lubrication Schedule ....................................................................................................................... 23

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Table of Contents
DRAWINGS with PART NUMBER BREAKDOWNS ................................................................... 25-51
Frame and Drum Assembly .............................................................................................................. 26-29
Paddle Assembly .............................................................................................................................. 30-33
Hand Clutch Assembly ..................................................................................................................... 34-35
S iral Blades Assembly .................................................................................................................... 36-37
Gas Engine Drive Train .................................................................................................................... 38-41
Electric Motor Drive Train ............................................................................................................... 42-43
O tional S ring Axle Assembly ....................................................................................................... 44-45
Standard Axle Assembly .................................................................................................................. 46-47
Trailer Light Assembly..................................................................................................................... 48-49
Decal Identification .......................................................................................................................... 50-51
CALIFORNIA PROPOSITION 65 .................................................................................................. IBC
655PM, 755PM, 855PM

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User Information Foreword/Service Information
These instructions include:
Safety regulations
O erating instructions
Maintenance instructions
These instructions have been prepared for operation
on the construction site and for the maintenance
engineer.
These instructions are intended to sim lify o eration of
the machine and to avoid malfunctions through im ro er
o eration.
Observing the maintenance instructions will increase the
reliability and service life of the machine when used on
the construction site and reduce re air costs and down-
times.
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 guide-
lines of the civil engineering trade association. Ob-
serve safety rules for the operation of equipment and
the pertinent regulations for the prevention of acci-
dents.
Stone Construction Equi ment, Inc. is not liable for the
function of the machine when used in an im ro er
manner and for other than the intended ur ose.
O erating errors, im ro er maintenance and the use of
incorrect o erating materials are not covered by the
warranty.
The above information does not extend the warranty and
liability conditions of business of Stone Construction
Equi ment, Inc.
Stone Construction Equipment, Inc.
P.O. Box 150, Honeoye, New Yor 14471
Phone: [phone]
Fax: [phone]
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.

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, and 6 months for all other products from the date of shipment. The foregoing
shall be the exclusive remedy of the buyer and the exclusive 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, bearsonly the warrantygiven bysuch othermanufacturer. (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. The warranty is two years for
eccentric bearings on the forward plate compactors, mortar and plaster mixer drums, trowel gearboxes
andfiveyearsontheBulldogtrenchrollereccentricbearings.) A Warranty Evaluation Formmustaccompany
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 failure to follow documented service
instructions. Theforegoing warrantyis exclusiveof allother warrantieswhether writtenor oral,expressed
or implied. No warranty of merchantability or fitness for a particular purpose shall apply. The agents,
dealerandemployees of Manufacturerare notauthorized tomake modificationto thiswarranty,oradditional
warranties binding on Manufacturer. Therefore, additional statements, whether oral or written, do not
constitute warranty and should not be relied upon.
TheManufacturer’ssole responsibilityforanybreach oftheforegoingprovision ofthiscontract,with respect
toany productor partnotconforming tothe Warranty orthe descriptionherein contained, isat itsoption (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 forspecial orconsequential damages includingbut notlimited to:Loss of profitsor revenues,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 willbeallowed forproducts lostordamaged intransit. Such claims shouldbe filedwiththe carrier
within fifteen days.
EffectiveApril 1, 1998.
4/98 P/N 51018
Stone Construction Equipment, Inc.
32 East Main Street, P. O. Box 150
Honeoye, NY 14471-0150
Phone: [phone] • 1-716-229-5141
Fax: [phone]
www.stone-equip.com • e-mail: [email protected]
Bred Tough, Born To Work. The
Way It Ought To Be.

