WB 16 - Wacker Neuson

Transcription

www.wackergroup.com
0155919en
003
1106
Concrete Buggy
WB 16 /...
OPERATOR’S MANUAL
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WB 16 /...
Table of Contents
1.
Foreword
3
2.
Safety Information
4
2.1
2.2
2.3
2.4
2.5
2.6
3.
Technical Data
3.1
3.2
3.3
3.4
3.5
4.
Laws Pertaining to Spark Arresters ...................................................... 4
Operating Safety .................................................................................. 5
Operator Safety while using Internal Combustion Engines .................. 7
Service Safety ...................................................................................... 8
Label Locations .................................................................................. 10
Safety and Information Labels ............................................................ 11
17
Engine ................................................................................................ 17
Machine .............................................................................................. 18
Lubrication .......................................................................................... 19
Sound Measurements ........................................................................ 19
Dimensions ......................................................................................... 20
Operation
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
21
Application .......................................................................................... 21
Operation and Service Locations ....................................................... 22
Before Starting ................................................................................... 23
To Start ............................................................................................... 24
To Stop ............................................................................................... 25
Operation ............................................................................................ 26
Braking Machine ................................................................................. 28
Operating the Bucket .......................................................................... 29
Operation on Slopes ........................................................................... 30
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Table of Contents
5.
WB 16 /...
Maintenance
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
31
Engine Maintenance ............................................................................31
Maintenance Schedule ........................................................................31
Engine Oil ............................................................................................33
Air Cleaner ..........................................................................................34
Spark Plug ...........................................................................................35
Sediment Cup ......................................................................................35
Carburetor ...........................................................................................36
Hydraulic System Cleanliness .............................................................37
Hydraulic Oil Requirements .................................................................38
Hydraulic Oil Level ..............................................................................39
Changing Hydraulic Oil & Filter ...........................................................40
Wheel Bearings ...................................................................................41
Brake Adjustment ................................................................................43
Neutral Switch .....................................................................................45
Transporting Machine ..........................................................................47
Lifting Machine ....................................................................................48
Cleaning ..............................................................................................49
Storage ................................................................................................50
Hydraulic Schematic/Diagram .............................................................51
Electrical Schematics ..........................................................................53
Troubleshooting ...................................................................................55
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WARNING
1.
CALIFORNIA
Proposition 65 Warning:
Engine exhaust, some of its constituents, and certain vehicle
components, contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproductive
harm.
Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2006 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
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Safety Information
2.
WB 16 /...
Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of
personal injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
DANGER
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAUTION
NOTICE: Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage
Note: Contains additional information important to a procedure.
2.1
Laws Pertaining to Spark Arresters
Notice: State Health Safety Codes and Public Resources Codes
specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.
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WB 16 /...
2.2
Operating Safety
WARNING
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Safety Information
Familiarity and proper training are required for the safe operation of
equipment. Equipment operated improperly or by untrained personnel
can be dangerous. Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.
2.2.1
All safety instructions and decals are in place to help ensure the safe
operation of the machine. Disregard of these safety instructions could
result in accidents and/or injury.
2.2.2
The buggy is an industrial machine which needs to be operated as
such. The operator is the only rider the machine was designed for. NO
ADDITIONAL RIDERS!
2.2.3
Use caution when operating at high speeds. It is necessary to
decrease speed when turning, approaching objects or people, and
when conditions call for conservative driving, i.e. inclines, declines,
uneven surfaces, blind corners, or other obstacles that may obscure
vision.
2.2.4
NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
2.2.5
When operating the dumping feature of the machine, the operator and
other personnel need to stay clear of the bucket when it is dumping its
contents and afterwards when the bucket is returning to the stored
position.
2.2.6
This machine was not designed to tow other machines. Accidents and/
or injury may occur as a result from towing. NO TOWING!
2.2.7
When operating in confined areas, the operator needs to be aware of
his own position and the position of others to prevent trapping
someone between the machine and another object.
2.2.8
When the machine is being used in a walk-behind fashion, the
operating platform must be raised and locked into its upright position.
Travel speed should be reduced when walking behind the buggy to
prevent trips or falls.
2.2.9
When the machine is being used in a ride-on fashion, the operator’s
platform must be lowered and locked into its horizontal position and
must be free of any foreign matter which may jeopardize the safety of
the operator. NEVER stand on any other part of the buggy. NEVER
mount or dismount a moving buggy.
2.2.10
Operate the buggy only in daylight or good artificial light.
5
Safety Information
WB 16 /...
2.2.11 DO NOT operate the machine under the influence of drugs, alcohol, or
other substance that may impair the performance of the operator.
2.2.12 Watch out for traffic when operating near or crossing roadways.
2.2.13 The operator must understand all the rules and signals (both visual
and auditory) of the job site.
2.2.14 Do not operate in areas with flammable or explosive atmospheres.
Refer to OSHA standard 29CFR Part 1910.178 for the areas where the
WB16 can be safely operated.
2.2.15 Only load or dump the bucket on flat, level ground or the buggy may
tip over.
2.2.16 Do not load the buggy beyond its rated capacity.
2.2.17 Only operate buggy when tires are properly inflated.
2.2.18 The bucket should not be filled to its rated capacity when transporting
material up or down slopes, on uneven surfaces, or on varying ground
conditions to avoid spilling material out of the bucket.
2.2.19 Side slope operation is not permitted.
2.2.20 Walk around the buggy before starting it to see if any items are worn,
damaged, leaking, etc. that may make the buggy dangerous to
operate.
2.2.21 Stop and inspect the equipment if you strike an object. If necessary,
make repairs before restarting.
2.2.22 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.
