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Cellboost BOXER 427W User's Manual

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1. E e 2 2 j oO Pi EI a D D E ES E E Q z 5 vlt Clo o D Q S S E K ie le E S ll L S S E _ S s _ S Ia olge Sjz je Il lS gt L I I ls LEI QIHlSTl os olQ a D Wye kel S OINle lols Slol x E j 5 e 3 S s ol isles lt A u jo 2 JO Jo jo e a E TIN a jo JB Joo E 2 5 Operating Controls Safety Decals Continued 2127 Item No Description Boxer Decal Safety Instructions Decal Engine Throttle Decal Made In USA Decal Auxiliary Power Control Warning Pinch Point Warning Brute Decal CO CO N OO BY oj N gt Fuel Fill Warning Operating Controls Operating Controls Description Creep When a hydraulically powered auxiliary attachment is in use this control allows the operator to adjust the machine travel speed Boom Raise and Lower This lever controls the raising and lowering of the boom assembly Left Travel Motor Control Pushing the lever forward rotates the left side wheels for forward travel Pulling the lever backwards rotates the left side wheels for reverse travel Right Travel Motor Control Pushing the lever forward rotates the right side wheels for forward travel Pulling the lever backwar
2. o CC Li SES ATT qr JOE TZ nl it ay dr AHI 5 MH SH E E Nees fe IEN 3 eX E 2025 Figure 3 31 Attachment Hydraulic Hose Routing 12 The attachment is now ready to use Before starting the engine make sure that the Auxiliary Hydraulic control lever is in the NEUTRAL position If this control is left in either the forward or reverse position and the engine is started the attachment will begin to function 3 22 Pre Start Inspection and Operation Operating Instructions for a Hydraulic Attachment 1 Move the engine throttle to the full speed setting Raise the attachment off the ground and position it for use e Make sure that you are standing on the operator s platform DO NOT step off of the platform when the auxiliary attachment s power is engaged If you release the AUXILIARY hand control operator presence control the attachment will automatically stop all motion The Auxiliary Hydraulics will not function properly unless the HIGH LOW switch in set to the HIGH position 2 Set the HIGH LOW switch Item 2 Figure 3 32 to the HIGH position before activating the AUXILIARY control lever If this switch is not set properly the auxiliary hydraulics and travel controls will not function properly 3 With your right hand squeeze the AUXILIARY attachment control lever Item 1 Figure 3 32 toward
3. Follow the instructions in Removal of Attachment earlier in this section to complete the attachment removal 3 25 Pre Start Inspection and Operation 6 7 06 Fifth Proof Section 4 Routine Service and Maintenance The following information presents the routine service and maintenance required to make sure that the machine functions safely and properly More detailed service information is contained in the Service Manual Table 1 Service Cycle Table New Daily Machine Weekly Monthly Activity 10 Hours 20 Hours 50 Hours 200 Hours Annual Safety Placards YandR Fuel vy and A Engine Oil v and A R Hr Engine Oil Filter R R Air Filter y Hr R Fuel Filter y R Spark Arrestor on muffler v Engine Idle Speed v Spark Plugs v R Check and Clean Battery v v Terminals and Battery Hydraulics Hydraulic Filter R R Hydraulic Fluid Level YandA R Hydraulic Hoses v Grease wee Tire Pressure v Visual Check for v Loose Missing Fasteners y Check and Adjust Track v v Tension Service Cycle R Replace vz Check A Add First 20 operational hours then follow normal service cycle Extremely dusty or dirty working conditions may require more frequent service replacement Under very wet and muddy conditions more frequent lubrication may be required 4 1 Routine Service and Maintenance
4. 12 Crank the engine until it starts Run the engine until it rans smoothly 4 21 Routine Service and Maintenance SE 6 7 06 Fifth Proof Section 5 Troubleshooting The following procedures will assist you in determining the potential cause of a machine operating problem IMPORTANT Make sure to follow all safety precautions stated in this manual when doing any work on the machine Corrective Action Problem Possible Causes Starter does not turn the Auxiliary hydraulics lever is engine over either in Forward or Reverse position with no hydraulically powered attachment installed Move lever to neutral position e Battery is dead Charge the battery If battery does not hold a charge replace the battery e Electrical connections are corroded or loose Check electrical connections for good contact Remove cables from battery terminals and fully clean battery terminals and cable clamps If the cable clamps can not be properly cleaned replace connectors Relay or starter switch is defective Contact Authorized Service Dealer e Engine is in hydraulic lock due to a cylinder filled with fuel ADANGER Make sure that the spark plug cables have been moved away from the engine block or any other metal surface A spark could ignite the fuel causing a fire or explosion Allow engine to cool before attempting this procedure Remove spark p
5. Section 3 Pre Start Inspection and Operation AADANGER IMPROPER USE OF THE COMPACT UTILITY LOADER COULD CAUSE SERIOUS INJURY OR DEATH BEFORE OPERATING THE WHEEL LOADER OR PERFORMING MAINTENANCE THE OPERATOR MUST READ AND UNDERSTAND THE ENTIRE OPERATOR S MANUAL REVIEW MACHINE CONTROLS LOCATE AND REVIEW ALL WARNINGS AND SAFETY PLACARDS AND RELEVANT OPERATOR SAFETY MATERIALS INCLUDING WRITTEN VISUAL VIDEO OR VERBAL INSTRUCTIONS Pre Start Inspection It is very important to do a visual inspection of the machine before beginning operation This inspection should include e Check all decals and warning signs for damage e Check engine oil e Check and refill gas tanks e Check hydraulic lines and hoses for signs of damage or leaks e Inspect the machine for any signs of damage or loose fasteners e Check fluid levels and any signs of leaking fluids e Do all Daily Service Checks e Check machine controls to make sure that they automatically return to the neutral position NOTE The following procedures have several additional service checks and adjustments that will need to be followed if your machine is equipped with a track drive system The following information presents details on these inspection points and service checks Daily Service Checks Table 1 Service Cycle Table Activity Daily 10 Hours Fuel v and R Engine Oil v and A Engine Oil Filter Air Filter Fuel Filter Engi
6. Clean air filter separator tube Clean both air filter elements Replace both air filter elements Drain fuel system and replace with fresh clean fuel Excessive engine load Reduce engine load Engine overheated Clean cooling fins and remove any debris from around engine Faulty spark plugs Low compression Replace spark plugs See engine manual Exhaust restriction Clean spark arrestor See engine manual SMART SPARK malfunction applicable models See engine manual Low battery Replace battery See engine manual Incorrect governor setting See engine manual Engine Uses Excessive Amount of Oil Incorrect oil viscosity or type Drain engine oil and replace with proper type Clogged or improperly assembled breather See engine manual Breather reed broken See engine manual Worn or broken piston rings See engine manual Worn cylinder bore See engine manual Worn valve stems valve guides See engine manual 5 8 Troubleshooting Problem Possible Causes Corrective Action Crankcase over filled Drain engine oil and replace with proper quantity Blown head gasket overheated See engine manual Oil Leaks from Oil Seals Gaskets Crankcase breather is clogged or inoperative See engine manual Breather reed broken See engine manu
7. Daily Maintenance Procedures Do the following procedures daily or every 10 operating hours 1 Check condition of all warning and instructional decals Before operating the machine replace any missing or damaged decals NOTE Make sure to read and understand all WARNING and SAFETY decals before operating the machine 2 Check engine fuel and fill as needed be sure engine is OFF a The Brute has a saddle tank Item 1 Figure 4 1 on each side of the machine Ga Ve o E GC A CAUTION Figure 4 1 Fuel Level Check b Each of the tanks has a gas gauge located in the filler cap Item 2 Figure 4 1 Remove cap and visually inspect fuel level to make sure that the indicator is showing the proper fuel level Make sure that each tank has been filled on a daily basis Carefully pour gas into the tank not exceeding the max fill indication shown by the gauge in the fuel cap e Allow engine to cool before filling fuel tanks e Do not overfill because gas could spill onto hot engine parts and ignite or explode 4 2 Routine Service and Maintenance 3 Check engine oil a Make sure that the engine is OFF b Pull out the dipstick Item 1 Figure 4 2 and look for the FULL line fl WE 2010 Figure 4 2 Oil Lev
8. than the right than the left control lever The control lever The farther forward the aN farther forward the left control is AiG A right control is TS moved the faster e A moved the faster A aN the right turn will the left turn will be be made See d g made See D Figure 3 14 J Figure 3 15 7 K NS Sg lt Figure 3 14 Figure 3 15 Right Hand Turn Left Hand Turn in Forward in Forward Right Turn During Reverse Travel Left Turn During Reverse Travel Move the left hand Move the right control lever hand control lever farther backward farther backwards than the right than the left control lever The control lever The farther forward the farther forward the y left control is Aa T right control is PTEN moved the faster S moved the faster Ss the right turn will the left turn will be d be made See ER made See Ko Figure 3 16 J Figure 3 17 S 7 Se N e 2133 2140 Figure 3 16 Right Hand Turn ae in Reverse in Reverse 3 13 Pre Start Inspection and Operation Spin Turn balance Make sure to use the machine hand holds while doing a spin turn to maintain your Move the travel control levers in opposite directions to spin the machine on it axis To spin left move the right control lever forward while pulling the left control lever backwards to spin turn to the right push the left control lever forwards and while pulling the right control
9. 3 Pre Start Inspection and Operation e Some examples of common hydraulic hose damage are shown in Figure 3 3 2051 Figure 3 3 Hydraulic Hose Damage 1 End fittings damaged or leaking 2 Outer covering chafed or cut and wire reinforcing is exposed 3 Hose shows signs of kinking or crushing 4 Outer covering ballooning 5 Check for loose or missing fasteners e Inspect for any loose or missing bolts e Tighten or replace any missing bolts immediately 6 While you are performing the daily maintenance inspect the machine for any signs of damage such as missing or damaged components cracked welds etc 7 Check all 4 tires for the proper tire pressure The proper pressure level is shown on the side of the tire a Check the track assemblies to make sure that The tracks are in good condition and are not showing any signs of wear Track tension is properly set Track drive motors are not leaking oil or hydraulic fluid 8 Grease pivot shafts with proper type of grease There are 10 grease points on this machine see Figure 3 4 and Figure 3 5 Before starting the engine e Move all hydraulic control levers forward and release the lever Make sure that each lever automatically returns to the Neutral position e Move all hydraulic control levers rearward and release the lever Make sure that each lever automatically returns to the Neutral position The Auxiliary Control Lever will remain in either the
