Multiquip Automobile WBH16 User's Manual
Contents
1. Fuel Filler Cap Remove this cap to add unleaded gasoline to the fuel tank Make sure cap is tightened securely DO NOT over fill Throttle Lever Used to adjust engine RPM speed lever advanced forward SLOW lever back toward operator FAST Engine ON OFF Switch ON position permits engine starting OFF position stops engine operation Recoil Starter pull rope Manual starting method Pull the starter grip until resistance is felt then pull briskly and smoothly Fuel Valve Lever OPEN to let fuel flow CLOSE to stop the flow of fuel Choke Lever Used in the starting of a cold engine or in cold weather conditions The choke enriches the fuel mixture Air Filter Prevents dirt and other debris from entering the fuel system Release the latches on the sides of the air filter cover to gain access to filter element NOTICE Operating the engine without an air filter or with a damaged or worn air filter will allow dirt to enter the engine causing rapid engine wear PAGE 16 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 INSPECTION Table 3 Oil Type Season Temperature 25 C Higher SAE 10W 30 Spring Fall 25 C 10 C SAE 10W 30 20 SAE 10W 10 GASOLINE CHECK DANGER Motor fuels are highly flammable and can be dangerous if mishandled DO NOT smoke while refueling DO NOT attempt to refuel the pump if the engi2. Dump Pedal Use this pedal to place the tub in the dump position vertical press pedal a second time to return tub to the travel position horizontal HydraulicTank Cap Remove this cap to add hydraulic oil Tank holds approximately 6 0 U S gallons DO NOT over fill Forklift Pockets Use these fork lift pockets to lift the power buggy with a forklift Remember to insert the forks of the fork lift a minimum of 24 inches into power buggy s fork lift pockets Dump Control Lever Use this lever forward to place the tub in the dump position vertical move the lever backward to return the tub to travel position horizontal Towing Hook Use this hook to tow the buggy if it gets stuck This hook is NOT intended for towing the buggy on public roads at high speeds Battery Used in the electric start power buggy WBH16E only Always use gloves and eye protection when handling the battery 10 11 12 13 14 15 16 Figure 2 WBH16 WBH16E Power Buggy Components Tub or Bucket Used for the transportation of material Tub holds approximately 16 cubic feet 0 59 cubic yards of water Handle Bar Steering This handle bar is used to steer the buggy When driving the buggy use both hands and hold onto both handle bar grips Kill Switch In the event of an emergency press this button to stop the engine Fuel Tank Cap Remove this cap to add fuel Tank holds approximately 5 5
3. Tire inflation pressure is the most important factor in tire life 1 Check tire pressure when the tires are cold before operation 2 Do not bleed air from tires when they are hot 3 Check inflation pressure weekly during use to ensure the maximum tire life and tread wear 4 Refer to Table 4 Tire Wear Troubleshooting to pinpoint the causes and solutions of tire wear problems WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 25 TROUBLESHOOTING Troubleshooting Power Buggy k Place lever in either forward or reverse position Forward Reverse lever in neutral position Loss of Travel Check hydraulic motors Parking brake partially engaged Release parking brake f Hydraulic oil level low Check hydraulic oil level add hydraulic oil if System Operating Hot necessary Defective cooling fan Inspect cooling fan replace if necessary Dump cylinder is internally bypassing oil Replace dump cylinder Difficulty in stopping Brakes out of adjustment Brake lining worn Replace brake lining Low on fuel or fuel tank empty Add fuel Defective kill switch Check kill switch Replace if necessary Engine will not start Engine ON OFF switch in OFF position Set engine ON OFF switch to ON position Fuel Shut off valve CLOSED Open Fuel shut off valve f Low engine speed Check engine speed Adjust engine speed if Slow Dumping necessar y Speed cable out of adjustmen
4. WBH16 WBH16E Power Buggy Proposition 65 Warning main 5 10 11 12 Dimensions U 13 General Information 14 COMM OS US 15 Basic 16 17 18 19 23 Maintenance 24 25 Troubleshooting 26 28 Hydraulic System Diagram 29 NOTICE Specifications and part numbers are subject to change without notice PAGE 4 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 SAFETY INFORMATION Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages Safety Hazard Lethal exhaust gas hazards Symbol Explosive fuel hazards Burn hazards ea Rotating parts hazards Hydraulic fluid hazards Do not operate or service the equipment before reading the entire manual Safety precautions should be followed at all times when operating this equipment Failure to read and understand the safety O messages and operating instructions could 44 result in injury to yourself and others SAFETY MESSAGES The
5. Power Buggy is equipped with a 6 inch dump height which provides clearance and enables the operator to maneuver over any form height In addition it has a unique polyethylene tub design that reduces concrete splatter A low center of gravity has been incorporated into the design which provides added safety when maneuvering the buggy in tight areas A 5 5 gallon fuel tank allows for extended uninterrupted use Maximum speed of the power buggy is rated at 7 25 MPH The maximum weight capacity of the Power Buggy is 2 500 105 1 136 kg The outer wheels can be removed to allow the buggy to pass through a 32 in 81 28 cm door Hand and foot controls are provided for ease of dumping and stopping of the WBH16 WBH16E Multiple lift points have been provided to allow for easy access of a forklift when lifting is required The WBH16 WBH1EE is powered by a HONDA GX390K1 air cooled gasoline engine rated at 13 HP at 3600 RPM The engine drives a variable displacement hydrostatic transmission which is activated by a cable controlled hand lever The hydraulic fluid flows to a divider valve which directs the fluid to the forward reverse and dumping systems The operator controls the forward and reverse machine PAGE 14 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 COMPONENTS Engine The WBH16 uses a HONDA GX390K1QA2 recoil start engine The WBH16E uses a HONDA GX390K1QAE2 electric start engine
