SET UP / PARTS MANUAL

Transcription

1 LITTLE WONDER Shredding MAN Rev. A Original Language Instructions MODELS: HP KOHLER HP KOHLER SET UP / PARTS MANUAL

2 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals, wiring insulation, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

3 LITTLE WONDER IMPORTANT MESSAGE On behalf of everyone at Little Wonder, we would like to thank you for your purchase of a Little Wonder Petrol Powered Shredding Truckloader. This professional truckloader was designed to the highest standards to ensure you many hours of uninterrupted service. This manual provides the information necessary for safe and efficient operation and service. For your safety, it is critically important that you read and understand this entire manual before operating your Shredding Truckloader. LITTLE WONDER SCHILLER GROUNDS CARE, INC STREET ROAD, P.O. BOX 38 SOUTHAMPTON, PA TABLE OF CONTENTS... FIGURES... PAGE SAFETY SET-UP SERVICE / MAINTENANCE... 12, 13 DECALS... 14, 15 INTAKE HOSE/ DISCHARGE CHUTE BASE UNIT INTAKE HOSE, DISCHARGE CHUTE, BASE UNIT PARTS LIST... 18,

4 SAFETY LITTLE WONDER NOTICE!!! Unauthorized modifications may present extreme safety hazards to operators and bystanders and could also result in product damage. Schiller Grounds Care, Inc. strongly warns against, rejects and disclaims any modifications, add-on accessories or product alterations that are not designed, developed, tested and approved by Schiller Grounds Care, Inc. Engineering Department. Any Schiller Grounds Care, Inc. product that is altered, modified or changed in any manner not specifically authorized after original manufacture including the addition of after-market accessories or component parts not specifically approved by Schiller Grounds Care, Inc. will result in the Schiller Grounds Care, Inc. Warranty being voided. Any and all liability for personal injury and/or property damage caused by any unauthorized modifications, add-on accessories or products not approved by Schiller Grounds Care, Inc. will be considered the responsibility of the individual(s) or company designing and/or making such changes. Schiller Grounds Care, Inc. will vigorously pursue full indemnification and costs from any party responsible for such unauthorized post-manufacture modifications and/or accessories should personal injury and/or property damage result. This symbol means: ATTENTION! BECOME ALERT! Your safety and the safety of others is involved. Signal word definitions: The signal words below are used to identify levels of hazard seriousness. These words appear in this manual and on the safety labels attached to Schiller Grounds Care, Inc. machines. For your safety and the safety of others, read and follow the information given with these signal words and/or the symbol shown above. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor or moderate injury. It may also be used to alert against unsafe practices or property damage. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. MODEL NUMBER: This number appears on sales literature, technical manuals and price lists. SERIAL NUMBER: This number appears only on your unit. It contains the model number followed consecutively by the serial number. Use this number when ordering parts or seeking warranty information. 4

5 LITTLE WONDER SAFETY MAINTENANCE SAFETY In general - Maintain machine according to manufacturer's schedule and instructions for maximum safety and best results. - Park machine on level ground. - Never allow untrained personnel to service machine. - Guards should only be removed by a qualified technician for maintenance or service. - Adjust or repair only after the engine has been stopped and the fan has stopped moving. - Disconnect spark plug wire(s) before doing any maintenance. - Replace parts if worn, damaged or faulty. For best results, always replace with parts recommended by the manufacturer. - Do not dismantle the machine without releasing or restraining forces which may cause parts to move suddenly. - Provide adequate support, e.g. jack stands for lifted machine or parts if working beneath. - Do not put hands or feet near or under rotating parts. - Clean up spilled oil or fuel thoroughly. - Replace faulty mufflers. - To reduce fire hazards, keep the engine, muffler, and fuel storage area free of grass, leaves, debris buildup or grease. - Particular care must be taken when adjusting the carburetor while the engine is running. Keep hands and feet clear. - Keep all nuts, bolts and screws tight to be sure the equipment is in safe working condition. - Replace worn or damaged parts for safety. - Use only replacement parts supplied by original manufacturer. - Stop the engine and allow to cool before storing. - Do not store the machine or fuel container near heating appliances with an open flame such as a water heater or an appliance with a pilot light. - Keep petrol (gasoline) storage area free of grass, leaves and excessive grease to reduce fire hazard. - Keep the machine and fuel containers in a locked storage place to prevent tampering and to keep children from playing with them. Fans Fuel Do not straighten or weld fans. Replace damaged or failed fans. - Petrol (gasoline) and diesel fuels are flammable; petrol (gasoline) vapors are explosive. Use extra care when handling. - Store only in containers specifically designed for fuel. WARNING - When refueling or checking fuel level: - Stop the engine and allow to cool; - Do not smoke; - Refuel outdoors only; - Use a funnel; - Do not overfill; - If fuel is spilled, do not attempt to start the engine until the spill is cleaned up and vapors have cleared. - Replace caps on fuel containers and tanks securely. Sparks from static electricity can start fires or cause explosions. Flowing fuel can generate static electricity. To prevent static electricity sparks: - Keep containers electrically grounded. Do not fill containers in a vehicle or on a truck or trailer bed with a plastic liner. Fill containers on the ground away from the vehicle. - When practical, remove petrol (gasoline) powered equipment from the truck or trailer and refuel it on the ground. If equipment must be refueled on the truck or trailer, refuel from a portable container rather than a dispenser nozzle. - Keep the dispenser nozzle in contact with the rim of the fuel tank or container opening until fueling is complete. Do not use a nozzle lock-open device. - If petrol (fuel) is spilled on clothing change it immediately. 5