10. 4 10 Routine Service and Maintenance f With the tracks still off the ground start the engine and rotate just the track being adjusted three or four times in both forward and reverse Shut off the engine after rotating the track g Remeasure the deflection dimension h Repeat the measurement and adjustment procedure on the other track assembly i Lower the machine onto the ground 3 8 1 2 Figure 4 14 Track Tension Adjustment 4 11 Routine Service and Maintenance Weekly Maintenance Procedures Do the following procedures weekly or every 50 operating hours 1 Do all Daily maintenance procedures 2 Change engine oil and oil filter see engine manual First 50 operating hours only then follow the normal service cycles 3 Check the in line fuel filter Item 1 Figure 4 15 for signs of water restrictions or contamination Replace as needed Figure 4 15 Fuel Filter 4 Check Spark Arrestor Item 1 Figure 4 16 for a build up of carbon Clean with a stiff brush as needed NOTE Make sure that the exhaust system has cooled before cleaning the spark arrestor 2050 Figure 4 16 Clean Spark Arrestor 4 12 Routine Service and Maintenance 5 Check both spark plugs Items 1 and 2 Figure 4 17 for damage to the spark plug cables 2044 Figur
11. Creep Control Lever 3 24 Pre Start Inspection and Operation Removal of Hydraulically Powered Attachments After use the quick couples and hydraulic fluid will be very hot Wear gloves when disconnecting the auxiliary hydraulic lines To remove a hydraulically powered attachment 1 2 Lower the attachment to the ground and shut off the engine Move the hydraulic control levers forward or backward to release any stored hydraulic pressure Some of the female couplings will have a lock button preventing accidental disconnection To release this type of quick connect rotate the collar on the female quick connect Item 1 Figure 3 34 to align the notch on the collar with the lock button Item 2 Figure 3 34 Slide the collar backwards on the female quick connect Item 4 Figure 3 34 until it stops against the lock button The male connector will be released Move the attachment hose away from the bulkhead fitting If the female connector does not have the lock pin type collar just slide the collar backwards until the male connector is released 5 P Let AIDS Ara Um i ply 2 SP K Li I LI I im 2030 Figure 3 34 Quick Connect Locking Collar Repeat this procedure on the other hydraulic line Cover the hose connections with the dust caps Item 5 Figure 3 34 and store the hydraulic hoses to prevent damage
12. for the creep control lever is straight downwards This position turns the control system off Rotating the CREEP control lever fully clockwise to the top will send all of the hydraulic power to the attachment with no power going to the travel system Hold the main travel control levers in either the fully forward or reverse position Rotate the CREEP control lever Item 1 Figure 3 33 to adjust the travel speed as needed NOTE Rotating the creep control lever controls travel speed e counter clockwise increases the travel speed from very slow to full operating speed The faster the machine travels the less hydraulic power will be directed to the attachment e clockwise decreases the travel speed from full operating speed to full stop The slower the machine travels the more hydraulic power will be directed to the attachment Lower the attachment to the work position Rotate the CREEP control lever to adjust the machines travel speed to match the working conditions NOTE When the creep travel speed has been set properly steering and direction control can be adjusted by using either or both of the travel control levers To return to full operating speed release both travel control levers and rotate the CREEP control lever downwards past the highest speed setting into the detent OFF position The full speed control range will be returned to the main travel control levers P 2142 Figure 3 33
13. lever backwards Figure 3 18 D EET ei as E 2141 Figure 3 18 Spin Turn 3 14 Pre Start Inspection and Operation Attachment Installation and Removal Attachment Lock Pins The mounting plate located at the front of the machine provides for the easy installation and safe use of the wide variety of available attachments This system is very easy to use but requires the proper use of the attachment lock pins There are two positions for the attachment lock pins the unlocked position and the locked position Once the machine has picked up an attachment shut off the engine and rotate the attachment locks into the locked position Item 1 Figure 3 19 As you rotate the lock pin it will drop downwards securing the attachment to the machine If the lock pin does not drop into the locked position start the engine and either raise or lower the attachment slightly until the lock pins snap into place 1 1 J Pins Locked 2022 Figure 3 19 Attachment Locks in Locked Position Until the attachment lock pins are fully in the locked position the attachment has not been safely secured to the machine Do not stand near the attachment until it is fully secured to the machine To release an attachment rotate the attachment locks to the unlocked position Item 1 Figure 3 20 The lock pins will automa
14. properly The cogging condition is most likely to occur while operating in a reverse direction pulling a heavy load and during the first 50 hours of track usage It is caused by the tension spring being fully compressed due to high track load If a cogging condition occurs immediately stop machine travel and auxiliary functions and reverse travel direction slightly to de compress track tension Continued cogging will cause the track drive sprocket to seat into the rubber track incorrectly and cause damage to the track If cogging occurs stop travel function and check for and remove any debris or foreign matter in the drive system check track for proper tension as shown in Section 4 of this manual and resume operation Forward Travel Reverse Travel Push both control levers forwards to travel straight forward The farther these are moved the faster the machine will travel See Figure 3 12 2135 Figure 3 12 Forward Travel Pull both control levers backwards to travel straight backwards The farther these are moved the faster the machine will travel See Figure 3 13 2136 Figure 3 13 Reverse Travel 3 12 Pre Start Inspection and Operation Right Turn During Forward Travel Left Turn During Forward Travel To turn to the To turn to the left right move the left move the right hand control lever hand control lever farther forward farther forward
15. AN AREA THAT IS WELL VENTILATED 5 WIPE UP ANY GASOLINE THAT SPILLS 1 Park the machine on a level surface to make sure that the fuel tanks will be completely drained 2 Lower the boom and stop the engine Remove the key 3 Allow the engine to cool completely 4 Shut off fuel at the fuel shut off valve Item 1 Figure 4 26 by rotating the valve handles horizontally across the fuel lines Left Side of Engine Right Side of Engine 2041 2033 Figure 4 26 Fuel Shut Off Valves 4 20 Routine Service and Maintenance 5 Remove the spring clamps Items 2 Figure 4 27 from above and below the fuel filter and remove the fuel lines 2047 Figure 4 27 Fuel Filter 6 One at a time open the fuel valves and allow the fuel to drain into a suitable container NOTE Both fuel tanks can be drained through the fuel feed line going to the fuel filter Make sure that the container selected to store the fuel can contain the capacity of both fuel tanks IMPORTANT Make sure to dispose of the old gasoline in an appropriate manner NOTE Now is the best time to install a new fuel filter because the fuel tank is empty 7 Install the fuel line onto the new fuel filter 8 Slide the hose clamp close to the fuel filter to secure the fuel line 9 Open the fuel valves in the fuel line 10 Refill the tank with fresh clean fuel 11 Check for leaks and wipe up any spilled fuel
16. Forward or Reverse position detents until it is manually moved to the Neutral position e If any of the levers other than the Auxiliary Control Lever does not automatically return to the Neutral position DO NOT use the machine until repairs have been completed 3 4 Pre Start Inspection and Operation 2128 Figure 3 4 Lubrication Points Pre Start Inspection and Operation 2034 Figure 3 5 Loader Arm Lift Cylinder Base Lubrication Point NOTE Extremely dusty or dirty working conditions may require more frequent service replacement Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly 3 6 Pre Start Inspection and Operation Cylinder Lock Installation 1 Start the engine See Machine Start up in this section for engine starting instructions 2 Fully raise the loader arm 3 Shut off the engine 4 While holding the loose end of the cylinder lock Item 1 Figure 3 6 pull the safety lock pin Item 2 Figure 3 6 outwards releasing the cylinder lock Ln Pivot the cylinder lock downwards to the support position Item 3 Figure 3 6 6 Fully reinsert the safety lock pin Item 4 Figure 3 6 securing the cylinder lock in the support position NOTE Make sure that the safety lock pin goes behind the loader arm cylinder 7 Lower the loader arm assembly until it is supported by
17. Item 1 Figure 4 13 holding the filter cover Item 2 Figure 4 13 in place NOTE Press downwards on filter cover to relieve the upwards pressure from the spring Remove the filter cover and spring Item 3 Figure 4 13 c Remove the filter element Item 4 Figure 4 13 and replace with a new filter element d Inspect the filter cover O ring Item 5 Figure 4 13 for any signs of wear or damage f Replace as needed Reinstall spring and filter cover NOTE Make sure that the O ring is properly seated in the filter cover Start and run the engine for about 30 seconds Using the hydraulic oil level dip stick Item 7 Figure 4 13 check the hydraulic oil level Add the appropriate hydraulic fluid as needed 2073 Figure 4 13 Hydraulic Oil Filter Assembly 4 Check for proper track tension if equipped a Raise the machine off the ground and support it using a device capable of safely support ing 3000 lbs See Figure 4 14 for suggested location of the support devices b Tilt the bucket downwards until the cutting edge is touching the ground See Figure 4 14 c Lower the loader arm assembly pushing the front of the machine upwards Continue raising the machine until the rear drive sprocket is off the ground Shut off the engine d Measure the gap between the bottom of the center bogey guide roller Item 1 Figure 4 14 and the track The proper tension will be about a 3 8 1 2 deflection
