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6-7-06 - Fifth Proof

5-1

Section 5 – Troubleshooting

The following procedures will assist you in determining the potential cause of a machine
operating problem.

Make sure to follow all safety precautions stated in this manual when

doing any work on the machine.

Problem

Possible Causes

Corrective Action

Starter does not turn the

engine over.

• Auxiliary hydraulics lever is

either in Forward or Reverse

position with no hydraulically

powered attachment installed.

• Move lever to neutral

position.

• Battery is dead.

• Charge the battery.

• If battery does not hold a

charge, replace the battery.

• Electrical connections are

corroded or loose.

• Check electrical connections

for good contact.

• Remove cables from battery

terminals and fully clean

battery terminals and cable

clamps.

• If the cable clamps can not be

properly cleaned, replace

connectors.

• Relay or starter switch is

defective.

• Contact Authorized Service

Dealer.

• Engine is in hydraulic lock due

to a cylinder filled with fuel.

• Make sure that the spark plug

cables have been moved

away from the engine block

or any other metal surface. A

spark could ignite the fuel

causing a fire or explosion.

• Allow engine to cool before

attempting this procedure.

• Remove spark plugs and turn

engine over to pump excess

fuel from engine cylinder.

IMPORTANT

DANGER

Содержание BOXER 427 Operators

Страница 1: ...Boxer 427 and Boxer 427W Operators Manual COMPACT TM COMPACT Part No 999 860 SN 992 and Higher BIG POWER IN ALL PLACES...

Страница 2: ...6 7 06 Fifth Proof...

Страница 3: ...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...

Страница 4: ...facturing 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 sh...

Страница 5: ...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...

Страница 6: ...6 7 06 Fifth Proof iv Mertz Manufacturing LLC P O Box 150 Ponca City OK 74602 Affix Stamp Here...

Страница 7: ...ecautions indicated whenever you see the Safety Alert symbol no matter which signal word appears next to the Safety Alert symbol INDICATES A HAZARDOUS SITUATION THAT IF NOT AVOIDED IS VERY LIKELY TO C...

Страница 8: ...6 7 06 Fifth Proof vi...

Страница 9: ...2 1 Rear View 2 2 Side View 2 3 Operating Controls 2 4 Safety Decals 2 5 Operating Controls Description 2 7 Section 3 Pre Start Inspection and Operation 3 1 Pre Start Inspection 3 1 Daily Service Che...

Страница 10: ...Brake in Maintenance Procedures 4 9 Weekly Maintenance Procedures 4 12 Monthly Maintenance Procedures 4 14 Annual Maintenance Procedures 4 18 General Maintenance 4 20 Draining Fuel Tank Gasoline 4 20...

Страница 11: ...nto 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 an...

Страница 12: ...erson 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...

Страница 13: ...rior 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 no...

Страница 14: ...ions 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...

Страница 15: ...e 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 s...

Страница 16: ...nnecting any hydraulic lines Hot hydraulic fluid can cause severe burns Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death When troubleshooting a hydrauli...

Страница 17: ...ble 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...

Страница 18: ...6 7 06 Fifth Proof 1 8 Safety Precautions...

Страница 19: ...Item No Description 1 Attachment mounting plate 2 Tilt cylinder 3 Auxiliary hydraulic quick connects 4 Boom 5 Fuel tank 6 Fuel filler cap 7 Operating controls 8 Hand grab rail 9 Manual holder 10 Lift...

Страница 20: ...w 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 holder 7 Fuel filler cap 8 Fuel tank 9 Ignition switch and key...

Страница 21: ...of 2 3 Operating Controls Side View Item No Description 1 Rear drive wheel 2 Front drive wheel 3 Spark arrestor 4 Fuel tank 5 Attachment mounting plate 6 Boom 7 Air filter 8 Operator s platform 8 5 6...

Страница 22: ...ge selector switch 2 Attachment tilt control 3 Attachment raise control 4 Engine throttle 5 Travel creep speed control 6 Fuel filler cap 7 Fuel tank 8 Service panel lock 9 Hand grip rail 10 Left trave...

Страница 23: ...afety Decals Item No Description 1 Auxiliary Power Control Warning 2 Pinch Point Warning 3 Fuel Fill Warning 4 Boxer decal 5 Mertz corporate decal 6 Cylinder Lock Installation Warning 7 Brute Decal 8...

Страница 24: ...ed Item No Description 1 Boxer Decal 2 Safety Instructions Decal 3 Operating Controls Information Plate 4 Engine Throttle Decal 5 Made In USA Decal 6 Auxiliary Power Control Warning 7 Pinch Point Warn...