2.2.23 ALWAYS operate the machine with all safety devices and guards in
place and in working order.
2.2.24 ALWAYS remain aware of changing positions and movement of other
equipment and personnel on the job site.
2.2.25 ALWAYS remain aware of changing surface conditions and use extra
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpectedly.
2.2.26 ALWAYS use caution when operating near the edges of pits, trenches
or platforms. Check to be sure ground surface is stable enough to
support the weight of the machine and operator and there is no danger
of the machine sliding, falling or tipping.
2.2.27 ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
2.2.28 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from the moving parts of the equipment.
2.2.29 ALWAYS read, understand, and follow procedures in the Operator’s
Manual before attempting to operate the equipment.
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WB 16 /...
2.3
2.2.30
ALWAYS store the equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach of
children.
2.2.31
NEVER leave machine running unattended and the engine running
without the parking brake engaged.
2.2.32
NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and may
cause burns.
2.2.33
NEVER use accessories or attachments that are not recommended by
Wacker. Damage to equipment and injury to the user may result.
2.2.34
NEVER operate the machine with the fuel cap loose or missing.
Operator Safety while using Internal Combustion Engines
DANGER
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Safety Information
Internal combustion engines present special hazards during operation
and fueling. Read and follow the warning instructions in the engine
owner’s manual and the safety guidelines below. Failure to follow the
warnings and safety guidelines could result in severe injury or death.
2.3.1
DO NOT run the machine indoors or in an enclosed area such as a
deep trench unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
2.3.2
DO NOT run engine indoors or in an area with poor ventilation unless
exhaust hoses are used.
2.3.3
DO NOT refuel a hot or running engine.
2.3.4
DO NOT run the engine near open flames.
2.3.5
DO NOT spill fuel when refueling the engine.
2.3.6
ALWAYS refill the fuel tank in a well-ventilated area.
2.3.7
ALWAYS replace the fuel tank cap after refueling.
2.3.8
ALWAYS keep the area around a hot exhaust pipe free of debris to
reduce the chance of an accidental fire.
7
Safety Information
2.4
WB 16 /...
Service Safety
WARNING
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
2.4.1
DO NOT attempt to clean or service the machine while it is running.
Rotating parts can cause severe injury.
2.4.2
DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
2.4.3
DO NOT test for spark on gasoline-powered engines if the engine is
flooded or the smell of gasoline is present. A stray spark could ignite
the fumes.
2.4.4
DO NOT use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.4.5
DO NOT modify the equipment without the express written approval of
the manufacturer.
2.4.6
ALWAYS check all external fasteners at regular intervals.
2.4.7
ALWAYS keep the area around the muffler free of debris such as
leaves, paper, cartons, etc. A hot muffler could ignite the debris and
start a fire.
2.4.8
ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker Corporation.
2.4.9
ALWAYS disconnect the spark plug on machines equipped with
gasoline engines, before servicing, to avoid accidental start-up.
2.4.10 ALWAYS keep the machine clean and labels legible. Replace all
missing and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
2.4.11 ALWAYS switch off the power supply at the battery disconnect before
adjusting or maintaining the electrical equipment.
2.4.12 Equipment should be inspected on a hard, smooth, flat surface, wheels
should be properly chocked in both directions, and the spark plug wire
should be disconnected to prevent accidental starting.
2.4.13 ALWAYS let the engine cool before transporting or servicing it.
2.4.14 ALWAYS replace all guards, fasten doors and make sure all safety
devices operate properly after making repairs or servicing the
equipment.
2.4.15 ALWAYS check that the lug nuts holding the wheels are tight and that
none are missing.
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WB 16 /...
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Safety Information
2.4.16
Inspect all hydraulic hoses and fittings. Check for any unusual wear or
leaks. All fittings should be fastened tightly.
2.4.17
All adjustments and repairs MUST be completed before operation.
NEVER operate the machine with a known problem or deficiency! All
repairs and adjustments should be completed by a qualified
technician.
2.4.18
All controls, handle bars, and the operating platform should be free of
oil, dirt, and other materials which could hinder the safe operation of
the machine.
2.4.19
Clean up all oil or fuel spillage promptly.
9
Safety Information
2.5
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WB 16 /...
Label Locations
10
WB 16 /...
2.6
Safety Information
Safety and Information Labels
Wacker machines use international pictorial labels where needed.
These labels are described below:
Label
Meaning
Open the fuel flow valve.
Close the choke.
Pull out the engine kill button
Place throttle in the IDLE position.
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Safety Information
Label
WB 16 /...
Meaning
Turn key to right until engine turns over.
Release and key will return to "ON".
Open the choke.
Pull the rewind starter.
Place throttle in the FAST position.
Push in the engine kill button.
Turn engine key switch to “OFF” position.
Close the fuel flow valve.
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WB 16 /...
Label
Safety Information
Meaning
Push the button for machine direction.
DANGER!
Engines emit carbon monoxide; operate only in
well-ventilated area.
Read the operator's manual for machine information.
DANGER!
No sparks, flames or burning objects near
machine.
Shut off the engine before refueling.
WARNING!
Wear eye, ear, and head protection when operating machine.
WARNING!
Hot surface!
WARNING!
Pinch point
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Safety Information
Label
WB 16 /...
Meaning
WARNING!
Machine rollover or instability could occur if
operated on side slope if the load limit is
exceeded, or if outside front tires are removed.
WARNING!
Never leave machine running unattended and
the engine running without the parking brake
engaged.
CAUTION!
Lifting point.
Operator’s Manual must be stored on machine.
Replacement Operator’s Manual can be
ordered through your local Wacker distributor.
Key switch positions.
OFF
ON
Hydraulic oil drain.
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WB 16 /...
