Instruction/ maintenance manual of the product 999-823 Cellboost
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COMP ACT COMP ACT TM COMP ACT COMP ACT Part No. 999-823 Serial No.s 005 and Higher BIG PO WER IN ALL PLA CES 1 18 Operator ’ s Manual.
1 18 Operator ’ s Manual W rite your machine’ s Serial Number in the space below for future reference. The serial number is located on the metal tag on the left side of the machine. Remove the service access panel to locate the Serial Number plate.
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i Boxer Product W arranty W ARRANTY AND LIABILITY LIMIT A TIONS Mertz Manufacturing, LLC wa rrants each new Compact Uti lity T rencher manufactured (hereinafter referred to as the equipment) by us to .
ii hereunder , on warranties or otherwise, sh all be limited to the cost of repair or replacement of defective parts as herein specified. Further Me rtz Manufacturing, LLC's maximum liab ility he.
iii TRACK LIMITED PRORA TED W ARRANTY POLICY ST A TEMENT Compact Power Inc provid es a limited w arranty to the orig inal purchaser that th e original tracks used on consumer pro duct s sold by Compact Powe r or its authorized Distributor/Dealer , and manufactured by its subsidiary Mertz Mfg.
iv W arranty service must be performed by Co mpact Power or its au thorized De aler's service rep resentativ e The following items are not cover ed by this T rack Limited W arranty: Parts that are not genuine o rig inal manufact urer servi c e par ts ar e n ot cove red by thi s warranty .
v Boxer W arranty Registration Dear Customer , Mertz Man ufacturing, LL C wishes to thank you for your pu rchase. We are committed to providing our customers with the finest pr od ucts and prod uct support available in any market to day . T o do this, we need to update our database with some specific in formation.
vi Mertz Manufacturing, LLC P .O. Box 150 Ponca City , OK 74602 Affix St am p Here.
vii Safety Introduction Be Prepared - Get to Know All Operating and Safety Inst ructions This is the Safety Alert Sym bol. 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.
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ix T able of Contents Boxer Product Warranty ...................................................................................... i Track Limited Warranty Policy Statement ....................................................... iii Safety Introduction .
x Configuring the Chain ........................................................................ 4–29 Parts List .................................................................................................. 4–30 Boxer 118 Hydraulic Interconnect Diagram .
1-1 Section 1 – Safety Precautions Since Mertz Manufacturing has no direct control over machin e application or operation, following the proper safety prac tices is the responsibility of the owner and/or operator . Remember that this unit is only as safe as those who operate it .
1-2 Safety Precautions OPERA TING SAFETY • Plan ahead and learn as much as possible about 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.
1-3 Safety Precautions • If the unit should beg in to tip or become unstabl e, DO NOT try to stabilize the unit with your legs or arms. • If the unit is involved in an accident or in advertently damaged dur ing operation, stop and perform a thorough inspection.
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 zards a nd stri ctl y follow sa fe ma intenan ce p rac tices . Fa il ure to com ply wit h thes e safety precautions may result in se rious personal injury and/or death.
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.
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 trench boo m is resting on the ground.
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 away fr om sparks or open flames.
1-8 Safety Precautions.
2-1 Section 2 – Oper ating Control s Component Locations Right Front View Item No. Description 1 Operating Controls 2 Hydraulic Fluid Level Dipstick and T ank Fill Port 3 Hydraulic T ank 4 T rack Ad.
2-2 Operating Controls Lef t Re ar V iew Item No. Description 1 Fuel Gauge and Fuel Filler Cap 2 Gas T ank 3 Rock Guard 4 S poils Auger 5 Left T rack Assembly 6 Operator's Platform 7 T rencher Ac.
2-3 Operating Controls Operating Co ntro ls Item No. Description 1 Fuel Gauge and Fuel Filler Cap 2 Left Hand Grip 3 T rencher Boom Raise and Lower Control Lever 4 Left T ravel Control Lever 5 Right T.
2-4 Operating Controls Safety Decals Item No. Description 1 1 18 Model N umber 2 Keep Distance W arning 3 CPI Logo 4 Burn Hazard Warning 5 Tie Down and Lif ting Hazard Decals 6 Boxer Logo 7 Crush Haza.
