KOVACO MiniZ400 Operating instructions

MiniZ400
Operating
and Maintenance
Manual

KOVACO Electric, a.s.,
1st edition 2020

TABLE OF CONTENTS
MANUFACTURER’S ADDRESS AND CONTACT DETAILS.....................................................................................................................11
1. INTRODUCTION ...........................................................................................................................................................................................13
1.1 GENERAL INFORMATION.........................................................................................................................................................................13
1.2 CE MARKING................................................................................................................................................................................................15
1.3 MACHINE ACCESSORIES.......................................................................................................................................................................15
2. INFORMATION ABOUT DOCUMENTATION....................................................................................................................................... 16
2.1 DATE OF PUBLICATION AND STATUS OF THIS MANUAL .........................................................................................................16
2.2 COPYRIGHT AND TRADEMARK RIGHTS..........................................................................................................................................16
2.3 EXPLANATION OF THE SYMBOLS AND ABBREVIATIONS USED...........................................................................................16
2.3.1 LIST OF ABBREVIATIONS .................................................................................................................................................................... 17
2.3.2 ILLUSTRATIVE IMAGES .......................................................................................................................................................................18
3. ENVIRONMENTAL IMPACTS................................................................................................................................................................... 19
3.1 PACKAGING .................................................................................................................................................................................................19
3.2 DISPOSAL OF COMPONENTS AND BATTERIES ...........................................................................................................................19
4. USE OF THE SKID-STEER LOADER....................................................................................................................................................... 19
4.1 CORRECT USE.............................................................................................................................................................................................19
4.2 CORRECT USE WHEN TOWING...........................................................................................................................................................19
4.3 IMPROPER USE ........................................................................................................................................................................................ 20
4.4 PLACE OF USE ......................................................................................................................................................................................... 20
4.5 PARKING AT TEMPERATURES BELOW -10 °C............................................................................................................................... 20
4.6 USE OF WORK PLATFORMS............................................................................................................................................................... 20
4.7 RESIDUAL RISK...........................................................................................................................................................................................21
4.8 STABILITY....................................................................................................................................................................................................22
4.9 SPECIAL RISKS RELATED TO THE USE OF THE LOADER AND ITS ATTACHMENTS......................................................22
5. OVERVIEW OF RISKS AND PREVENTIVE MEASURES.................................................................................................................... 22
5.1 RISKS FOR STAFF .....................................................................................................................................................................................23
6. SAFETY .........................................................................................................................................................................................................23
6.1 DEFINITIONS OF TERMS ........................................................................................................................................................................23
6.1.1 OPERATOR................................................................................................................................................................................................23
6.1.2 PROFESSIONAL .....................................................................................................................................................................................23
6.1.3 DRIVER.......................................................................................................................................................................................................23
6.2 BASIC SAFETY RULES............................................................................................................................................................................24
6.2.1 DRIVER OBLIGATIONS.........................................................................................................................................................................24
6.3 BASIC SAFETY RULES FOR OPERATION ........................................................................................................................................24