Label
Safety Information
Meaning
Hydraulic oil reservoir fill tube.
Tie-down point.
A nameplate listing the model number, item
number, revision number, and serial number is
attached to each unit. Please record the information found on this plate so it will be available
should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to
specify the model number, item number, revision number, and serial number of the unit.
This machine may be covered by one or more
patents.
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Safety Information
WB 16 /...
Notes
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WB 16 /...
3.
Technical Data
Technical Data
3.1
Engine
Part No.
WB16A /...
0009282, 0009283,
0009285, 0009288
WB16AE /...
0009284, 0009287,
0009290, 0009293
Engine
Engine Type
4-cycle, single cylinder, air cooled
Engine Make
Honda
Engine Model
GX 390 K1 QWA2
GX 390 K1 QNE
Rated Power
kW (Hp)
9.7 (13.0)
Displacement
cm³ (in³)
389 (23.7)
Spark Plug
NGK BPR 6ES
Electrode Gap
mm (in.)
Starter
type / V
0.7–0.8 (0.028–0.031)
Manual
Electric 12V
Engine Speed - full load
rpm
3600 ±100
Engine Speed - idle
rpm
1450 ±100
Air Cleaner
type
Dual Element
Battery
Fuel
Fuel Tank Capacity
Fuel Consumption
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—
V / size
12 VDC
Regular Unleaded Gasoline
type
45 (12)
l (gal.)
4.3 (1.1)
l (gal.)/hr.
17
Technical Data
3.2
WB 16 /...
Machine
Part No.
WB16A /...
0009282, 0009283,
0009285, 0009288
WB16AE /...
0009284, 0009287,
0009290, 0009293
Buggy
Operating Weight
Max. Travel Speed
Forward:
Reverse:
Max. Bucket Capacity
4 Tires:
2 Tires:
Gradability
Turning Radius
Inner:
Outer:
Tire Inflation Pressure
Front:
Rear:
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kg (lbs.)
608 (1340)
kph (mph)
685 (1510)
11.3 (7.0)
11.3 (7.0)
m³ (ft³)/kg(lb.)
1134 (2500) / 16 (0.45)
408 (900) / 16 (0.45)
%
20
mm (in.)
1040 (41)
1435 (57)
4 tires each @ 50 psi. max.
2 tires each @ 28 psi.
18
–
WB 16 /...
3.3
Technical Data
Lubrication
Part No.
WB16 /...
0009282, 0009283, 0009284, 0009285
0009287, 0009288, 0009290, 0009293
Lubrication
Engine Lubrication
Hydraulic System
type
l (qt.)
SAE 10W30 SF, SE
1.1 (1.16)
type
l (gal.)
10W30 AW
20.1 (5.3)
Grease Zirk Lubricant
3.4
Alvania EP2
Sound Measurements
The required sound specification, Paragraph 1.7.4.f of 89/392/EEC
Machinery Directive, is:
Sound power level (LWA) = 96 db(A)
This value was determined according to ISO 3744.
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Technical Data
3.5
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WB 16 /...
Dimensions
20
WB 16 /...
4.
Operation
Operation
4.1
Application
This machine is designed for moving concrete where pumping and
trucks cannot reach. The WB16 assists in jobsite and demolition
cleanup, and transporting materials that need to be distributed.
The variable speed hydrostatic drive system with squeeze grip and
forward/reverse control delivers smooth, steady performance.
The thumb operated dump control allows for easy dumping and
spreading of materials, while keeping both hands on handlebars.
The buggy is designed to travel up to 7.0 mph (11.2 km/hr) in both
forward and reverse direction.
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Operation
4.2
WB 16 /...
Operation and Service Locations
See Graphic: wc_gr00398
Ref.
Description
Ref.
Description
1.
Starter Grip
10.
Engine Kill Switch
2.
Hydraulic Tank Sightglass
11.
Bucket Dump Switch
3.
Keyswitch (On / Off)
12.
Hydraulic Tank Fill Port
4.
Operator’s Manual Holder
13.
Fuel Fill Cap
5.
Operator Platform
14.
Bucket
6.
Brake Lever
15.
Right Side Cover
7.
Left Side Cover
16.
Tie-Down / Fork Lift Pocket (4)
8.
Fuel Tank
17.
Platform Locking Pin
9.
Forward / Reverse Twist-Grip or
Squeeze-Grip Control
18.
Battery
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WB 16 /...
4.3
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Operation
Before Starting
4.3.1
Read and understand the safety and operating instructions at the
beginning of this manual.
4.3.2
Check:
•
Oil level in the engine
•
Fuel level
•
Condition of the air cleaner
•
Tightness of the external fasteners
•
Condition of the fuel lines
23
Operation
4.4
WB 16 /...
To Start
Manual Start:
Make sure that the parking brake is fully applied and in the locked
position.
4.4.1
Open fuel valve by moving lever to the right (a1).
Note: If engine is cold, move choke lever to close position (b1). If
engine is hot, set choke to open position (b2 ).
4.4.2
Move the throttle lever (c) slightly to the left.
4.4.3
Turn the key switch to “I” (on) position (g1).
4.4.4
Pull the kill button (d) out.
4.4.5
Pull starter rope (h).
Do not allow the starter grip to snap back against the engine. Return
it gently to prevent damage to the starter.
CAUTION
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4.4.6
As the engine warms up, gradually move the choke lever to the OPEN
position (b2 ).
4.4.7
Position the throttle lever (c) to the maximum engine speed of 3600
rpm, release the parking brake and move into operation.
24
WB 16 /...
Operation
Electric Start:
Make sure that the parking brake is fully applied and in the locked
position.
4.4.1
Open fuel valve by moving lever to the right (a1).
