TM COMPACT Boxer 427 and Boxer 427W Operators Manual
Part No. 999-860 (SN 992 and Higher) BIG POWER IN ALL PLACES 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 apparent, 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 of 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. 6-7-06 - Fifth Proof i 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, loss 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 ii 6-7-06 - Fifth Proof 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 you 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. Fold Name: _______________________________________________________ Address:______________________________________________________ City: ____________________ State: Zip: ___________________ Telephone No. _________________________________________________ Location Purchased: ____________________________________________ Date Purchased: __________ Salesman: __________________________ ____ I have received a copy of the Owners Manual for my engine. ____ I need a copy of the Owners Manual for my engine. Signed: ______________________________________________________ Model No. _______________ Serial No. ___________________________ 6-7-06 - Fifth Proof iii Affix Stamp Here Mertz Manufacturing, LLC P.O. Box 150 Ponca City, OK 74602 iv 6-7-06 - Fifth Proof 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 throughout 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. 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. WARNING
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. CAUTION
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. 6-7-06 - Fifth Proof v vi 6-7-06 - Fifth Proof Table of Contents
Brute Product Warranty....................................................................................... i Safety Introduction ............................................................................................. 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 ...................................................................... 1­1 GENERAL SAFETY ................................................................................... 1­1 OPERATING SAFETY ............................................................................... 1­2 SERVICE & MAINTENANCE SAFETY ...................................................... 1­4 ELECTRICAL SYSTEM HAZARDS ........................................................... 1­4 Battery Hazards................................................................................... 1­5 Jump Starting/Battery Charging Hazards ............................................ 1­5 Hydraulic System Hazards .................................................................. 1­6 Fueling Hazards .................................................................................. 1­7 Section 2 ­ Operating Controls ..................................................................... 2­1 Component Locations ................................................................................ 2­1 Front View ........................................................................................... 2­1 Rear View ............................................................................................ 2­2 Side View............................................................................................. 2­3 Operating Controls .............................................................................. 2­4 Safety Decals ...................................................................................... 2­5 Operating Controls Description ........................................................... 2­7 Section 3 ­ Pre-Start Inspection and Operation........................................... 3­1 Pre-Start Inspection.................................................................................... 3­1 Daily Service Checks ................................................................................. 3­1 Cylinder Lock Installation ........................................................................... 3­7 Cylinder Lock Removal........................................................................ 3­7 Operating Instructions ................................................................................ 3­8 Machine Start-up ................................................................................. 3­8 Machine Shut-down........................................................................... 3­10 Transportation ................................................................................... 3­10 Machine Travel Controls .......................................................................... 3­12 Attachment Installation and Removal ....................................................... 3­15 Attachment Lock Pins........................................................................ 3­15 Installation of Non-Hydraulically Powered Attachments .................... 