8.4 IDENTIFICATION POINTS .......................................................................................................................................................................41
8.5 MANUFACTURER’S LABEL ...................................................................................................................................................................42
9. COMMISSIONING.......................................................................................................................................................................................43
9.1 CONNECTING THE BATTERY PLUG .................................................................................................................................................43
9.2 CHECKS AND ACTIONS BEFORE COMMISSIONING..................................................................................................................44
10. OPERATION................................................................................................................................................................................................45
10.1 OPTIMUM OPERATING CONDITIONS TO CONSERVE THE BATTERY CAPACITY ..........................................................45
10.1.1 RECOMMENDED SPEEDS ..................................................................................................................................................................45
10.1.2 DRIVING STYLE.....................................................................................................................................................................................45
10.1.3 SURFACE.................................................................................................................................................................................................45
10.2 BASIC INSTRUCTIONS FOR CORRECT USE OF THE CHARGING EQUIPMENT ..............................................................46
10.3 CHECKING THE CONDITION OF TRACKS.................................................................................................................................... 50
10.4 ENTERING AND EXITING THE LOADER ........................................................................................................................................ 50
10.5 SWITCHING ON THE IGNITION AND PUTTING THE LOADER INTO OPERATION ..........................................................51
10.6 CHANGING THE FLOW RATE OF HYDRAULIC OIL ..................................................................................................................52
10.7 WORK LIGHTS .........................................................................................................................................................................................52
10.8 ROAD LIGHTS .........................................................................................................................................................................................52
10.9 BEACON ...................................................................................................................................................................................................52
11. LOADER CONTROL – TRAVEL .............................................................................................................................................................53
12. CONTROLLING LOADER WITH A WORK ADD-ON .........................................................................................................................54
13. CONTROLLING LOADER WITH AN AUXILIARY HYDRAULIC DEVICE ..................................................................................... 55
14. REMOTE CONTROL MINIZ 400 ........................................................................................................................................................... 56
15. LIST OF OPTIONAL ATTACHMENTS ..................................................................................................................................................57
16. CLASSIFICATION OF ROCKS ............................................................................................................................................................... 58
16.1. CLASS 1.......................................................................................................................................................................................................58
16.2. CLASS 2....................................................................................................................................................................................................58
16.3. CLASS 3 ....................................................................................................................................................................................................58
16.4. CLASS 4 ....................................................................................................................................................................................................58
16.5. CLASS 5....................................................................................................................................................................................................59
16.6. CLASS 6....................................................................................................................................................................................................59
16.7. CLASS 7.....................................................................................................................................................................................................59
17. PREVENTIVE MAINTENANCE............................................................................................................................................................... 60
17.1 INSPECTION AND MAINTENANCE SCHEDULE ........................................................................................................................... 60
17.2 CORRELATION TABLES FOR OILS AND LUBRICATING GREASES.......................................................................................62
17.2.1 HYDRAULIC TANK................................................................................................................................................................................62
17.2.2 TRANSMISSION GEARS ....................................................................................................................................................................62
6.3.1 INSURANCE COVERAGE ON A CONSTRUCTION SITE...........................................................................................................24
6.3.2 ALTERATIONS AND MODIFICATIONS..........................................................................................................................................24
6.3.3 CHANGES TO THE DRIVER’S PROTECTIVE ROOF AND ROOF LOAD .............................................................................26
6.3.4 USE OF NON-ORIGINAL PARTS......................................................................................................................................................26
6.3.5 LOADER DEFECTS AND DAMAGE, INCORRECT USE OF SAFETY DEVICES .................................................................27
6.3.6 RISK TO STABILITY ..............................................................................................................................................................................27
6.3.7 MEDICAL DEVICES...............................................................................................................................................................................27
6.4 INSULATION TEST ..................................................................................................................................................................................28
6.5 SAFETY INSTRUCTIONS FOR HANDLING CONSUMABLES.....................................................................................................28
6.5.1 ALLOWABLE CONSUMABLES .........................................................................................................................................................28
6.5.2 OILS...........................................................................................................................................................................................................28
6.5.3 HYDRAULIC FLUID...............................................................................................................................................................................30
6.5.4 BATTERY ACID......................................................................................................................................................................................30
6.5.5 DISPOSAL OF CONSUMABLES........................................................................................................................................................31
6.6 EMISSIONS..................................................................................................................................................................................................31
6.6.1 BATTERY....................................................................................................................................................................................................31
6.7 FIRE SAFETY ...............................................................................................................................................................................................31
6.8 SAFETY RULES WHEN WORKING......................................................................................................................................................32
6.9 SAFETY RULES FOR MAINTENANCE ...............................................................................................................................................32
6.10 SECURITY RULES FOR TRAVELLING ON PUBLIC ROADS ......................................................................................................33
6.11 LOADING, CLAMPING WHEN LOADING..........................................................................................................................................33
6.12 IT IS PROHIBITED:...................................................................................................................................................................................34
7. TECHNICAL DESCRIPTION......................................................................................................................................................................34
7.1 LAYOUT OF AGGREGATES ..................................................................................................................................................................35
7.2 ELECTRIC MOTOR ..................................................................................................................................................................................35
7.3 HYDRAULIC SYSTEM..............................................................................................................................................................................36
7.4 BRAKE SYSTEM.........................................................................................................................................................................................36
7.5 WORK DEVICE...........................................................................................................................................................................................36
7.6 CLAMPING ON ATTACHMENT............................................................................................................................................................36
7.6.1 THE "MINIZ" QUICK CLAMP................................................................................................................................................................36
7.7 ELECTRICAL INSTALLATIONS..............................................................................................................................................................37
7.8 TREADING PLATFORM........................................................................................................................................................................... 37
8. VIEWS ............................................................................................................................................................................................................38
8.1 OUTSIDE VIEW OF THE LOADER .......................................................................................................................................................38
8.2 OVERVIEW OF THE DRIVER’S PLACE .............................................................................................................................................39
8.3 OVERVIEW OF REMOTE CONTROL..................................................................................................................................................40