18. MMMM GE LLL BOXER eh Vs EEE BIG POWER IN ALL PLACES Boxer 427 and Boxer 427W Operators Manual Part No 999 860 SN 992 and Higher ML 6 7 06 Fifth Proof Brute Product Warranty WARRANTY AND LIABILITY LIMITATIONS Mertz Manufacturing LLC warrants each new Compact Utility Loader manufactured hereinafter referred to as the equipment by us to be free from defects in materials and workmanship for a period of one 1 year or 1000 operational hours whichever occurs first from the date of delivery This warranty is effective provided that the equipment warranted hereunder is operated by the purchaser in accordance with generally approved practices is properly maintained in accordance with the instructions contained in this owner s manual and is operated within the manufacturer s rated capacity limitations Any parts of the equipment found to be defective within the warranty period shall be repaired or replaced at Mertz Manufacturing LLC s sole option Repairs must be performed at Mertz Manufacturing LLC facilities or at an authorized dealer facility Any part or parts proving defective within the above specified time will be repaired or replacement parts furnished F O B Ponca City Oklahoma providing such parts are returned transportation prepaid and found to be defective by the manufacturer The purchaser is responsible to keep maintenance records to substantiate proper maintenance If a defect becomes appare
19. ake sure that the hydraulic fluid is at or slightly above the marker hole in the dip stick If you are checking the fluid level after a period of use the hydraulic system and hydraulic fluid will be very hot Wear gloves when inspecting the hydraulic fluid level Ge lt i meet ij Figure 4 4 Hydraulic Fluid Level Dip Stick e Add the proper hydraulic fluid ISO 46 premium hydraulic oil or equivalent until the fluid level is at or slightly above the marker hole in the dipstick IMPORTANT Do not over fill the hydraulic system Damage to the hydraulic system might result 4 4 Routine Service and Maintenance 6 Check hydraulic hoses Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death When troubleshooting a hydraulic system for leaks always use cardboard or wood as a detector DO NOT USE YOUR BARE HANDS If you are injected with hydraulic oil or any other fluids immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries a Fully raise the loader arm and secure the safety support b Open the front service cover and secure with the safety support lock pin Figure 4 5 Install Safety Support c Press the lock button on the upper inspection panel locks which will release the panel locks Item 2 Figure 4 6 Remove the inspection panel Item 1 Fig
20. al Loose or improperly torqued fasteners See engine manual Piston blow by or leaky valves See engine manual Restricted exhaust Clean spark arrestor See engine manual This information is from the engine manual included with the machine General Specifications Wheel Unit Engine Power Gasoline 27 HP Engine Manufacturer Kohler Engine Description Command Pro Air Cooled Wheel Base 36 Width 42 5 Weight 1 850 LBS Tip Capacity 1 750 LBS Dump Angle 34 Dump height Si Hinge pin height 69 Travel speed 4 5 MPH Fuel tank capacity 10 GAL Overall Operating Height 91 Overall height 49 Overall Length with bucket 87 Ground clearance 5 625 Overall Length without bucket 69 Operating Capacity 50 of tip load 875 LBS 5 9 Troubleshooting Track Unit Engine Power Gasoline 27 HP Engine Manufacturer Kohler Engine Description Command Pro Air Cooled Wheel Base 37 Width 43 5 Weight without bucket 2 250 LBS Tip Capacity 1 800 LBS Dump Angle 34 Dump height 56 Hinge pin height fully raised 70 Travel speed 3 5 MPH Fuel tank capacity 10 GAL Overall Operating Height fully raised 93 Overall height 50 Overall Length with bucket 90 Ground clearance 7 0 Overall Length without bucket 70 Operating Capacity 50 of tip loa
21. allation 4 When the machines mounting plates top edge is seated in the attachment mounting plate curl the machines mounting plate backwards slightly to allow the lower edge of the machines mounting plate to slide into position See Figure 3 27 2032 Figure 3 27 Hydraulically Powered Attachment Installed 3 19 Pre Start Inspection and Operation 5 Shut the engine off 6 Rotate the attachment lock pins Item 1 Figure 3 27 Item 1 Figure 3 28 into the locked position securing the attachment to the machine 1 1 J Pins Locked 2022 Figure 3 28 Attachment Locks in Locked Position 7 Start the engine and test the security of the attachment connection by fully lowering with loader arm and tilting the attachment downwards until the front tires slightly lift off the ground 8 Shut off the engine 9 Move any of the main hydraulic controls forward and backward to release any stored hydraulic pressure 10 Attach the hydraulic hoses to the quick connects See Figure 3 29 NOTE There are two hydraulic hoses that need to be connected The quick connect system prevents you from incorrectly connecting the hydraulic hoses but both hoses need to be connected for the attachment to operate a With the engine OFF move the AUXILIARY control lever Item 1 Figure 3 29 toward the hand hold or the FORWARD position or move the lever BACKWARD into the REVERSE d
22. and replace with fresh clean fuel Spark plug lead disconnected Check to make sure that both spark plug leads are securely attached to the spark plug and that they are not damaged Poor quality of fuel Drain fuel system and replace with fresh clean fuel Faulty spark plug s Replace spark plugs Loose wires or connections that intermittently ground the ignition kill circuit Engine overheated Tighten connections Clean cooling fins and remove any debris from around engine Faulty ignition module or incorrect air gap Carburetor adjusted incorrectly See engine manual See engine manual SMART SPARK malfunction applicable models Dirt or water in the fuel system See engine manual Drain fuel system and replace with fresh clean fuel Stale fuel and or gum in carburetor Drain fuel system and replace with fresh clean fuel See engine manual Faulty spark plugs Replace spark plugs Fuel supply inadequate Fill fuel tanks Open both fuel valves Open vent on fuel tank cap Clean or replace fuel lines 5 6 Troubleshooting Problem Possible Causes Corrective Action Engine Overheats Idle speed adjusting screw improperly set See engine manual Idle fuel adjusting needle improperly set Some models See engine manual Low compression See engine manual Restrict
23. any attachment e Wearing protective clothing and gear such as hard hats safety glasses safety shoes hearing protection breathing protection and long pants and shirts is highly recommended Do not operate in clothing or shoes which will expose skin or feet to possible flying debris e Clothing should be relatively close fitting Loose clothing rings and other jewelry should be avoided because of the danger of catching them on machine parts or controls or on any rotating parts either on the machine or any attachment Keep hands fingers clear from all rotating parts e Never touch engine parts or machine components while they are hot e Always perform the Standard Shut Down Procedure shown in this manual if the unit will be left unattended for any length of time e Use only original CPI or approved replacement parts and attachments Imitation parts may lead to unit damage and or injury to personnel The machines warranty may be voided if unauthorized parts and attachments are used 1 1 Safety Precautions OPERATING SAFETY Plan ahead and learn as much as possible about your job site area before beginning any work Know the exact location of overhead power lines or obstructions Have all buried lines such as gas electric water telephone and cable TV marked by the proper authorities Prior to use perform the Pre Start Inspection and Daily Maintenance to make sure that the unit is in safe operating conditio
24. by a doctor trained in the treatment of penetrating fluid injuries e Hydraulic fluid can cause permanent eye injury Wear safety glasses or a full face shield to provide appropriate eye protection e When venting or filling the hydraulic system loosen the filler cap slowly to allow any pressure in the hydraulic tank to be released and remove the cap gradually 1 6 Safety Precautions Fueling Hazards Most fuels are highly flammable Observe the following precautionary practices to reduce the possibility of a serious accident e Always refuel the unit in an open well ventilated area away from sparks or open flames A DANGER Gasoline Engines Shut the engine off before attempting to fuel the machine Never refuel a unit while it is running Allow engine to cool before re fueling Always use a funnel or pour spout when filling the tanks Gasoline is extremely flammable and highly explosive when fueling Under certain circumstances a static charge can develop and ignite the gasoline Make sure that you are standing on the ground when filling the gas tanks If you are filling the gas tanks from a service vehicle make sure to connect the service vehicles ground cable to the machine before beginning the fueling process and keep the fuel nozzle in constant contact with the rim of the machines fuel tank To avoid static sparks when using a portable fuel container keep the fuel container nozzle in contact with the tank opening duri
25. ceeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeseesaeeeeesneeeestaees 3 8 Machine Gtart up 3 8 Machine Gbut down 3 10 Transportation sieis aaea aieeaa aee ao aaiae ioh ies 3 10 Machine Travel Controls cccceeecceeeeeeeeeeeeeeeeeeesaeeeeeseeeeeeesneeeeessaees 3 12 Attachment Installation and Hemoval 3 15 Attachment Lock Pm 3 15 Installation of Non Hydraulically Powered Attachments 0000 0 3 16 Removal of Attachment 3 18 Installation of Hydraulically Powered Attachments 0ssseeeseeeeenee 3 18 Operating Instructions for a Hydraulic Attachment 3 23 Travel Creep Control 3 24 Removal of Hydraulically Powered Attachments 00sneessneeeseeeene 3 25 Section 4 Routine Service and Maintenance sccssscssssssssseesssesessseees 4 1 Daily Maintenance Procedures esesesseeeeeesserirtrsesseritrrrensserinnnneneseennnnn 4 2 New Machine Brake in Maintenance Procedures eeeeeeesseeeeeeeeseeeeee 4 9 Weekly Maintenance Procecdures A 4 12 Monthly Maintenance Procedures sseseeeeeesssseieeeeesserirrrrreessrrinrrnneseent 4 14 Annual Maintenance Procedures eeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeneeeeeeeeess 4 18 General Maintenance cccccecceeeeeeceeeeeeeeceeeeeeeeesceeeeeeeeeeeeetesnseeeeees 4 20 Draining Fuel Tank Gasolme 4 20 Section 5 Troubleshooting ccsssecssseresseseesecensceessceessseeeseeceessceeeneeeenes 5 1 Engine Troubles
26. d 900 LBS 5 10 6 7 06 Fifth Proof COMPACT Compact Power Inc P O Box 40 Fort Mill SC 29716 Phone 800 476 9673 Fax 803 548 2762 Web Site http www cpiequipment com Part No 999 860