6. U S gallons Do not over fill Speed Control Sets the power buggy s travel speed When fully depressed the buggy will be at FULL speed When released the buggy will STOP Parking Brake Lever When this lever is activated pulled down the parking brake will be set To release the brake pull the lever upwards Travel Lever When the travel lever is pushed forward the buggy will travel in the forward direction Placing the travel lever in the backward position will cause the buggy to travel in the reverse direction Center position is neutral Brake Pedal Press this pedal with the right foot to stop the buggy Operator Platform When the buggy is in use the operator shall ALWAYS stand on this platform while holding onto the handle bar steering WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 15 BASIC ENGINE Figure 3 Honda GX390K1 Engine Spark Plugs Provides spark to the ignition system Set spark plug gap to 0 70 0 76 mm 0 028 0 030 in Clean spark plug once a week Muffler Used to reduce noise and emissions Engine components can generate extreme heat To prevent burns DO NOT touch these areas while the engine is running or immediately after operating NEVER Operate the engine with the muffler removed ally 7 pS 8 10 Fuel Tank Holds unleaded gasoline For additional information refer to engine owner s manual
7. dipstick 4 lf the oil level is low Figure 5 fill to the edge of the oil filler hole with the recommended oil type Table 3 Maximum oil capacity is 400 cc Figure 5 Oil Level WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 17 INSPECTION PARKING BRAKE CHECK Check the brakes as outlined in the maintenance section of this manual LINKAGE CHECK Check and make sure that all linkages within the buggy are functioning correctly STEERING CHECK 1 Check and make sure that the power buggy s steering turns freely and that there is no binding 2 Make sure that the zerk fitting for the steering has been lubricated DUMP CYLINDER CHECK 1 Check the power buggy s dump cylinder as outlined in the operation section of this manual 2 Make sure that both zerk fittings for the dump cylinder have been lubricated HYDRAULIC OIL CHECK Visually read the hydraulic sight glass Figure 7 to see if the hydraulic oil level is low 4 If the hydraulic oil is low add enough hydraulic oil to bring oil level to a normal safe operating level 9 NORMAL OPERATING LEVEL 0 Figure 7 Hydraulic Sight Glass PAGE 18 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 OPERATION 4 Place the choke lever Figure 10 inthe OPEN position if starting a warm engine or the temperature is warm DO NOT attempt to operate the power 0 buggy until the Saf
8. four safety messages shown below will inform you about potential hazards that could injure you or others The safety messages specifically address the level of exposure to the operator and are preceded by one of four words DANGER WARNING CAUTION or NOTICE SAFETY SYMBOLS DANGER Indicates a hazardous situation which if not avoided WILL result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in DEATH or SERIOUS INJURY Indicates a hazardous situation which if not avoided COULD result in MINOR or MODERATE INJURY NOTICE Addresses practices not related to personal injury WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 5 SAFETY INFORMATION NOTICE This equipment should only be operated by trained and qualified personnel 18 years of age and older Whenever necessary replace nameplate operation and safety decals when they become difficult read Manufacturer does not assume responsibility for any accident due to equipment modifications Unauthorized equipment modification will void all warranties NEVER use accessories or attachments that are not recommended by Multiquip for this equipment Damage to the equipment and or injury to user may result ALWAYS know the location of the nearest re fire extinguisher ALWAYS know the location of the nearest first aid kit ALWAYS know the location of
9. has not the buggy is placed into operation run the engine for started repeat steps 1 through 3 several minutes Check for fuel leaks and noises that would associate with a loose guard or cover PRE CHECK RECOIL START 1 Engage the parking brake lever Figure 15 and attempt to rock the buggy back and forth If the wheels turn 1 Follow steps 1 through 4 of the Electric Start procedure during the rocking motion adjust the brakes as outlined 2 Place the Engine ON OFF switch Figure 13 in the ON position ENGINE S ON OFF SWITCH Figure 15 Parking Brake Lever 2 Place the engine s throttle lever Figure 11 in the slow idle position Figure 1 Engine ON OFF Switch Star 3 Check the speed control lever Figure 16 located on 3 Grasp the starter grip Figure 14 and slowly pull it the right side of the handle bar The speed control out The resistance becomes the hardest at a certain should work freely when squeezed by hand and return position corresponding to the compression point Pull to the closed position when released the starter grip briskly and smoothly for starting STARTER GRIP Figure 14 Starter Grip CONTROL Figure 16 Speed Control Lever NOTICE DO NOT pull the starter rope all the way to the end DO NOT release the starter rope after pulling Allow it to rewind as soon as possible PAGE 20 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9
