PARTS MANUAL. B-16, B-21, and TB-16 Scoot-Crete Power Buggies

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1 PARTS MANUAL B-16, B-21, and TB-16 Scoot-Crete Power Buggies (Revised April, 2009) 1 Part #

2 GENERAL ARRANGEMENT DANGER DO NOT OPERATE THIS MACHINE WITH YOUR BACK FACING THE CONTROLS! THIS MACHINE IS DESIGNED TO DUMP LOOSE FREE FLOWING MATERIALS. DUMPING MATERIALS THAT ARE NOT FREE FLOWING CAN CAUSE A SUDDEN LOAD SHIFT, TIP THE MACHINE FORWARD, AND THROW THE OPERATOR! ALWAYS TRAVEL IN REVERSE DOWN GRADES WITH A LOADED MACHINE. WHEN ON A GRADE NEVER TURN AND ALWAYS TRAVEL IN A STRAIGHT LINE. DANGER DANGER a a

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4 B-16 / B-21/TB-16 DECALS B-16 B B-21, TB B TB-16 DANGER ALWAYS TRAVEL IN REVERSE DOWN GRADES WITH A LOADED MACHINE. WHEN ON A GRADE NEVER TURN AND ALWAYS TRAVEL IN A STRAIGHT LINE. DANGER THIS MACHINE IS DESIGNED TO DUMP LOOSE FREE FLOWING MATERIALS. DUMPING MATERIALS THAT ARE NOT FREE FLOWING CAN CAUSE A SUDDEN LOAD SHIFT, TIP THE MACHINE FORWARD, AND THROW THE OPERATOR! DANGER DO NOT OPERATE THIS MACHINE WITH YOUR BACK FACING THE CONTROLS! BOTH SIDES OF OPERATOR'S PLATFORM 37 BOTH SIDES OF FRAME 35 BOTH SIDES OF FRAME 6

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6 B-16 AND B-21 STEERING COLUMN FOR HANDLEBAR MOUNTED DUMP ASSEMBLY SEE PAGES TORQUE TO 23 FT LBS 7 18 FOR MACHINES BUILT AFTER OCTOBER FOR MACHINES BUILT PRIOR TO OCTOBER ADDED TO MACHINES BUILT AFTER OCTOBER 2007 RUBBER ISOLATOR 22 8 REF. FRAME CONSOLE 1 10 NOTE: PRESS CLAMPING COLLAR 10 CLEAN OIL FROM THREADS AND APPLY (1) DROP OF SAFE-T-LOK SNUG AGAINST BEARING 11. T-70 TO THREADS LOCTITE AT ASS'Y 2-PLACES 2 2 NOTE: LOCTITE AT ASS'Y (2-PLACES) 3/32" TURNING CLEARANCE REQUIRED AFTER ASSEMBLY REF. FRAME ENGINE MOUNTING PLATE STEERING COLUMN DESIGN ON MACHINES MANUFACTURED PRIOR TO NOVEMBER

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8 TB-16 HALF-TRACK STEERING COLUMN 26 FRONT OF MACHINE TOP VIEW /32" TURNING CLEARANCE REQUIRED AFTER ASSEMBLY

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10 B-16 AND B-21 SERVICE AND PARKING BRAKE SYSTEM Refer to page 14 for parts listing HHCS HEX NUT FACE BOLT HEAD AS SHOWN FOR TIRE CLEARANCE. 48 LOCKNUT REF. RIGHT SIDE FRAME RAIL DETAIL C-C FLAT WASHER MUST HAVE 3/32" CLEARANCE ADJUST GAP FOR 3/16" CLEARANCE 49 FOR SPRING 49 REF.HEXNUT REF. RIGHT SIDE FRAME RAIL DETAIL A-A 48 SPRING 44 BRAKE PEDAL 44 B A A B C C 46 STEEL LOCKNUT. TORQUE TO 120 FT.LBS. 5/8 JAM NUT 3/4 HEXNUT FLAT WASHERS 5/8"NC X 2-3/4"LG., HEX HEAD CAP SCREW DETAIL B-B ADJUST CLEARANCE OF BRAKE PEDAL WITH BOLT ASSEMBLY BY TIGHTENING 5/8"NC-10 JAM NUT AGAINST FLAT WASHER. THEN BACK OFF JAM NUT 1/4 TURN. THEN TIGHTEN 5/8"NC STEEL LOCKNUT TO 120 FT.LBS. 12

