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.
!
!
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

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4.3 IMPROPER USE
The operator or the driver, as opposed to the manufacturer, is liable for risks arising out of the incorrect use of the device.
The use of the machine for purposes other than specified in this operating manual is prohibited.
4.4 PLACE OF USE
The loader can be used both outdoors and indoors. Use on public roads is prohibited.
If you want to use the loader on public roads, it must meet the requirements of the national standards of the country where
it is being operated.
The road must have sufficient carrying capacity (tarmac, concrete).
Driving up or down a slope is permitted provided that the prescribed indications and specifications in this operating manual
are observed.
The loader can be used indoors and outdoors, from northern regions to the tropical zones (temperature range -15 to +35 °C).
4.5 PARKING AT TEMPERATURES BELOW -10 °C
4.6 USE OF WORK PLATFORMS
Danger
The loader must not be used in places where there is a risk of fire, explosion or corrosion.
Loading and stacking loads on inclined surfaces or ramps is prohibited.
Danger
The use of work platforms is prohibited!
Caution
Batteries may freeze!
If the loader is parked for a long time in an environment with temperatures below -5 °C, the
batteries will cool down. The electrolyte may freeze and damage the batteries. In such an event,
the loader will not be ready for operation.
If the ambient temperature drops below -5 °C, park the loader in such conditions only for a short
time, or only for as long as absolutely necessary, or ensure that the battery is connected to the
charger throughout the duration of parking.
4.7 RESIDUAL RISK
Even with careful operation and compliance with all standards and regulations, risks when the loader is being used cannot
be completely excluded.
The components of the loader and of the entire system meet current safety requirements. Even when the loader is used
exclusively for its intended purpose and all instructions are followed, certain residual risks cannot be ruled out.
Such residual risks cannot be completely excluded even outside the narrow risk zone around the loader. Persons in the
vicinity of the loader must be extremely vigilant so that they can react immediately in the event of a malfunction, crash,
accident, etc.
The risks include:
leakage of operating fluids as a result of cracks or ruptures of pipes and tanks;
a risk of an accident when driving over difficult terrain or surfaces such as slopes, smooth or uneven surfaces, or
in poor visibility, etc.;
falling, tripping, etc. when mounting the loader, especially in wet weather or with leaking working fluids,
or on icy surfaces;
a risk of fire and explosion caused by batteries and electric voltage;
human error as a result of non-compliance with safety regulations;
unattended damage or wrong and worn parts;
insufficient maintenance and inspections;
use of the wrong consumables;
not observing inspection intervals.
The manufacturer is not liable for accidents involving the loader which may occur as a result of the operator’s non-compliance
with these instructions – whether intentional or as a result of negligence.
Danger
All persons in the vicinity of the loader must be instructed on the risks arising from its use.
Danger
Danger of injury when the loader overturns! Maintain a sufficient distance from the machine!
If the inclination exceeds five degrees, the machine can only be operated by remote control. It is
forbidden to ride on the machine.

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4.8 STABILITY
Stability tests have been performed on the loader in accordance with the latest technical standards; its stability is
guaranteed provided that the loader is used correctly and for the intended purpose. However, these standards only take
into consideration static and dynamic centrifugal forces that may manifest themselves in the types of applications that are
in accordance with the operating rules and with the intended purpose.
Consequently, loss of stability or the risk of exceeding a tolerable distribution of forces as a result of improper use or
operation cannot be completely excluded. Loss of stability can be prevented or minimized in the following ways:
always secure the load against slipping, e.g. by tying it;
always transport precarious loads in suitable containers;
always drive slowly when turning;
drive with the load lowered;
align the load as close to the centre of the loader as possible.
try to avoid turning when driving transversely on slopes or on sloping surfaces;
never drive on slopes or sloping surfaces with the load facing downhill;
do not drive on the edges of ramps or on stairs.
4.9 SPECIAL RISKS RELATED TO THE USE OF THE LOADER AND ITS ATTACHMENTS
If the loader is used in another manner than the standard one, or when the vehicle operator is unsure whether the loader
can be used properly and without the risk of accidents, the consent of the machine manufacturer and the attachment
manufacturer must always be obtained.
