Instruction/ maintenance manual of the product 427W Cellboost
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Boxer 427 and Boxer 427W Operators Manual COMP ACT TM COMP ACT Part No. 999-86 0 (SN 992 and Higher) BIG PO WER IN ALL PLA CES.
6-7-06 - Fifth Proof.
6-7-06 - Fifth Proof i Brute Product W arranty W ARRANTY AND LIABILITY LIMIT A TIONS Mertz Manufacturing, LLC warrants each ne w Compact Utility Lo ader manufactured (hereinafter referred to as the eq.
6-7-06 - Fifth Proof ii The sole liability of Mert z Manufactu rin g, LLC and th e exclusive remedy of the purchaser arising out of the manu facture, sale, or u se of the equipment pro vided hereunder , on warranties or otherwise, shal l be l imited to the cost of repair or replacement of defective parts as herein sp ecified.
6-7-06 - Fifth Proof iii Brute W arranty Registration Dear Customer , Mertz Manufa cturing, LL C wishes to thank yo u for your purchase. We are committed to providing our customers with the finest pr oducts and pr oduct support available in any ma rket today .
6-7-06 - Fifth Proof iv Mertz Manufacturing, LLC P .O. Box 150 Ponca City , OK 74602 Affix Sta m p Here.
6-7-06 - Fifth Proof v Safety Introduction Be Prepared - Get to Know All Operating and Safety Inst ructions This is the Safety Alert Sym b ol . 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 ac cidents.
6-7-06 - Fifth Proof vi.
6-7-06 - Fifth Proof vii T able of Content s Brute Product Warranty .............................................. ......................................... i Safety Introduction ........................................................................
6-7-06 - Fifth Proof viii Section 4 – Routine Service and Maintenance ............................................. 4–1 Daily Maintenance Procedures .................................................................. 4–2 New Machine Brake-in Maintenance Procedures .
6-7-06 - Fifth Proof 1-1 Section 1 – Safety Precautions Since Mertz Manufacturing has no direct control over machin e application or operation, following the proper safety practices is the responsibility of the owner and/or operator .Remember th at this uni t is only as safe as those w ho operate it.
6-7-06 - Fifth Proof 1-2 Safety Precautions OPERA TING SAFETY • Plan ahead and learn as much as possible abou t your job-site area before beginning any work. • Know the exact location of overhe ad power lines or obstructions. • Have all buried lines such as ; gas, electric, wate r , telephone and cable TV , marked by the proper authorities.
6-7-06 - Fifth Proof 1-3 Safety Precautions • Never attempt to operate any attachment without first unders tanding proper in stallation and operating procedures. The center of gravity , st ability , and operating characteristic s of the entire machine wil l change with the use of different attachment s.
6-7-06 - Fifth Proof 1-4 Safety Precautions SERVICE & MAINTENANCE SAFETY Maintenance work can be hazardous if not done in a careful manne r . All personnel should realize the ha zar ds and s trictl y foll ow safe mainte nan ce p ractic es. Fail ure t o comp ly with the se safety precautions may result in se rious personal injury and/or death.
6-7-06 - Fifth Proof 1-5 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 charge d.
6-7-06 - Fifth Proof 1-6 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 of f. Cycle all hydrau lic controls after the loader boo m is resting on the ground.
6-7-06 - Fifth Proof 1-7 Safety Precautions Fueling Haza rds Most fuels are highly flammable. Observe the following precautio nary practices to reduce the possibility of a serious accident: • Always refuel the unit in an o pen, well ventil ated area awa y from sparks or open fla mes.
6-7-06 - Fifth Proof 1-8 Safety Precautions.
6-7-06 - Fifth Proof 2-1 Section 2 – Oper ating Control s Component Locations Front View Item No. Description 1 Attachment mounting plate 2 Tilt cylinder 3 Auxiliary hydraul ic quick connects 4 Boom.
6-7-06 - Fifth Proof 2-2 Operating Controls Rear View Item No. Description 1 Operator's platform 2 Engine oil dip stick/fill tube 3 Engine 4 Engine choke knob 5 Air cleaner assembly 6 Manual hold.