11 REF. FRAME CASTLE NUT

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13 TB-16 (HALF TRACK) SERVICE AND PARKING BRAKE SYSTEM Refer to page 18 for parts listing A A 5/8" STEEL LOCK NUT FRAME 7 DETAIL A-A 5/8 JAM NUT 5/8" SAW FLAT WASHER 5/8" X 2-1/4" HHCS 8 16 ADJUST CLEARANCE OF BRAKE PEDAL WITH BOLT ASSEMBLY 8 BY TIGHTENING 5/8"NC-10 JAM NUT AGAINST FLAT WASHER. THEN BACK OFF JAM NUT 1/4 TURN. THEN TIGHTEN 5/8"NC STEEL LOCKNUT TO 120 FT.LBS.

14 REF. FRAME CASTLE NUT SQUARE KEY 79 BRAKE BAND 76 WHEEL HUB WITH STUDS 17

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16 B-16 B-21 HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (1 OF 3) refer to pages 23 & 24 for parts listing DIRECTIONAL CONTROL VALVE FRONT VIEW 37 IN OUT B A OUT TO FILTER "IN" PORT HYDRAULIC SYSTEM FRONT VIEW DUMP VALVE FRONT VIEW 4 OUT 47 IN

17 B-16 B-21 HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (2 OF 3) refer to pages 23 & 24 for parts listing CONNECT TO "EXTEND" PORT CYLINDER EXTEND PORT 2 1) CENTER CYLINDER ON MOUNTING LUGS. 2) ADD TWO(2) 1" SAE FLATWASHERS TO EACH SIDE OF LUG, AS SHOWN. CONNECT TO MOTOR PORT "B" CONNECT TO MOTOR PORT "A" CYLINDER RETURN PORT CONNECT TO MOTOR PORT "A" CONNECT TO MOTOR PORT "B" ASSEMBLY NOTE: -USE PASTE TYPE PIPE DOPE WITH TEFLON ON ALL PIPE THREADS, LA-CO "SLIC-TITE" PASTE OR EQUAL. DO NOT USE TEFLON TAPE. -PUT EDGING MATERIAL AROUND ALL FRAME HOLES BEFORE INSTALLING HOSES. -WIRE TIE ALL HOSES TOGETHER ON EACH SIDE OF BUGGY, AWAY FROM CYLINDER. -SEE SPECIAL RELIEF PRESSURE SETTING INFORMATION FOR DUMP AND DIRECTIONAL CONTROL VALVES. -CLEAN OIL FROM THREADS ON BALL KNOBS AND ALL SET SCREWS AND APPLY 1 DROP OF SAFE-T-LOK (T-70) OR EQUAL. CONNECT TO PORT "B" OF DIRECTIONAL CONTROL VALVE 46 CONNECT TO PORT "A" OF DIRECTIONAL CONTROL VALVE OUT CONNECT TO PORT "B" OF DIRECTIONAL CONTROL VALVE CONNECT TO PORT "A" OF DIRECTIONAL CONTROL VALVE 6 46 FLOW 20 IN CONNECT TO "IN" PORT OF CHARGE PRESSURE INLET PORT. IN A B DUMP VALVE TOP VIEW CONNECT 21 TO "OUT" PORT PORT OF DUMP VALVE OUT OUT A B IN 50 DIRECTIONAL CONTROL VALVE TOP VIEW NEAR SIDE AND FAR SIDE DIRECTIONAL CONTROL VALVE RIGHT SIDE VIEW 25 TYP.