5. OVERVIEW OF RISKS AND PREVENTIVE MEASURES
Caution
This table is meant as an aid in determining occupational hazards and applies to all types of
drives. The table may not cover all possible hazards.
Observe the national regulations of the country in which the loader is used!
HAZARD MEASURE(S) CHECK NOTE COMMENTS
Loader equipment does not comply with local
regulations Inspection O
If in doubt, contact the competent inspectorate
or the insurance company that provides the
employer’s liability insurance.
Deficiencies in driver skills and qualifications Driver training (internal and external) O -
Use by unauthorized persons Access with key for authorized personnel
only O -
Loader is not in a safe condition Repeated tests and elimination of
deficiencies ODecree on the Protection of Safety and Health in the Operation of Technical Equipment
When recharging the traction battery
see the Decree on the Protection of Safety
and Health in the Operation of Technical
Equipment or the operating manual
OEnsure proper ventilation; insulation value within
permissible range
When using battery chargers
See the Decree on the Protection of Safety
and Health in the Operation of Technical
Equipment
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5.1 RISKS FOR STAFF
In line with the Decree on Safety and Health Protection in the Operation of Technical Equipment and applicable laws on
occupational health and safety in the given country of operation, the operator has to determine and assess the operating risks
and define the necessary measures to ensure the occupational health and safety of staff. The operator must therefore draw up
an appropriate operating manual and provide it to the driver. An authorized person must be appointed.
6. SAFETY
6.1 DEFINITIONS OF TERMS
6.1.1 OPERATOR
The operator is a natural person or legal entity that operates the loader, or under whose responsibility the loader is used.
The operator must ensure that the skid-steer loader is used only for the designated purpose and in accordance with the
safety regulations set out in this operating manual.
The operator must ensure that all users have read and understood the safety information.
The operator is responsible for the timetabling and correct execution of regular safety inspections. We recommend following
national operating specifications.
6.1.2 PROFESSIONAL
A qualified professional is defined as a mechanic or person who meets the following requirements:
completed professional qualification for the work, which demonstrably confirms their professional knowledge.
Such proof of education is a vocational certificate or similar document.
Professional practice proving that the professional has gained practical experience with loaders during a confirmed
period of their professional practice. Over the period, the person has become acquainted with the full range
of indications that require inspections to be carried out, for example on the basis of the results of assessments
of potential risks or daily checks.
Current professional practice in the field of operating loaders and other appropriate professional qualifications are key.
A qualified professional must have experience with carrying out said checks and inspections. Moreover, a qualified
professional must monitor current advances in technologies pertinent to the loader and to the risks assessed.
6.1.3 DRIVER
This skid-steer loader may only be driven by a qualified person who has reached at least 18 years of age, has obtained a driver’s
licence, has demonstrated experience with driving and handling to the operator or their authorized representative and has
received special training in driving the loader. Special knowledge of the respective skid-steer loader is also required.
The requirements for training in accordance with § 3 of the Act on Health and Safety at Work and § 9 of the Decree on
Safety in the Workplace are met if the driver has been trained in accordance with the requirements. Follow the applicable
regulations in your country.
Caution
The design and equipment of this loader comply with Directive 2006/42/EC on machinery
and are thus marked with the CE symbol. These elements are therefore not included in the risk
assessment. The attachments have their own CE markings and thus are not included either.
Nevertheless, the operator must choose a type of loader and its accessories that comply with
local operating regulations.

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6.2 BASIC SAFETY RULES
6.2.1 DRIVER OBLIGATIONS
The driver must be instructed in their duties!
Any incorrect use of this machine may cause serious physical harm or even fatal injuries!
Use by unauthorized persons is prohibited!
During working hours, the driver is responsible for the loader! The driver must not allow unauthorized persons to use the
loader. When the driver leaves the loader, they are obliged to secure it against unauthorized use, e.g. by removing the key.