6 SAFETY LITTLE WONDER BATTERY Battery acid is caustic and fumes are explosive and can cause serious injury or death. To reduce the risk of personal injury when working near a battery: When working with battery acid, use protective equipment such as, but not limited to, goggles, face shield, rubber gloves and apron. Avoid leaning over a battery. Do not expose a battery to open flames or sparks. WARNING Be sure batteries with filler caps are properly filled with fluid. Do not allow battery acid to contact eyes or skin. Flush any contacted area with water immediately and get medical help. Charge batteries in an open, well ventilated area, away from sparks and flames. Unplug charger before connecting or disconnecting from battery Jump starting 1. Be sure the jumper cables are in good condition. Turn off the ignition and all electrical accessories on both machines. 2. Position the machine with a good (charged) battery next to but not touching the machine with the dead battery so jumper cables will reach. 3. When making cable connections: - make sure the clamps do not touch anywhere except to intended metal parts, - Never connect a positive ("+" or red) terminal to a negative (" " or black) terminal. - Make sure the cables won't get caught in any parts after the engines are started. 4. Connect one end of the first jumper cable to the positive terminal on one battery. Connect the other end to the positive terminal on the other battery. 5. Connect one end of the other cable to the negative terminal of the machine with a good (charged) battery. Make the final connection on the engine of the machine to be started, away from the battery. 6. Start the vehicle with the good battery, then the machine with the discharged battery. 7. Remove the cables in the exact reverse order of installation. When removing each clamp, take care it does not touch any other metal parts while the other end remains attached. 6

7 LITTLE WONDER SET-UP DEBRIS RECEPTACLE The Shredding Truckloader is intended to be used in conjunction with a truck or trailer mounted debris receptacle to load landscape debris for removal from a work site to storage, dump or processing site. These receptacles or debris bodies or boxes are provided by the user and are the responsibility of the user. Following are some considerations to keep in mind when designing / building, or buying a debris receptacle on a vehicle. 1. It must be road worthy. INSTALL SHREDDING FRAME (Figure #1) 1. Secure the Truckloader Frame to an appropriate mounting surface with (4) 3/4" (18mm) bolts and nuts. Four 3/4" X 4 bolts and four 3/4" flanged nylon locking nuts are supplied. 2. The unit may be lifted using either the frame lifting bars or the lift lug located above the engine. The lift lug has a maximum capacity of 225KG (500 lbs). 2. It must be constructed sturdily enough to contain the high velocity and force of entering debris to prevent injury to bystanders and damage to property. 3. Sufficient screen area must be provided to allow the air produced by the truckloader to escape while containing the lighter debris. A bigger screen area reduces the speed of the air through the screen and helps reduce the amount of debris that will be held to the screen. The screen area should be in the last area to be fill so it stays clean. If the air cannot escape, the truckloader will not be able to generate a vacuum to pick up debris. Figure #1 LIFTING LUG 4. It should prevent the debris from blowing out during transport to an unloading site. 5. Provision must be made for unloading. FRAME LIFTING BARS FRAME DECK MOUNTING HOLES 7