18 B-16 B-21 HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (3 OF 3) refer to pages 23 & 24 for parts listing *B-16 PARTS ONLY **B-21 PARTS ONLY 19 * ** REF: ENGINE * 70 ** 71 ** * * ** * ** * * **

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21 TB-16 (HALF TRACK) HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (1 OF 3) refer to page 29 for parts listing 5 DIRECTIONAL CONTROL VALVE FRONT VIEW IN OUT 104 OUT B A 93 TO HEAT EXCHANGER "OUT" PORT HYDRAULIC SYSTEM FRONT VIEW 102 OUT IN DUMP VALVE FRONT VIEW 4 DUMP VALVE FRONT VIEW HYDRAULIC SYSTEM FRONT VIEW 26

22 TB-16 (HALF TRACK) HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (2 OF 3) refer to page 29 for parts listing 90 CONNECT TO "EXTEND" PORT CYLINDER EXTEND PORT 90 1) CENTER CYLINDER ON MOUNTING LUGS. 2) ADD TWO(2) 1" SAE FLATWASHERS TO EACH SIDE OF LUG, AS SHOWN. 92 CONNECT TO MOTOR PORT "B" CONNECT TO MOTOR PORT "A" CYLINDER RETURN PORT CONNECT TO MOTOR PORT "A" CONNECT TO MOTOR PORT "B" 91 ASSEMBLY NOTE: -USE PASTE TYPE PIPE DOPE WITH TEFLON ON ALL PIPE THREADS, LA-CO "SLIC-TITE" PASTE OR EQUAL. DO NOT USE TEFLON TAPE. -PUT EDGING MATERIAL AROUND ALL FRAME HOLES BEFORE INSTALLING HOSES. -WIRE TIE ALL HOSES TOGETHER ON EACH SIDE OF BUGGY, AWAY FROM CYLINDER. -SEE SPECIAL RELIEF PRESSURE SETTING INFORMATION FOR DUMP AND DIRECTIONAL CONTROL VALVES. -CLEAN OIL FROM THREADS ON BALL KNOBS AND ALL SET SCREWS AND APPLY 1 DROP OF SAFE-T-LOK (T-70) OR EQUAL. CONNECT TO PORT "A" OF DIRECTIONAL CONTROL VALVE CONNECT TO PORT "A" OF DIRECTIONAL CONTROL VALVE CONNECT TO PORT "B" OF DIRECTIONAL CONTROL VALVE OUT CONNECT TO PORT "B" OF DIRECTIONAL CONTROL VALVE FLOW IN CONNECT TO "IN" PORT OF CHARGE PRESSURE INLET PORT. 102 IN B CONNECT 102 TO "OUT" PORT OF HEAT EXCHANGER CONNECT 101 TO "IN" PORT OF HEAT EXCHANGER OUT 104 B 1 IN FAR SIDE 25 TYP. OUT A A DUMP VALVE TOP VIEW DIRECTIONAL CONTROL VALVE TOP VIEW DIRECTIONAL CONTROL VALVE RIGHT SIDE VIEW 27

23 TB-16 (HALF TRACK) HYDRAULIC SYSTEM HYDRAULIC SYSTEM GENERAL ARRANGEMENT (3 OF 3) refer to page 29 for parts listing 72 REF: ENGINE OIL FILTER ASS'Y IN 102 HEAT EXCHANGER "IN" PORT IN OUT VIEW OF DUMP VALVE AS VIEWED FROM REAR OF BUGGY HEAT EXCHANGER "OUT" PORT 28

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25 BUCKET AND BASE PLATE ASSEMBLY FOR POLY BUCKET 37 FOR STEEL BUCKET /2 USS FLAT WASHER 3/8"NC CARRIAGE BOLT REF. STEEL BUCKET 3/8 USS FLAT WASHER REF. BASE PLATE 34 3/8"NC STEEL CRIMP LOCK NUT CARRIAGE BOLT ASSEMBLY 37 FOR STEEL BUCKET 10 OR 32 30

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27 TRAVEL SPEED CONTROL ASSEMBLY 4 22 REF: HANDLEBAR CUT ONE(1) SIDE OF RUBBER BUSHING THRU. AND INSTALL ON CABLE 9 EXTENSION SPRING REPAIR KIT /4' FLAT WASHER HYDRAULIC RESERVOIR END PLATE 1 4 "NC HEX NUT 1/4"NC NYLOCK LOCKNUT (TORQUE TO 80 IN.LBS.) EYE BOLT SEE SPECIAL ASSEMBLY INSTRUCTIONS 4-15/16" OVERALL LENGTH TO OUTSIDE EDGES OF SPRING LOOPS LOCKNUT 14 TORQUE: 22 FT.-LBS CENTER BOTH FLAT WASHERS ON TRANSMISSION SHIFT STUD WHEN TIGHTENING LOCKNUT 14 HEX NUT 32