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Technical Data 655PM, 755PM, 855PM –
Specifications
MODEL
Origin
Dimensions
Operating Wt. lbs/Kg
Batch Capacity (Bags)
Batch Capacity cu. t. / cu. m.
Total Volume cu. t. / cu. m.
L x W x H in. / cm
Operating System
Engine
Drive & Clutch
Standard Features
Drum Wrap in. / mm
Drum End in. / mm
Pour Lip in. / mm
Drum Lock in. / mm
Paddles:
Number
Mixing Action
Paddle Sha t
Frame/Axle:
Tow Pole
Axle - extendible
Tires
Cowl:
Other Features:
Bag Splitter
Sa ety Guard
Guard Li ter
Sa ety Chain
Warranty:
Warranty Machine
Warranty Drum Bearing
Drum Warranty
Options:
755PM
U.S.A.
565 / 257
2 - 2 1/2 bags
7 / .20
8.1 / .23
68 x 34 x 54 / 173 x 86 x 137
6 hp Robin / 4.5 kw
7 hp B&S / 5.2 kw
7 hp B&S /P / 5.2 kw
7.5 hp Robin / 5.6 kw
8 hp B&S / 6.0 kw
8 hp Honda / 6.0 kw
1 1/2 hp / 1.1 kw Electric
V-Belt to Gears
Front Post Hand Clutch
11 ga. .120 / 3.05
7 ga. .179 / 4.55
7 ga. .179 / 4.55
automatic (patented)
4
Simple figure 8
1 1/2" / 38.1 mm round
Post Gussett, pintle,
pin or ball hitch
34" - 46" / 86 - 117 cm
4.80 x 12 (high speed)
16 galv., stainless steel hinge,
diamond shaped expanded
steel vent. panels
standard
lift away, heavy-duty
standard (patented)
standard
6 months
lifetime on patented
quadruple bearings and seals
2 years
spiral blades
13 in. / 33 cm tire
spring axle
655PM
U.S.A.
550 ./ 250
1 1/2 - 2 bags
6 / .17
6.9 / .20
64 x 34 x 54 / 163 x 86 x 137
5 hp B&S / 3.7 kw
5.5 hp Honda / 4.10 kw
6 hp Robin / 4.5 kw
7 hp B&S / 5.2 kw
7 hp B&S /P / 5.2 kw
7.5 hp Robin / 5.6 kw
8 hp B&S / 6.0 kw
8 hp Honda / 6.0 kw
1 1/2 hp / 1.1 kw Electric
V-Belt to Gears
Front Post Hand Clutch
11 ga. .120 / 3.05
7 ga. .179 / 4.55
7 ga. .179 / 4.55
automatic (patented)
4
Simple figure 8
1 1/2" / 38.1 mm round
Post Gussett, pintle,
pin or ball hitch
34" - 46" / 86 - 117 cm
4.8 x 12 (high speed)
16 galv., stainless steel hinge,
diamond shaped expanded
steel vent panels
standard
lift away, heavy-duty
standard (patented)
standard
6 months
lifetime on patented
quadruple bearings and seals
2 years
spiral blades
855PM
U.S.A.
605 / 275
2 1/2 - 3 bags
8 / .23
9.0 / .25
76 x 34 x 54 / 193 x 86 x 137
7 hp B&S / 5.2 kw
7 hp B&S /P / 5.2 kw
7.5 hp Robin / 5.6 kw
8 hp B&S / 6.0 kw
8 hp Honda / 6.0 kw
10 hp B&S /C / 7.5 kw
2 hp / 1.5 kw Electric
V-Belt to Gears
Front Post Hand Clutch
11 ga. .120 / 3.05
7 ga. .179 / 4.55
7 ga. .179 / 4.55
automatic (patented)
4
Simple figure 8
1 1/2" / 38.1 mm round
Post Gussett, pintle,
pin or ball hitch
34" - 46" / 86 - 117 cm
B78 x 13 (high speed)
16 galv., stainless steel hinge,
diamond shaped expanded
steel vent. panels
standard
lift away, heavy-duty
standard (patented)
standard
6 months
lifetime on patented
quadruple bearings and seals
2 years
spiral blades
plastic drums
spring axle