27. ds rotates the right side wheels for reverse travel Attachment Tilt Pushing the lever forwards tilts the attachment plate forwards lowering the attachment Pulling the lever backwards tilts the attachment plate backwards raising the attachment Attachment Activation Lever With your right hand squeeze the AUXILIARY attachment control lever towards the hand hold to activate the attachment in the FORWARD motion NOTE The lever is spring loaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping attachment motion If you want to reverse the operation of the attachment move the auxiliary control lever to the REVERSE position The control lever will remain in the REVERSE position detent until it is moved to the NEUTRAL position NOTE If using the auger FORWARD activates clockwise rotation BACKWARD activates counter clockwise rotation 2 7 Operating Controls 7 High Low Speed Range Selector Switch Selects the speed range that the travel speed operates within 8 Ignition Switch 9 Low Oil Warning Light when the light turns on it indicates that the engine oil level is low Shut down engine immediately and add oil 10 Engine Throttle The engine throttle is located on the control panel cowling just underneath the operating controls Moving the control lever upwards increases the engine speed and moving the lever downwards slows the engine to idle speed 2 8
28. e 4 17 Check Spark Plugs and Cables 6 Check the battery Item 1 Figure 4 18 and cable connections Items 2 and 3 Figure 4 18 for signs of leaking corrosion or damage Some items have been removed for clarity 2045 Figure 4 18 Battery and Cable Connections 6 7 06 Fifth Proof ES Routine Service and Maintenance Monthly Maintenance Procedures Do the following procedures monthly or every 200 operating hours 1 Do all Daily and Weekly maintenance procedures 2 Replace engine oil and engine oil filter see engine manual 3 Replace the outer paper element Item 3 Figure 4 19 and check inner element Item 2 Figure 4 19 2046 Figure 4 19 Check Engine Air Filter a Unhook the two retaining clips and remove the end cap Item 4 Figure 4 19 from the air cleaner housing Item 1 Figure 4 19 b Pull the outer air cleaner element Item 3 Figure 4 19 out of the housing c After the main element is removed check the condition of the inner element Item 2 Figure 4 19 It should be replaced whenever it appears dirty typically every other time the main element is replaced Clean the area around the base of the inner element before removing it so dirt does not get into the engine d Do not wash the paper element and inner element or use pressurized air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler e
29. e cover Item 1 Figure 4 25 and secure in the raised position using the safety support lock pin Item 2 Figure 4 25 f Locate the large hex nut on the filter housing assembly 4 Figure 4 25 Attached to this hex nut you will find the hydraulic level dip stick g Unscrew and remove the hydraulic fluid dip stick Item 3 Figure 4 25 h Fill the hydraulic tank with the proper hydraulic fluid ISO 46 Premium hydraulic fluid or equivalent through the dip stick port Using the hydraulic fluid dipstick make sure that the hydraulic fluid is at or slightly above the marker hole in the dip stick si aN Bs Figure 4 25 Hydraulic Fluid Level Dip Stick IMPORTANT Do not over fill the hydraulic system Damage to the hydraulic system might result i Reinstall and secure the dipstick assembly j Start the machine and run the engine at low idle for several minutes Shut off the engine k Recheck the hydraulic fluid level as described above 6 Replace hydraulic filter See page 4 10 Step 3 4 19 Routine Service and Maintenance General Maintenance Draining Fuel Tank Gasoline AADANGER 1 GASOLINE IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE 2 A FIRE OR EXPLOSION FROM GASOLINE CAN BURN YOU OR OTHERS AND CAUSE PROPERTY DAMAGE 3 DRAIN FUEL FROM TANKS WHEN THE ENGINE IS COLD 4 FUEL TANKS SHOULD ONLY BE DRAINED IN
30. e the throttle control lever to the mid range engine speed and set the transport speed to the LOW range Raise the attachment so that it will clear the ramp of the transport trailer NOTE The longer the attachment like the trencher the more the attachment needs to either be tilted or raised It is recommended to back the machine onto the transport trailer and position the machine so that the heaviest weight center of balance is towards the front hitch end of the trailer See Figure 3 10 The Brute is designed for maximum working balance When traveling on an incline always have the heaviest portion of the machine pointing uphill 2 Follow general load carrying safety Always carry the heaviest load pointing uphill NOTE When operating without an attachment the operator becomes the load Q XG p e E E Satz CEA 2019 Figure 3 10 Transport Position on Trailer 3 When the machine is positioned on the trailer properly lower the attachment to the trailer deck 4 Shut the engine off and remove the key 5 Secure the unit to the transport vehicle with DOT Department of Transportation approved chains binders and DOT guidelines Make sure to use the appropriate tie down locations on the machine and trailer 3 10 Pre Start Inspection and Operation 6 Gasoline Units Only Shut off the in fuel valves underneath each of the fuel tanks Item 1 Figure 3 11 when transporting the un
31. ed fuel tank cap vent Open vent on fuel tank cap Engine overheated cooling system air circulation problem Air intake grass screen cooling fins or cooling shrouds clogged Clean cooling fins and remove any debris from around engine Clean cooling fins and remove any debris from around engine Excessive engine load Reduce load on engine Low crankcase oil level Add engine oil High crankcase oil level Faulty carburetor Drain engine oil and replace with proper quantity See engine manual Lean fuel mixture SMART SPARK malfunction applicable models See engine manual See engine manual Engine Knocks Excessive engine load Reduce engine load Low crankcase oil level Add engine oil Old or improper fuel Drain fuel system and replace with fresh clean fuel Internal wear or damage See engine manual Hydraulic lifter malfunction See engine manual Quality of fuel Drain fuel system and replace with fresh clean fuel Incorrect grade of oil Drain engine oil and replace with proper grade of oil 5 7 Troubleshooting Problem Possible Causes Corrective Action Engine Loses Power Low crankcase oil level Add engine oil High crankcase oil level Drain engine oil and replace with proper quantity Dirty air cleaner element Dirt or water in the fuel system
32. ed off boom drops downward quickly and then stops Cylinder seals are leaking Replace cylinder seals The machine does not travel in either forward or reverse directions Engine is not running at full speed Advance throttle to full engine speed e Hydraulic fluid is cold Fully warm hydraulic fluid e Hydraulic fluid level is low Check and fill the hydraulic fluid tank with the appropriate hydraulic fluid e Fuel tanks are empty and engine stops Fill fuel tanks with fuel e If all above has been checked Contact authorized service dealer Tested with warm oil and no more than 530 Ibs 240 Kg in the bucket Measure the downward drop at the attachment lock pins on the back of the mount plate 5 3 Troubleshooting Engine Troubleshooting When engine trouble occurs check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below Problem Possible Causes Corrective Action Engine Cranks But Will Not Start Empty fuel tanks Fill fuel tanks Fuel shut off valves closed Open both fuel shut off valves Poor fuel dirt or water in the fuel system Drain fuel system and replace with fresh clean fuel Clogged fuel line Clean or replace fuel lines Spa
33. eeseeeesees 1 1 GENERAL SAFETY tbe eh eege bet eh EA 1 1 OPERATING SARETY its Ae EE eR BN AMS e 1 2 SERVICE amp MAINTENANCE SAFETY seeeeeeeeeeseeeessrnesrrrsesrrrssrrrrssrrrnes 1 4 ELECTRICAL SYSTEM HAZARDS isesneeeseeesereesrernerrrrnesrrrssrrnnssrrrnstne 1 4 Battery HaZards 2 2 eer i aaa pae aaa E aar a ia a A 1 5 Jump Starting Battery Charging Hazardes 1 5 Hydraulic System Hazards ssseeeseeeeeneeeeenreeerneserrnestnrnertnnneennennnen 1 6 Fueling Hazards isiin ea eea eaea ea eaaa Eei eiea 1 7 Section 2 Operating Controls cccscssssesssessseeseeeesseeeseeeseneeeseeeesseeeneaes 2 1 Component Locations ccccccccccccsssessseeeeeeeesssssneeeeeeeessesssseeeeeesssssstaaeees 2 1 Front VIS W eseis asrine treas paea EE d REENEN Aa 2 1 Rear ET 2 2 SIDS WOW eessen See TE EE cele EE E ETE 2 3 Operating Controls cccccceeeececeeeeceeeeeeeeececeeeeeeeeceeeeseseeeeseneeeeseaees 2 4 Safety Decal e dree ERER EENS 2 5 Operating Controls Description c c cceeeeeceeeeeeeeeeeeeeeeeeeteeeeeenees 2 7 Section 3 Pre Start Inspection and Operation sscsssseseseeeeeneneeee 3 1 Pre Start Inspechon 3 1 Daily Service Checks ccceccececceeecececeeeeeeeeeeeaeeeeecaeeeeeeeeeeeeseeeesseeeees 3 1 Cylinder Lock Installation ccccccceeeeececeeeeceeeeeeeeeeeeeeeeeeeeneeeeessneeeeessaees 3 7 Cylinder Lock Removal 3 7 Operating Instructions ccceeeece
34. el Check c If the oil level is between the FULL and ADD lines the oil level is within the normal use range If the oil level is below the ADD line carefully add the proper amount of oil through the engine oil filler tube Item 1 Figure 4 2 It is important to add the correct type of engine oil as stated in the engine manual NOTE Extremely dusty or dirty working conditions may require more frequent checking filling and or changing of engine oil d After filling the oil wait a few minutes and check the oil level again IMPORTANT Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine 4 Release dirt from separator tube at the bottom of the air filter by squeezing the rubber dust ejector valve Item 1 Figure 4 3 underneath the air filter 2020 a Figure 4 3 Air Filter Dirt Release 4 3 Routine Service and Maintenance 5 Check hydraulic oil level fill as needed with the proper hydraulic oil be sure engine is OFF a Remove the two lock knobs securing the front service cover b Raise cover Item 1 Figure 4 4 and secure in the raised position using the safety support lock pin Item 2 Figure 4 4 c Locate the large hex nut Item 3 Figure 4 4 on the filter housing assembly 4 Figure 4 4 Attached to this hex nut you will find the hydraulic level dip stick d Unscrew and remove the hydraulic fluid dip stick Item 3 Figure 4 4 M
35. er key The key will automatically return to the RUN position Slowly push the choke knob inwards If the engine begins to sputter pull the choke knob outwards slightly until the engine smoothes out As soon as the engine warms up and begins to run rough push the choke knob inwards to the normal operating position Leave the throttle setting at about the halfway position and allow the engine to idle This will begin warming the hydraulic oil NOTE In cold weather 32 F 0 C after about 5 minutes of engine idling operate all of the main hydraulic controls to cycle warmed hydraulic oil through the hydraulic lines into the cylinders and hydraulic motors Allow the engine to idle for another 5 minutes before beginning any machine operations IMPORTANT If the engine oil drops below the engine manufacturers required levels a warning horn will sound Immediately shut down the engine to prevent severe damage DO NOT use the machine until repairs have been made 3 9 Pre Start Inspection and Operation Machine Shut down To safely shut the machine down the operator must 1 Park the machine on a solid level area 2 Lower the loader arm and attachment to the ground 3 Idle the engine for 5 10 minutes to allow the machine to cool down 4 Shut off the engine 5 Clean off any accumulated mud and or dirt from the machines operating surfaces i e operator s platform drive wheels etc Transportation 1 Mov