6-7-06 - Fifth Proof 2-3 Operating Controls Side View Item No. Description 1 Rear drive wheel 2 Front drive wheel 3 S park arrest or 4F u e l t a n k 5 Attachment mounting plate 6 Boom 7 Air filter 8 .
6-7-06 - Fifth Proof 2-4 Operating Controls Operating Co ntro ls Item No. Description 1 S peed ran ge selector switch 2 Attachment tilt control 3 Attachment raise control 4 Engine throttle 5 Travel cr.
6-7-06 - Fifth Proof 2-5 Operating Controls Safety Decals Item No. Description 1 Auxiliary Po wer Control Warning 2 Pinch Point Warning 3 Fuel Fill W arning 4 Boxer decal 5 Mertz corporate decal 6 Cyl.
6-7-06 - Fifth Proof 2-6 Operating Controls Safety Decals (Continued) Item No. Description 1 Boxer Decal 2 Safety Instructions Decal 3 Operating Controls Information Plate 4 Engine Throttle Decal 5 Ma.
6-7-06 - Fifth Proof 2-7 Operating Controls Operating Co ntro ls Descriptio n 1. Creep – When a hydraulically powered auxiliary attach ment is in use, this control allows the operator to adjust the ma chi ne travel speed. 2. Boom Raise and Lower – This lever controls the raising and lowering of the boom assembly .
6-7-06 - Fifth Proof 2-8 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 W arning Light – when the light turns on, it indi cates that the engine oil leve l is low .
6-7-06 - Fifth Proof 3-1 Section 3 – Pre-S t art In spection and Operation IMPROPER USE OF THE COMPACT UTILITY LOADER COULD CAUSE SERIOUS INJURY OR DEATH.
6-7-06 - Fifth Proof 3-2 Pre-Start Inspection and Operation Do the following pre-start service checks: 1. Check condition of all warning and instructi onal decals. Replace any damaged decals with genuine CPI replacement decals. 2. Check engine oil - • Make sure that t he engine is OF F .
6-7-06 - Fifth Proof 3-3 Pre-Start Inspection and Operation Figure 3–2 Fuel Level Check • Carefully pour the gas into the tank, not exceeding the max fill on the fuel gauges. • Allow engine to cool be for e filling fuel tanks. • Do not overfill because gas could spill onto hot engine parts and ignite or explode.
6-7-06 - Fifth Proof 3-4 Pre-Start Inspection and Operation • Some examples of common hydraulic hose damage are shown in Figure 3–3. Figure 3–3 Hydraulic Hose Damage 1. End fittings damaged or leaking 2. Outer covering chafed or cut, and wire rein forcing is exposed 3.
6-7-06 - Fifth Proof 3-5 Pre-Start Inspection and Operation Figure 3–4 Lubrication Points 2128.
6-7-06 - Fifth Proof 3-6 Pre-Start Inspection and Operation Figure 3–5 Loader Arm Lift Cylinder Base Lubrication Point NOTE: Extremely dusty or dirty working conditi ons may require more frequent service/ replacement. Make sure to install the cylinder lock be fore performing any service work unde rneath the raised loader arm assembly .
6-7-06 - Fifth Proof 3-7 Pre-Start Inspection and Operation Cylinder Lock Inst allation 1. Star t the en gine. (See Machine Start-up in th is section for engine starting instructions).
6-7-06 - Fifth Proof 3-8 Pre-Start Inspection and Operation Operating Instructions Machine St art-up T o start the ma chine, the operat or mus t: 1. Stand on the operator's platform (Item 1, Figure 3–7). Figure 3–7 Operator's Platform and Safety T readle 2.
6-7-06 - Fifth Proof 3-9 Pre-Start Inspection and Operation 4. Rotate and hold the start switch (Item 1, Figure 3–9) in the ST AR T position until the engine starts. NOTE: The low engine oil pressure warning horn w ill sound when the ignition key is turned to the “ON” position.