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Technical Data Machine Sound and Vibration
Measurements
Sound and Vibration Measurements
Sound Pressure Values as measured are per the following:
Noise 1 Model/Configuration
Sound Pressure 655PM
8hp Honda
Tow pole end 92dBA
Cowl end right side (exhaust) 98dBA
Cowl end back of unit 98dBA
Cowl end left side 94dBA
Sound Pressure measurements were taken with Simpson model 886-2 type 2 meter,
calibrated 2/21/97
Acceleration measurements were taken with Quest Tech model VI-100 meter, calibrated
4/17/96
Sound and vibration measurements obtained with machine operating at maximum.
Test date was 7/29/98 with test conditions at 23 degrees Celsius
\\mktg\stone1\netaldus\pm5\engr\bonnie\bln\sound_pm.doc

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Technical Data Hardware
--GR2

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Technical Data Torque Chart - Imperial
SAE GRADE 8
Coarse Thread
SIZE PLATED
1/4 –20 (.250) 9 ft. lbs. 12 Nm
5/16 –18 (.3125) 18 ft. lbs. 24 Nm
3/8 –16 (.375) 33 ft. lbs. 45 Nm
7/16 –14 (.4375) 52 ft. lbs. 70 Nm
1/2 –13 (.500) 80 ft. lbs. 108 Nm
9/16 –12 (.5625) 115 ft. lbs. 156 Nm
5/8 –11 (.625) 159 ft. lbs. 215 Nm
3/4 –10 (.750) 282 ft. lbs. 382 Nm
7/8 –9 (.875) 454 ft. lbs. 615 Nm
1 –8 (1.000) 682 ft. lbs. 925 Nm
SAE GRADE 8
Fine Thread
SIZE PLATED
1/4 –28 (.250) 10 ft. lbs. 14Nm
5/16 –24 (.3125) 20 ft. lbs. 27 Nm
3/8 –24 (.375) 37 ft. lbs. 50 Nm
7/16 –20 (.4375) 58 ft. lbs. 79 Nm
1/2 –20 (.500) 90 ft. lbs. 122 Nm
9/16 –18 (.5625) 129 ft. lbs. 175 Nm
5/8 –18 (.625) 180 ft. lbs. 244 Nm
3/4 –16 (.750) 315 ft. lbs. 427 Nm
7/8 –9 (.875) 501 ft. lbs. 679 Nm
1 –12 (1.000) 746 ft. lbs. 1011 Nm
1 –14 (1.000) 764 ft. lbs. 1036 Nm
SAE GRADE 5
Coarse Thread
SIZE PLATED
1/4 –20 (.250) 6 ft. lbs. 8 Nm
5/16 –18 (.3125) 13 ft. lbs. 18 Nm
3/8 –16 (.375) 23 ft. lbs. 31 Nm
7/16 –14 (.4375) 37 ft. lbs. 50 Nm
1/2 –13 (.500) 57 ft. lbs. 77 Nm
9/16 –12 (.5625) 82 ft. lbs. 111 Nm
5/8 –11 (.625) 112 ft. lbs. 152 Nm
3/4 –10 (.750) 200 ft. lbs. 271 Nm
7/8 –9 (.875) 322 ft. lbs. 436.5 Nm
1 –8 (1.000) 483 ft. lbs. 655 Nm
SAE GRADE 5
Fine Thread
SIZE PLATED
1/4 –28 (.250) 7 ft. lbs. 10Nm
5/16 –24 (.3125) 14 ft. lbs. 19 Nm
3/8 –24 (.375) 26 ft. lbs. 35 Nm
7/16 –20 (.4375) 41 ft. lbs. 56 Nm
1/2 –20 (.500) 64 ft. lbs. 87 Nm
9/16 –18 (.5625) 91 ft. lbs. 123 Nm
5/8 –18 (.625) 128 ft. lbs. 173 Nm
3/4 –16 (.750) 223 ft. lbs. 302 Nm
7/8 –14 (.875) 355 ft. lbs. 481 Nm
1 –12 (1.000) 529 ft. lbs. 717 Nm
1 –14 (1.000) 541 ft. lbs. 733 Nm