Страница 25: ...erse 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 attach...

Страница 26: ...il 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 c...

Страница 27: ...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 automaticall...

Страница 28: ...the engine oil filler tube Item 1 Figure 3 1 It is important to add the correct type of engine oil as stated in the engine manual NOTE Extremely dusty or dirty working conditions may require more freq...

Страница 29: ...er 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...

Страница 30: ...lies 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 sha...

Страница 31: ...6 7 06 Fifth Proof 3 5 Pre Start Inspection and Operation Figure 3 4 Lubrication Points 2128...

Страница 32: ...oader Arm Lift Cylinder Base Lubrication Point NOTE Extremely dusty or dirty working conditions may require more frequent service replacement Make sure to install the cylinder lock before performing a...

Страница 33: ...y reinsert the safety lock pin Item 4 Figure 3 6 securing the cylinder lock in the support position NOTE Make sure that the safety lock pin goes behind the loader arm cylinder 7 Lower the loader arm a...

Страница 34: ...rator must 1 Stand on the operator s platform Item 1 Figure 3 7 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 leve...

Страница 35: ...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...

Страница 36: ...her 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 tr...

Страница 37: ...t to prevent possible carburetor flooding due to vibration Figure 3 11 Fuel Shut Off Valves NOTE Never tow or pull the machine Damage to the hydraulic motors could result If the machine is totally in...

Страница 38: ...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 o...

Страница 39: ...ever The farther forward the right control is moved the faster the left turn will be made See Figure 3 15 2138 Figure 3 15 Left Hand Turn in Forward Right Turn During Reverse Travel Left Turn During R...

Страница 40: ...alance 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 tur...

Страница 41: ...p downwards securing the attachment to the machine If the lock pin does not drop into the locked position start the engine and either raise or lower the attachment slightly until the lock pins snap in...

Страница 42: ...he female attachment mounting plate to remove any debris that might interfere with the attachment installation 2 Start the machines engine lower the loader arm and tilt the mounting plate forwards NOT...

Страница 43: ...position See Figure 3 22 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 attac...

Страница 44: ...ttachment Installation of Hydraulically Powered Attachments There are many hydraulically powered attachments available that are very easy to install To install any of these attachments 1 Position the...

Страница 45: ...t 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 Figure 3 26 Hydraulically Powered Attac...

Страница 46: ...rward and backward to release any stored hydraulic pressure 10 Attach the hydraulic hoses to the quick connects See Figure 3 29 NOTE There are two hydraulic hoses that need to be connected The quick c...

Страница 47: ...achments male coupling Item 3 Figure 3 30 into the female bulkhead quick connect coupling Item 1 Figure 3 30 on the machine and push until the connector locks into position e Repeat the above process...

Страница 48: ...routed to keep them out of the way during operation and prevent them from being damaged Figure 3 31 Attachment Hydraulic Hose Routing 12 The attachment is now ready to use Before starting the engine m...

Страница 49: ...gure 3 32 to the HIGH position before activating the AUXILIARY control lever If this switch is not set properly the auxiliary hydraulics and travel controls will not function properly 3 With your righ...

Страница 50: ...of the hydraulic power to the attachment with no power going to the travel system 3 Hold the main travel control levers in either the fully forward or reverse position 4 Rotate the CREEP control lever...

Страница 51: ...le quick connect Item 1 Figure 3 34 to align the notch on the collar with the lock button Item 2 Figure 3 34 4 Slide the collar backwards on the female quick connect Item 4 Figure 3 34 until it stops...

Страница 52: ...6 7 06 Fifth Proof 3 26 Pre Start Inspection and Operation...

Страница 53: ...conditions may require more frequent service replacement Under very wet and muddy conditions more frequent lubrication may be required Activity Daily 10 Hours New Machine 20 Hours Weekly 50 Hours Mon...

Страница 54: ...engine is OFF a The Brute has a saddle tank Item 1 Figure 4 1 on each side of the machine Figure 4 1 Fuel Level Check b Each of the tanks has a gas gauge located in the filler cap Item 2 Figure 4 1 R...

Страница 55: ...1 Figure 4 2 It is important to add the correct type of engine oil as stated in the engine manual NOTE Extremely dusty or dirty working conditions may require more frequent checking filling and or ch...

Страница 56: ...hydraulic level dip stick d Unscrew and remove the hydraulic fluid dip stick Item 3 Figure 4 4 Make sure that the hydraulic fluid is at or slightly above the marker hole in the dip stick If you are c...

Страница 57: ...ith hydraulic oil or any other fluids immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries a Fully raise the loader arm and secure the safety support b Open th...