Note: If engine is cold, move choke lever to close position (b1). If
engine is hot, set choke to open position (b2 ).
4.4.2
Move the throttle lever (c) slightly to the left.
4.4.3
Pull the kill button (d) out.
4.4.4
Turn the key switch to “ON” position (e1).
4.4.5
Hold switch in "START" position (e2) until engine starts.
Do not hold switch in "START" position for more than 5 seconds.
CAUTION
Note: If the engine does not start, wait 10 seconds, and turn switch to
"START" again.
4.5
4.4.6
When engine starts, allow switch to return to "ON" position (e1).
4.4.7
As the engine warms up, gradually move the choke lever to the OPEN
position (b2 ).
4.4.8
Position the throttle lever (c) to the maximum engine speed of 3600
rpm, release the parking brake and move into operation.
To Stop
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4.5.1
Allow the buggy to come to a complete stop on a flat, level surface.
Make sure the squeeze grip (f) has returned to the neutral position,
and set the parking brake.
4.5.2
Throttle down the engine by pushing engine throttle (c) to the right.
4.5.3
Push the kill button (d) in and turn the key switch to the "OFF" position
(e2 / g2). Remove the key to prevent unauthorized use.
4.5.4
Close fuel valve by moving lever to the left (a2).
25
Operation
4.6
WB 16 /...
Operation
WARNING
CAUTION
CAUTION
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To ensure safe operation, the operator must hold the handlebars with
both hands and have both feet firmly in place on the operator’s
platform.
The direction and speed of the buggy are controlled by the right hand
squeeze grip and rocker switch. With the rocker switch in the (a1)
position and squeezing the grip towards you (b) causes the buggy to
travel forward at a speed proportional to the amount the grip is
squeezed (i.e. the more you squeeze, the faster the buggy goes).
Releasing the squeeze grip causes the drive system to return to
neutral. To stop the buggy, gradually release the squeeze grip until it
is at its end. Once the buggy is at a complete stop, apply the parking
brake (e). To travel in reverse, put the rocker switch in the (a2) position
and squeeze the grip the same as in the forward position. Use caution
when traveling in reverse to avoid obstacles.
The machine must be operated at the maximum engine speed of 3600
rpm when traveling in forward or reverse. At low idle, the machine will
go forward when the throttle lever is squeezed regardless of the
forward/reverse position of the rocker switch.
Note: When the squeeze grip is actuated and the rocker switch is in
the a1 (forward) position, the buggy will not be able to change direction
into reverse. The squeeze grip must be fully released and the buggy
allowed to come to a complete stop before switching direction of the
rocker switch.
Use caution when operating at high speeds. It is necessary to
decrease speed when turning, approaching objects or people, and
when conditions call for conservative driving, i.e. inclines, declines,
uneven surfaces, and varying ground conditions.
Note: Never move the buggy unless the bucket is in its fully stored
position.
If the buggy needs to be left unattended, the operator must:
1) Bring the machine to a complete stop.
2) Set and lock the parking brake.
3) Push in the kill button to stop the engine.
4) Turn the key switch to the off position.
5) Turn gas switch to the off position.
26
WB 16 /...
Operation
Note: The buggy is hydrostatically driven, therefore, if you are
transporting a full load and you need more power, it is necessary to
operate at slower speeds. The slower the buggy moves, the more
power it will have.
Machine rollover or instability could occur if operated on side slope if
the load is exceeded, or if outside front tires are removed.
CAUTION
a1
b
a2
wc_gr000374
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27
Operation
4.7
WB 16 /...
Braking Machine
The braking system or “scrub brake” is used to slow down and stop the
machine. It engages the front wheels of the buggy by the friction
caused by two brake pads when activated by the foot lever. The brake
locking feature or “parking brake”, when engaged, ensures the buggy
will not move on sloped areas.
To engage the scrub brake, step down on the foot lever (a) until the
buggy comes to a complete stop. To disengage, lift foot off of lever and
allow to spring back.
To engage the parking brake, rotate the plunger (b) downward until it
locks in place.
CAUTION
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The parking brake is designed to hold the machine on an incline with
the engine off. Do not drive against the parking brake in the engaged
position.
28
WB 16 /...
4.8
Operation
Operating the Bucket
4.8.1
Allow the buggy to come to a complete stop on flat, level ground.
Note: The dump controls consist of two push buttons mounted on the
handle bar near the left handgrip.
4.8.2
Dump the bucket by depressing the upper push button (a).
4.8.3
Return the bucket to its stored position by depressing the lower push
button (b).
Note: Never operate dump bucket while the buggy is in motion. Make
sure people and obstacles are clear of the bucket and pinch points
while it is dumping and as it returns to its stored position.
Note: The dump bucket will not operate if the engine speed is below
approximately 2000 r.p.m.
Note: Never move the buggy unless the bucket is in its fully stored
position.
wc_tx000019gb.fm
29
Operation
4.9
WB 16 /...
Operation on Slopes
When operating on slopes or hills special care must be taken to reduce
the risk of personal injury or damage to the equipment. Always operate
the machine up and down hills rather than from side to side. For safe
operation and for protection of the engine, continuous duty use should
be restricted to front/rear slopes of 11° (20% grade) or less.
NEVER operate machine on side slopes. The machine may roll over,
even on stable ground.
WARNING
wc_tx000019gb.fm
30
WB 16 /...
5.
Maintenance
Maintenance
5.1
Engine Maintenance
The chart below lists basic engine maintenance. Refer to the engine
manufacturer’s Operation Manual for additional information on engine
maintenance.
Honda
Daily
before
starting
Check fuel level.

Check engine oil level.