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Technical Data
Property Class 8.8
ZINC-PLATED Coarse Thread Fine Thread
SIZE Nm ft. lbs. Nm ft. lbs.
M6 9.9 7 10 7
M8 24 18 25 18
M10 48 35 49 36
M12 83 61 88 65
M14 132 97 140 103
M16 200 148 210 155
M20 390 288 425 313
M24 675 498 720 531
Property Class 10.9
ZINC-PLATED Coarse Thread Fine Thread
SIZE Nm ft. lbs. Nm ft. lbs.
M6 14 10 14 10
M8 34 25 35 26
M10 67 49 68 50
M12 117 86 125 92
M14 185 136 192 142
M16 285 210 295 218
M20 550 406 600 443
M24 950 701 1000 738
Property Class 12.9
ZINC-PLATED Coarse Thread Fine Thread
SIZE Nm ft. lbs. Nm ft. lbs.
M6 16.5 12 16.5 12
M8 40 30 42 31
M10 81 60 82 60
M12 140 103 150 111
M14 220 162 235 173
M16 340 251 350 258
M20 660 487 720 531
M24 1140 841 1200 885
Conversion Factor: 1 ft. lb. = 1.3558 Nm
Torque Chart - Metric

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Technical Data Location and Use of Controls
Before o erating this unit, it is im ortant to
familiarize yourself, and any other ersonnel who
will be using it, with the location and ro er use of
the controls to insure safe and efficient o eration.
A. Always make sure that the drum latch is in the
lock osition (down) before starting u machine.
With engine running, turn clutch lever to the
right to turn addles or to the left to sto .
B. To dum mix from drum, sto addles, move
drum latch u and ull dum handle down.
Always use caution when dum ing mix.
C. Always grease drum seals as recommended in
the maintenance chart. The grease urges dirt--
rolonging bearing life.
D. Always kee drum and addles clean. Never run
machine with hardened mix or foreign objects in
drum--doing so damages addles and/or engine.

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Health & Safety
SAFETY
These machines are designed to carry out the function of
mixing material of the non-cohesive, bituminous and
granular varieties.
If used correctly, they will provide an effective and safe
means of mixing and meet the appropriate performance
standards.
It is essential that the operator of the machine is ad-
equately trained in its safe operation, be authorized to
operate it, and have sufficient knowledge of the machine
to ensure that it is in full working order, before being put
to use.
Safety Training

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Health & Safety Safety Precautions
· Before using this equi ment, study the entire Owners Manual to become familiar
with its o eration. Do not allow untrained or unauthorized ersonnel, es ecially
children, to o erate this equi ment. Use only factory authorized arts for service.
· When warning decals are destroyed or missing, contact the Manufacturer immedi-
ately at 1-800-888-9926 for re lacement. For the safety of yourself and others, it is
im erative that the following rules are observed. Failure to do so may result in
serious injury or death.
· This notation a ears before warnings in this manual. It means that the following
ste s must be carried out to avoid the ossibility of ersonal injury or death. These
warnings are intended to hel the technician avoid otential hazards encountered in
normal service rocedures. We strongly recommend the reader take advantage of
the information rovided to revent ersonal injury or injury to others.
Warning - Loose Hardware
· With ower off, daily check for loose hardware. Immediately inform your su ervi-
sor to have it corrected--Do Not Run the Mixer.
Warning-Handling Fuel
· Trans ort and handle fuel only when contained in a roved safety containers.
· Do not smoke when refueling the mixer or during any other fuel handling o eration.
· Do not refuel the mixer with the unit running or while hot.
· If fuel is s illed during refueling, wi e it off the engine immediately and discard the
rag in a safe lace.
· Do not o erate the equi ment if fuel or oil leaks exist  re air immediately.
· Never o erate this equi ment in an ex losive atmos here.

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Health & Safety Safety Precautions
Warning-Operating
· Never erform any work on the mixer while it is running.
· Before working on the mixer, sto the engine and un lug disconnect the s ark lug
wire(s) to revent accidental starting. If electric, un lug motor.
· Kee cowl closed during o eration.
· Kee hands, clothing and jewelry away from all moving arts.
· Kee all guards in lace, including drum guards.
· Never stick your hands or any solid object into the drum while it is in o eration.
Warning-Hot Surfaces
· Avoid contact with hot exhaust system and engines.
· Allow engine to cool before erforming any re airs or service.
Warning-Ventilation
· Never o erate any gas owered mixer in a oorly ventilated or enclosed area.
· Avoid rolonged breathing of exhaust gases.
Warning-Extension Cords
· Always use the ro er size grounded extension cord, conforming to the National
Electric Code and Local Ordinances.
· Ins ect all extension and electrical cords for cuts, frayed wire and broken connec-
tors before use. Do not use cords if not in good condition.
· Do not route extension cords through standing water.
· Do not o erate the mixer in standing water.
· When cleaning the mixer, never s ray water over the motor.