6-7-06 - Fifth Proof 3-10 Pre-Start Inspection and Operation Machine Shut-do wn T o safely shut the machine down, the operator must: 1. Park the machine on a solid, level area. 2. Lower the load er arm and attachment to the ground. 3. Idle the engine for 5 - 10 minutes to allow the machine to cool down.
6-7-06 - Fifth Proof 3-11 Pre-Start Inspection and Operation 6. (Gasoline Units Only) Shut off the in-fuel valves un derneath each of the fuel tanks (Item 1, Figure 3–1 1) when transporting the unit to pr event possible carburetor flooding due to vibration.
6-7-06 - Fifth Proof 3-12 Pre-Start Inspection and Operation Machine T ravel Controls • Levers and controls should return to the neutral position when they are released. • Make sure that a ll of the c ontrols are in the neutral (middle) position before starting the engine.
6-7-06 - Fifth Proof 3-13 Pre-Start Inspection and Operation Right T urn During Forward T ravel Left T urn During Fo rward Travel T o 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.
6-7-06 - Fifth Proof 3-14 Pre-Start Inspection and Operation Spin T urn Make sure to use the machine hand holds while doing a spin turn to maintain your balance.
6-7-06 - Fifth Proof 3-15 Pre-Start Inspection and Operation Att achment Inst allation and Removal Att achment Lock Pins The mounting plate locate d at the front of the machine provides for the easy installation and safe use of the wide variety of available atta ch ments.
6-7-06 - Fifth Proof 3-16 Pre-Start Inspection and Operation Make sure to keep your hand s and feet away from the attachment during the unlocking process.
6-7-06 - Fifth Proof 3-17 Pre-Start Inspection and Operation 4. When the machines mounting plates top edge is seated in the attachment mounting p late, curl the machines mounting plate back wards slightly to allow the lower edge of the machines mounting plate to slide into position.
6-7-06 - Fifth Proof 3-18 Pre-Start Inspection and Operation Removal of Attachment 1. Lower the attachment ont o 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).
6-7-06 - Fifth Proof 3-19 Pre-Start Inspection and Operation 3. Slowly drive towards the att ach ment and align the top edge of the male mounting plate (Item 1, Figure 3–26) and the upper lip of the female a ttachment mounting plate (Item 2, Figure 3– 26) .
6-7-06 - Fifth Proof 3-20 Pre-Start Inspection and Operation 5. Shut the engine off. 6. Rotate the attachment lock pi ns (Item 1, Figure 3–27, Item 1, Figure 3–28) into the locked position securing the attachme nt to the machine. Figure 3–28 Attachment Locks in Locked Position 7.
6-7-06 - Fifth Proof 3-21 Pre-Start Inspection and Operation b. Remove the protective cove rs (Items 2, 6, Figure 3–30) from the attachment quick connectors. c. Wipe of f the end of each of the connectors (Items1, 3, Figure 3–30) to remove any dirt or debris.
6-7-06 - Fifth Proof 3-22 Pre-Start Inspection and Operation 1 1.Ma ke su re that the hy draulic hoses ar e routed s o that they will not be in the way or d amaged 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 .
6-7-06 - Fifth Proof 3-23 Pre-Start Inspection and Operation Operating Instruction s 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. • Make sure that you ar e standing on the operator's platform.
6-7-06 - Fifth Proof 3-24 Pre-Start Inspection and Operation T ravel Creep Control The travel syste m on th e ma chine can be adjus ted to make the attachme nt more ef fective in tough digging situations. The travel “creep” control allows the travel speed to be adjusted from full speed forward or reverse to n o movement at all.
6-7-06 - Fifth Proof 3-25 Pre-Start Inspection and Operation Removal of Hydraulically Powered Attachments After use, the q uick couples and hydraulic flu id will be very hot. W ear gloves when disconnecting the aux iliary hydraulic lines. T o remove a hydraulical ly powered attachment; 1.
6-7-06 - Fifth Proof 3-26 Pre-Start Inspection and Operation.