17.2.3 ALL GREASE-LUBRICATED POINTS..............................................................................................................................................62
17.3 DESCRIPTION OF MAINTENANCE ACTIVITIES ............................................................................................................................63
17.3.1 OIL CHANGE IN THE HYDRAULIC SYSTEM................................................................................................................................63
17.3.2 MAINTENANCE OF HYDRAULIC CYLINDERS ...........................................................................................................................63
17.3.3 CHECKING AND TENSIONING TRACKS......................................................................................................................................63
17.3.4 CHECKING AND TIGHTENING TRAVEL WHEELS ....................................................................................................................63
17.3.5 CHANGING OIL IN GEARBOXES....................................................................................................................................................63
17.3.6 MAINTENANCE OF THE LOADER’S ELECTRICAL EQUIPMENT..........................................................................................64
18. TECHNICAL SPECIFICATIONS OF THE MACHINE......................................................................................................................... 65
19. DIMENSIONAL DRAWING OF THE MACHINE ............................................................................................................................... 66
20. USER ACCOUNT..................................................................................................................................................................................... 68
GARAGE SECTION..........................................................................................................................................................................................69
COMPANY ADMINISTRATION SECTION (Picture 15)...........................................................................................................................70
ACCOUNT SECTION ......................................................................................................................................................................................72
NOTES................................................................................................................................................................................................................74

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MANUFACTURER’S ADDRESS AND CONTACT DETAILS
KOVACO Electric a.s.,
U Hellady 4, 140 00 Prague 4, Czech Republic, Company ID: 089 00 213, Tax ID: CZ 089 00 213, www.kovacoelectric.com,
email: [email protected]

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1. INTRODUCTION
1.1 GENERAL INFORMATION
The skid-steer loader described in this operating manual meets the requirements of the relevant technical standards and
safety regulations.
The MiniZ 400 skid-steer loader must not be used on public roads.
Our skid-steer loaders are manufactured in accordance with the latest technical knowledge. It is thus sufficient to handle
the skid-steer loader safely and to maintain its functionality.
You will find the necessary information for that in this operating manual. Read this manual carefully and follow the instructions
before putting the skid-steer loader into operation. By consequently following the instructions in this manual you will ensure
a long service life of the loader and its reliable operation, and you will prevent accidents and malfunctions, many of which
are unnecessary.
Make sure that each worker has read and understood these instructions before starting to work with the loader.
Before using the loader, verify that the vehicle operator:
is informed about the correct use of the loader and its safe operation;
has read and understood the operating manual for the loader at hand;
has read and understood ALL the safety labels on the loader;
is actually a person that works in the operating zone;
has familiarized themselves with operating the controls of the loader in a safe and empty area before starting to work with
the loader.
Thank you for having read and for following the instructions in this manual. If you have any questions or suggestions for
improvements, or if you find an error, contact an authorized service centre.
Danger
When working with the product, you may be exposed to chemicals such as ethylene glycol, which
in some states is considered to cause birth defects or other fertility disorders. Do not swallow this
chemical. Wash your hands after handling to prevent accidental ingestion.
Danger
When working with the product, you may be exposed to chemicals such as lead and its
compounds, which in some states are considered to cause cancer, birth defects or other fertility
disorders. Wash your hands thoroughly when handling parts that contain lead.
Danger
Stand at a safe distance. There must be no persons present in the area while the machine is
turning. Pushing or squeezing may cause serious injury or death.