3­16 Removal of Attachment ..................................................................... 3­18 Installation of Hydraulically Powered Attachments............................ 3­18 Operating Instructions for a Hydraulic Attachment ............................ 3­23 Travel Creep Control ......................................................................... 3­24 Removal of Hydraulically Powered Attachments ............................... 3­25 6-7-06 - Fifth Proof vii Section 4 ­ Routine Service and Maintenance ............................................. 4­1 Daily Maintenance Procedures .................................................................. 4­2 New Machine Brake-in Maintenance Procedures ...................................... 4­9 Weekly Maintenance Procedures............................................................. 4­12 Monthly Maintenance Procedures ............................................................ 4­14 Annual Maintenance Procedures ............................................................. 4­18 General Maintenance ............................................................................... 4­20 Draining Fuel Tank (Gasoline)........................................................... 4­20 Section 5 ­ Troubleshooting .......................................................................... 5­1 Engine Troubleshooting**........................................................................... 5­4 General Specifications ............................................................................... 5­9 Wheel Unit ........................................................................................... 5­9 Track Unit .......................................................................................... 5­10 viii 6-7-06 - Fifth Proof 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
· Never operate the Brute without first completely reading and understanding this Owner's
Manual. · Only authorized, qualified, and trained personnel are allowed to operate this machine. · Never operate the machine under the influence of alcohol, awareness altering drugs, or
medications that would affect your ability to operate safely. · KEEP CHILDREN CLEAR FROM THE WORK SITE AREA AT ALL TIMES! · NEVER ALLOW A CHILD TO OPERATE OR RIDE ON THE MACHINE · 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. Keep all non-operating personnel away from the machine during operation. Passengers must never be allowed to ride on the machine or any attachment. 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. 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. Never touch engine parts or machine components while they are hot. Always perform the "Standard Shut Down Procedure" shown in this manual, if the unit will be left unattended for any length of time. 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. · · · · · · · · 6-7-06 - Fifth Proof 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 condition. · 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 surface 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 6-7-06 - Fifth Proof 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 operation, 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 should 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 · · · · · · · · · · · · · 6-7-06 - Fifth Proof 1-3 Safety Precautions SERVICE & 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. WARNING
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 and 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 6-7-06 - Fifth Proof 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 sulfuric 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 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. 6-7-06 - Fifth Proof 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: · Cycle all hydraulic controls to release residual pressure. · Wait for the hydraulic fluid to cool down before disconnecting any hydraulic lines. Hot
hydraulic fluid can cause severe burns. WARNING
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. · Hydraulic fluid can cause permanent eye injury. Wear safety glasses or a full face shield to
provide appropriate eye protection. · 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 6-7-06 - Fifth Proof Safety Precautions Fueling Hazards Most fuels are highly flammable. Observe the following precautionary practices to reduce the possibility of a serious accident: · Always refuel the unit in an open, well ventilated area away from sparks or open flames. 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 during 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. 6-7-06 - Fifth Proof 1-7 Safety Precautions 1-8 6-7-06 - Fifth Proof Section 2 ­ Operating Controls
Component Locations