10. the reach of children and unauthorized personnel DO NOT operate the power buggy at excessive speeds Reckless operation may cause accidents and severe injury Slow down when approaching people wet areas and going up and down grades It is the responsibility of the operator to adjust speed as necessary depending on the conditions of the road or path ALLOW extra time to stop when operating the power buggy ion wet surfaces or loosely graded materials ONLY remove the outer tires when it is necessary to reduce the width of the power buggy in order to access narrow work areas If outer tires are removed the power buggy must only be used on level solid surfaces such as concrete asphalt or compacted stone to prevent the power buggy from tipping The maximum load must also be reduced to 1000 Ib m DO NOT dump materials that are large and chunky These types of material may shift causing the power buggy to tip and throw the operator off the machine The power buggy is intended for dumping free flowing and loose materials such as dry soil slag and wet concrete DO NOT dump materials from bucket while the power buggy is moving For walk behind operation the operator platform must be stowed and locked in the up position The speed should also be reduced to 3 mph or slower NOTICE ALWAYS ensure power buggy is securely placed on appropriate blocks or jackstands when performing maintenance requires elevation o
11. 12 03 10 OPERATION 3 When using the buggy for the first time test the brake With the right foot step up and place it on the brake pedal Figure 18 Gradually apply pressure to the BRAKE PEDAL Figure 18 Brake Pedal Test the brake at different speeds until you are comfortable with stopping the buggy If the brakes do not seem to stop the buggy adequately refer to the maintenance section of this manual for brake adjustment instructions When starting and stopping is confirmed to be functioning properly the buggy is ready for operation SHUTDOWN NORMAL Correct shutdown is important to safe operation Follow these general steps Come to a full stop Engage the parking brake Figure 15 Place the throttle lever Figure 11 in the slow position Idle engine 3 5 minutes for gradual cooling Turn the engine on off switch Figure 12 or Figure 13 to the OFF position to shut down the engine Cycle hydraulic controls to eliminate residual pressure Remove ignition key on electric start models Block wheels if on a slope or incline 1 2 3 PARKING BRAKE DIRECTION LEVER Before the power buggy can be put into operational use it is best to perform a test run to make certain that all components are functioning properly Place the buggy on flat solid ground Engage the parking brake lever Place the engine s throttle control Figure 11 in the SLOW idle position Place the power buggy s direction
12. 3700 Fax 310 637 3284 Warranty Department 800 421 1244 Fax 310 537 1173 310 537 3700 UNITED KINGDOM Multiquip UK Limited Head Office Tel 0161 339 2223 Fax 0161 339 3226 Unit 2 Northpoint Industrial Estate Globe Lane Dukinfield Cheshire SK16 4UJ Contact sales multiquip co uk Tel 800 421 1244 Fax 800 537 3927 Fax 310 537 4259 Fax 310 943 2238 Tel 52 222 225 9900 Fax 52 222 285 0420 UNITED STATES Multiquip Corporate Office 18910 Wilmington Ave Carson CA 90746 Contact mq multiquip com Service Department 800 421 1244 310 537 3700 Technical Assistance 800 478 1244 MEXICO MQ Cipsa Carr Fed Mexico Puebla KM 126 5 Momoxpan Cholula Puebla 72760 Mexico Contact pmastretta cipsa com mx Tel 450 625 2244 Tel 877 963 4411 Fax 450 625 8664 CANADA Multiquip 4110 Industriel Boul Laval Quebec Canada H7L 6V3 Contact jmartin multiquip com COPYRIGHT 2010 MULTIQUIP INC Multiquip Inc the MQ logo and the Whiteman logo are registered trademarks of Multiquip Inc and may not be used reproduced or altered without written permission All other trademarks are the property of their respective owners and used with permission This manual MUST accompany the equipment at all times This manual is considered a permanent part of the equipment and should remain with the unit if resold VSL MULTIQUIP The information and specifications included in this pu
13. GGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 7 SAFETY INFORMATION ALWAYS block the power buggy with appropriate blocks when leaving the power buggy parked on a slope To prevent unexpected loss of control DO NOT start engine on a sloping surface Ensure that the speed control lever works freely and returns to the closed position DO NOT start engine unless speed control linkage is working properly Make sure that the tires are inflated to the manufacturer s recommended tire pressure NEVER operate the power buggy with bad or worn tires ALWAYS replace defective tires with new ones ALWAYS make sure the hydraulic dumping mechanism of the tub is working properly Avoid sudden stops and starts and changes in direction Operate the controls smoothly DO NOT jerk the steering or any other controls NEVER attempt to work the control except from the operator s position NEVER drive or tow the power buggy in traffic or on public roads ALWAYS keep the machine in proper running condition Fix damage to machine and replace any broken parts immediately The entire power buggy tub step plate shroud wheels etc should be cleaned after every use Make sure there is no buildup of concrete grease oil or debris on the machine ALWAYS store equipment properly when it is not being used Equipment should be stored clean dry location out of
14. OPERATION MANUAL MULTIQUIP WHITEMAN SERIES MODEL WBH16 GX390K1QA2 GASOLINE ENGINE RECOIL START MODEL WBH16E GX390K1QAE2 GASOLINE ENGINE ELECTRIC START POWER BUGGY Revision 9 12 03 10 To find the latest revision of this publication visit our website at www multiquip com THIS MANUAL MUST ACCOMPANY THE EQUIPMENT ALL TIMES PROPOSITION 65 WARNING CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents and some dust created by power sanding sawing grinding drilling and otherconstruction activities contains chemicals known to the State of California to cause cancer birth defects and other reproductive harm Some examples of these chemicals are e Leadfromlead based paints e Crystalline silicafrom bricks Cementand other masonry products e Arsenicandchromiumfrom chemically treated lumber Your risk from these exposures varies depending on how often you dothis type of work reduce your exposure to these chemicals ALWAYS work in a well ventilated area and work with approved safety equipment such as dust masks that are specially designed to filter out microscopic particles PAGE 2 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 5 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 3 TABLE OF CONTENTS