Inspect air filter. Replace as needed.

After
first
20 hrs.
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
*
Change engine oil and filter.

Clean air cleaner.

*
Check and clean spark plug.

Clean sediment cup.

Check and adjust idle speed.

**
Check and adjust valve clearances.

**
Replace fuel filter.

**
* Service more frequently in dusty conditions.
**These items should be serviced by an authorized Honda dealer, unless the owner has the proper
tools and is mechanically proficient. See Honda shop manual.
5.2
Maintenance Schedule
Machine
Daily
before
starting
Check external hardware.
Check level of hydraulic fluid.
Check and adjust wheel bearing movement.
Change hydraulic oil and filter.
Check condition of fuel line. Replace when necessary.
Perform wheel and spindle bearing maintenance
Clean fuel tank.
wc_tx000077gb.fm
31
Every
50
hrs.
Every
100
hrs.
Every
200
hrs.

Maintenance
WB 16 /...
The following items should be cleaned daily and should be free of dirt,
concrete, or other debris.
•
Brake shoes and linkages
•
Operator’s platform
•
All hand and foot controls
•
Tires and steering controls
•
Bucket lift cylinder and drive motors
•
Bucket and hinge pin
•
Twist grip linkages
•
Squeeze grip linkages
•
Shroud and louvered panel
•
Pump & hoses
Hydraulic System Maintenance:
5.2.1
CAUTION
5.2.2
CAUTION
wc_tx000077gb.fm
Inspect all hydraulic lines and connections daily. Check for any
unusual wear, gouges, or leaks in the system.
Any hose or fitting that leaks or has any kind of deformity must be
changed immediately!
Check the hydraulic oil level every day. Refill the tank if the level is less
than ½ full in the sightglass.
If any hydraulic fluid is put in the fuel tank, or any gas is put in the
hydraulic system, completely drain the affected system and refill with
new, clean, correct fluid.
Lubrication:
Apply grease to the zirk fittings on the bucket hinge pins and the pillow
bearings on the steering shaft.
32
WB 16 /...
5.3
Maintenance
Engine Oil
5.3.1
Drain the oil while the engine is still warm.
5.3.2
Remove the oil filler plug (a) and the drain plug (b) to drain the oil.
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect any liquid that drains off.
Dispose of this liquid in accordance with environmental protection
legislation.
wc_tx000077gb.fm
5.3.3
Install the drain plug.
5.3.4
Fill the engine crankcase with the recommended oil up to the level of
the plug opening (c). See Technical Data for oil quantity and type.
5.3.5
Install the oil filler plug.
33
Maintenance
5.4
WB 16 /...
Air Cleaner
The engine is equipped with a dual element air cleaner. Service air
cleaner frequently to prevent carburetor malfunction.
NOTICE: NEVER run engine without air cleaner. Severe engine
damage will occur.
NEVER use gasoline or other types of low flash point solvents for
cleaning the air cleaner. A fire or explosion could result.
WARNING
To service:
wc_tx000077gb.fm
5.4.1
Remove air cleaner cover (a). Remove both elements and inspect
them for holes or tears. Replace damaged elements.
5.4.2
Wash foam element (b) in solution of mild detergent and warm water.
Rinse thoroughly in clean water. Allow element to dry thoroughly. Soak
element in clean engine oil and squeeze out excess oil.
5.4.3
Tap paper element (c) lightly to remove excess dirt. Replace paper
element if it appears heavily soiled.
34
WB 16 /...
5.5
Maintenance
Spark Plug
Clean or replace the spark plug as needed to ensure proper operation.
Refer to the engine owner’s manual.
The muffler becomes very hot during operation and remains hot for a
while after stopping the engine. Do not touch the muffler while it is hot.
WARNING
Note: Refer to the Technical Data for the recommended spark plug
type and the electrode gap setting.
5.5.1
Remove the spark plug and inspect it.
5.5.2
Replace the spark plug if the insulator is cracked or chipped.
5.5.3
Clean the spark plug electrodes with a wire brush.
5.5.4
Set the electrode gap (a).
5.5.5
Tighten the spark plug securely.
NOTICE: A loose spark plug can become very hot and may cause
engine damage.
5.6
Sediment Cup
wc_tx000077gb.fm
5.6.1
Turn the fuel valve off.
5.6.2
Remove the sediment cup (a) and the O-ring (b).
5.6.3
Wash both thoroughly in a nonflammable solvent. Dry and reinstall
them.
5.6.4
Turn the fuel valve on and check for leaks.
35
Maintenance
5.7
WB 16 /...
Carburetor
5.7.1
Start the engine and allow it to warm up to operating temperature.
5.7.2
Set the pilot screw (a) two turns out. See Note.
5.7.3
With the engine idling, turn the pilot screw (a) in or out to the setting
that produces the highest rpm.
5.7.4
After the pilot screw is adjusted, turn the throttle stop screw (b) to
obtain the standard idle speed. See Technical Data.
Note: On some engines the pilot screw is fitted with a limiter cap (c)
to prevent excessive enrichment of the air-fuel mixture in order to
comply with emission regulations. The mixture is set at the factory and
no adjustment should be necessary. Do not attempt to remove the
limiter cap. The limiter cap cannot be removed without breaking the
pilot screw.
wc_tx000077gb.fm
36
WB 16 /...
5.8
Maintenance
Hydraulic System Cleanliness
Keeping the hydraulic oil clean is a vital factor affecting the service life
of hydraulic components. Oil in hydraulic systems is used not only to
transfer power, but also to lubricate the hydraulic components used in
the system. Keeping the hydraulic system clean will help avoid costly
downtime and repairs.