Front View 2125 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Attachment mounting plate Tilt cylinder Auxiliary hydraulic quick connects Boom Fuel tank Fuel filler cap Operating controls Hand grab rail Manual holder Lift cylinder lock Lift cylinder (beneath cylinder lock) Hydraulic oil cooler 6-7-06 - Fifth Proof 2-1 Operating Controls Rear View 7 7 6 8 4 9 10 5 2 3 1
2144 Item No. 1 2 3 4 5 6 7 8 9 10 Operator's platform Engine oil dip stick/fill tube Engine Engine choke knob Air cleaner assembly Manual holder Fuel filler cap Fuel tank Ignition switch and key Engine hour meter Description 2-2 6-7-06 - Fifth Proof Operating Controls Side View 6 5 7 4 3 8 2
Item No. 1 2 3 4 5 6 7 8 Rear drive wheel Front drive wheel Spark arrestor Fuel tank Attachment mounting plate Boom Air filter Operator's platform 1
Description 2005-a 6-7-06 - Fifth Proof 2-3 Operating Controls Operating Controls 2126 Item No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Speed range selector switch Attachment tilt control Attachment raise control Engine throttle Travel creep speed control Fuel filler cap Fuel tank Service panel lock Hand grip rail Left travel motor control Right travel motor control Auxiliary attachment hydraulic control 2-4 6-7-06 - Fifth Proof Operating Controls Safety Decals 1 2 3 8 7 6 4 5
2007-a Item No. 1 2 3 4 5 6 7 8 Description Auxiliary Power Control Warning Pinch Point Warning Fuel Fill Warning Boxer decal Mertz corporate decal Cylinder Lock Installation Warning Brute Decal Pinch Point Warning 6-7-06 - Fifth Proof 2-5 Operating Controls Safety Decals (Continued) 6 7 5 4 3 9 2 7 8 1 2127 Item No. 1 2 3 4 5 6 7 8 9 Description Boxer Decal Safety Instructions Decal Operating Controls Information Plate Engine Throttle Decal Made In USA Decal Auxiliary Power Control Warning Pinch Point Warning Brute Decal Fuel Fill Warning 2-6 6-7-06 - Fifth Proof Operating Controls Operating Controls Description 2129 1. Creep ­ When a hydraulically powered auxiliary attachment is in use, this control allows the operator to adjust the machine travel speed. 2. Boom Raise and Lower ­ This lever controls the raising and lowering of the boom assembly. 3. 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. 4. Right Travel Motor Control ­ Pushing the lever forward rotates the right side wheels for forward travel. Pulling the lever backwards rotates the right side wheels for reverse travel. 5. 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. 6. 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. 6-7-06 - Fifth Proof 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 6-7-06 - Fifth Proof Section 3 ­ Pre-Start Inspection and Operation DANGER
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: · Check all decals and warning signs for damage. · Check engine oil. · Check and refill gas tanks. · Check hydraulic lines and hoses for signs of damage or leaks. · Inspect the machine for any signs of damage or loose fasteners. · Check fluid levels and any signs of leaking fluids. · Do all Daily Service Checks. · 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 Fuel Engine Oil Engine Oil Filter Air Filter Fuel Filter Engine Idle Speed Spark Plugs Battery Hydraulics - Hydraulic Filter - Hydraulic Fluid - Hydraulic Hoses Grease Tires/Tracks Visual Check for Loose/Missing Fasteners Battery Daily (10 Hours) and R and A *** Service Cycle - R = Replace = Check ***Under very wet, muddy, dusty or dirty working conditions more frequent lubrication may be required. 6-7-06 - Fifth Proof 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 · Make sure that the engine is OFF. · Pull out the dipstick and look for both the full and add oil lines (Item 1, Figure 3­1) indicated by the letters "F" and "A". The correct oil level is between those two lines. F x x OK x x x
A 1
2130 Figure 3­1 Engine Oil Level Check · If the 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 3­1). 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. · 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.Check engine fuel and fill as needed - be sure engine is OFF 3. The Brute has two saddle gas tanks (Item 1, Figure 3­2). Each of the tanks has a gas gauge located in the filler cap (Item 2, Figure 3­2). 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 6-7-06 - Fifth Proof Pre-Start Inspection and Operation 2131 Figure 3­2 Fuel Level Check · Carefully pour the gas into the tank, not exceeding the max fill on the fuel gauges. CAUTION
· Allow engine to cool before filling fuel tanks. · Do not overfill because gas could spill onto hot engine parts and ignite or explode. 4. Check all hydraulic hoses, lines and fittings. WARNING
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. · Visually inspect all of the hydraulic hoses, lines and fittings for signs of damage, wear or leaking. · If any signs of damage are visible, do not operate the machine until repairs have been made. 6-7-06 - Fifth Proof 3-3 Pre-Start Inspection and Operation · Some examples of common hydraulic hose damage are shown in Figure 3­3.