2-5 Operating Controls Operating Co ntro ls Description 1. Boom Raise and Lower – This lever controls the rais ing and lowering of the trencher boom assembly . 2. Left T ravel Motor Control – Pushing the lever forward rota tes the left si de track for forward travel.
2-6 Operating Controls 7. Engine Chok e – Moving the lever to the left sets the choke for easier cold engine starting Moving the lever to the right opens the choke and allows the warm ed up engine to run properly .
3-1 Section 3 – Pre-S t art In spection and Operation IMPROPER USE OF THE COMP ACT TRENCHER COULD CAUSE SERIOUS INJUR Y OR DEA TH. BEFORE OPERA TIN G THE MACHI NE, OR PERFORMING MAINTENANCE, THE OPE.
3-2 Pre-Start Inspection and Operation Before starting the engine, do the fo llowing pre-start service checks: 1. Check condition of all warning and instructi onal decals.
3-3 Pre-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 proper am ount of oil through the e ngine oil filler (Item 3, Figure 3–2 ). It is important to add the correct type of engine oil as stat ed in the engine manual.
3-4 Pre-Start Inspection and Operation Hydraulic oil under pressure can penetrat e body tissue causin g serious injury and possible death. When troubleshooting a hydrau lic system for leaks, a lways use cardbo ard or wood as a detector . DO NOT USE YOUR BARE HANDS.
3-5 Pre-Start Inspection and Operation 8. Grease pivot shafts with proper type of grea se. There ar e 5 grease poi nts on this machin e, see Figure 3–4 .
3-6 Pre-Start Inspection and Operation Before starting the engine: • Move all hydraulic contr ol levers forward and release the lever . Make sure that each lever automat ical ly r etu rns to the Neutral position. • Move all hydraulic contr ol levers re arward and relea se the lever .
3-7 Pre-Start Inspection and Operation Operating Instructions Machine St art-up T o start the machine, the ope rat or must: 1. Stand on the operator's platform (I tem 1, Figure 3–5 ). 2. Move the throttle lever (Item 2, Figure 3–5 ) to about half way between fast and id le engine speeds.
3-8 Pre-Start Inspection and Operation In extremely cold weather fully warm machine to prevent a possible machine run-away condition. Machine Shut-do wn T o safely shut the machine down, the operator must: 1. Park the machine on a solid, level area. 2.
3-9 Pre-Start Inspection and Operation 3. When the machine is positioned on the trailer pr operly , lowe r the boom 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 T r ansportation) approved chains, binders (Items 1 and 2, Figure 3–6 ), and DOT guidelines.
3-10 Pre-Start Inspection and Operation Figure 3–7 Machine Lifting 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.
3-11 Pre-Start Inspection and Operation The “cogging” condition is most likely to occur while operating in a forward direction pulling a heavy load, and during the first 50 hours of track us ag e. It is caused by the tension spring b eing fully compressed due to high track load.
3-12 Pre-Start Inspection and Operation Right T urn Durin g Fo rward Travel Left T urn Durin g Forward 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.
3-13 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. Move the travel control levers in opposite directions to spin the machine on it axis.
3-14 Pre-Start Inspection and Operation • Do not travel up or acr oss a slope steeper than 15°. See Figur e 3–15 . • Keep boom as low as possible when traveling on slopes or rough terrain. Figure 3–15 Slide Slope T ravel • Keep the heavy end of the machine towa rds the uphi ll dir ection when traveling up or down a slope.
3-15 Pre-Start Inspection and Operation Operating Instructions BEFORE BEGINNING ANY TRENCHI NG , MAKE SURE THA T THE WORK AREA HAS BEEN INSPECTED AND MARKED FOR UNDERGROU ND UTILITIES OR POTENTIAL OBSTRUCTIONS. ANY CONT AC T WITH UNDERGROUND UTILITIES CAN POTENTIALL Y CAUSE INJURY OR DEA TH.