Major sources of hydraulic system contamination include:
•
Particles of dirt introduced when the hydraulic system is opened
for maintenance or repair
•
Contaminants generated by the mechanical components of the
system during operation
•
Improper storage and handling of hydraulic oil
•
Use of the wrong type of hydraulic oil
•
Leakage in lines and fittings
To minimize hydraulic oil contamination:
CLEAN hydraulic connections before opening the lines. When adding
oil, clean the hydraulic tank filler cap and surrounding area before
removing it.
AVOID opening the pumps, motors, or hose connections unless
absolutely necessary.
PLUG or cap all open hydraulic connections while servicing the
system.
CLEAN and cover the containers, funnels, and spouts used to store
and transfer the hydraulic oil.
CHANGE the hydraulic filters and oils at the recommended service
intervals.
wc_tx000077gb.fm
37
Maintenance
5.9
WB 16 /...
Hydraulic Oil Requirements
Wacker recommends the use of a good petroleum-based, anti-wear
hydraulic oil in the hydraulic system of this equipment. Good anti-wear
hydraulic oils contain special additives to reduce oxidation, prevent
foaming, and provide for good water separation.
When selecting hydraulic oil for your machine, be sure to specify antiwear properties. Most hydraulic oil suppliers will provide assistance in
finding the correct hydraulic oil for your machine.
Avoid mixing different brands and grades of hydraulic oils.
Most hydraulic oils are available in different viscosities.
The SAE number for an oil is used strictly to identify viscosity—it does
not indicate the type of oil (engine, hydraulic, gear, etc.).
When selecting a hydraulic oil be sure it matches the specified SAE
viscosity rating and is intended to be used as a hydraulic oil. See
Technical Data—Lubrication.
wc_tx000077gb.fm
38
WB 16 /...
Maintenance
5.10 Hydraulic Oil Level
A hydraulic oil level sightglass (a) is located on the hydraulic tank and
is visible through the rear of machine.
Check the oil level with the machine standing on a level surface. The
oil level should be at the halfway mark on the sightglass. If the level is
low, remove the filler cap (b) and top up with hydraulic oil as
necessary.
If hydraulic oil continually needs to be added, inspect hoses and
connections for possible leaks. Repair hydraulic leaks immediately to
prevent damage to hydraulic components.
wc_tx000077gb.fm
39
Maintenance
WB 16 /...
5.11 Changing Hydraulic Oil & Filter
Change the hydraulic oil and oil filter after every 100 hours of use or
every six months, which ever comes first.
Stop the machine, switch off the engine, and apply the parking brake
with the machine standing on a level surface.
Note: In the interests of environmental protection, place plastic
sheeting and a container under the machine to collect the liquid which
drains off. Dispose of this liquid properly.
5.11.1 Remove the drain plug (c) from underneath the frame below the
hydraulic tank.
5.11.2 Allow the hydraulic oil to drain into a suitable container.
5.11.3 When all the oil has drained out, reinstall the drain plug.
5.11.4 Remove nine screws (d) mounting the front cover (e) to the buggy.
5.11.5 Place a plastic bag around the filter (f) to contain any oil spillage.
5.11.6 Unscrew the old filter.
5.11.7 Install the new filter. Screw the new filter on by hand, making sure that
it is not cross threaded.
Use only original spare parts.
CAUTION
5.11.8 Tighten using both hands.
5.11.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfway
up the sightglass (a).
5.11.10 Run the engine briefly, then stop the engine and check for leaks.
5.11.11 Check the level in the sightglass, and top up if necessary.
wc_tx000077gb.fm
40
WB 16 /...
Maintenance
5.12 Wheel Bearings
Work on a hard, flat surface. Chock the wheels in both directions. Lift
the back end of the buggy slightly off the ground. Use jack stands or
supports capable of holding the empty weight of the buggy (1180 lbs.
or 1380 lbs. with foam-filled tires). Only qualified technicians should
work on the buggy.
Clean and re-pack the wheel hub bearing:
5.12.1
Remove four lug nuts (a) from the wheel hub (b).
5.12.2
Remove the grease cap (c), cotter pin (d), and castle nut (e) from end
of steering rod shaft (f).
5.12.3
Slide the wheel (g) and hub off the shaft.
5.12.4
Thoroughly clean the bearings (h) and the wheel hub.
Note: There is one bearing on the outside of the hub. There is a seal
(j) and a bearing on the inside of the hub.
5.12.5
Lubricate both of the bearings using a heavy-duty bearing grease and
reassemble.
Note: Make sure that the cotter pin is in place before returning the
grease cap.
Adjustment:
wc_tx000077gb.fm
5.12.1
Work on a hard, flat surface. Chock the wheels in both directions.
5.12.2
Remove the wheel grease cap (c).
5.12.3
Remove the cotter pin (d) going through the castle nut (e) and tighten
the castle nut until snug.
5.12.4
Back off the castle nut until the nut is lined up with the first available
hole for the pin to go through, then re-pin the castle nut.
41
Maintenance
wc_tx000077gb.fm
WB 16 /...
42
WB 16 /...
Maintenance
5.13 Brake Adjustment
Work on a hard, flat surface. Chock the wheels in both directions. Use
jack stands or supports capable of holding the empty weight of the
buggy (1180 lbs. or 1380 lbs. with foam-filled tires). Only qualified
technicians should work on the buggy.
Adjustment:
5.13.1
The brake pad (a) is adjusted at the yoke (b) located at the brake pad.
5.13.2
To adjust the yoke, loosen jamnut (c) and remove cotter pin holding
yoke to brake pad.
5.13.3
Turning the yoke clockwise or counter-clockwise will shorten or
lengthen the linkage distance (d) to provide approximately 63 mm (21/2") of clearance between the brake pad and the tire with the parking
brake (e) off.
