TM COMPACT BIG POWER IN ALL PLACES Boxer 427 and Boxer 427W Operators Manual Part No.
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.
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.
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.
Affix Stamp Here Mertz Manufacturing, LLC P.O.
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.
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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 ......................................................................
Section 4 – Routine Service and Maintenance ............................................. 4–1 Daily Maintenance Procedures .................................................................. 4–2 New Machine Brake-in Maintenance Procedures ...................................... 4–9 Weekly Maintenance Procedures............................................................. 4–12 Monthly Maintenance Procedures ............................................................ 4–14 Annual Maintenance Procedures ........
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.
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.
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.
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.
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.
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.
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.
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Section 2 – Operating Controls Component Locations Front View 2125 Item No.
Operating Controls Rear View 7 7 8 6 4 9 10 5 3 2 1 2144 Item No.
Operating Controls Side View 6 5 7 4 8 3 2 Item No.
Operating Controls Operating Controls 2126 Item No.
Operating Controls Safety Decals 1 2 3 8 7 6 4 5 2007-a Item No.
Operating Controls Safety Decals (Continued) 6 7 5 4 8 7 3 9 2 1 2127 Item No.
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.
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.
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 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 3–1) indicated by the letters “F” and “A”. The correct oil level is between those two lines.
Pre-Start Inspection and Operation 2131 Figure 3–2 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.
Pre-Start Inspection and Operation • Some examples of common hydraulic hose damage are shown in Figure 3–3. 3 2 1 4 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 • Inspect for any loose or missing bolts. • Tighten or replace any missing bolts immediately. 6.
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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. CAUTION Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly.
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. 5. Pivot the cylinder lock downwards to the support position (Item 3, Figure 3–6). 6.
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). 1 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.
Pre-Start Inspection and Operation 4. 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. 1 2134 Figure 3–9 Engine Keyswitch 5. As soon as the engine starts, release the starter key. The key will automatically return to the RUN position. 6.
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.
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 unit to prevent possible carburetor flooding due to vibration. 1 1 Left Side of Engine 2041 Right Side of Engine 2033 Figure 3–11 Fuel Shut Off Valves NOTE: • Never tow or pull the machine. Damage to the hydraulic motors could result.
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.
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 3–14. 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 3–15.
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 3–18.
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.
Pre-Start Inspection and Operation CAUTION 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 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 nonhydraulically powered attachments: 1. Position the attachment on a level surface.
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. 1 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.
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 2021 Figure 3–24 Attachment Locks in Unlocked Position 4. Start the engine and rotate the mounting plate downwards. 5. Back away from the attachment. NOTE: It may be necessary to lower the loader arm assembly slightly to fully disengage from the attachment.
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.
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 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.
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. 1 4 2 5 3 6 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.
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. 2025 Figure 3–31 Attachment Hydraulic Hose Routing 12.The attachment is now ready to use. CAUTION Before starting the engine, make sure that the Auxiliary Hydraulic control lever is in the NEUTRAL position.
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. CAUTION • 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.
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.
Pre-Start Inspection and Operation Removal of Hydraulically Powered Attachments CAUTION 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. Lower the attachment to the ground and shut off the engine. 2. Move the hydraulic control levers forward or backward to release any stored hydraulic pressure. 3.
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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.
Routine Service and Maintenance 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.
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. F x x OK x x x A 1 2010 Figure 4–2 Oil Level 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).
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.
Routine Service and Maintenance 6. Check hydraulic hoses. 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. a. Fully raise the loader arm, and secure the safety support. b.
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. 2012 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.
Routine Service and Maintenance 7. Grease pivot shafts with proper type of grease. There are 10 grease points on this machine, see Figure 4–9 and Figure 4–10.
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.
Routine Service and Maintenance 1 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).
Routine Service and Maintenance 3. Change the hydraulic filter. See Service Manual and Figure 4–13. a. Remove the three bolts (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. b. 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.