2 3 1 4
Figure 3­3 Hydraulic Hose Damage 1. End fittings damaged or leaking 2051 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 · Inspect for any loose or missing bolts. · 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 3­4 and Figure 3­5. CAUTION
Before starting the engine: · Move all hydraulic control levers forward and release the lever. Make sure that each lever automatically returns to the Neutral position. · 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 Forward or Reverse position detents until it is manually moved to the Neutral position. · 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 6-7-06 - Fifth Proof Pre-Start Inspection and Operation 2128 Figure 3­4 Lubrication Points 6-7-06 - Fifth Proof 3-5 Pre-Start Inspection and Operation 2034 Figure 3­5 Loader Arm Lift Cylinder Base Lubrication Point NOTE: Extremely dusty or dirty working conditions may require more frequent service/ replacement. CAUTION
Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly. 3-6 6-7-06 - Fifth Proof 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 3­6), pull the safety lock pin (Item 2, Figure 3­6) outwards, releasing the cylinder lock. 5. Pivot the cylinder lock downwards to the support position (Item 3, Figure 3­6). 6. Fully reinsert the safety lock pin (Item 4, Figure 3­6), 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 the cylinder lock. 2014 Figure 3­6 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 3­6) fully outwards. 4. Rotate the cylinder lock (Item 3, Figure 3­6) upwards to the storage position (Item 1, Figure 3­6). 5. Fully insert the safety lock pin (Item 2, Figure 3­6) to secure the cylinder lock in the storage position. 6-7-06 - Fifth Proof 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 3­7). 1
Figure 3­7 Operator's Platform and Safety Treadle 2132 2. Pull the engine CHOKE knob (Item 2, Figure 3­8) fully outwards. 3. Move the throttle lever (Item 1, Figure 3­8) to about half way between fast and idle engine speeds. 2 2133 Figure 3­8 Throttle and Choke Settings 3-8 6-7-06 - Fifth Proof Pre-Start Inspection and Operation 4. Rotate and hold the start switch (Item 1, Figure 3­9) 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. 1 2134 Figure 3­9 Engine Keyswitch 5. As soon as the engine starts, release the starter key. The key will automatically return to the RUN position. 6. 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. 7. 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 (32º F [0º 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. 6-7-06 - Fifth Proof 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. Move 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 3­10. CAUTION
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. 2019 Figure 3­10 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 6-7-06 - Fifth Proof Pre-Start Inspection and Operation 6. (Gasoline Units Only) Shut off the in-fuel valves underneath each of the fuel tanks (Item 1, Figure 3­11) when transporting the unit to prevent possible carburetor flooding due to vibration.
1 1 Left Side of Engine 2041 Right Side of Engine 2033 Figure 3­11 Fuel Shut Off Valves NOTE: · Never tow or pull the machine. Damage to the hydraulic motors could result. · If the machine is totally in-operable, using lifting straps or cables and a machine that can safely lift 4,000 lbs (1820 Kg), lift the machine and place on a trailer. 6-7-06 - Fifth Proof 3-11 Pre-Start Inspection and Operation Machine Travel Controls WARNING
· Levers and controls should return to the neutral position when they are released. · Make sure that all of the controls are in the neutral (middle) position before starting the engine. · Operate the controls gradually and smoothly. Excessive speed and quick control movements without regard for working conditions could cause an unsafe situation. · 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 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 3­12. Pull both control levers backwards to travel straight backwards. The farther these are moved, the faster the machine will travel. See Figure 3­13. Figure 3­12 Forward Travel 2135 Figure 3­13 Reverse Travel 2136 3-12 6-7-06 - Fifth Proof Pre-Start Inspection and Operation Right Turn During Forward Travel Left Turn During Forward Travel To turn to the right, move the left hand control lever farther forward than the right control lever. The farther forward the left control is moved, the faster the right turn will be made. See Figure 3­14.
2137 To turn to the left, move the right hand control lever farther forward than the left control lever. The farther forward the right control is moved, the faster the left turn will be made. See Figure 3­15. Figure 3­14 Right Hand Turn in Forward Figure 3­15 Left Hand Turn in Forward 2138 Right Turn During Reverse Travel Left Turn During Reverse Travel Move the left hand control lever farther backward than the right control lever. The farther forward the left control is moved, the faster the right turn will be made. See Figure 3­16. Move the right hand control lever farther backwards than the left control lever. The farther forward the right control is moved, the faster the left turn will be made. See Figure 3­17. Figure 3­16 Right Hand Turn in Reverse 2139 Figure 3­17 Left Hand Turn in Reverse 2140 6-7-06 - Fifth Proof 3-13 Pre-Start Inspection and Operation Spin Turn CAUTION
Make sure to use the machine hand holds while doing a spin turn to maintain your balance. 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 lever backwards. Figure 3­18. Figure 3­18 Spin Turn 2141 3-14 6-7-06 - Fifth Proof Pre-Start Inspection and Operation Attachment Installation and Removal
Attachment Lock Pins The mounting plate located at the front of the machine provides for t