6-7-06 - Fifth Proof 4-1 Section 4 – Routine Se rvice and Maintenance The following information presents the routine service and maint ena nce requi red to ma ke sure that the machin e functions safel y and properly . More detailed se rvice infor mation is contained in the Service Manual.
6-7-06 - Fifth Proof 4-2 Routine Service and Maintenance Daily Maintenance Procedures Do the following procedures daily or every 10 operating hours: 1. Check condition of all warning and instructi onal decals. Before operating the machine, replace any missing or damaged decals.
6-7-06 - Fifth Proof 4-3 Routine Service and Maintenance 3. Check engine oil - a. Make sure that the engine is OFF . b. Pull out the dipstick (It em 1, Figure 4–2) and look for the “FULL” line. Figure 4–2 Oil Level Check c. If the oil level is between the FULL and ADD li nes, the oil level is within the normal use range.
6-7-06 - Fifth Proof 4-4 Routine Service and Maintenance 5. Check hydraulic oil level, fill as needed with the proper hydraulic oil - be sure engine is OFF a.
6-7-06 - Fifth Proof 4-5 Routine Service and Maintenance 6. Check hydraulic hoses. Hydraulic oil under pressure can penetrat e body tissue causin g se rious injury and possible death. When troubleshooting a hydrau lic system for leaks, a lways use cardbo ard or wood as a detector .
6-7-06 - Fifth Proof 4-6 Routine Service and Maintenance d. Follow all of the hoses, line and tubes from th e control valve to their end (Items 1, 2, 4 and 5, Figure 4–7). Inspect the connections and look for signs of le aking hydraulic fluid, wear or damage.
6-7-06 - Fifth Proof 4-7 Routine Service and Maintenance 7. Grease pivot shafts with proper type of grea se. There are 10 grease points on this machine, see Figure 4–9 and Figure 4–10.
6-7-06 - Fifth Proof 4-8 Routine Service and Maintenance Figure 4–10 Loader Arm Lift Cylinder Base Lubrication Point NOTE: Extremely dusty or dirty working conditi ons may require more frequent service/ replacement. 8. Check all 4 tires for the proper tire pressure.
6-7-06 - Fifth Proof 4-9 Routine Service and Maintenance Figure 4–1 1 Engine Oil Cooler New Machine Brake-in Maintenance Proc edures Do the following after the first 20 operating hours for a new machine only . 1. Change engine oil - see engine manual.
6-7-06 - Fifth Proof 4-10 Routine Service and Maintenance 3. Change the hydraulic filter . Se e Service Manual and Figure 4–13. a. Remove the three bolts (Item 1, Figure 4–13) holding the filter cover (Item 2, Figure 4–1 3) in place. NOTE: Press downwards on filter cover to reliev e the upwards pressure from the spring.
6-7-06 - Fifth Proof 4-11 Routine Service and Maintenance e. If an adjustment is needed, fully remove th e adjustment nut keeper (Item 2, Figure 4–14) and rotate the adjustment nut (Ite m 3, Fi gure 4–14) u ntil the pr oper track deflection measurement is achieved.
6-7-06 - Fifth Proof 4-12 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 cy cles) 3.
6-7-06 - Fifth Proof 4-13 Routine Service and Maintenance 5. Check both spark plugs (Items 1 and 2, Figur e 4–17) for damage to the spark plug cables. Figure 4–17 Check S park Plugs and Cables 6. Check the battery (Item 1, Figure 4–18) and cable connections (Item s 2 and 3, Figure 4–18) for signs of leaking, corrosion or damage.
6-7-06 - Fifth Proof 4-14 Routine Service and Maintenance Monthly Maintenance Procedures Do the following procedures monthly or every 200 operating hours: 1. Do all Daily and W eekly maintenance procedures 2. Replace engine oil and engine oi l filt er - se e engine manual 3.
6-7-06 - Fifth Proof 4-15 Routine Service and Maintenance i. Reinstall the end cap (Item 4, Figure 4–19) so the dust ejector valv e is down and secure the end cap with the two reta inin g clips. *In extremely dusty or dirty operating conditi ons, this service cycle may need to be shortened.