Routine Service and Maintenance e. If an adjustment is needed, fully remove the adjustment nut keeper (Item 2, Figure 4–14) and rotate the adjustment nut (Item 3, Figure 4–14) until the proper track deflection measurement is achieved. Reinstall and secure the adjustment nut keeper (Item 2, Figure 4–14). NOTE: It may be necessary to rotate the adjustment nut slightly to align the adjustment nut keeper bolt. f.
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. 1 Figure 4–15 Fuel Filter 4.
Routine Service and Maintenance 5. Check both spark plugs (Items 1 and 2, Figure 4–17) for damage to the spark plug cables. 2 1 2044 Figure 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.
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) 1 2 3 4 2046 Figure 4–19 Check Engine Air Filter a.
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.
Routine Service and Maintenance 5. Check battery signs of leakage or for corrosion on the battery cables. • On a monthly basis, check the battery (Item 1, Figure 4–22) for signs of leaking electrolyte. If any signs of damage are visible, remove and replace the battery. CAUTION Wear the proper protective clothing when handling the battery. Leaking battery fluid contains acid that can cause burns. Fumes from the leaking fluid can cause respiratory problems.
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.
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.
Routine Service and Maintenance e. Raise 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.
Routine Service and Maintenance General Maintenance Draining Fuel Tank (Gasoline) DANGER 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 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.
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. 1 2 2 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.
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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. Problem Possible Causes Starter does not turn the engine over. Corrective Action • Auxiliary hydraulics lever is either in Forward or Reverse position with no hydraulically powered attachment installed. • Move lever to neutral position. • Battery is dead.
Troubleshooting Problem Possible Causes Engine will not start, starts hard, or fails to keep running. Engine looses power. 5-2 • Auxiliary hydraulics lever is not in neutral position with a hydraulically powered attachment installed. Corrective Action • 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.
Troubleshooting Problem Possible Causes Engine overheats. Corrective Action • Engine load is excessive. • Reduce ground speed. • Reduce speed of attachment. • 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. • Remove obstruction from cooling fins and air passages. Abnormal engine vibration. • Engine mounting bolts are loose.
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 Engine Cranks But Will Not Start Corrective Action • Empty fuel tanks. • Fill fuel tanks • Fuel shut-off valves closed. • Open both fuel shut off valves.
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 in vacuum hose. • See engine manual.
Troubleshooting Problem Possible Causes Engine Runs But Misses • Dirt or water in the fuel system. Corrective Action • Drain fuel system 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. Engine Will Not Idle • Poor quality of fuel. • Drain fuel system and replace with fresh, clean fuel. • Faulty spark plug(s). • Replace spark plugs.
Troubleshooting Problem Possible Causes Corrective Action • 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. • Restricted fuel tank cap vent. • Open vent on fuel tank cap. Engine Overheats Engine Knocks • Engine overheated-cooling system/air circulation problem. • Clean cooling fins and remove any debris from around engine.
Troubleshooting Problem Possible Causes Engine Loses Power Corrective Action • Low crankcase oil level. • Add engine oil. • High crankcase oil level. • Drain engine oil and replace with proper quantity. • Dirty air cleaner element. • Clean air filter separator tube. • Clean both air filter elements. • Replace both air filter elements. • Dirt or water in the fuel system. • Drain fuel system and replace with fresh, clean fuel. • Excessive engine load. • Reduce engine load. • Engine overheated.
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, • Crankcase breather is Gaskets clogged or inoperative. • See engine manual. • Breather reed broken. • See engine manual. • Loose or improperly torqued fasteners. • See engine manual. • Piston blow-by or leaky valves. • See engine manual. • Restricted exhaust.
Troubleshooting Track Unit Engine Power: (Gasoline) Engine Manufacturer: Engine Description: Wheel Base: Width: Weight (without bucket): Tip Capacity: Dump Angle: Dump height: Hinge pin height (fully raised): Travel speed: Fuel tank capacity: Overall Operating Height (fully raised): Overall height: Overall Length (with bucket): Ground clearance: Overall Length (without bucket): Operating Capacity, 50% of tip load: 5-10 27 HP Kohler Command Pro Air Cooled 37" 43.5 " 2,250 LBS 1,800 LBS 34° 56" 70" 3.
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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/ 6-7-06 - Fifth Proof Part No.