15. W Figure 1 WBH16 WBH16E Dimensions WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 13 GENERAL INFORMATION travel by manually shifting the control valve which directs the hydraulic fluid flow to the two drive wheel motors The flow to the dump cylinder is also controlled by a manually operated control valve This hydraulic system uses a parallel loop configuration operating at a maximum of 1450 PSI The system also features a neutral position which allows the power buggy to be moved in the event of an emergency The hydraulic oil is filtered by a screen type filter located in the hydraulic tank then doubled filtered within the system by a 10 micron cartridge spin on return filter All operators must have training before operating the WBH16 WBH16E For your safety warnings are the machine and in this manual Failure to obey these warnings can cause severe injury or even death DO NOT attempt to operate the power 0 buggy until the Safety Information General Information and Inspection sections of this manual have been read and thoroughly understood The MQ Whiteman Power Buggy Models WBH16 recoil start and WBH16E electric start are intended for the transportation of concrete concrete spreading and spot pouring In addition the WBH16 WBH16E is designed for landscaping applications material sub base distribution job site cleanup and material transport The
16. attery to open flames sparks cigarettes etc The battery contains combustible gases and liquids If these gases and liquids come into contact with a flame or spark an explosion could occur ALWAYS wear safety glasses when handling the battery to avoid eye irritation The battery contains acids that can cause injury to the eyes and skin Use well insulated gloves when picking up the battery ALWAYS keep the battery charged If the battery is not charged combustible gas will build up DO NOT charge battery if frozen Battery can explode When frozen warm the battery to at least 61 F 16 C ENGINE SAFETY m DO NOT place hands or fingers inside engine compartment when engine is gt g running NEVER operate the engine with heat shields or guards removed Keep fingers hands hair and clothing away i from all moving parts to prevent injury 5 m ALWAYS shut down the engine before 6 performing service or maintenance DO NOT remove the engine oil drain plug while the engine is hot Hot oil will gush out of the oil tank and severely scald any persons in the general area of the power buggy NEVER touch the hot exhaust manifold Say muffler or cylinder Allow these parts to cool before servicing equipment Make certain the operator knows how to and is capable of turning the engine OFF in case of an emergency NOTICE NEVER run engine without an air filte
17. blication were in effect at the time of approval for printing Illustrations descriptions references and technical data contained in this manual are for guidance only and may not be considered as binding Multiquip Inc reserves the right to discontinue or change specifications design or the information published in this publication at any time without notice and without incurring any obligations Your Local Dealer is
18. e fuel exhaust gases contain poisonous carbon monoxide This gas is colorless and odorless and can cause death if inhaled The engine of this equipment requires an adequate free flow of cooling air NEVER operate this equipment in any enclosed or narrow area where free flow of the air is restricted If the air flow is restricted it will cause injury to people and property and serious damage to the equipment or engine NEVER operate the equipment an explosive atmosphere or near combustible materials An explosion or fire could result causing severe bodily harm or even death NEVER use your hand to find hydraulic leaks Use a piece of wood or cardboard Hydraulic fluid injected into the skin must be treated by a knowledgeable physician immediately or severe injury or death can occur OFF Accidental starting can cause severe injury Z or death ALWAYS place the ON OFF switch in the OFF position NEVER disconnect any or safety devices These devices are intended for operator safety Disconnection of these devices can cause severe injury bodily harm or even death Disconnection of any of these devices will void all warranties NEVER approach power lines with any part of the buggy unless all local state provincial and federal OSHA required safety precautions have been taken Use extreme caution when approaching high voltage power lines WBH16 WBH16E POWER BU
19. erly Examples of potentially hazardous waste are used motor oil fuel and fuel filters DO NOT use food or plastic containers to lt amp dispose of hazardous waste DO NOT pour waste oil or fuel directly onto the ground down a drain or into any water source ALWAYS recharge the battery in a well ventilated environment to avoid the risk of a dangerous concentration of combustible gases f the battery liquid dilute sulfuric acid comes into contact with clothing or skin rinse skin or clothing immediately with plenty of water f the battery liquid dilute sulfuric acid comes into contact with eyes rinse eyes immediately with plenty of water and contact the nearest doctor or hospital to seek medical attention ALWAYS disconnect the NEGATIVE battery terminal before performing service on the equipment ALWAYS keep battery cables in good working condition Repair or replace all worn cables LIFTING SAFETY NEVER allow any person or animal to stand underneath the equipment while lifting NOTICE When lifting of the power buggy is required use a properly rated forklift Forklift pockets are provided on the power buggy s frame Make sure the forklift arms are insert into the power buggy s fork lift pockets a minimum of 24 inches Before lifting make sure that the lifting bale is not damaged NEVER tip the engine to extreme angles during lifting as it may cause oil to grav