CAUTION
wc_tx000077gb.fm
When reassembling yoke to brake pad, replace the old cotter pin with
a new one.
43
Maintenance
wc_tx000077gb.fm
WB 16 /...
44
WB 16 /...
Maintenance
5.14 Neutral Switch
The neutral switch is found on machines with squeeze-grip-type
control; BOMs 9266 and higher. The purpose of the neutral switch is
to make sure that the machine is at rest (no flow from pump to drive
motors) before the FORWARD/REVERSE rocker switch will operate
when placed in the REVERSE position. This helps prevent sudden
changes of direction which may throw the operator off the machine,
cause the operator to loose control of the machine, and/or cause
unnecessary wear and tear on the drive motors. When in the open
position, (squeeze-grip control engaged) the neutral switch opens the
FORWARD/REVERSE rocker switch circuit. When open, no power
flows to the control valve solenoid, thus there is no change in the
position of the valve’s spool, it remains in the spring-loaded
FORWARD position.
Check continuity of neutral switch monthly. To check continuity:
5.14.1
Turn the engine off.
5.14.2
Find the 4-wire Weatherpak connector coming out of the junction box
and separate the male (a) & female (b) halves of the connector.
5.14.3
Using a multimeter (ohmmeter), test the black and red wires, of the
female half of the connector, for continuity. A continuity signal should
be received.
Squeezing the squeeze-grip control should cause the continuity signal
to stop.
If the proper continuity signals are not received, readjust the neutral
switch.
Before adjusting the neutral switch, check the function of the squeezegrip control. Make certain that the cable (c) does not bind and that the
pump control arm (d) reaches the neutral position (wheels do not turn)
when the squeeze-grip control is in its home position (not being
squeezed). Reset the drive pump neutral if necessary. See section
Setting Drive Pump Neutral.
To adjust the neutral switch:
wc_tx000077gb.fm
5.14.4
Start the engine and run it at full throttle. Press the bucket dump switch
to place the bucket in the dump position.
5.14.5
Stop the engine.
5.14.6
Remove the front access panel.
45
Maintenance
WB 16 /...
5.14.7 Back off the thumb wheel (e) so that the thumb wheel does not contact
the neutral switch plunger (f).
5.14.8 Using an appropriate lift or hoist, raise the front end of the machine so
that the drive wheels no longer touch the ground. Support the machine
with appropriate stands or jacks.
5.14.9 Start the engine. Run the engine at high throttle. Check that the drive
wheels do not spin when in neutral. If the drive wheels do spin, set the
hydraulic neutral on the pump. See section Setting the Hydraulic Pump
Neutral.
5.14.10 Rotate the thumb wheel until it touches the neutral switch plunger.
Then, turn the thumb wheel another 1/2-turn (180°).
5.14.11 Tighten the jam nut (g).
5.14.12 Remove the blocks and using an appropriate lift or hoist, lower the
machine back to the ground.
5.14.13 Recheck the continuity of the neutral switch. Squeeze the squeezegrip control. The continuity should cease after approximately 3/8-inch
movement of the control cable.
R B
D C B A
b
b
a
a
D C B A
G LL R B
d
f
e
c
g
d
wc_gr002725
wc_tx000077gb.fm
46
WB 16 /...
Maintenance
5.15 Transporting Machine
The buggy is equipped with one front tie-down (a), located in between
the four tires on the front plate.
Note: When transporting the buggy on a trailer, chock the wheels in
both directions.
Note: Make sure that the fuel valve on the engine is shut off.
Tie-down the buggy as follows:
5.15.1
Use one strap in each rear fork pocket (b), pulling down and away from
the machine.
5.15.2
Use two straps on the front tie-down (a), one pulling down to the right
and the other pulling down to the left.
Note: Make sure all straps are properly secured and tightly fastened!
wc_tx000077gb.fm
47
Maintenance
WB 16 /...
5.16 Lifting Machine
WARNING
When lifting the buggy, all personnel must be clear of the machine.
Do not stand near or under the machine while it is being lifted.
Do not lift the buggy with the bucket loaded.
Side lifting instructions using a forklift:
•
Place one fork through the fork pocket (a) under the chassis tubes.
•
Place the second fork under chassis tubes (b) near the engine.
Rear lifting instructions using a forklift:
•
Raise the operator’s platform into its locked, upright position.
•
Place one fork through each set of fork pockets (c1 and c2) located
underneath the engine platform.
Do not lift the buggy by lifting from the bucket or hydraulic cylinder.
CAUTION
Lifting instructions using a hoist:
•
Make sure the bucket is empty, raise it to the dump position, and turn
off the engine.
•
Place slings, chains or hooks through each lifting eye (d) on the
machine (2 places). Use two slings or chains with a minimum length
of 2 meters (6 feet) on each leg, connected to a central lifting device.
Ensure that all lifting devices have sufficient weight-bearing capacity.
•
Lift the buggy a few inches off of the ground and check to see how it is
balanced. If the buggy is not fairly level, lower the buggy onto the
ground, partially lower or raise the bucket, and turn off the engine.
Repeat this procedure until the buggy is levelled out.
Note: Position of the bucket is dependant on several factors, including
position of the operator’s platform, amount of fuel in the gas tank, etc.
wc_tx000077gb.fm
48
WB 16 /...
Maintenance
5.17 Cleaning
When pressure washing the machine, avoid using harsh chemicals
and only use moderate water pressure 35 – 70 bar (500–1000 psi).
Avoid direct pressure to the following components:
wc_tx000077gb.fm
•
Engine
•
Hydraulic
•
Water tank / Plastic parts
•
Hoses
•
Labels
49
Maintenance
WB 16 /...