8 SET-UP INSTALL DISCHARGE CHUTE (Figure #2) 1. Slide the flange clamp ring over the discharge chute down onto its flange. 2. Lift the discharge chute with the discharge clamp ring and place on top of the transition discharge tube flange as shown. 3. Align the holes of the flange clamp ring with the transition tube studs and secure with (3) 3/8-16 nylon lock nuts and (3) knobs in an alternating pattern. Tighten the nuts and back off just enough that the chute can be rotated. Rotate the chute to the desired direction. Tighten knobs to lock the chute in place. INSTALL BOOM ARM (Figure #3) LITTLE WONDER 1. Install a thrust washer, the boom arm assembly, and a second thrust washer onto the shaft of the boom column assembly. 2. Secure the boom arm assembly and washers with a 1-8 flange lock nut. Tighten the nut, then back it off so the boom arm can pivot freely. 3. Grease the pivot fitting unless grease appears at either end of the boom column. 4. Install lynch pin as shown. BOOM ARM ASSEMBLY ROTATE TO DESIRED POSITION DISCHARGE CLAMP RING KNOB NUT DISCHARGE CHUTE Figure #3 FIGURE #3 BOOM COLUMN LOCK NUT Figure #2 FIGURE #4 THRUST WASHER GREASE FITTING LINCH PIN THRUST WASHER 8

9 LITTLE WONDER SET-UP HOSE ASSEMBLY-(Figure #4) 1. Remove hose from the box. 2. With the assistance of a second person, hold the hose at both ends, and stretch as far as possible. This will maximize the hose length and open the internal diameter. 3. Insert the hose flange assembly into one of the open ends as shown. Secure hose to the hose flange assembly with hose clamp. 4. Insert the intake nozzle into the end of the hose opposite the hose flange as shown. Secure hose to the intake nozzle with the hose clamp. See parts list for part numbers. 5. Install the intake nozzle handle to the intake nozzle with (4) 3/8-16 X 2-3/4 flange bolts and (4) 3/8-16 nylon lock nuts. Figure #4 HOSE FLANGE ASSEMBLY HOSE INTAKE NOZZLE HANDLE HOSE CLAMP INTAKE NOZZLE HOSE CLAMP BOLT NUT 9

10 SET-UP LITTLE WONDER HOSE ASSEMBLY-(Figure #5) 1. Loosen the knob and rotate the flapper retainer to allow the inlet flapper to be lifted upward. 2. Hold the inlet flapper up, then install the hose assembly by inserting the flange of the hose flange assembly into the space (gap) between the face of the inlet assembly flange and the back face flange retainer plate as shown. The pin located in the upper right corner of the inlet assembly flange prevents the hose flange assembly from sliding out. 3. Orient the intake nozzle to your preferred position and lock it in place by tightening the two knobs attached to the flange retainer plate and flapper retainer. Tightening the knobs, will push the flange of the hose flange assembly against the flange of the inlet assembly and activates the safety switch plate. THIS MUST BE DONE TO OPERATE THIS UNIT. Figure #5 INLET FLAPPER PIN INLET ASSEMBLY HOSE FLANGE ASSEMBLY HOSE ASSEMBLY FLAPPER RETAINER FLANGE RETAINER PLATE KNOB 10

11 LITTLE WONDER CHAIN LOOP ASSEMBLY TO BOOM ARM ASSEMBLY (Figure #6) 1. Install the threaded end of the chain loop assembly through the hole at the end of the boom arm assembly. Secure with a 1/2-13 nylon lock nut. 2. The level position of the hose assembly to the inlet flange assembly can be controlled by adjusting the position of the nut on the thread of the chain loop assembly. ATTACH HOSE TO BOOM ARM (Figure #6) 1. Wrap the hose band around the hose directly under chain loop assembly. Install a 5/16 x 1-3/4 bolt through the hose bands and tighten nylon locknuts to the end of the threads. 2. Attach the hose band to the chain loop assembly by connecting the chain to the bolt with a carabiner quick clip. 3. Make sure the hose band is in the proper position with respect to the hose to allow free movement with the boom arm assembly. ADD OIL TO THE ENGINE Fill the crankcase with the proper oil to the full mark on the dipstick. See the engine manual fir oil specifications. FILL THE FUEL TANK Fill the fuel tank with unleaded regular grade petrol (gasoline). Do not overfill. CONNECT THE BATTERY SET-UP Connect the red battery cable to the positive terminal of the battery with one 1/4-20X1 bolt and one 1/4-20 nut provided. Make this battery connection first. SECOND Connect the black battery cable found to the negative terminal of the battery with one 1/4-20X1 bolt and one 1/4-20 nut provided. Make this battery connection last. NUT (720576) BOOM ARM ASSEMBLY CHAIN LOOP ASSEMBLY NUT (720585) BOLT (720588) HOSE BAND Figure #6 FIGURE #6 11

