Cellboost BOXER 999-823 User Manual

COMP ACT COMP ACT TMCOMP ACT COMP ACT Part No. 999-823Serial No.s 005 and HigherBIG POWER IN ALL PLACES118 Operator’s Manual

viMertz Manufacturing, LLCP.O. Box 150Ponca City, OK 74602AffixStampHere

viiSafety IntroductionBe Prepared - Get to Know All Operating and Safety InstructionsThis is the Safety Alert Symbol. Wherever it appears, either in t

viii

ixTable of ContentsBoxer Product Warranty... iTrack Limited Warrant

xConfiguring the Chain... 4–29Parts List ...

1-1Section 1 – Safety PrecautionsSince Mertz Manufacturing has no direct control over machine application or operation, following the proper safety pr

1-2Safety PrecautionsOPERATING SAFETY • Plan ahead and learn as much as possible about your job-site area before beginning any work.• Know the exact l

1-3Safety Precautions• 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 in

1-4Safety PrecautionsSERVICE & MAINTENANCE SAFETY Maintenance work can be hazardous if not done in a careful manner. All personnel should realize

1-5Safety PrecautionsBattery HazardsBefore working with batteries, the following are important points about battery safety that you should be aware of

118 Operator’s ManualWrite your machine’s Serial Number in the space below for future reference. The serial number is located on the metal tag on the

1-6Safety PrecautionsHydraulic System Hazards The hydraulic system is under pressure whenever the engine is running and may hold pressure even after t

1-7Safety PrecautionsFueling HazardsMost fuels are highly flammable. Observe the following precautionary practices to reduce the possibility of a seri

1-8Safety Precautions

2-1Section 2 – Operating ControlsComponent LocationsRight Front ViewItem No. Description1 Operating Controls2 Hydraulic Fluid Level Dipstick and Tank

2-2Operating ControlsLeft Rear ViewItem No. Description1 Fuel Gauge and Fuel Filler Cap2 Gas Tank3 Rock Guard4 Spoils Auger5 Left Track Assembly6 Oper

2-3Operating ControlsOperating ControlsItem No. Description1 Fuel Gauge and Fuel Filler Cap2 Left Hand Grip3 Trencher Boom Raise and Lower Control Lev

2-4Operating ControlsSafety DecalsItem No. Description1 118 Model Number2 Keep Distance Warning3 CPI Logo4 Burn Hazard Warning5 Tie Down and Lifting H

2-5Operating ControlsOperating Controls Description1.Boom Raise and Lower – This lever controls the raising and lowering of the trencher boom assembly

2-6Operating Controls7. Engine Choke – Moving the lever to the left sets the choke for easier cold engine starting Moving the lever to the right open

3-1Section 3 – Pre-Start Inspection and OperationIMPROPER USE OF THE COMPACT TRENCHER COULD CAUSE SERIOUS INJURY OR DEATH. BEFORE OPERATING THE MACHIN

3-2Pre-Start Inspection and OperationBefore starting the engine, do the following pre-start service checks:1. Check condition of all warning and instr

3-3Pre-Start Inspection and Operation• If the engine oil level is below the add line, indicated by the letter “A” on the dipstick, carefully add the p

3-4Pre-Start Inspection and OperationHydraulic oil under pressure can penetrate body tissue causing serious injury and possible death. When troublesho

3-5Pre-Start Inspection and Operation8. Grease pivot shafts with proper type of grease. There are 5 grease points on this machine, see Figure 3–4.The

3-6Pre-Start Inspection and OperationBefore starting the engine: • Move all hydraulic control levers forward and release the lever. Make sure that eac

3-7Pre-Start Inspection and OperationOperating InstructionsMachine Start-upTo start the machine, the operator must:1. Stand on the operator's pla

3-8Pre-Start Inspection and OperationIn extremely cold weather fully warm machine to prevent a possible machine run-away condition.Machine Shut-downTo

3-9Pre-Start Inspection and Operation3. When the machine is positioned on the trailer properly, lower the boom to the trailer deck.4. Shut the engine

3-10Pre-Start Inspection and OperationFigure 3–7 Machine LiftingMachine Travel Controls • Levers and controls should return to the neutral position wh