36. etent position This will release the hydraulic pressure locked in the auxiliary hydraulic lines Leave the control lever in the REVERSE detent position DAA O 2074 1 Figure 3 29 Auxiliary Control Lever 3 20 Pre Start Inspection and Operation b Remove the protective covers Items 2 6 Figure 3 30 from the attachment quick connectors c Wipe off the end of each of the connectors Items1 3 Figure 3 30 to remove any dirt or debris 2024 Figure 3 30 Auxiliary Hydraulic Quick Connects d Insert the attachments male coupling Item 3 Figure 3 30 into the female bulkhead quick connect coupling Item 1 Figure 3 30 on the machine and push until the connector locks into position e Repeat the above process to connect the attachments female quick connect Item 5 Figure 3 30 on the other hose to the male bulkhead connector Item 4 Figure 3 30 on the machine f Check the security of both connections by gently tugging on the attachment hoses to make sure that the quick connects are seated properly 3 21 Pre Start Inspection and Operation 11 Make sure that the hydraulic hoses are routed so that they will not be in the way or damaged during machine operation Figure 3 31 shows how the hoses might be routed to keep them out of the way during operation and prevent them from being damaged
37. f merchant ability and fitness for a particular purpose are excluded from this contract further the foregoing warranty is made solely to the first purchaser and may not be transferred in any form The sole liability of Mertz Manufacturing LLC and the exclusive remedy of the purchaser arising out of the manufacture sale or use of the equipment provided hereunder on warranties or otherwise shall be limited to the cost of repair or replacement of defective parts as herein specified Further Mertz Manufacturing LLC s maximum liability hereunder arising from any cause whatsoever including but not limited to breach of contract or tort including negligence shall not exceed the contract price of the equipment furnished hereunder Mertz Manufacturing LLC shall not be responsible for work done equipment or parts furnished or for parts or repairs made by others unless the work is specifically ordered by Mertz Manufacturing LLC In no event shall Mertz Manufacturing LLC be liable for removing defective parts or for reinstalling said parts when repaired or replaced by anyone other than Mertz Manufacturing LLC or an authorized service facility or for any costs incurred with such removal or reinstallation CONSEQUENTIAL DAMAGES Notwithstanding any other provision of this agreement in no event shall Mertz Manufacturing LLC be liable whether arising under contract tort including negligence or otherwise for loss of anticipated profits los
38. face to give way under the machine causing it to become unstable Never exceed the rated capacity of the machine When using attachments know their capacity ratings and unit limitations Unit specifications can be found in the Operator s Manual 1 2 Safety Precautions Never attempt to operate any attachment without first understanding proper installation and operating procedures The center of gravity stability and operating characteristics of the entire machine will change with the use of different attachments Operate all controls slowly and smoothly and never abruptly stop any function This can cause the machine to become unstable Always look in the direction of travel Come to a complete stop prior to reversing travel directions Reduce speed and proceed with caution when traveling in reverse or turning Never travel with the loader boom or attachment raised Lower the boom or attachment as soon as possible and travel with the boom at the lowest safe height When traveling with a loaded bucket or forks the load should be level and the bucket or forks tilted back to reduce spilling or loosing the load Approach corners slowly turning too fast or sharp may cause the machine to tip over Stay alert when operating near traffic or roadways If the unit should begin to tip or become unstable DO NOT try to stabilize the unit with your legs or arms If the unit is involved in an accident or inadvertently damaged during operatio
39. fore starting the engine Check engine fuel and fill as needed be sure engine is OFF 3 The Brute has two saddle gas tanks Item 1 Figure 3 2 Each of the tanks has a gas gauge located in the filler cap Item 2 Figure 3 2 Remove cap and visually inspect fuel level to make sure that the indicator is showing the proper fuel level Make sure that each tank has been filled on a daily basis 3 2 Pre Start Inspection and Operation Figure 3 2 Fuel Level Check e Carefully pour the gas into the tank not exceeding the max fill on the fuel gauges e Allow engine to cool before filling fuel tanks e Do not overfill because gas could spill onto hot engine parts and ignite or explode 4 Check all hydraulic hoses lines and fittings Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death When troubleshooting a hydraulic system for leaks always use cardboard or wood as a detector DO NOT USE YOUR BARE HANDS If you are injected with hydraulic oil or any other fluids immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries e Visually inspect all of the hydraulic hoses lines and fittings for signs of damage wear or leaking e If any signs of damage are visible do not operate the machine until repairs have been made 3
40. furthest ground point away from the battery Never make the final connection at the starter or dead battery Sparks may ignite the explosive gases surrounding the battery When disconnecting cables after jump starting remove the negative cable first and then the positive cable IMPORTANT DO NOT let the cable clamps touch when disconnecting them Severe damage can occur to the booster battery or machine Never charge a battery or attempt to jump start a frozen battery The sudden surge in electrical power could cause the battery to explode 1 5 Safety Precautions Hydraulic System Hazards The hydraulic system is under pressure whenever the engine is running and may hold pressure even after the engine is shut off Cycle all hydraulic controls after the loader boom is resting on the ground Some components will retain residual or trapped pressure Use extreme caution when removing any hydraulic component During inspection of the hydraulic system e Cycle all hydraulic controls to release residual pressure e Wait for the hydraulic fluid to cool down before disconnecting any hydraulic lines Hot hydraulic fluid can cause severe burns Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death When troubleshooting a hydraulic system for leaks always use cardboard or wood as a detector DO NOT USE YOUR BARE HANDS If you are injected with hydraulic oil or any other fluids immediately seek treatment
41. he male mounting plate into the upper lip of the female attachment mounting plate 2020 Figure 3 21 Non powered Attachment Installation 3 16 Pre Start Inspection and Operation 4 When the machines mounting plates top edge is seated in the attachment mounting plate curl the machines mounting plate backwards slightly to allow the lower edge of the machines mounting plate to slide into position See Figure 3 22 2029 Figure 3 22 Attachment Installed 5 Shut the engine off 6 Rotate the attachment lock pins Item 1 Figure 3 22 and Item 1 Figure 3 23 into the locked position securing the attachment to the machine 1 1 J Pins Locked 2022 Figure 3 23 Attachment Locks in Locked Position 7 Test the security of the attachment connection by fully lowering with loader arm and tilting the attachment downwards until the front tires slightly lift off the ground 3 17 Pre Start Inspection and Operation Removal of Attachment 1 Lower the attachment onto a firm level surface 2 Shut off the machine engine 3 Rotate the attachment lock pins to the UNLOCKED position Item 1 Figure 3 24 1 1 Pins Unlocked Ka aS 2021 Figure 3 24 Attachment Locks in Unlocked Position 4 Start the engine and rotate the mounting plate downwards 5 Back a
42. hen handling the battery Leaking battery fluid contains acid that can cause burns Fumes from the leaking fluid can cause respiratory problems e Check both of the battery cables Items 2 and 3 Figure 4 22 for signs of damage or cor rosion Loosen the cable clamps and remove the cable from the battery Clean the termi nals with a battery brush Reinstall and secure the cable clamps NOTE To prevent corrosion spray on a battery protectent and sealer onto both terminals and cable clamps e Check the battery hold down clamp Item 4 Figure 4 22 to make sure that the battery is being held securely to the machine 2045 Figure 4 22 Battery and Connections 6 Check for proper track tension if equipped a Raise the machine off the ground and support it using a device capable of safely support ing 3000 Ibs See Figure 4 23 for suggested location of the support devices b Tilt the bucket downwards until the cutting edge is touching the ground See Figure 4 23 c Lower the loader arm assembly pushing the front of the machine upwards Continue raising the machine until the rear drive sprocket is off the ground Shut off the engine d Measure the gap between the bottom of the center bogey guide roller Item 1 Figure 4 23 and the track The proper tension will be about a 3 8 1 2 deflection 4 16 Routine Service and Maintenance f With the t
43. hooting cccccccccceeeeeeeeeeeeeeeeeeeeeeeeseeeeeeseaeeeeseneeeeees 5 4 General Specifications ccccceccceeeeceeeeeeeeeeeeeeeeeeeseaeeeesenaeeeeseneeeeessaees 5 9 WW heel Units ut eiert eee a nese Se eed 5 9 Trak ET 5 10 viii Section 1 Safety Precautions Since Mertz Manufacturing has no direct control over machine application or operation following the proper safety practices is the responsibility of the owner and or operator Remember that this unit is only as safe as those who operate it Safety tips shown throughout this Operator s Manual must be followed at all times GENERAL SAFETY e Never operate the Brute without first completely reading and understanding this Owner s Manual e Only authorized qualified and trained personnel are allowed to operate this machine e Never operate the machine under the influence of alcohol awareness altering drugs or medications that would affect your ability to operate safely e KEEP CHILDREN CLEAR FROM THE WORK SITE AREA AT ALL TIMES e NEVER ALLOW A CHILD TO OPERATE OR RIDE ON THE MACHINE e Serious injury or death involving children can occur Stay ALERT and be aware of your surroundings at all times Stop operations if children wander onto the job site Resume work only when the operating area is clear e Keep all non operating personnel away from the machine during operation Passengers must never be allowed to ride on the machine or