12 SERVICE / MAINTENANCE REMOVING AND REPLACING THE FAN AND TALON RING (Figure 7) 1. Stop engine and remove key. Wait for fan to stop rotating. 2. Disconnect spark plug wires from spark plugs. 3. Disconnect safety switch from engine. 4. Unbolt and remove the inlet assembly from the housing face. 5. Remove bolt securing fan and talon ring to engine crankshaft. 6. Pull the talon ring off the face of the fan hub. 7. Rotate the fan to align the blades with the notches in the housing face. (Figure 1) 8. Install a 3/4-16X5" long grade 5 (or better) bolt in the hub to jack or push the fan from the crankshaft of the engine (Little Wonder P/N jacking screw is recommended.) **NOTE: the orientation of the fan with respect to the keyway upon removal. This is important when reinstalling the fan. LITTLE WONDER 9. Inspect fan and talon ring for damaged or worn blades. If the fan or talon ring is damaged or excessively worn, replace with a new part. 10. Reinstall the fan onto the crankshaft and orient it to the same position as removed in Step 7. Once the fan is aligned properly with the keyways of the fan hub and engine crankshaft in line, slide the fan completely onto the crankshaft. 11. To reinstall the talon ring, align the "D" hole in the ring with the mating shape found on the fan hub. 12. Secure the fan and talon ring with a new bolt. Apply a drop of 242 Loctite before installation. Torque to 244Nm (188ft.lbs.) 13. Reinstall the inlet assembly. 14. Reconnect safety switch and spark plug wires. Figure 7 CHAMFERED EDGE OF LINER FAN ASSEMBLY RUBBER LINER LINER HARDWARE TALON RING ALIGN FAN BLADE WITH HOUSING NOTCH FOR FAN INSTALLATION AND REMOVAL USE HOLE IN FAN BACK PLATE TO ALIGN FAN HUB KEYWAY WITH KEY ON THE CRANK SHAFT REMOVE NUTS TO DETACH INLET ASSEMBLY BOLT (720572) FIGURE # 12

13 LITTLE WONDER SERVICE / MAINTENANCE LINER REPLACEMENT AND EXCHANGE 1. Complete steps 1-7 of Removing and Replacing Fan and Talon Ring. 2. Inspect fan and talon ring. Replace if damaged or excessively worn. 3. Unbolt and remove the hardware securing the liner to the housing. 4. Remove the liner from the housing by wrapping it and pulling it through the front of the housing. 5. When installing the new liner into the housing, make sure the chamfered edge of the liner is installed in the vertical position at the discharge opening of the housing. 5. As you position the liner against the wall of the housing, make sure the holes of the liner line up with the slots in the housing. 6. Secure the liner to the housing (one hole at a time) with the 10 bolts, washers, and nuts. When installing the hardware, insert the bolts through the inside surface of the liner and install the washers and the nuts to the outside face of the housing. 7. Complete steps 8-13 of Removing and Replacing Fan and Talon Ring. 13

14 DECALS LITTLE WONDER

15 LITTLE WONDER DECALS ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY LABEL-LW HOUSING WARNING LABEL-THROWN OBJECTS LABEL-LIFT HOOK LABEL-SEVERED FINGERS LABEL-HOT SURFACE 1 15