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Danger
Risk of bruising or contusions! The machine may move unexpectedly without warning and cause
injury or death. Before leaving the machine, lower the work tool to the ground, lock the controls
and remove the key.
Danger
High-pressure cylinder. Do not remove any parts until overpressure has been released from the
system. This will prevent serious or fatal injuries.
Danger
Improper troubleshooting and repair procedures can result in serious injury. The following
troubleshooting and repair procedures should only be performed by qualified personnel who are
thoroughly familiar with this equipment.
Danger of explosion!
Danger of explosion! Improper connection of connecting cables can lead to an explosion and
injury or death.
Caution
Damage to the structure, the machine overturning, modifications, alterations or improper repairs
may adversely affect the protective properties of this structure and invalidate its certification. Do
not weld anything onto the structure or drill any holes into it. Consult the manufacturer about the
possibilities for modifications to the protective structure so that the certificate is not revoked.
!
1.2 CE MARKING
The manufacturer uses the CE mark to demonstrate the conformity of the skid-steer loader with the standards and
regulations in force at the time of sale. This fact is confirmed by the CE Declaration of Conformity. The CE mark is indicated
on the manufacturer’s label.
Unauthorized interference with the structure of the skid-steer loader or its attachments may cause safety risks.
It also invalidates the Declaration of Conformity.
The CE Declaration of Conformity must be kept in a safe place and be made available to the competent authorities.
1.3 MACHINE ACCESSORIES
Ignition switch key (two pieces)
Battery charger
Distilled water tank
Basic shovel

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2. INFORMATION ABOUT DOCUMENTATION
This operating manual describes all the measures necessary for the safe operation and proper maintenance of the skid-
steer loader in all its possible versions at the time of printing. Special versions according to customer requirements are
documented in a separate operating and maintenance manual. If in doubt, contact an authorized service centre.
For all technical queries, provide the identification number of the skid-steer loader with each of them. Each skid-steer loader
comes with several operating manuals. These manuals must be kept in a safe place and be available at all times to the driver
and the operator’s staff. The location for their storage is specified in detail in the "Views" chapter. Should the operating
manual get lost, the operator must immediately obtain a replacement from the manufacturer. The operating manual is on
the spare parts list and can be re-ordered as a spare part. The personnel responsible for operating and maintaining the
equipment must read and understand this operating manual. The operator has to ensure that all users have received, read
and understood this operating and maintenance manual.
2.1 DATE OF PUBLICATION AND STATUS OF THIS MANUAL
The date of publication of this operating manual is indicated on the title page.
KOVACO is constantly working on the further development of skid-steer loaders. This operating manual is therefore subject
to change. No complaints based on the information or images provided herein will be accepted.
Contact an authorized service centre for technical support for your skid-steer loader.
2.2 COPYRIGHT AND TRADEMARK RIGHTS
This manual, including its parts, may not be reproduced, translated or provided to third parties without the express written
consent of the manufacturer.
2.3 EXPLANATION OF THE SYMBOLS AND ABBREVIATIONS USED
Danger
Denotes procedures that must be strictly observed to avoid hazards to life.
Danger of explosion!
Warning of a possible explosion.
Caution
Denotes technical requirements to which particular attention needs to be paid.
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2.3.1 LIST OF ABBREVIATIONS
This list of abbreviations applies to all types of operating manuals. Not all the abbreviations given here may be used in this
operating manual.
Caution
Notices concerning the environment.
UNIT SYMBOL NAME OF UNIT EXPLANATION
°C degree Celsius unit of temperature
OH operating hour one hour of machine work
°F degree Fahrenheit unit of temperature
A ampere unit of electric current
Ah ampere hour electric charge storage capacity unit
dB decibel unit of sound intensity
cm centimetre unit of length (1 cm = 10 mm)
cm3cubic centimetres unit of volume
g gram unit of weight
h/d hours daily hours driven per day
kg kilogram unit of weight (1 kg = 1000 g)
kg/m3kilograms per cubic metre density unit (object weight to size ratio)
km/h kilometres per hour unit of speed
kN kilonewton unit of force (1 kN = 1000 N)
kW kilowatt power supply unit
kWh/h kilowatt-hours per hour energy consumption
N newton unit of force (1 N = 10-3 kN)
Nm newton metre unit of torque
L/min litres per minute unit of consumption
m metre unit of length (1 m = 100 cm)
m/s2metres per second to the power of two unit of acceleration
min minute unit of time (1 min = 60 s)
rpm revolutions per minute unit of revolutions per minute
mm millimetre unit of length (1 mm = 10-3 m)