20. es Look for soft soil deep mud and standing water Watch for anything that might make you lose control or cause the power buggy to tip over ALWAYS clear away trash and debris Pick up anything that might puncture the tires m ALWAYS make sure aisles ramps doorways and passages are clear ALWAYS plan your work Make sure you know where you will make your pickups dumps and turns Before you take a load know where you will place it M NEVER operate the power buggy facing backwards In a backwards position the operator cannot properly activate the manual brake emergency switch grip the handles or steer the machine ALWAYS face in the direction of the bucket DO NOT operate the power buggy on unsafe haul roads load areas and dump areas DO NOT operate power buggy on excessive slopes with a grade higher than 10 6 forward and backward or side to side 00 NOT operate power buggy on extremely uneven surfaces NEVER allow riders other than the operator on the power buggy ALWAYS secure the step plate platform in the upright position when using the power buggy over rough terrain DO NOT stand on the power buggy step plate platform when walking in rough terrain Walk behind the power buggy DO NOT touch lean or reach through the dump mechanism or permit others to do so NEVER climb on the power buggy or dump mechanism POWER BUGGY SAFETY DANGER Engin
21. ety Information General CHOKE LEVER Information and Inspection sections of this manual have been read and thoroughly understood ELECTRIC START WBH16E ONLY 1 Before attempting to start the power buggy make sure that the safety kill switch Figure 19 is not pushed in The power buggy will not start with the kill switch engaged 5 Move the throttle lever halfway between the FAST and SLOW position Figure 11 for starting Figure 10 Engine Choke Lever Open 2 Place the engine fuel lever to the ON position Figure 8 THROTTLE LEVER Figure 8 Engine Fuel Lever ON Position 3 Place the choke lever Figure 9 in the CLOSED position if starting a cold engine Figure 11 Throttle Lever CHOKE LEVER 6 Place the engine ON OFF switch Figure 12 in the ON position Figure 9 Engine Choke Lever Closed NOTICE The CLOSED position of the choke lever enriches the fuel mixture for starting a cold engine The OPEN position provides the correct fuel mixture for normal operation after starting and for restarting a warm engine Figure 12 Engine ON OFF Switch Electric Start WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 19 OPERATION 7 Make sure the choke lever is in the OPEN position 4 Ifthe engine has started slowly push the choke lever Figure 10 before operating the power buggy Before inward to the RUN position If the engine
22. f the buggy ALWAYS make sure the power buggy s brakes working properly Check brake linkage and adjust as required NEVER operate the power buggy with a defective braking system Ensure brakes are applied when leaving or when using on a slope When parking on a slope position the power buggy at a right angle to a slope Ensure that the parking brake is engaged and holds the power buggy safely in place when parking on a slope PAGE 8 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 SAFETY INFORMATION ALWAYS use extreme caution when working with flammable liquids DO NOT fill the fuel tank while the engine is running or hot DO NOT overfill tank since spilled fuel could ignite if it comes into contact with hot engine parts or sparks from the ignition system Store fuel in appropriate containers in well ventilated areas and away from sparks and flames DO NOT leave the power buggy in the vicinity of ovens furnaces or radiant heaters Heat could raise the pressure of the fuel so that vented gas could ignite BATTERY SAFETY ELECTRIC START ONLY DANGER DO NOT drop the battery There is a possibility that the battery will explode NEVER use fuel as a cleaning agent DO NOT smoke around or near the equipment Fire or explosion could result from fuel vapors or if fuel is spilled on a hot engine DO NOT expose the b
23. g nuts periodically x Dy 4106 NUTS LUG NUTS PNEUMATIC AIR GUN TORQUE WRENCH Figure 25 Lug Nut Torque Sequence PUMP CONTROL LEVER ADJUSTMENT the power buggy tends to creep in the forward or reverse direction after you release the speed control lever the pump control lever requires adjustment 3 Place the machines drive wheels on jacks or blocks free from ground contact 4 Locate the pump control lever adjusting bolt 5 Loosen the jam nut 6 Start the engine and place the buggy s directional control lever in the forward then reverse directions while observing for wheel movement 7 pump lever has a very sensitive neutral position of about 1 32 to 1 16 If the wheels are creeping turn the adjusting bolt in very slight increments If wheels are creeping in reverse turn the adjusting bolt counterclockwise If wheels are creeping forward turn the adjusting bolt clockwise TIRES WHEELS LUG NUTS Tires and wheels are very important an d critical components of the buggy When specifying or replacing the wheels it is important that the wheels tires and axle are properly matched DO NOT attempt to repair or modify a wheel DO NOT install an inner tube to correct a leak through the rim the rim is cracked the air pressure in the inner tube may cause pieces of the rim to explode break off with great force and can cause serious eye or bodily injury TIRES WEAR INFLATION