16 INTAKE HOSE / DISCHARGE CHUTE LITTLE WONDER

17 17 LITTLE WONDER BASE UNIT X2 X2 X2 X10 X9 X2 X2 X10 X10 10 X

18 PART NUMBER LIST LITTLE WONDER ITEM# PART NUMBER DESCRIPTION 22HP 27HP HP KOHLER ENGINE HP KOHLER ENGINE OIL DRAIN VALVE /8 SQ. x 3 LG KEY PAINTED SKID FRAME /4-10 x 4 LG HEAVY HEX CAP SCREW /4-10 GRADE G LOCK FLANGE NUT /4 ROUND TUBE PLUG WASHER, FLAT.406 X X 9GA /8 SAE FLAT WASHER /8-16 WIZ NUT GAS TANK /8 x 1-3/4 LG. GR 8 HEX BOLT /8 SAE GRADE 8 FLAT WASHER /8-16 NYLON INSERT NUT GAS TANK FUEL CAP GAS TANK OUTLET FITTING FUEL LINE HOSE FUEL LINE HOSE CLAMP HEAVY DUTY 12V BATTERY BATTERY HOLD DOWN BLACK BATTERY CABLE RED BATTERY CABLE /4-20 x 1 LG. HEAVY HEX CAP SCREW /4-20 LOCK FLANGE NUT BOLT, SERRATED FLANGE, 5/16-24 x 3/4 LG, LOCKING PATCH PAINTED HOUSING ASSEMBLY /8-16 x 1-1/4 LG. GR 5 HEX BOLT INSERT-RIVNUT 5/ RUBBER LINER /16-18 x 1 LG. GR 5 HEX BOLT /16 SAE GRADE 8 FLAT WASHER C 5/16-18 NYLON INSERT NUT PAINTED TRANSITION DISCHARGE TUBE /16-18 x 3/4 LG SQ. NECK CARRIAGE BOLT LINCH PIN w/ LAYNARD /32 I.D. 1 1/4 O.D. WASHER /16-18 GRADE G LOCK FLANGE NUT FAN HUB SPACER HP BALANCED FAN ASSEMBLY HP BALANCED FAN ASSEMBLY TALON RING ASSEMBLY /8-18 x 3 LG. GR 8 HEAVY HEX CAP SCREW INLET ASSEMBLY INLET ASSEMBLY B 5/16-18 WIZ NUT HOSE FLANGE RETAINER PLATE HOSE FLANGE RETAINER PLATE /16 WASHER FLAPPER RETAINER

19 LITTLE WONDER PART NUMBER LIST ITEM# PART NUMBER DESCRIPTION 22HP 27HP /16-18 FEMALE THREADED KNOB PAINTED SWITCH PLATE /16-18 x 4 LG GRADE 8 BOLT SAFETY SWITCH WIRE ASSEMBLY A CLIP WIRE HARNESS INLET FLAPPER INLET FLAPPER PAINTED BOOM ARM ASSEMBLY /2 x 1/4 WALL SQUARE TUBE PLUG THRUST WASHER GRADE G LOCK FLANGE NUT CHAIN LOOP ASSEMBLY /2-13 NYLON INSERT NUT CARABINER QUICK CLIP HOSE BAND HOSE BAND /16-18 x 1-3/4 LG GRADE 8 BOLT DISCHARGE chute without liner DISCHARGE CLAMP RING /8-16 NYLON INSERT NUT (YELLOW ZINC) /8-16 FEMALE THREADED KNOB HOSE FLANGE ASSEMBLY HOSE FLANGE ASSEMBLY DIA. x 10 LG INTAKE HOSE DIA. X 10 LG INTAKE HOSE PLASTIC INTAKE NOZZLE PLASTIC INTAKE NOZZLE PLASTIC INTAKE NOZZLE HANDLE PLASTIC INTAKE NOZZLE HANDLE HOSE CLAMP left handed /8-16 x 2-3/4 LG. GR 5 HEX BOLT hose 6 x 12-1/4 diameter HOSE CLAMP right handed housing guard liner WASHER 5/16 X X.1 THICK chute liner with studs discharge chute with liner seal discharge

20 2 year limited Service & Warranty policy for Shredding TruckLoader The Little Wonder Shredding TruckLoader is guaranteed against defects in material and workmanship for a period of TWO YEAR from date of purchase, when used for RESIDENTIAL SERVICE, or COMMERCIAL SERVICE. Any Little Wonder Shredding TruckLoader or part found to be defective within the warranty period is to be returned to any registered Little Wonder Dealer. Engines for all gasoline powered products are warranted separately by the engine manufacture for a period of a year. Therefore, there are no warranties made, expressed or implied, for engines for gasoline powered products by Little Wonder. Transportation charges for parts and units submitted for replacement under this warranty must be borne by the purchaser. THIS WARRANTY shall not be effective if the product has been subject to misuse, negligence or accident, or if the product has been repaired or altered outside of our Southampton factory in any respect which affects its condition or operation. Little Wonder shall not be liable for any special indirect or consequential damages arising from defective equipment. Any implied warranty, including merchantability of fitness for a particular purpose, shall not extend beyond the written warranty period. THIS WARRANTY shall only be effective if the enclosed Warranty/Registration card is properly filled out and returned to Little Wonder, Schiller Grounds Care, Inc. at time of purchase. WARNING DANGER THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. LITTLE WONDER Schiller Grounds Care, Inc STREET ROAD, P.O. BOX 38 SOUTHAMPTON, PA PHONE FAX LWONDER P/N / Specifications, descriptions, and illustrative material in this literature are as accurate as known at the time of publication, but are subject to change without notice.