5.18 Storage
WARNING
NEVER store the buggy in a heated shelter or in an enclosed, poorly
ventilated enclosure, with gasoline in the engine or fuel tank. Gasoline
fumes may reach an open flame, spark, or pilot light and cause an
explosion.
Temporary storage:
Between uses, do the following:
5.18.1 Allow the buggy to cool before storing.
5.18.2 Clean all debris off of the buggy.
5.18.3 Chock the wheels to prevent the buggy from rolling.
5.18.4 Keep the buggy in an area away from where children may come in
contact with it. Remove the key to prevent unauthorized use.
Long-term storage:
If the unit is to be stored for more than 30 days, also:
5.18.1 Drain the fuel tank into an approved container.
5.18.2 Change the engine oil.
5.18.3 Prepare the engine for storage:
•
Remove the spark plugs and pour approximately 1.5 ml
(½ ounce) of SAE 30W oil into each engine cylinder through the
spark plug opening.
•
Reinstall the spark plugs, leaving the ignition wires disconnected
to prevent engine from starting.
•
Crank the engine for one or two seconds to distribute the oil
inside the engine cylinders.
•
Reconnect the ignition wires.
5.18.4 Clean the entire buggy and engine compartment.
5.18.5 Remove dirt from the cooling fins on the engine cylinders and on the
blower housing.
5.18.6 Cover entire machine and place in a dry, protected area.
5.18.7 Remove the battery from the machine (if applicable) and charge it
periodically.
5.18.8 Check the pressure in the tires (non-foam-filled only).
wc_tx000077gb.fm
50
WB 16 /...
Maintenance
5.19 Hydraulic Schematic/Diagram
See Graphic: wc_gr000264 & wc_gr000828
Ref.
Description
Ref.
Description
1.
Pump
6.
Dump pressure relief valve
2.
Hydraulic tank
7.
Dump valve
3.
Return filter
8.
Dump cylinder
4.
Drive pressure relief valve
9.
Directional valve
5.
Drive motor
10.
Flow limiter fittings
(9283, 9287, 9288, 9293)
9
wc_tx000077gb.fm
51
Maintenance
wc_tx000077gb.fm
WB 16 /...
52
WB 16 /...
Maintenance
5.20 Electrical Schematics
See Graphic: wc_gr000266 & wc_gr000265
Ref.
Description
Ref.
Description
1.
Foward/Reverse switch
12.
Dump valve
1a.
Forward
12a.
Solenoid 1
1b.
Reverse
12b.
Solenoid 2
2.
Electrical box
13.
Engine control box
3.
Fowrad/Reverse solenoid valve
13a.
Off
4.
Engine kill switch on handle bar
13b.
Run
5.
Engine
13c.
Start
6.
Neutral switch N.C.
14.
Voltage regulator/rectifier
7.
Key switch (2-way)
15.
Fuse (15a)
7a.
On
16.
Solenoid
7b.
Off
17.
Starter
8.
Oil level swtich
18.
Battery
9.
Coil
19.
Rectifier
10.
Charge coil
20.
Circuit breaker
11.
Dump bucket switch
21.
Resistor
11a.
Raise
22.
Relay
11b.
Lower
23.
Diode
Wire Colors
B
Black
R
Red
Y
Yellow
Or
Orange
G
Green
T
Tan
Br
Brown
Pr
Purple
L
Blue
V
Violet
Cl
Clear
Sh
Shield
P
Pink
W
White
Gr
Gray
LL
Light blue
wc_tx000077gb.fm
53
Maintenance
WB 16 /...
Manual Start
Gr
Pr
B
L
23
G
22
R
R
R
R
Y
R
21
7
19
7a
R
22
G
Y
7b
B/R
B
Or
20
W
W
Br
W
wc_gr000266
Electric Start
G
L
Gr
B Pr
23
22
R
R
R
21
R
Y
19
R
Y
20
B/R
Or
W
22
B
G
W
Br
W
wc_gr000265
wc_tx000077gb.fm
54
WB 16 /...
Maintenance
5.21 Troubleshooting
Problem / Symptom
Reason / Remedy
Engine does not start or runs
erratically.
• Check fuel level. Fill tank with fresh fuel.
• Open fuel valve if closed.
• Check run/stop key switch position.
• Check position of handle-mounted engine stop
switch.
• Check/replace spark plug.
• Check engine oil level.
• Clean air filter.
• Check in-line fuel filter.
Engine runs; Machine does
not travel.
• Release parking brake.
• Check hydraulic fluid level. Add fluid as necessary.
• Check squeeze-grip control cable. Repair/replace
cables as necessary.
• Check pump control arm for excess play. Tighten
arm.
• Check engine/pump coupler. Replace coupler if it is
malfunctioning.
Engine runs; Poor machine
operation.
• Check fuel level. Fill fuel tank with fresh fuel.
• Check pump control arm for excess play. Tighten
arm.
• Check engine/pump coupler. Replace coupler if it is
malfunctioning.
Machine “creeps” in neutral.
• Check neutral adjustment setting on pump.
wc_tx000077gb.fm
55
Maintenance
Problem / Symptom
Bucket will not dump.
WB 16 /...
Reason / Remedy
• Bucket overfilled. Remove some material.
• Engine not running fast enough. Increase engine
speed.
• Circuit breaker in electrical box is tripped. Reset circuit breaker.
• Dump bucket solenoids not functioning. Check wires
to and condition of solenoids. Repair or replace as
necessary.
wc_tx000077gb.fm
56
Wacker Construction Equipment AG
·
Preußenstraße 41
· D-80809 München
· Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21