24. gap points dirty Set correct spark gap and clean points present at the spark plug proper spart gap p y park gap pomis Condenser insulation worn or short circuiting Replace condenser Spark plug wire broken or short circuiting Replace defective spark plug wiring Wrong fuel type Flush fuel system and replace with correct 9 type of fuel Difficult to start fuel is available spark is Water or dust in fuel system Flush fuel system present and compression is normal a Air cleaner dirty Clean or replace air cleaner Choke open Close choke Suction exhaust valve stuck or protruded Reseat valves Piston ring and or cylinder worn Replace piston rings and or piston Difficult to start fuel is available spark is Cylinder head and or spark plug not tightened present and compression is low properly Torque cylinder head bolts and spark plug Head gasket spark plug gasket damaged No fuel in fuel tank Fill with correct type of fuel Apply lubricant to loosen fuel cock lever PEP ps y replace if necessary 0 2 Fuel filter lines clogged Replace fuel filter Fuel tank cap breather hole clogged Clean or replace fuel tank cap Air in fuel line Bleed fuel line Replace head and spark plug gaskets WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 27 TROUBLESHOOTING Troubleshooting Engine continued Symptom O O Posse Problem Solution T Water i
25. inuously applied to the dump pedal or the dump control lever is held in the forward position WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 23 MAINTENANCE 5 Replace hydraulic oil after every 200 hours of operation The hydraulic oil filter should be changed each time the hydraulic oil is changed HYDRAULIC DRIVE MOTORS The hydraulic drive motors are extremely reliable and will not need maintenance or repair under normal conditions Should any problems develop with the hydraulic drive motors contact Multiquip s service department BRAKE ADJUSTMENT Brake adjustment can be made on the brake linkage rod located on the right side of the buggy Place the parking brake lever in the engaged position The parking brake should be adjusted so that the buggy will not move Adjustment is provided by a knob at the end of the parking brake lever To tighten turn the knob counterclockwise Adjust the knob sufficiently tight so that when the parking brake lever is actuated considerable pressure is required to place it in the over center or ON position With the parking brake engaged the buggy should not move when the engine is started and the travel lever pushed forward 1 CHASSIS LUBRICATION The WBH16 WBH16E is equipped with zerk fittings Lubricate these zerk fittings each day before operating the buggy Lubricate with high grade chassis lubricant at all lubricating points lis
26. itate into the cylinder head making the engine start difficult DO NOT lift machine to unnecessary heights NEVER lift the equipment while the engine is running ALWAYS use ramps capable of supporting the weight of the power buggy and the operator to load and unload the power buggy PAGE 10 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 SPECIFICATIONS Table 1 Specifications Power Buggy 44 in 1 117 6 mm Maximum Weight Capacity 30 25 in 738 65 mm 2 500 Ibs Dual Wheels 1 136 kg Overall Width Single Wheel 43 25 in 1 098 6 mm Turning Radius Tires Drive Wheels 5 2 4 80 x 8 0 in Tires Steering 122 x 203 mm WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 11 SPECIFICATIONS Table 2 Specifications Engine GX390K1QA2 Recoil Start GX390K1QAE2 Electric Start 3 46 x 2 51 in Bore X Stroke 88 x 64 mm 19 5 ft lbs 2 7 kg m 2 500 rpm 1 gal hr Specific Fuel Consumption 3 78 liters hr Cyclone Type 82 78 5 5 68 3 Ibs 31 0 kg I 15 9 17 7 x 17 4 Outside Dimensions L X W X H 405 X 450 X 443 mm PAGE 12 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 DIMENSIONS DIMENSIONS ARE IN INCHES 45 474 10 758 26 703 44 001 31 800 SIDE VIEW DIMENSIONS ARE IN INCHES El E 5 SSD REAR VIE
27. lever Figure 17 in the forward direction Figure 17 Direction Lever Slowly squeeze the speed control lever slightly Figure 16 for a short period of time to test the brake holding capacity If the buggy moves forward adjust the brakes as outlined in the maintenance section of this manual If the buggy does not move forward release the speed control and disengage the parking brake If the buggy creeps forward or reverse while the parking brake is disengaged the machine will require service adjustment of the pump control lever as outlined in the maintenance section of this manual 1 2 3 TRAVELING With the engine running and parking brake released place the direction lever Figure 17 in the forward direction Squeeze the speed control lever Figure 16 slightly until the buggy begins to move in a forward direction Initially let the buggy travel at about 3 MPH WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 21 1 OPERATION DO NOT steer the buggy left or right when traveling up or down on a grade Travel in a straight path Avoid sudden and quick turns When steering turn the handle bar slowly Always face the controls when traveling TRAVELING ON A SLOPE 1 When traveling slope itis necessary to determine the grade of the path The WBH16 WBH16E can travel up down or side to side on a maximum grade of 10 6 Do not
28. n fuel system Flush fuel system and replace with correct Weak in power compression is proper but type of fuel misfires Dirty spark plug Clean or replace spark plug Ignition coil defective Replace ignition coil Spark plug heat value incorrect Replace with correct type of spark plug Wrong type of fuel Replace with correct type of fuel Engine overheats Cooling fins dirty Clean cooling fins Clear intake of dirt and debris Replace air Intake air restricted cleaner elements as necessary Oil level too low or too high Adjust oil to proper level Governor adjusted incorrectly Adjust governor Rotational speed fluctuates Governor spring defective Replace governor spring Fuel flow restricted Check entire fuel system for leaks or clogs Recoil mechanism clogged with dust and Clean recoil assembly with soap and water Recoil starter malfunctions if applicable dirt Spiral spring loose Replace spiral spring Loose damaged winid Ensure tight clean connections on battery 9 9 and starter Starter malfunctions ae Battery insufficiently charged Recharge or replace battery Starter damaged or internally shorted Replace starter Check and clean valves Check muffler and Over accumulation of exhaust products replace if necessary Burns too much fuel eplace spark plug with manufacturer s Wrong spare Puy suggested type Lubricating oil is wrong viscosity Replace lubricating oil with cor