44. hould be avoided as reduced traction could cause the machine to slide down the slope Do not attempt to install or remove attachments on a slope Never park the unit on a slope 1 3 Safety Precautions SERVICE amp MAINTENANCE SAFETY Maintenance work can be hazardous if not done in a careful manner All personnel should realize the hazards and strictly follow safe maintenance practices Failure to comply with these safety precautions may result in serious personal injury and or death Use only CPI supplied or approved replacement parts and attachments Imitation parts may lead to unit damage and or injury to personnel Warranty may be voided if unauthorized parts and attachments are used Wear the proper protective clothing and personal safety equipment necessary to perform the maintenance or service required Keep the machine free of grass leaves or other debris build up Clean up oil or fuel spillage Fuel or oil leaks or spills can create a fire or explosion hazard Prior to performing maintenance or service park the unit in a level area away from obstructions and or work site hazards Be sure the area has adequate light and is well ventilated NEVER operate the machine inside a closed area Clean up any oil grease mud water or snow which might cause the floor surface to become slippery If the machine requires maintenance take the machine out of service and attach a Do Not Operate tag at the control panel a
45. in vacuum hose See engine manual Leaking cracked vacuum hose to fuel pump Replace hose Intake system leak See engine manual Diode in wiring harness failed in open circuit mode See engine manual Engine Starts Hard Auxiliary control lever is in either Forward or Reverse position Move control lever to the Neutral position Dirt or water in the fuel system Drain fuel system and replace with fresh clean fuel Clogged fuel line Loose or faulty wires or connections Clean or replace fuel lines Tighten connections Replace wires See engine manual Faulty or misadjusted choke or throttle controls Adjust choke and or throttle control cables See engine manual Faulty spark plugs Replace spark plugs Low compression See engine manual Weak spark See engine manual Fuel pump malfunction causing lack of fuel See engine manual Engine overheated cooling air circulation restricted Clean cooling fins and remove any debris from around engine Quality of fuel Drain fuel system and replace with fresh clean fuel Flywheel key sheared See engine manual Intake system leak See engine manual 5 5 Troubleshooting Problem Possible Causes Corrective Action Engine Runs But Misses Engine Will Not Idle Dirt or water in the fuel system Drain fuel system
46. it to prevent possible carburetor flooding due to vibration Left Side of Engine gt 7 5 Right Side of Engine 2041 2033 Figure 3 11 Fuel Shut Off Valves NOTE e Never tow or pull the machine Damage to the hydraulic motors could result e Ifthe machine is totally in operable using lifting straps or cables and a machine that can safely lift 4 000 Ibs 1820 Kg lift the machine and place on a trailer 3 11 Pre Start Inspection and Operation Machine Travel Controls e Levers and controls should return to the neutral position when they are released e Make sure that all of the controls are in the neutral middle position before starting the engine e Operate the controls gradually and smoothly Excessive speed and quick control movements without regard for working conditions could cause an unsafe situation e Make sure to maintain your grip on both of the hand grips any time the machine is in motion NOTE If your machine is equipped with a track drive system additional safety systems have been built into the track drive Due to the spring tension system built into the track drive system as a safety mechanism the machine can be put into an extreme situation during which the drive sprocket will bypass the rubber track guide holes causing a popping noise called cogging This situation is part of the track drive systems safety design and indicates that this portion of the safety system is functioning
47. lements as required Handle new elements carefully do not use if the sealing surfaces are bent or damaged Check all parts for wear cracks or damage Replace any damaged components ep Con If needed install the new inner element followed by the outer element Slide each fully into place in the air cleaner housing 4 14 Routine Service and Maintenance i Reinstall the end cap Item 4 Figure 4 19 so the dust ejector valve is down and secure the end cap with the two retaining clips In extremely dusty or dirty operating conditions this service cycle may need to be shortened 4 Replace fuel filter Item 1 Figure 4 20 Shut off fuel at both of the fuel shut off valves Item 1 Figure 4 21 by rotating the valve handle horizontally across the fuel line shutting off the fuel Remove the spring clamps Item 2 Figure 4 20 from above and below the fuel filter and remove the fuel lines Replace the fuel filter with a new filter 2047 Figure 4 20 Fuel Filter Left Side of Engine Right Side of Engine 2041 2033 Figure 4 21 Fuel Shut Off Valves 4 15 Routine Service and Maintenance 5 Check battery signs of leakage or for corrosion on the battery cables e Ona monthly basis check the battery Item 1 Figure 4 22 for signs of leaking electro lyte If any signs of damage are visible remove and replace the battery Wear the proper protective clothing w
48. lugs and turn engine over to pump excess fuel from engine cylinder 5 1 Troubleshooting Problem Possible Causes Corrective Action Engine will not start starts hard or fails to keep running Auxiliary hydraulics lever is not in neutral position with a hydraulically powered attachment installed Move lever to neutral position Fuel tanks are empty Fill fuel tanks with gasoline Choke is not on Pull choke control fully outwards Air cleaner is dirty Clean air filter housing and replace the filter elements Spark plug wires are loose or disconnected Spark plugs are pitted fouled or gap is incorrect Install wires on spark plugs If the spark plug wires do not stay connected contact Authorized Service Dealer Install new correctly gapped spark plugs Dirty or contaminated fuel filter Replace fuel filter Dirt water or stale fuel is in fuel system Drain fuel in tanks into an appropriate storage container and dispose of bad fuel properly Refill fuel tanks with fresh clean fuel Replace fuel filter 30 Amp fuse blown Replace fuse Engine looses power Engine load is excessive Reduce ground speed Reduce speed of attachment Air cleaner is dirty Clean air filter housing and replace the filter elements Engine oil level in crankcase is low Add the appropriate engine oil to crankcase See engine man
49. n Never operate a malfunctioning unit Keep hands gloves shoes control knobs and operator platform clean Slippery controls can cause you to lose control which may result in an accident Always keep a firm grip on the hand rails located at the operator s platform during travel and operations to prevent falling off the unit When working on an unfamiliar construction site review understand and follow job site safety rules Keep the work site clear of all non operating personnel Should a person enter the work area stop machine operation until the work area is clear Prior to unloading the unit and starting to work inspect the path you will travel and work site area for potential hazards Some of the hazardous conditions you may encounter are Holes Deep ditches or excavations Drop offs Soft un compacted soil Culverts Deep mud Standing Water Large rocks Slippery surfaces Steep slopes Tall grass trees or shrubs If any of these conditions exist correct the hazard or obstruction If any of these conditions can not be corrected avoid operating or traveling near them Be extremely cautious traveling through or near trees brush shrubs or any obstacles which might obscure your vision These might hide potential hazards such as the edge of a steep slope deep holes large rocks etc Never operate near a ditch or embankment where loose or soft ground conditions could cause the sur
50. n stop and perform a thorough inspection Make sure the unit is in safe operating condition prior to resuming work Be alert to any unusual reaction to any of the controls If anything unusual is noticed shut the machine down and thoroughly inspect it to determine the cause of the problem Do not operate the machine until all required repairs have been made If the unit must be left unattended shut the machine down and make sure that it can not be started by an unauthorized individual Operating on steep slopes can be dangerous and there is a greater risk of the machine tipping over or becoming unstable The list of rules below must be understood and followed for maximum safety Avoid excessively steep slopes or unstable surfaces If travel on a slope is necessary keep the load low and proceed with extreme caution DO NOT travel ACROSS excessively steep slopes under any circumstances Travel straight up and down slopes with the heavy end of the machine pointing up the incline When the machine has no load the operator s platform end of the machine is considered the heavy end When the machine is loaded or has an attachment on the front of the machine the front is considered the heavy end Turning on slopes is not a recommended practice however if you must turn on slopes reduce travel speed to as slow as possible and exercise extreme caution Avoid sharp turns or sudden movements Wet or slick ground conditions s
51. nd remove the ignition key If maintenance or repairs require the boom to be raised the Hydraulic Cylinder Lock must be installed Know where all pinch points and rotating parts on the unit are These areas must be avoided to prevent serious injury Remove only those guards or covers on the component being serviced and replace them immediately upon completion of the work Never attempt to adjust or service engine or machine components while they are hot ELECTRICAL SYSTEM HAZARDS Prior to working on the electrical system Disconnect battery cables removing the battery ground cable first When re connecting the battery connect the battery ground cables last Never allow battery cables to contact hydraulic lines or rub against sharp edges 1 4 Safety Precautions Battery Hazards Before working with batteries the following are important points about battery safety that you should be aware of Batteries are always surrounded by extremely explosive gases This is especially true when the battery is being charged To avoid explosion Do not smoke near batteries Keep arcs sparks and open flames away from batteries Perform battery service work only in a well ventilated area Electrolyte Hazards NOTE The batteries on the machine may be either be wet cell or gel cell It is still important to know and follow these warnings and cautions Battery electrolyte in standard wet cell batteries contains s