3-11Pre-Start Inspection and OperationThe “cogging” condition is most likely to occur while operating in a forward direction pulling a heavy load, and

3-12Pre-Start Inspection and OperationRight Turn During Forward Travel Left Turn During Forward TravelTo turn to the right, move the left hand contro

3-13Pre-Start Inspection and OperationSpin Turn Make sure to use the machine hand holds while doing a spin turn to maintain your balance.Move the trav

3-14Pre-Start Inspection and Operation • Do not travel up or across a slope steeper than 15°. See Figure 3–15.• Keep boom as low as possible when trav

3-15Pre-Start Inspection and OperationOperating Instructions BEFORE BEGINNING ANY TRENCHING, MAKE SURE THAT THE WORK AREA HAS BEEN INSPECTED AND MARKE

3-16Pre-Start Inspection and OperationFigure 3–17 Trencher Boom in Raised Position3. Depress (step on) and hold the operator presence control (Item 1,

3-17Pre-Start Inspection and Operation4. With your right hand, move the trencher control lever (Item 1, Figure 3–19) to the right to activate the tren

3-18Pre-Start Inspection and Operation6. When the trencher boom (Item 1, Figure 3–21) has reached the proper digging depth the rock shield (Item 2, Fi

3-19Pre-Start Inspection and Operation10. When all trenching has been completed, raise the trencher boom out of the trench and move the trencher out o

3-20Pre-Start Inspection and Operation

4-1Section 4 – Routine Service and MaintenanceThe following information presents the routine service and maintenance required to make sure that the ma

iBoxer Product WarrantyWARRANTY AND LIABILITY LIMITATIONS Mertz Manufacturing, LLC warrants each new Compact Utility Trencher manufactured (hereinafte

4-2Routine Service and MaintenanceDaily Maintenance ProceduresBefore starting the engine, do the following pre-start service checks:1. Check condition

4-3Routine Service and Maintenancec. If the engine oil level is below the add line, indicated by the letter “A” on the dipstick, carefully add the pro

4-4Routine Service and Maintenance4. Check Air Filtera. Reach underneath the control panel plate to access the top of the engine.b. Remove the air fil

4-5Routine Service and MaintenanceFigure 4–4 Hydraulic Hose Damage1. End fittings damaged or leaking2. Outer covering chafed or cut, and wire reinforc

4-6Routine Service and MaintenanceFigure 4–5 Grease Zerk Locations10. Check for proper track tension.a. Remove the track adjusting wrench (Item 2, Fig

4-7Routine Service and Maintenanceb. Place a solid object, such as a concrete block or 8" H x 8" W x 48" L piece of lumber, under the o

4-8Routine Service and MaintenanceBefore starting the engine:• Move all hydraulic control levers forward and release the lever. Make sure that each le

4-9Routine Service and Maintenance3. Change the hydraulic filter. See Service Manual and Figure 4–9.• The hydraulic filter will be filled with hydraul

4-10Routine Service and Maintenancec. Start and run the engine for about 30 seconds. Using the hydraulic oil level dip stick (Item 1, Figure 4–10), ch

4-11Routine Service and MaintenanceWeekly Maintenance ProceduresDo the following procedures weekly or every 50 operating hours:1. Do all Daily mainten

iihereunder, on warranties or otherwise, shall be limited to the cost of repair or replacement of defective parts as herein specified. Further Mertz M

4-12Routine Service and MaintenanceMonthly Maintenance ProceduresDo the following procedures monthly or every 200 operating hours:1. Do all Daily and

4-13Routine Service and Maintenance4. Replace fuel filter.• GASOLINE IS VERY FLAMMABLE. HANDLE WITH EXTREME CAUTION.• MAKE SURE THAT THE ENGINE HAS BE

4-14Routine Service and MaintenanceFigure 4–13 Fuel Filter ReplacementMake sure to clean up any spilled fuel from in and around the engine compartment

4-15Routine Service and Maintenance10. Loosen the cable clamps and remove the cable from the battery. Clean the terminals with a battery brush. Reinst

4-16Routine Service and MaintenanceAnnual Maintenance ProceduresDo the following procedures annually:1. Do all Daily, Weekly and Monthly maintenance p