29. ne is hot or running 1 Remove the gasoline cap Figure 6 located on top of fuel tank FUEL FUEL TANK Figure 6 Fuel Tank 2 Visually inspect to see if fuel level is low If fuel is low replenish with unleaded fuel 3 When refueling be sure to use a strainer for filtration Do not top off fuel Wipe up any spilled fuel TIRE PRESSURE CHECK The wheels and tires of the WBH16 WBHI16E are very important in its effective operation 1 Check the tires regularly to make certain the lugs nuts are tight 2 Make sure tires are inflated to manufacturer s suggested tire pressure Do not operate the buggy with bad or worn tires BEFORE STARTING 1 Read safety information at the beginning of manual 2 Clean the machine removing dirt and dust particularly the engine cooling air inlet carburetor and air cleaner 3 Check the air filter for dirt and dust If air filter is dirty replace air filter with a new one 4 Check carburetor for external dirt and dust Clean with dry compressed air 5 Check fastening nuts and bolts for tightness ENGINE OIL CHECK 1 To check the engine oil level place the buggy on secure level ground with the engine stopped 2 Remove the filler cap dipstick from the engine oil filler hole Figure 4 and wipe it clean Figure 4 Engine Oil Dipstick Removal Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the
30. r or with a dirty air filter Severe engine damage may occur Service air filter frequently to prevent engine malfunction NEVER tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the yY maximum allowable FUEL SAFETY DO NOT start the engine near spilled fuel or combustible fluids Fuel is extremely flammable and its vapors can cause an explosion if ignited 2 ALWAYS refuel in a well ventilated area away from sparks and open flames WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 9 SAFETY INFORMATION TRANSPORTING SAFETY NOTICE ALWAYS shutdown engine before transporting Tighten fuel tank cap securely and close fuel cock to prevent fuel from spilling When transporting of the power buggy is required place the power buggy on a flat bed truck or equivalent and tie down securely ALWAYS make sure all tie downs and block are place and the bucket is completely lowered in the flat horizontal position and securely latched Place chock blocks underneath wheel to prevent rolling When transporting the power buggy on a truck or trailer know the overall height to avoid contacting overhead obstructions such as bridges and power lines Check the truck and ramp capacities ENVIRONMENTAL SAFETY NOTICE Dispose of hazardous waste prop
31. rect viscosity Exhaust color is continuously white Replace rings Air cleaner clogged Clean or replace air cleaner Choke valve set to incorrect position Adjust choke valve to correct position Carburetor defective seal on carburetor broken Poor carburetor adjustment engine runs too ON OFF device not activated ON Turn on ON OFF device 5 h Will not start no power with key if Battery disconnected or discharged Check cable connections Charge or replace applicable battery Ignition switch wiring defective Replace ignition switch Check wiring Exhaust color is continuously black Replace carburetor or seal PAGE 28 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 HYDRAULIC SYSTEM DIAGRAM HYDRAULIC HYD OIL FILTER 200 MICRON MESH P N 18229 DUMP CYLINDER P N 18022 RELIEF VALVE 800 PS1 P N 18035 17 SPIN ON RETURN FILTER 10 MICRON DIRECTION VALVE P N 11402 DUMP VALVE P N 18058 P N 18064 DRIVE MOTOR NORMALLY UP TO 17 GPM P N 18011 DRIVE MOTOR DRIVE MOTOR NORMALLY UP TO NORMALLY UP TO 17 GPM 17 GPM P N 18011 P N 18022 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 PAGE 29 OPERATION MANUAL HERE S HOW TO GET HELP PLEASE HAVE THE MODEL AND SERIAL NUMBER ON HAND WHEN CALLING MQ Parts Department 800 427 1244 Fax 800 672 7877 310 537
32. t Adjust speed control cable System jerky when started Defective drive motors Check drive motors replace if necessary Difficult to steer Un lubricated steering column Lubricate steering column Parking brake will not hold Brake linkage out of adjustment Use smaller diameter hose or replace hose PAGE 26 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 TROUBLESHOOTING Troubleshooting Engine Spark plug bridging Check gap insulation or replace spark plug Carbon deposit on spark plug Clean or replace spark plug Short circuit due to deficient spark plug insulation Water in fuel tank Difficult to start fuel is available but no spark at spark plug If insufficient compression repair or replace Spark plug is bluish white engine If injected air leaking correct leak If carburetor jets clogged clean carburetor Check spark plug insulation replace if worn Check transistor ignition unit is broken and replace defective unit Check if voltage cord cracked or broken and replace Check if spark plug if fouled and replace Add oil as required Oil pressure alarm lamp blinks upon starting Check automatic shutdown circuit if applicable sensor if applicable No spark present at tip of spark plug ON OFF switch is shorted Check switch wiring replace switch Ignition coil defective Replace ignition coil Dieu ii available ang Shark Improper spark