3-16 Pre-Start Inspection and Operation Figure 3–17 Trencher Boom in Raised Position 3. Depress (step on) and hold the ope rator presence control (Item 1, Figure 3–18 ) in the “down” or activated position wi th your right foot.
3-17 Pre-Start Inspection and Operation 4. With your right hand, move the trencher control lever (Item 1, Figure 3–19 ) to the right to activate the trencher cha in in the FOR W ARD motion. The control will remain in the forward position until you either move the lever into the Neutral position or step off the op erator presence control.
3-18 Pre-Start Inspection and Operation 6. When the trencher boom (Item 1, Figure 3–21 ) has reached the proper digging depth the rock shield (Item 2, Figure 3–21 ) and spoils auger (Item 3, Figure 3–21 ) will direct the dirt that has been remove d from the tr ench away from th e machine.
3-19 Pre-Start Inspection and Operation 10. When all trenc hing has been completed , raise the trench er boom out of the trench and move the trencher out of the way . When the trenching has been comp leted, move the engine throttle to the idle position and allow the engine to cool off at idle for 3 - 4 minutes.
3-20 Pre-Start Inspection and Operation.
4-1 Section 4 – Routine Se rvice and Maintenance The following information presents the routine service and maintenance r equi red to ma ke sure that the machin e functions safely and properly . More detailed se rvice information is contained in the Service Manual.
4-2 Routine Service and Maintenance Daily Maintenance Procedures Before starting the engine, do the fo llowing pre-start service checks: 1. Check condition of all warning and instructi onal decals. Replace any damaged decals with genuine BOXER repl acement de cals.
4-3 Routine Service and Maintenance c. If the engine oil level is below the add line , indicated by the letter “A” on the dipstick, carefully add the proper am ount of oil through the engine oil filler (Item 3, Figure 4–1 ). It is important to add the corre ct type of engine oil as stated in the engine manual.
4-4 Routine Service and Maintenance 4. Check Air Filter a. Reach underneath the control panel pl ate to acce ss the top of the engine. b. Remove the air filter cover (Item 1, Figure 4–3 ) and inspect the outer air filter sleeve (Item 4, Figure 4–3 ).
4-5 Routine Service and Maintenance Figure 4–4 Hydraulic Ho se 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 6. Check for loose or missing fasteners a.
4-6 Routine Service and Maintenance Figure 4–5 Grease Zer k Locations 10. Check for proper track tension. a. Remove the track adju sting wrench (Item 2, Figure 4–6 ) from the right track assembly . Make sure that the rubber grommets re main on the threaded studs (Item 3, Figure 4–6 ).
4-7 Routine Service and Maintenance b. Place a solid object, such as a concret e bl ock or 8" H x 8" W x 48" L piece of lumber, under the operator's platform. c. T ilt the trencher boom downwards until the lowest cutting edge is touching the ground.
4-8 Routine Service and Maintenance Before starting the engine: • Move all hydraulic contr ol levers forward and release the lever . Make sure that each lever automat ical ly r etu rns to the Neutral position. • Move all hydraulic contr ol levers re arward and relea se the lever .
4-9 Routine Service and Maintenance 3. Change the hydraulic filter . See Service Manual and Figure 4–9 . • The hydraulic filter will be filled with hy draulic fluid. Make sur e to dispose of the used hydraulic filter in an appropriat e manner and ac cording to S tate and Local regulations.
4-10 Routine Service and Maintenance c. S tart and run the engine for about 30 seco nds. Using the hydraulic oil level dip stick (Item 1, Figure 4–10 ), check the hydr aulic oil level. Add the appropriate h ydraulic fluid as needed through the filler port (Item 2, Figure 4–10 ) on top of the upper hydraulic oil tank (Item 3, Figure 4–10 ).
4-11 Routine Service and Maintenance Weekly Maintenance Procedures Do the following procedures weekly or every 50 operating hours: 1. Do all Daily maintenance procedures Check the battery (Item 3, Figure 4–1 1 ) and cable connecti ons (Items 1 and 2, Figure 4–11 ) for signs of leaking, corrosion or damage.
4-12 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 oil filter - se e en gine manual 3.