52. ne Idle Speed Spark Plugs Battery Hydraulics v Hydraulic Filter Hydraulic Fluid v Hydraulic Hoses v Grease fi Tires Tracks v Visual Check for Loose Missing Fasteners v Battery Service Cycle R Replace VY Check Under very wet muddy dusty or dirty working conditions more frequent lubrication may be required 3 1 Pre Start Inspection and Operation Do the following pre start service checks 1 Check condition of all warning and instructional decals Replace any damaged decals with genuine CPI replacement decals 2 Check engine oil e Make sure that the engine is OFF e Pull out the dipstick and look for both the full and add oil lines Item 1 Figure 3 1 indicated by the letters F and A The correct oil level is between those two lines 2130 Figure 3 1 Engine Oil Level Check e Ifthe engine oil level is below the add line indicated by the letter A on the dipstick carefully add the proper amount of oil through the engine oil filler tube Item 1 Figure 3 1 It is important to add the correct type of engine oil as stated in the engine manual NOTE Extremely dusty or dirty working conditions may require more frequent checking filling and or changing of engine oil e After filling the oil wait a few minutes and check the oil level again IMPORTANT Make sure to securely reinstall the dipstick into the dipstick tube be
53. ng filling Make sure to move the unit from the transport truck or trailer and only refuel the unit on the ground using an approved container When filling a portable gas container always place it on the ground Never fill a portable gas container while it is inside a vehicle truck pick up bed or any surface Keep sparks and flames away from fuel Due to the potential for static discharge do not use any handheld electronic devices i e cell phones etc while fueling the machine Do not smoke while refueling or when handling the fuel container Never cut or weld on or near fuel lines tanks or containers Never overfill the tank Clean up spilled fuel immediately Store fuel in an approved container and keep out of the reach of children 1 7 Safety Precautions as 6 7 06 Fifth Proof Section 2 Operating Controls Component Locations Front View 7 8 i 5 12 SCH 5 H wi 10 11 gt ei SE A 3 HA T E amp B E D B S SE ond 1 2125 Item No Description 1 Attachment mounting plate 2 Tilt cylinder 3 Auxiliary hydraulic quick connects 4 Boom 5 Fuel tank 6 Fuel filler cap 7 Operating controls 8 Hand grab rail 9 Manual holder 10 Lift cylinder lock 11 Lift cylinder beneath cylinder lock 12 Hydraulic oil cooler 2 1 Operating Contr
54. nt it is the purchaser s responsibility to notify Mertz Manufacturing LLC or an authorized dealer of said defect The purchaser agrees to return the defective equipment or parts to Mertz Manufacturing LLC or to an authorized dealer facility freight prepaid within fifteen 15 days after the defective condition is discovered All warranties if any extended to Mertz Manufacturing LLC by manufacturers and suppliers of component parts accessories or other goods included in the manufacturing of Mertz Manufacturing LLC products will be assigned if contractually permitted to the purchaser Specific component warranty details will be provided to the purchaser upon request This warranty excludes the following maintenance items including but not limited to seals track grousers roller bearings filters and spark plugs equipment that has been repaired replaced or altered by someone other than Mertz Manufacturing LLC or an authorized service facility without prior approval from Mertz Manufacturing LLC unless however if Mertz Manufacturing LLC in its sole opinion determines that the defective condition of the equipment was in no way caused by or was attributable to said repairs replacements or alternatives Mertz Manufacturing LLC and the purchaser agree that in consideration of the above expressed warranty all other warranties other than title either expressed or implied whether arising under law or equity including warranties o
55. ols Rear View 2144 Item No Description Operator s platform Engine oil dip stick fill tube Engine Engine choke knob Air cleaner assembly Manual holder Fuel filler cap CO CO N OO A N Fuel tank Ignition switch and key CH Engine hour meter Operating Controls Side View 2005 a Item No Description Rear drive wheel Front drive wheel Spark arrestor Fuel tank Attachment mounting plate Boom Air filter Co Ni OO By oj P gt Operator s platform 2 3 Operating Controls Operating Controls 6 8 9 10119 8 liz S P Bo beet Item No Description 1 Speed range selector switch 2 Attachment tilt control 3 Attachment raise control 4 Engine throttle 5 Travel creep speed control 6 Fuel filler cap 7 Fuel tank 8 Service panel lock 9 Hand grip rail 10 Left travel motor control 11 Right travel motor control 12 Auxiliary attachment hydraulic control 2 4 Operating Controls Safety Decals F N e O N
56. oughout this manual and on labels on the machine indicate hazards or unsafe practices All three statements indicate that safety is involved Observe the precautions indicated whenever you see the Safety Alert symbol no matter which signal word appears next to the Safety Alert symbol A DANGER INDICATES A HAZARDOUS SITUATION THAT IF NOT AVOIDED IS VERY LIKELY TO CAUSE DEATH OR EXTREMELY SERIOUS INJURY IT MAY ALSO BE USED TO ALERT AGAINST EQUIPMENT THAT MAY EXPLODE OR DETONATE IF HANDLED OR TREATED CARELESSLY Indicates a hazardous situation that if not avoided could result in serious injury or death It may also be used to alert against a highly unsafe practice Indicates a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice IMPORTANT This type of statement is used to draw attention to a procedure that needs to be followed to prevent machine damage v 6 7 06 Fifth Proof Table of Contents Brute Product Warranty cccssccsssssseeesseessseeessneesseeeeseeeeseeeeseneesseesseeeeeneeesenaenes i Safety INtrOdUuction citirea aea a aneirin ea ieam ae ni eaaa Snina V Be Prepared Get to Know All Operating and Safety Instructions v Learn the Signal Words Used with the Safety Alert Symbol v Section 1 Safety Precautions cscscssscesseeesseeesseeesseeeesneeseeeeess
57. racks still off the ground start the engine and rotate just the track being adjusted three or four times in both forward and reverse Shut off the engine after rotating the track g Remeasure the deflection dimension h Repeat the measurement and adjustment procedure on the other track assembly i Lower the machine onto the ground 3 8 1 2 Figure 4 23 Track Tension Adjustment 4 17 Routine Service and Maintenance Annual Maintenance Procedures Do the following procedures annually 1 Do all Daily Weekly and Monthly maintenance procedures 2 Replace air filter See page 4 14 Step 3 3 Check engine idle speed Refer to engine manual 4 Replace spark plugs Refer to engine manual 5 Check replace hydraulic fluid a Place a suitable sized container under the Brute b Remove the hydraulic tank drain plug Item 1 Figure 4 24 and drain all hydraulic fluid from the machine NOTE Make sure to inspect the O ring on the drain plug Replace the O ring if any signs of damage are noted 2078 Figure 4 24 Hydraulic Tank Drain Plug c When all of the hydraulic fluid has drained out of the tank reinstall and secure the drain plug IMPORTANT Make sure to dispose of the used hydraulic fluid in an appropriate manner d Remove the two lock knobs securing the front service cover 4 18 Routine Service and Maintenance e Rais
58. rk plug leads disconnected Check to make sure that both spark plug leads are securely attached to the spark plug and that they are not damaged Faulty spark plugs Replace spark plugs Faulty ignition module s Test and replace faulty ignition module See engine manual SMART SPARK malfunction applicable models See engine manual Carburetor solenoid malfunction See engine manual Diode in wiring harness failed in open circuit mode See engine manual Vacuum fuel pump vacuum malfunction or oil in hose See engine manual Vacuum hose to fuel pump leaking cracked Replace hose Battery connected backwards Remove battery connections and reinstall Engine Starts But Does Not Keep Running Restricted fuel tank cap vent Clean fuel tank cap Replace fuel cap Poor fuel dirt or water in the fuel system Drain fuel system and replace with fresh clean fuel 5 4 Troubleshooting Problem Possible Causes Corrective Action Faulty or misadjusted choke or throttle controls Adjust choke and or throttle control cables See engine manual Loose wires or connections that short the kill terminal of ignition module to ground Tighten connections See engine manual Faulty cylinder head gasket See engine manual Faulty carburetor See engine manual Vacuum fuel pump malfunction or oil
59. s of use of capital or revenue non operational expenses increased expense of operation cost of purchased or replacement equipment damage to loads or contents of the equipment transportation expenses due to repairs claims of customers cost of money or for any special incidental or consequential loss or damage of any nature arising at any time or from any cause whatsoever This Warranty Agreement shall be governed by and construed and enforced in accordance with the laws of the State of Oklahoma Any litigation under this warranty will be held in Kay County in accordance with the laws of Oklahoma Mertz Manufacturing LLC P O Box 150 Ponca City OK 74602 PO BOX 150 74602 1701 N WAVERLY PONCA CITY OK 74601 PHONE 580 762 5646 FAX 580 767 8411 NT FAX 580 765 3934 www boxerok com MEG BY Wen MANUFACTURING LLC SERIALNO 842 Record SERIAL Number here Brute Warranty Registration Dear Customer Mertz Manufacturing LLC wishes to thank you for your purchase We are committed to providing our customers with the finest products and product support available in any market today To do this we need to update our database with some specific information Currently the warranty start date is listed as the date the Brute Compact Utility Loader left Mertz Manufacturing LLC This may be several months before you ever received the product Mertz Manufacturing LLC will restart the warranty date if yo