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2.3.2 ILLUSTRATIVE IMAGES
a) Illustrations of functions and procedures (Figure 1)
This document explains the (typically sequential) order in which certain functions or operations are run or performed. To
show these sequences, schematic images of the skid-steer loader are used.
b) Representation of the display operating unit (Figure 2)
Caution
These schematic images do not represent the actual design of the documented loader. The sole
purpose of the images used is to clarify working procedures.
Caution
The representations of operating states and values on the display operating unit are only for
reference purposes and differ depending on the particular equipment of the loader at hand.
Consequently, the depictions showing specific operating states and values may differ. Information
not related to the descriptions is not provided.
Figure 1 Figure 2
3. ENVIRONMENTAL IMPACTS
3.1 PACKAGING
For added protection, some parts of the skid-steer loader are wrapped in packaging during transport. This packaging must
be completely removed before first use.
4. USE OF THE SKID-STEER LOADER
4.1 CORRECT USE
The loader described in this operating manual is suitable for loading, sweeping and moving rocks in Classes 1 to 4 using the
basic shovel, and for pulling rocks, digging narrow grooves and drilling pits in rocks in Classes 1 and 2 according to ČSN
73 3050, using specifically designated attachments. You will find the classification of rocks at the end of the manual. The
loader may only be used for its designated purpose as specified and described in this operating manual.
If the loader is to be used for any purpose other than those specified in the operating manual, the approval of the manufacturer
and, if applicable, of the competent authorities is required in order to mitigate the potential risks.
The maximum weight of a lifted load is stated on the rating plate and must not be exceeded.
4.2 CORRECT USE WHEN TOWING
This skid-steer loader is suitable for occasional towing of loads and is equipped with towing eyes for this purpose. The
loader must not be used for occasional towing for more than 5% of its daily operating time. Consult the manufacturer when
the skid-steer loader is to be used for towing more regularly.
3.2 DISPOSAL OF COMPONENTS AND BATTERIES
The skid-steer loader is made of various materials. If any components or batteries need to be replaced or disposed of, they must be:
properly disposed of;
used elsewhere, or
recycled in accordance with regional and national guidelines.
Environmental Notices
After delivery of the skid-steer loader, the packaging material must be disposed of in an
appropriate manner.
Environmental Notices
We recommend cooperating with a waste disposal company for disposal.
When disposing of batteries, be sure to follow the provisions in the battery manufacturer’s
handling manual.
BOOM STRUT