4-13 Routine Service and Maintenance 4. Repl ac e fuel filter . • GASOLINE IS VER Y FLAMMABLE. HANDLE WITH EXTREME CAUTION. • MAKE SURE THA T THE ENGINE HAS BEEN ALLOWED TO COOL BEFORE PERFORMING THIS OPERA TION. • MAKE SURE THA T THERE ARE NO OPEN FLAMES IN TH E WORK AREA.
4-14 Routine Service and Maintenance Figure 4–13 Fuel Filter Rep lacement Make sur e to clean up any sp illed fuel fr om in and ar ound the engine compartment of the machine. Spil led fuel may be ignited by a hot engine. 5. Check battery signs of leakage or for corrosion on the battery cables.
4-15 Routine Service and Maintenance 10. Loosen the cable clam ps an d remove the cable from the batt ery . Clean the te rmi n als with a battery brush. Reinstall an d secure the cable clamps. 1 1. Check the battery hold do wn clamp (Items 4 and 7, Figure 4–14 ) to make sure that the battery is being held secu rely to the machine.
4-16 Routine Service and Maintenance Annual Maintenance Procedures Do the following procedures annually: 1. Do all Daily , W eekly and Monthly maintenance procedures 2. Repl ace air filte r . Se e page 4-12 , Step 3. 3. Check engine idle speed (Refer to engine manual) 4.
4-17 Routine Service and Maintenance d. Replace hydraulic filter . See page 4-9 , S tep 3. The hydraulic dipstick is located underneath the hydrau lic filler cap, located on top of the upper hydraulic tank. See Figure 4–16 . e. Unscrew the dipstick assembly and remove from the mach ine.
4-18 Routine Service and Maintenance General Maintenance Draining Fuel T ank 1. GASOLINE IS EXTREMEL Y FLAMMABLE AND HIGHL Y EXPLOSIVE. 2) A FIRE OR EXPLOSION FROM GASOLI NE CAN BURN YOU OR OTHERS AND CAUSE PROPERTY DAMAGE. 3) DRAIN FUEL FROM T ANKS WHEN THE ENGINE IS COLD.
4-19 Routine Service and Maintenance 5. Loosen the lower intake hose clamp (Item 3, Figure 4–17 ) at the fuel filter (Item 2, Figure 4– 17 ). Slide the clamp along the fuel line (Item 3, Figure 4–17 ), away from the filter . 6. Pull the fuel line off of the fuel filter a nd position the line in a suitable sized container .
4-20 Routine Service and Maintenance Adjusting Digg i ng Chain T ens ion Adjust the digging chain tension every 25 operati ng hours. With the tren cher parallel to the ground, make sure that there is 1¾" to 2" of chain sag between the bottom of the boom and the top of the bottom chain span.
4-21 Routine Service and Maintenance If the chain tension needs to be adjusted: 1. Loosen the adjustment bolt lock nut (Item 2, Figure 4–19 ) 2. Rota te the chain adju stment bolt (Item 3, Figure 4–19 ) to increase or decrease pressure on the boom until the proper chain sag is measured.
4-22 Routine Service and Maintenance T re ncher Boom Re placement Adjust the digging chain tension every 25 operati ng hours. With the tren cher parallel to the ground, make that there is 1¾" to 2" of chai n sag between the bottom of the boom and the top of the bottom chain s pan.
4-23 Routine Service and Maintenance 10. Reinstall the boom guard (Item 1 , Figure 4–20 ) Figure 4–20 Trencher Boom Assembly 1 2 3 4 5 6 7 2463.
4-24 Routine Service and Maintenance Replacing the Digging T eeth Due to the high amount of wear placed on the digging teeth, you will ne ed to replace them periodically .
4-25 Routine Service and Maintenance Replacing the Drive Sprocket Overtime, the drive sprocket will wear , especially when used in sandy or clay soils. When this happens, the digging chain will begin to slip. If the chain slips, replace the drive sprocket, as follows: 1.
4-26 Routine Service and Maintenance 10. Install the spoils auger and secu re it using the nut removed earlier . 1 1. Set the upper span of the chain into place on the trencher boom , and then wrap th e chain around the roller at the end of th e boom.