33. ted below Dump Cylinder Pivots two zerk fittings Bearing Pivot Blocks underside of tub four zerk fittings Steering Bearing Flange Front side of handle bar One zerk fitting 1 2 Remove rear wheel hubs and repack bearings after every 400 hours of operation ENGINE Refer to the Honda engine owner s manual for specific information 1 Check engine oil after every 10 hours of operation and maintain proper levels 2 Drain oil after every 50 hours of operation and refill with grade of oil recommended below Above 40 F 13 0 Below 40 F 13 S A E 20 ADDING HYDRAULIC OIL 1 Check the hydraulic oil level in the hydraulic oil tank by reading the hydraulic oil sight glass mounted on the hydraulic oil tank 2 If the hydraulic oil level is low fill to the proper level with MOBIL 300 GM DEXTRON FORD 2 33 FORD M2C41A hydraulic oil or equivalent 3 To gain access to the hydraulic oil filler hole Figure 24 the tub bucket must be put in the dump position vertical Start the engine as outlined in the starting procedure then place the tub in the dumping position Figure 24 Hydraulic Oil Tank Filler Cap 4 Use the tub support rod to support the tub then turn the engine OFF Remove the hydraulic oil filler cap and add hydraulic oil as required Fill to the normal operating mark as indicated on the hydraulic oil sight gauge NOTICE In clima
34. tes where temperatures are below 35 F hard starting may occur In these cases the hydraulic oil should be switched to a thinner 15 weight hydraulic fluid PAGE 24 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 MAINTENANCE Table 4 Tire Wear Troubleshooting AR PATTERN CAUSE SOLUTION Adjust pressure to Center Wear Over Inflation particular load per tire manufacturer Adjust pressure to Edge Wear Under Inflation particular load per tire manufacturer Loss of chamber Make sure load does Side Wear or overloading not exceed axle rating Align wheels Cupping Out of balance Check bearing adjust ment and balance tires Avoid sudden stops when possible and adjust brakes Wheel lockup amp tire skidding Flat Spots LUG NUT TORQUE REQUIREMENTS Itis extremely important to apply and maintain proper wheel mounting torque on the trailer Be sure to use only the fasteners matched to the cone angle of the wheel Proper procedure for attachment of the wheels is as follows 1 Start all wheel lug nuts by hand 2 Torque all lug nuts in sequence See Figure 25 DO NOT torque the wheel lug nuts all the way down Tighten each lug nut in 3 separate passes as defined by Table 5 Table 5 Tire Torque Requirements First Pass Second Pass Third Pass Wheel Size FrBS 88 3 After first road use retorque all lug nuts in sequence Figure 25 Check all wheel lu
35. the nearest phone or keep aphone on the job site Also know the phone numbers of the nearest ambulance doctor and fire department This information will be invaluable in the case of an emergency e GENERAL SAFETY NEVER operate this equipment without proper protective clothing shatterproof glasses respiratory protection hearing protection steel toed boots and other protective devices required by the job or city and state regulations O90000 Avoid wearing jewelry or loose fitting clothes that may snag on the controls or moving parts as this can cause serious injury NEVER operate this equipment when not feeling well due to fatigue illness or when under medication NEVER operate this equipment under the influence of drugs or alcohol ALWAYS clear the work area of any debris tools etc that would constitute a hazard while the equipment is in operation No one other than the operator is to be in the working area when the equipment is in operation DO use the equipment for any purpose other than its intended purposes or applications PAGE 6 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 SAFETY INFORMATION ALWAYS inspect the surface over which you will travel Look for holes drop offs and obstacles Look for rough and weak spots on docks ramps or floor Look for oil spills wet spots and slippery surfac
36. travel on steeper slopes To determine the grade of your path of travel use the formula and graph in Figure 21 100 95 3 9 8513 22 80 SNS mae 2 85 90 1 N 655 2 lt 89095 5 9 ss 3 Rag so a 505 DISTANCE 0 g 455 s 40 3515 HEIGHT V DIRECTION OF TRACT i gt GRADE 100 H D 254 205 6 e LEVEL BASE LINE 100 95 85 7 a 6 80 3 2 3 o S zs lt 576 80 89 90 a 52 1 5515 lt 1 655 gt gt gt 60 9 9 F oF 99 9 2 5 55 3 D a 9 505 k DISTANCE 0 e 45 403 gt 4 HEIGHT H E OF GRADE 100 H D 25 208 2 1 195 10 EF sH 5 LEVEL LINE Figure 21 Determining Grade of Slope EMERGENCY SHUTDOWN The WBH16 WBH16E is equipped with a safety kill switch This switch is located on the right side of the handle bar 1 Press the power buggy s kill switch Figure 19 and listen for the engine to stop Figure 19 Safety Kill Switch 2 Engage the parking brake Figure 15 Turn the ignition switch Figure 12 to the OFF position STEERING To steer the buggy use the handle bar in front of the operator platform 1 To turn left when traveling in the forward direction turn the handle bar clockwise Fig
37. ure 20 BUGGY IS STEERED LEFT WHEN HANDLE BAR IS TURNED CLOCKWISE s TURN HANDLE BAR CLOCKWISE TO STEER BUGGY TO THE LEFT Figure 20 Steering the Buggy 2 To turn right when traveling in the forward direction turn the handle bar in the counterclockwise direction PAGE 22 WBH16 WBH16E POWER BUGGY OPERATION AND PARTS MANUAL REV 9 12 03 10 OPERATION NOTICE Releasing either one dump control lever or pedal before dump is completed will cause the tub to return to the horizontal position gt lt 7 K FON ES LEVER DUMP PEDAL Figure 23 Dump Pedal 2 To return the tub to its horizontal position simply release the dump control lever or remove your foot from the dump pedal 2 When going up or down a slope always travel in the forward direction Figure 22 CORRECT DIRECTION FOR TRAVELING DOWN A SLOPE CORRECT DIRECTION FOR TRAVELING UP A SLOPE Figure 22 Slope Travel Direction TUB BUCKET DUMPING The hydraulic dump can be controlled by hand dump control lever or foot dump pedal 1 activate the hydraulic dump press down on the dump pedal Figure 23 or move the dump control lever forward The tub will move to the vertical position as long as pressure is cont
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