60. s the hand hold to activate the attachment in the FORWARD motion NOTE The lever is spring loaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping attachment motion 2074 1 Figure 3 32 Auxiliary Attachment Controls 4 Lower the attachment to begin work 5 If you want to reverse the operation of the attachment move the auxiliary control lever Item 1 Figure 3 32 to the REVERSE position The control lever will remain in the REVERSE position detent until it is moved to the NEUTRAL position 3 23 Pre Start Inspection and Operation Travel Creep Control The travel system on the machine can be adjusted to make the attachment more effective in tough digging situations The travel creep control allows the travel speed to be adjusted from full speed forward or reverse to no movement at all To adjust the travel speed using the creep control move the engine throttle lever to the maximum engine speed and NOTE Make sure that the High Low travel speed switch Item 2 Figure 3 32 is in the HIGH position L Move the AUXILIARY control lever Item 1 Figure 3 32 to either the FORWARD or REVERSE position The travel speed CREEP control Item 1 Figure 3 33 is now active Start with the CREEP control in the fully engaged position rotate control fully clockwise which will send all hydraulic power to the attachment and the machine will not travel NOTE The OFF position
61. the cylinder lock Figure 3 6 Safety Lock Installation Cylinder Lock Removal 1 Start the engine and raise the loader arm to its full height 2 Shut off the engine 3 Pull the safety lock pin Item 4 Figure 3 6 fully outwards 4 Rotate the cylinder lock Item 3 Figure 3 6 upwards to the storage position Item 1 Figure 3 6 5 Fully insert the safety lock pin Item 2 Figure 3 6 to secure the cylinder lock in the storage position 3 7 Pre Start Inspection and Operation Operating Instructions Machine Start up To start the machine the operator must 1 Stand on the operator s platform Item 1 Figure 3 7 2132 Figure 3 7 Operator s Platform and Safety Treadle 2 Pull the engine CHOKE knob Item 2 Figure 3 8 fully outwards 3 Move the throttle lever Item 1 Figure 3 8 to about half way between fast and idle engine speeds 2133 Figure 3 8 Throttle and Choke Settings 3 8 Pre Start Inspection and Operation Rotate and hold the start switch Item 1 Figure 3 9 in the START position until the engine starts NOTE The low engine oil pressure warning horn will sound when the ignition key is turned to the ON position When the engine starts and oil pressure reaches normal the horn will shut off 2134 Figure 3 9 Engine Keyswitch As soon as the engine starts release the start
62. tically rise releasing the attachment from the machine If the pins do not release the attachment or are very hard to rotate start the engine and tilt the attachment slightly forwards or backwards until the pins can be rotated 3 15 Pre Start Inspection and Operation Make sure to keep your hands and feet away from the attachment during the unlocking process As the attachment becomes free from the machine it may move 1 1 Pins Unlocked e ken Ss Kaos J A m 2021 Figure 3 20 Attachment Locks in Unlocked Position Installation of Non Hydraulically Powered Attachments There are many available attachments that are very easy to install To install any of the non hydraulically powered attachments 1 Position the attachment on a level surface NOTE Clean the inside lower edge of the female attachment mounting plate to remove any debris that might interfere with the attachment installation 2 Start the machines engine lower the loader arm and tilt the mounting plate forwards NOTE Make sure that both of the attachment lock pins Item 1 Figure 3 20 are in the unlocked position See Attachment Lock Pins earlier in this section 3 Slowly drive towards the attachment and align the top edge of the male mounting plate Item 1 Figure 3 21 and the upper lip of the female attachment mounting plate Item 2 Figure 3 21 Tuck the upper edge of t
63. ts Routine Service and Maintenance 2034 Figure 4 10 Loader Arm Lift Cylinder Base Lubrication Point NOTE Extremely dusty or dirty working conditions may require more frequent service replacement 8 Check all 4 tires for the proper tire pressure The proper pressure level is shown on the side of the tire Make sure that the tires are not worn or damaged 9 Check for loose or missing fasteners a Inspect for any loose or missing bolts or fasteners b Tighten or replace any missing bolts or fasteners before operating the machine 10 Clean the engine oil cooler fins Item 1 Figure 4 11 of any dirt or debris If you are performing this service after a period of machine operation the oil cooler assembly will be very hot Wear gloves to protect your hands 4 8 Routine Service and Maintenance 2042 Figure 4 11 Engine Oil Cooler New Machine Brake in Maintenance Procedures Do the following after the first 20 operating hours for a new machine only 1 Change engine oil see engine manual 2 Change engine oil filter which is located on the left side of the engine see engine manual and Item 1 Figure 4 12 2072 Figure 4 12 Engine Oil Filter Routine Service and Maintenance 3 Change the hydraulic filter See Service Manual and Figure 4 13 a Remove the three bolts
64. u will complete the information below and return this form to us We will continue to use the date the Brute Compact Utility Loader left the factory as the warranty start date of record until we are told differently through receipt of this form Not returning the form could result in your being denied some of your warranty entitlements To have Mertz Manufacturing LLC reset the warranty start date please complete the form below and mail or fax it back to Mertz Manufacturing LLC P O Box 150 Ponca City OK 74602 Fax 580 767 8411 Please take the time to complete and return this warranty form Name Address City State Zip Telephone No Location Purchased Date Purchased Salesman have received a copy of the Owners Manual for my engine need a copy of the Owners Manual for my engine Signed Model No Serial No iii Affix Stamp Here Mertz Manufacturing LLC P O Box 150 Ponca City OK 74602 Safety Introduction Be Prepared Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol Wherever it appears either in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents Always observe safety precautions and follow recommended procedures Learn the Signal Words Used with the Safety Alert Symbol The words DANGER WARNING and CAUTION are used thr
65. ual for oil specifications Cooling fins and air passages under engine blower housing are plugged Remove obstruction from cooling fins and air passages Spark plugs are pitted fouled or gap is incorrect Install new correctly gapped spark plugs Dirty or contaminated fuel filter Replace fuel filter Dirt water or stale fuel is in fuel system Drain fuel in tanks into an appropriate storage container and dispose of bad fuel properly Refill fuel tanks with fresh clean fuel Replace fuel filter Spark arrestor plugged Clean spark arrestor 5 2 Troubleshooting Problem Possible Causes Corrective Action Engine overheats Abnormal engine vibration e Engine load is excessive Reduce ground speed Reduce speed of attachment e Engine oil level in crankcase is low Add the appropriate engine oil to crankcase See engine manual for oil specifications Cooling fins and air passages under engine blower housing are plugged Engine mounting bolts are loose Remove obstruction from cooling fins and air passages Tighten engine mounting bolts With the machines engine turned off the boom creeps downward more than 3 per hour less than 3 per hour is normal for this machine e Valve spool leakage Contact Service Dealer Cylinder seals are leaking Replace cylinder seals With the machines engine turn
66. ulfuric acid which is poisonous and can cause severe chemical burns To avoid personal injury Wear a face shield to prevent sulfuric acid contact with your eyes Wear chemical resistant gloves and clothing to keep acid off your skin and clothing Since wet cell batteries give off explosive gases use a flashlight to check the electrolyte level not an open flame such as a match Never check the battery by placing a metal object across the battery posts The resulting spark could ignite anything flammable causing fire or an explosion If electrolyte is splashed into your eyes flush them immediately with clean water and seek medical attention If electrolyte is swallowed seek medical attention immediately If electrolyte is splashed onto exposed skin or clothing flush and clean the area immediately with clean water and seek medical attention if necessary Jump Starting Battery Charging Hazards Follow the instructions for jump starting or battery charging in the engine owner s manual You must be at the operator s platform when attempting to start the unit with booster batteries and jumper cables so that you are at the controls when the engine starts Here are some general safety rules you must follow for jump starting the machine Make sure to connect the positive jumper cable to the positive RED remote starter lug on the right side of the machine chassis Connect the negative cable to the engine machine chassis or the
67. ure 4 6 Figure 4 6 Remove Upper Inspection Panel 4 5 Routine Service and Maintenance d Follow all of the hoses line and tubes from the control valve to their end Items 1 2 4 and 5 Figure 4 7 Inspect the connections and look for signs of leaking hydraulic fluid wear or damage Carefully inspect the quick couples Item 3 Figure 4 7 to make sure that they are not damaged or leaking Figure 4 7 Inspect Hydraulic Lines and Fittings e If any signs of damage are visible do not operate the machine until repairs have been made and documented f When the inspection has been completed reinstall the upper inspection cover and secure it in position by pressing the lock handles downwards g Some examples of common hydraulic hose damage are shown in Figure 4 8 1034 Figure 4 8 Hydraulic Hose Damage 1 End fittings damaged or leaking 2 Outer covering chafed or cut and wire reinforcing is exposed 3 Hose shows signs of kinking or crushing 4 Outer covering ballooning 4 6 Routine Service and Maintenance Grease pivot shafts with proper type of grease There are 10 grease points on this machine see Figure 4 9 and Figure 4 10 2128 Figure 4 9 Lubrication Poin
68. way from the attachment NOTE It may be necessary to lower the loader arm assembly slightly to fully disengage from the attachment Installation of Hydraulically Powered Attachments There are many hydraulically powered attachments available that are very easy to install To install any of these attachments 1 Position the attachment on a level surface NOTE Clean the lower edge of the female attachment mounting plate to remove any debris that might interfere with the attachment installation 2 Start the machine engine lower the loader arm and tilt the mounting plate forwards NOTE Make sure that both of the attachment lock pins Item 1 Figure 3 25 and Item 3 Figure 3 26 are in the unlocked position 1 1 l L Pins Unlocked E lt as 2021 Figure 3 25 Attachment Locks in Unlocked Position 3 18 Pre Start Inspection and Operation 3 Slowly drive towards the attachment and align the top edge of the male mounting plate Item 1 Figure 3 26 and the upper lip of the female attachment mounting plate Item 2 Figure 3 26 NOTE Make sure to position the attachments hydraulic hoses Item 4 Figure 3 26 so that they are not damaged during the installation process Tuck the upper edge of the male mounting plate into the upper lip of the female attachment mounting plate 2023 Figure 3 26 Hydraulically Powered Attachment Inst

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