4-27 Routine Service and Maintenance Chain Configuration Y ou can set up the chain in differen t configur ations, depending on the width of the trench desired and the soil conditions at the work site. Depending on the size of boom you purchased, you will either have a chain with: • 24 links (24 inch [60.
4-28 Routine Service and Maintenance Chain Maste r Link If the trencher chain needs to be removed from the trencher , it can be broken at the Master Link. When the Master Link is removed, the chain could fall off the tr encher frame. Keep your hands and feet from underneath the chain to prevent injury .
4-29 Routine Service and Maintenance Configuring the Ch a in T o configure the chain, comp le te the following p rocedures: Select the chain configuration you want to inst all from the chain config uration illustrations (Configurations A - E, Figure 4–2 2 ) and obtain all necessary parts.
4-30 Routine Service and Maintenance Part s List T rencher Chain Part s lis t Item # Description Quantity Part # 1 BOL T , 3/8"-24 X 2 1/4 "12 38242148 2 BOL T , 3/8"-24 X 2 3/4 "2.
4-31 Routine Service and Maintenance Figure 4–25 Cha in Configuration 12 10 11 2 9 8 8 12 10 11 6 9 16 8 13 10 14 4 Configuration A 14 10 13 8 17 3 14 15 13 8 1 Configuration B Configuration C Confi.
4-32 Routine Service and Maintenance Boxer 1 18 Hydraulic Interconnect Diagram Figure 4–26 Boxer 1 18 Hydraulic Interconnect Diagram AUX. V AL VE FIL TER, IN T ANK RETURN TO T ANK VENT TIL T CYL.
5-1 Section 5 – T roubleshooting The following procedures will assist you in determining th e potential cause of a machine operating problem. Problem Possible Causes Corrective Action S tarter does not turn the engine over . • T rencher control lever is either in Forward or Reverse position and the operator presence control is depressed.
5-2 Troubleshooting Engine looses power . • Engine load is excessive. • Reduce ground speed. • Reduce speed of tren cher . • Air cleaner is dirty . • Clean air filter h ousing and replace the filter elements. • Engine oil level in crankcase is low .
5-3 Troubleshooting The machine does not travel in either forward or reverse directions. • Engine is not running at full speed. • Advance throttle to full engine speed. • Hydraulic fluid is cold. • F ully warm hydraulic fluid. • Hydraulic fluid level is lo w .
5-4 Troubleshooting.
6-1 Section 6 – General Specifications Engine System T ype Kohler Command Pro Cooling System Air Cooled HP / KW 18 / 13.4 Fuel T ank 3.0 Gallons Air Cleaner S tandard Air Cleaner Hydraulic System Reservoir Capacity 13 gallons Filter 10 Micron Electrical System Battery 12 V olt Control System S t arting Keyed ignition switch.
6-2 General Specifications Noise Dat a T ests were performed in accordance with EU Machinery Directive 98/37/EC EN 474-10:2006 in addition to ISO/DIS 6394:2004. Engine RPM was @ 3600 rpm (max) rpm. The noise measurements were ma de wit h the opera tor present.
SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERA TION OF A COMP ACT UTILITY LOADER WITH AN A TT ACHMENT . DO NOT REMOVE THIS P AGE FROM THE MANUAL. 1 6 1 6 15 DEGREES MAX. 1. Fold this page along dotted line indicated above. DO NOT remove the page from the manual.
Compact Power Inc. P .O. Box 40 – For t Mill, SC 29716 Phone: 800-476-9673 – Fax: 803-548 -2762 Web Site: http://www . cpiequipment.com/ Part Number 999-823.
An important point after buying a device Cellboost 999-823 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Cellboost 999-823 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Cellboost 999-823 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Cellboost 999-823 you will learn all the available features of the product, as well as information on its operation. The information that you get Cellboost 999-823 will certainly help you make a decision on the purchase.
If you already are a holder of Cellboost 999-823, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Cellboost 999-823.
However, one of the most important roles played by the user manual is to help in solving problems with Cellboost 999-823. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Cellboost 999-823 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