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29 WHEEL ASSEMBLIES REFERENCE: WHEEL HUB 8 Drive/Front Wheel Assembly Steering/Rear Wheel Assembly 34

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31 CONSOLE MOUNTED DUMP LEVER ASSEMBLY 2 2 REFERENCE: REAR CONSOLE 1 1 REFERENCE: DUMP VALVE REFERENCE: CLEVIS PIN A REFERENCE: FRAME REAR DECK PLATE REFERENCE: 3/16"Ø X 1" OVERALL LENGTH CLEVIS PIN WITH COTTER PIN SUPPLIED WITH VALVE FACE AS SHOWN AT ASS'Y. REFERENCE: DUMP VALVE RIGHT SIDE VIEW DUMP PEDAL 9 A 10 REAR VIEW REF. NYLOCK LOCKNUT TORQUE TO 120 FT.LBS. REF. HEXNUT REFERENCE: REAR FRAME LEFT SIDE RAIL DUMP PEDAL ASSEMBLY TIGHTEN HEX NUT AGAINST FLAT WASHERS AND DUMP PEDAL. THEN BACK OFF THE HEX NUT ONE-HALF(1/2) TURN. AFTER ADJUSTMENT MAKE SURE THAT THE DUMP PEDAL WILL MOVE FREELY. TORQUE NYLOCK LOCK NUT TO 120 FT.LBS. REFERENCE: REAR FRAME LEFT SIDE RAIL 4 7 HEXNUT TOP VIEW ADJUST BOLT ASS'Y 23 SO THAT BOLT IS TIGHT IN FRAME AND PEDAL WILL MOVE FREELY. NYLOCK LOCKNUT 9 ONE(1) OR TWO(2) FLAT WASHERS AS REQUIRED. 3 DUMP LEVER 1 SECTION A-A REF. NYLOCK LOCKNUT TORQUE TO 25 FT.LBS. REF. HEXNUT REF. 3 FLAT WASHERS DUMP LEVER ASSEMBLY TIGHTEN HEX NUT AGAINST FLAT WASHERS AND DUMP LEVER. THEN BACK OFF HEX NUT ONE-HALF(1/2) TURN. AFTER DJUSTMENT MAKE SURE THAT DUMP LEVER WILL MOVE FREELY. TORQUE NYLOCK LOCK NUT TO 25 FT.LBS. 36

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33 X X XX X X XXX X X XXX X X X X X X X X XXX XXXXX XX XX X XXXX X XX XXXX X X XX X X X HANDLEBAR MOUNTED DUMP LEVER ASSEMBLY XXX XXXX X X X XXX PLACE TRIMMED HANDGRIP, ITEM 19, ON BOTH SIDES OF OF HANDLEBAR, ITEM 12, AT ASSEMBLY. X X 13/64" WIDE SLOT X 1-3/4" LG. FOR HANDLEBAR BUCKET DUMP LEVER DUMP BUCKET RETURN BUCKET CUT ONE(1) SIDE OF RUBBER BUSHING THRU. AND INSTALL ON CABLE INSTALL CORD GRIP IN "(.844") DIAMETER HOLE IN THE TOP OF CONSOLE # TO THE RIGHT OF REAR WHEEL STEERING COLUMN ASSEMBLY REFERENCE: FRAME REAR DECK PLATE 15 MOUNT LOOM CLAMP ON CARBURATOR STUD TO RETAIN CABLE 38 29