Страница 58: ...Hydraulic Lines and Fittings e If any signs of damage are visible do not operate the machine until repairs have been made and documented f When the inspection has been completed reinstall the upper in...

Страница 59: ...Fifth Proof 4 7 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 Figure 4 9 Lubrication Point...

Страница 60: ...shown on the side of the tire Make sure that the tires are not worn or damaged 9 Check for loose or missing fasteners a Inspect for any loose or missing bolts or fasteners b Tighten or replace any mis...

Страница 61: ...e 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 sid...

Страница 62: ...nd run the engine for about 30 seconds Using the hydraulic oil level dip stick Item 7 Figure 4 13 check the hydraulic oil level Add the appropriate hydraulic fluid as needed Figure 4 13 Hydraulic Oil...

Страница 63: ...2 Figure 4 14 NOTE It may be necessary to rotate the adjustment nut slightly to align the adjustment nut keeper bolt f With the tracks still off the ground start the engine and rotate just the track...

Страница 64: ...First 50 operating hours only then follow the normal service cycles 3 Check the in line fuel filter Item 1 Figure 4 15 for signs of water restrictions or contamination Replace as needed Figure 4 15 F...

Страница 65: ...for damage to the spark plug cables 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 da...

Страница 66: ...fter the main element is removed check the condition of the inner element Item 2 Figure 4 19 It should be replaced whenever it appears dirty typically every other time the main element is replaced Cle...

Страница 67: ...tened 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...

Страница 68: ...is being held securely to the machine Figure 4 22 Battery and Connections 6 Check for proper track tension if equipped a Raise the machine off the ground and support it using a device capable of safe...

Страница 69: ...ate 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 adjustm...

Страница 70: ...Place a suitable sized container under the Brute b Remove the hydraulic tank drain plug Item 1 Figure 4 24 and drain all hydraulic fluid from the machine NOTE Make sure to inspect the O ring on the d...

Страница 71: ...with the proper hydraulic fluid ISO 46 Premium hydraulic fluid or equivalent through the dip stick port Using the hydraulic fluid dipstick make sure that the hydraulic fluid is at or slightly above t...

Страница 72: ...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 Lower...

Страница 73: ...the container selected to store the fuel can contain the capacity of both fuel tanks Make sure to dispose of the old gasoline in an appropriate manner NOTE Now is the best time to install a new fuel...

Страница 74: ...6 7 06 Fifth Proof 4 22 Routine Service and Maintenance...

Страница 75: ...not hold a charge replace the battery Electrical connections are corroded or loose Check electrical connections for good contact Remove cables from battery terminals and fully clean battery terminals...

Страница 76: ...iate storage container and dispose of bad fuel properly Refill fuel tanks with fresh clean fuel Replace fuel filter 30 Amp fuse blown Replace fuse Engine looses power Engine load is excessive Reduce g...

Страница 77: ...nder seals are leaking Replace cylinder seals With the machines engine turned off boom drops downward quickly and then stops Cylinder seals are leaking Replace cylinder seals The machine does not trav...

Страница 78: ...isconnected Check to make sure that both spark plug leads are securely attached to the spark plug and that they are not damaged Faulty spark plugs Replace spark plugs Faulty ignition module s Test and...

Страница 79: ...Reverse position Move control lever to the Neutral position Dirt or water in the fuel system Drain fuel system and replace with fresh clean fuel Clogged fuel line Clean or replace fuel lines Loose or...

Страница 80: ...it Tighten connections Engine overheated Clean cooling fins and remove any debris from around engine Faulty ignition module or incorrect air gap See engine manual Carburetor adjusted incorrectly See e...

Страница 81: ...ive engine load Reduce load on engine Low crankcase oil level Add engine oil High crankcase oil level Drain engine oil and replace with proper quantity Faulty carburetor See engine manual Lean fuel mi...

Страница 82: ...around engine Faulty spark plugs Replace spark plugs Low compression See engine manual Exhaust restriction Clean spark arrestor See engine manual SMART SPARK malfunction applicable models See engine...

Страница 83: ...torqued fasteners See engine manual Piston blow by or leaky valves See engine manual Restricted exhaust Clean spark arrestor See engine manual Engine Power Gasoline 27 HP Engine Manufacturer Kohler En...

Страница 84: ...Width 43 5 Weight without bucket 2 250 LBS Tip Capacity 1 800 LBS Dump Angle 34 Dump height 56 Hinge pin height fully raised 70 Travel speed 3 5 MPH Fuel tank capacity 10 GAL Overall Operating Height...

Страница 85: ...6 7 06 Fifth Proof...

Страница 86: ...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 com Part No 999 860...

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