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Health & Safety
Warning-Eye Protection
· Always wear s lash goggles when o erating mixer.
Warning-Towing
· Warning: Do not tow the mixer with the drum in the dum osition. Mixer may
become unstable and ti over when hitting a curb, othole, or other obstruction.
· Warning: Always ro erly attach safety chains before mixer is towed. Maxi-
mum towing s eed 65 m. .h. (105 km/hr). Reduce s eed according to highway
conditions.
· Never leave mixer unattended while running.
· Mix only Mortar, Plaster, Terrazzo, Fire roofing and Grout.
· Do Not o erate machine if rocks, stones, ice or frozen materials are in mix
and/or in drum of mixer. The machine could jam, causing damage to the
equi ment or injury to the o erator.
Safety Precautions

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Maintenance
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
Maintenance Tasks

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Maintenance
TOW NG--Before attem ting to tow this mixer,
check the state and local laws that a ly to your
intended route and check the following:
1. Hitch attached to the towing vehicle securely.
2. Tow ole fully extended and bolted to mixer
securely.
3. Safety chain hooked u ro erly (see illustration
below or decal on mixer front ost).
4. Drum in the mixing osition and drum latch
engaged, clutch lever in the u osition.
5. Lug nuts and axle mount nuts tight.
WHEEL BEAR NG LUBR CAT ON--Fill wheel
hub with grease to inside diameter of outer races and
also fill hub grease ca . Never use grease heavier
than 265 A.S.T.M. enetration (No. 2 grade).
Grease bearing cone by machine or by hand method.
Force grease between rollers, cone and cage. (If
Ball Bearing Hub: force grease between balls.) It is
not recommended that a ressure grease fitting be
installed on the hub.
WHEEL BEAR NG ADJUSTMENT--Tighten the
adjusting nut with a 12" wrench, at the same time
turn the wheel in both directions, until there is a
slight bind to be sure all bearing surfaces are in
contact. Then back off adjusting nut 1/6 to 1/4 turn
or to the nearest locking hole or sufficiently to allow
the wheel to rotate freely within limits of 0.001" to
0.010" end lay. Lock nut at this osition.
HARDWARE--Periodically ins ect all hardware on
the mixer and engine / motor. Loose hardware can
contribute to early com onent failure and oor
erformance.
NOTE: Some hardware is used to retain arts that
have to move freely for correct o eration of this
unit. These items include the guard lifter and drum
guard. The hardware for these items should be snug
enough to revent excessive lay, yet loose enough
to allow the arts to ivot freely.
Wheel Bearing Lubrication/Wheel
Bearing Adjustment/Hardware/
Towing

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Maintenance
6. On extendible axles, axle extended to full
width and adjustment bolts tight.
7. On s ring axles - s ring mounting hardware
tight, main s rings and snubber s rings not
cracked or broken.
8. Tires in good sha e and at ro er inflation, for
maximum safety and load ca acity tires should
be inflated to the following ressures:
Tire size 4.80 x 12 @ 60 P.S.I.
Tire size 6.50 x 13 @ 32 P.S.I.
Refer to FRAME AND DRUM ASSEMBLY,
STANDARD AXLE ASSEMBLY and SPRING
AXLE ASSEMBLY sections of this manual for arts
identification and location.
Towing

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Maintenance
Bull Gear Assembly
1. Align Bull Gear key way opposite to gear mesh.
2. Adjust pinion for tooth alignment and engagement using
.030 feeler gage.
3. Tighten all four 4) pillow block bolts before removing
feeler gage.
Bull Gear Assembly