4-17Routine Service and Maintenanced. Replace hydraulic filter. See page 4-9, Step 3.The hydraulic dipstick is located underneath the hydraulic filler

4-18Routine Service and MaintenanceGeneral MaintenanceDraining Fuel Tank1. GASOLINE IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE.2) A FIRE OR EXPLOSION

4-19Routine Service and Maintenance5. Loosen the lower intake hose clamp (Item 3, Figure 4–17) at the fuel filter (Item 2, Figure 4–17). Slide the cla

4-20Routine Service and MaintenanceAdjusting Digging Chain TensionAdjust the digging chain tension every 25 operating hours. With the trencher paralle

4-21Routine Service and MaintenanceIf the chain tension needs to be adjusted:1. Loosen the adjustment bolt lock nut (Item 2, Figure 4–19)2. Rotate the

iiiTRACK LIMITED PRORATED WARRANTY POLICY STATEMENTCompact Power Inc provides a limited warranty to the original purchaser that the original tracks us

4-22Routine Service and MaintenanceTrencher Boom ReplacementAdjust the digging chain tension every 25 operating hours. With the trencher parallel to t

4-23Routine Service and Maintenance10. Reinstall the boom guard (Item 1, Figure 4–20)Figure 4–20 Trencher Boom Assembly12345672463

4-24Routine Service and MaintenanceReplacing the Digging TeethDue to the high amount of wear placed on the digging teeth, you will need to replace the

4-25Routine Service and MaintenanceReplacing the Drive SprocketOvertime, the drive sprocket will wear, especially when used in sandy or clay soils. Wh

4-26Routine Service and Maintenance10. Install the spoils auger and secure it using the nut removed earlier.11. Set the upper span of the chain into

4-27Routine Service and MaintenanceChain ConfigurationYou can set up the chain in different configurations, depending on the width of the trench desir

4-28Routine Service and MaintenanceChain Master LinkIf the trencher chain needs to be removed from the trencher, it can be broken at the Master Link.

4-29Routine Service and MaintenanceConfiguring the Chain To configure the chain, complete the following procedures: Select the chain configuration you

4-30Routine Service and MaintenanceParts ListTrencher Chain Parts listItem # Description Quantity Part #1 BOLT, 3/8"-24 X 2 1/4 "12 3824214

4-31Routine Service and MaintenanceFigure 4–25 Chain Configuration1210112988121011691681310144Configuration A141013817314151381Configuration BConfigur

ivWarranty service must be performed by Compact Power or its authorized Dealer's service representativeThe following items are not covered by thi

4-32Routine Service and MaintenanceBoxer 118 Hydraulic Interconnect DiagramFigure 4–26 Boxer 118 Hydraulic Interconnect DiagramAUX. VALVEFILTER,IN TAN

5-1Section 5 – TroubleshootingThe following procedures will assist you in determining the potential cause of a machine operating problem.Problem Possi

5-2TroubleshootingEngine looses power. • Engine load is excessive. • Reduce ground speed.• Reduce speed of trencher.• Air cleaner is dirty. • Clean

5-3TroubleshootingThe machine does not travel in either forward or reverse directions.• Engine is not running at full speed.• Advance throttle to full

5-4Troubleshooting

6-1Section 6 – General Specifications Engine SystemType Kohler Command ProCooling System Air CooledHP / KW 18 / 13.4Fuel Tank 3.0 GallonsAir Cleaner

6-2General SpecificationsNoise DataTests were performed in accordance with EU Machinery Directive 98/37/EC EN 474-10:2006 in addition to ISO/DIS 6394:

SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATIONOF A COMPACT UTILITY LOADER WITH AN ATTACHMENT.DO NOT REMOVE THIS PAGE FROM THE MANUAL.161615 DE

Compact Power Inc.P.O. Box 40 – Fort Mill, SC 29716 Phone: 800-476-9673 – Fax: 803-548-2762Web Site: http://www.cpiequipment.com/Part Number 999-823

vBoxer Warranty Registration Dear Customer,Mertz Manufacturing, LLC wishes to thank you for your purchase. We are committed to providing our customers