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35 13 HP HONDA ENGINE WITH RECOIL START 13 HP HONDA ENGINE WITH ELECTRIC START AND RECOIL BACKUP FOR BUGGY MODEL B SPEED CONTROL LEVER "IDLE" FUEL "OFF" SPEED CONTROL LEVER "MAXIMUM SPEED" 3 CHOKE LEVER "ON" CHOKE LEVER "OFF" FUEL "ON" TOP VIEW ADJUST THROTTLE LEVER LIMITING SCREW TO ACHIEVE /-0 RPM NO LOAD SPEED. SECURE SCREW WITH NUT 4 AS SHOWN. 40

36 ELECTRICAL CIRCUIT FOR B-16 WITH 13 HP HONDA ENGINE WITH RECOIL START. 7 8 TOP SURFACE OF ENGINE CONSOLE. 13 HP HONDA ENGINE, MODEL GX390 RECOIL START TO IGNITION COIL BLACK WIRE BLACK WIRE WITH RED STRIPE RED WIRE 4 3 GREEN BLOCK BROWN WIRE NORMALLY OPEN(NO) GREEN CONTACT BLOCK. BULLET RECEPTACLE CONNECTOR BLACK WIRE WITH RED STRIPE RED WIRE YELLOW WIRE GREEN WIRE BOTH WIRES 24" LONG OFF ON CONNECT RING TERMINAL TO 8mm STUD SECURING FUEL TANK. ENGINE ON-OFF SWITCH OIL LEVEL SWITCH BROWN WIRE 41

37 ELECTRICAL CIRCUIT FOR B-16 WITH 13 HP HONDA ENGINE WITH ELECTRIC START WITH RECOIL BACKUP. 2 BLACK BLACK TOP SURFACE OF ENGINE CONSOLE. 13 HP HONDA ENGINE, MODEL GX390 ELECTRIC START CONNECT TO REGULATOR/RECTIFIER BLACK WIRE WHITE WIRE 15 AMP FUSE WHITE WIRE WHITE WIRE STARTER MOTOR SOLENOID STARTER MOTOR ATTACH.250" WIDE INSULATED FEMALE PUSH-ON TERMINAL TO STARTER MOTOR SOLENOID BATTERY BATTERY SPECIFICATIONS: 12 VOLT, BCI GROUP #U1R WITH A MINIMUM COLD CRANK AMP (CCA) OF 300 AMPS. PULL OFF ELBOW FEMALE INSULATED CRIMP TERMINAL FROM "START" POST OF STARTER MOTOR SOLENOID. ATTACH THIS TERMINAL TO INSULATED MALE SPADE ATTACHED TO BLUE WIRE. GREEN WIRE YELLOW WIRE BLACK WIRE ATTACH.250" WIDE INSULATED CRIMP MALE SPADE TERMINAL. BLACK WIRE WITH WHITE STRIPE TO IGNITION COIL, BLACK WIRE WITH RED STRIPE WHITE WIRE BLACK WIRE BLACK WIRE WITH RED STRIPE NORMALLY CLOSED (NC) RED CONTACT BLOCK BULLET RECEPTACLE CONNECTOR RED WIRE BLACK WIRE WITH RED STRIPE YELLOW WIRE BLACK WIRE RECTIFIER RED WIRE YELLOW WIRE CONNECT RING TERMINAL TO 8mm STUD SECURING FUEL TANK. BROWN WIRE RED BLOCK GREEN WIRE GREEN BLOCK BROWN WIRE NORMALLY OPEN(NO) GREEN CONTACT BLOCK. ALL FOUR(4) WIRE 28" LONG ST LO BAT E IG COMBINATION (IGNITION) SWITCH AT ENGINE CONTROL PANEL GROUND TO CONTROL PANEL BOX BLACK WIRE OIL LEVEL SWITCH 42

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39 20 HP HONDA ENGINE WITH ELECTRIC START AND RECOIL BACKUP FOR BUGGY MODELS B-21 AND TB-16 SEE PAGE 22 FOR COUPLING ASSEMBLY ENGINE FUEL FILTER PORT MAXIMUM ENGINE SPEED ADJUSTING SCREW. ADJUST MAXIMUM ENJINE SPEED TO /-0 RPM UNDER NO LOAD. TURN C.W. TO INCREASE SPEED. SECURE SCREW WITH NUT 28 AS SHOWN. SPEED CONTROL 44