6-7-06 - Fifth Proof 4-16 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 electro- lyte. If any signs of dama ge are visible, remove and replace the battery .
6-7-06 - Fifth Proof 4-17 Routine Service and Maintenance f. W ith the tracks still of f the ground, start th e en gine and rotate just th e track being adjusted three or four times in both forward and revers e. Shut off the engine after rotating the track.
6-7-06 - Fifth Proof 4-18 Routine Service and Maintenance Annual Maintenance Procedures Do the following procedures annually: 1. Do all Daily , W eekly and Monthly maintenance procedures 2. Replace air filter** See page 4-14, S tep 3. 3. Check engine idle speed (Refer to engine manual) 4.
6-7-06 - Fifth Proof 4-19 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 th e filter housing assemb ly (4, Fi gure 4–25).
6-7-06 - Fifth Proof 4-20 Routine Service and Maintenance General Maintenance Draining Fue l T ank (G asoline) 1. GASOLINE IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE. 2. A FIRE OR EXPLOSION FROM GASOLINE CAN BURN YOU OR OTHERS AND CA USE PROPERTY DAMAGE.
6-7-06 - Fifth Proof 4-21 Routine Service and Maintenance 5. Remove the spring clamps (It ems 2, Figure 4–27) from above an d below the fuel filter and remove the fuel lines. Figure 4–27 Fuel Filter 6. One at a time, open the fuel valves and al low the fuel to drain into a suitable cont ainer .
6-7-06 - Fifth Proof 4-22 Routine Service and Maintenance.
6-7-06 - Fifth Proof 5-1 Section 5 – T roubleshooting The following procedures will assist you in determining th e potential cause of a machine operating problem. Make sure to follow all safety precau tions stated in this manual when doing any work on the machine.
6-7-06 - Fifth Proof 5-2 Troubleshooting Engine will not start, starts hard, or fails to keep running. • Auxiliary hydraulics lever is not in neutral position with a hydraulically powered attachment inst alled. • Move lever to neutral position. • Fuel tanks are empty .
6-7-06 - Fifth Proof 5-3 Troubleshooting *T ested with warm oil and no more than 530 lbs (240 Kg) in the bucket. Measure the downward drop at the attachment lock pi ns on the back of the mount plate. Engine overheats. • Engine load is excessive. • Reduce ground speed.
6-7-06 - Fifth Proof 5-4 Troubleshooting Engine T roubleshooting** 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 .
6-7-06 - Fifth Proof 5-5 Troubleshooting • 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.
6-7-06 - Fifth Proof 5-6 Troubleshooting Engine Runs But Misses • Dirt or water in the fuel system. • Drain fuel system and replace with fresh, clean fuel. • S park plug lead disco nnected • Check to make sure that both spark plug leads are securely attached to the spark plug and that they are not damaged.
6-7-06 - Fifth Proof 5-7 Troubleshooting • 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 .
6-7-06 - Fifth Proof 5-8 Troubleshooting Engine Loses Power • Low crankca se oil level. • Add engine oil. • High crankcase oil level. • D rain engine oil and replace with proper quantity . • Dirty air cleaner element. • Clean air filter separator tube.
6-7-06 - Fifth Proof 5-9 Troubleshooting **This information is from the engine man ual included with the mac hine . General Sp ecifications Wheel Unit • Crankcase over filled. • Drain engine oil and replace with proper quantity . • Blown head gasket/ overheated.
6-7-06 - Fifth Proof 5-10 Troubleshooting T rack Unit Engine Power: (Gasoline) 27 HP Engine Manufacturer: Kohler Engine Description: Command Pro Air Cooled Wheel Base: 37" Width: 43.
6-7-06 - Fifth Proof.
6-7-06 - Fifth Proof Compact Power Inc. P .O. Box 40 – Fort Mill, SC 29716 Phone: 800-476-9673 – Fax: 803-548 -2762 Web Site: http://www .cpiequipment.
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