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41 ELECTRICAL CIRCUIT FOR B-21 AND TB-16 WITH 20 HP HONDA ENGINE WITH ELECTRIC START AND RECOIL BACKUP. BLACK BLACK BATTERY SPECIFICATIONS: 12 VOLT, BCI GROUP #U1R WITH A MINIMUM COLD CRANK AMP (CCA) OF 300 AMPS. 8 TOP SURFACE OF ENGINE CONSOLE. CONNECT PLUG TO REGULATOR/ RECTIFIER GREY WIRE GREY WIRE WHITE WIRE WITH BLUE STRIPE BATTERY 20 HP HONDA ELECTRIC START ENGINE, MODEL GX620 TO FUEL SHUT OFF SOLENOID PULL OFF ELBOW FEMALE BLACK WIRE WITH YELLOW STRIPE INSULATED CRIMP TERMINAL ATTACH.250" WIDE FROM "START" POST OF STARTER INSULATED CRIMP MOTOR SOLENOID. ATTACH THIS MALE SPADE TERMINAL TO INSULATED MALE SPADE TERMINAL ATTACHED TO BLUE WIRE. ATTACH.250" WIDE INSULATED FEMALE PUSH-ON TERMINAL, TO THIS END OF BROWN WIRE. STARTER MOTOR SOLENOID STARTER MOTOR GREEN WIRE YELLOW WIRE BLACK WIRE CONNECT TO ALTERNATOR CHARGE COIL AT ENGINE FLYWHEEL BLACK WIRE WITH WHITE STRIPE BLACK WIRE WITH YELLOW STRIPE TO IGNITION COIL, BLACK WIRE WITH RED STRIPE CONNECT TO 12 VDC ACCESSORIES IF REQ'D. BLACK WIRE WHITE WIRE WHITE WIRE 25 AMP FUSE WHITE WIRE WHITE WIRE WHITE WIRE BLACK WIRE GROUND TO CONTROL PANEL BOX BLACK WIRE WITH RED STRIPE RED WIRE RED WIRE YELLOW WIRE RED BLOCK 1 2 GREEN WIRE 4 3 GREEN BLOCK BROWN WIRE CONNECT RING TERMINAL TO BOLT THAT CONNECTS GROUND WIRE FROM ENGINE ELECTRICAL CONTROL BOX OIL LEVEL SWITCH BROWN WIRE BULLET RECEPTACLE CONNECTOR BLACK WIRE WITH BLUE STRIPE YELLOW WIRE NORMALLY CLOSED(NC) RED CONTACT BLOCK GREEN WIRE RECTIFIER NORMALLY OPEN(NO) GREEN CONTACT BLOCK. ALL FOUR(4) WIRES 28" LONG ST LO BAT E IG COMBINATION (IGNITION) SWITCH AT ENGINE CONTROL PANEL GROUND TO CONTROL PANEL BOX BLACK WIRE 46

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43 TB16 TRACK ASSEMBLY Refer to page 50 for parts listing A. Idler Wheel Assembly

44 8 B. Track Assembly TB16 TRACK ASSEMBLY (continued) C. Cleat Assembly TRACK CLEAT ASSEMBLY SEQUENCE: 1) ASSEMBLE CONNECTING LINK 6, BUSHING 7, CARRIAGE BOLT 8, STEEL LOCKNUT 10 AS SHOWN, FOUR(4) PLACES PER CLEAT. TORQUE STEEL LOCKNUT TO 60 FT. LBS. THEN CONTINUE TIGHTENING NUT 10 UNTIL FLATS ON NUT LINE UP WITH HEX HOLE IN KEEPER PLATE. 2) ATTACH OUTSIDE KEEPER PLATE 5 TWO(2) PLACES PER CLEAT AS SHOWN. SECURE OUTSIDE KEEPER PLATE 5 WITH CARRIAGE BOLT 9 AND STEEL LOCK NUT 13. TORQUE TO 60 FT LBS ASSEMBLY STEP #1 CONNECTING LINK 6 / BUSHING 7 ASSEMBLY ASSEMBLY STEP # OUTSIDE KEEPER PLATE 5 ASSEMBLY

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