The driver has to:
read and understand the operating manual, which must be available to the driver at all times;
acquaint themselves with the safe operation of the loader;
wear protective equipment (protective clothing, safety shoes, safety helmet, goggles and gloves) according to
the conditions, the environment and the type of load handled;
be mentally and psychologically fit to drive the loader safely.
Danger
The ability to drive the loader may be impaired by the intake of drugs, alcohol or medication
that affect a person’s reactions! Persons under the influence of the above substances must not
perform any operations on or with the loader.
It is forbidden to push limbs under the work tool of the machine or under the running tracks.
There is a risk of amputation of the limb.
!
!
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6.3 BASIC SAFETY RULES FOR OPERATION
6.3.1 INSURANCE COVERAGE ON A CONSTRUCTION SITE
In many cases, public transport is not permitted on construction sites.
6.3.2 ALTERATIONS AND MODIFICATIONS
If you use the loader for work tasks not specified in regulations or in this operating manual, and the loader must be modified
or retrofitted, please note that any alteration of the design of the loader may affect its stability and performance, which may
result in various accidents. Therefore, contact your service centre or the manufacturer before making any modifications.
Without the manufacturer’s consent, it is prohibited to make changes that, among other things, adversely affect the stability
or load capacity of the loader or its safety functions.
Caution
In order to ensure that the loader has insurance coverage against claims by third parties for the
event of damage caused in areas with restricted public transport, the manufacturer recommends
that commercial liability insurance be taken out.
Caution
When welding on the loader, the batteries and all connections to the electrical control units must
be disconnected. More detailed information on these topics can be obtained from an authorized
service centre.
Caution
Additional openings in the battery cover present a risk of explosion! Volatile gases may be
released, which can explode and cause harm, including fatal injuries. Sealing the openings with
plugs does not provide an additional barrier to gas leakage.
Do not drill any holes into the battery cover!
Otherwise the structural stability of the battery cover will be compromised, and it may then break. It can hit the driver’s
position, which poses a risk of accident as a result of the uncontrolled movement of the controls while driving.
Should the manufacturer be wound up and its company is not taken over by a new owner (legal entity), the operator can
make modifications to the loader.
In doing so, however, the operator must observe the following rules:
production documents, test reports and assembly instructions related to the modification must be retained and
be available at all times;
check that the modifications have not affected the validity of the rating plate, information labels, warning labels or
the operating manual and, if necessary, correct these;
modificationscanonlybedesigned,approvedandimplementedbyadesignofficethatspecializesindesigningloaders
in accordance with the standards and directives in force at the time of the modifications.
Changes to the loader may only be made with the manufacturer’s prior written consent. If necessary, the consent of the
competent authority must be obtained.
Changes to the brake system, steering, controls, peripheral vision and special equipment (such as attachments) are also
subject to the manufacturer’s prior written consent.
!
!
Caution
Never allow a ride with a passenger. Never use the work tool as a platform for another person.
A failure to observe the vehicle-related instructions or warnings may result in injury or death.
Caution
Hot liquid can cause severe burns. Protect yourself with suitable protective clothing.

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!
!
Caution
Improper clamping of the work tool may cause injury or death. Do not start working with the
machine until you have made sure that the mechanism pins are fully inserted. Follow the work
procedures specified in the operating and maintenance manual.
Caution
This machine is equipped with a communication device. Where electric detonators are used, this
communication device should be switched off at a distance of 12 m (40') from the blasting point for
satellite systems, and at a distance of 3 m (10') from the blasting point for mobile systems, or at a
distance that complies with the applicable legal requirements. A failure to observe this provision
may result in interference with explosive blasting operations, which can result in serious injury or
death.
!
!
6.3.3 CHANGES TO THE DRIVER’S PROTECTIVE ROOF AND ROOF LOAD
6.3.4 USE OF NON-ORIGINAL PARTS
Original parts, attachments and accessories are specially designed for this loader. We would like to draw your attention
specifically to the fact that non-original parts, attachments and accessories from other suppliers have not been tested and
approved by KOVACO.
Before installing such components, we recommend obtaining the consent of the manufacturer and, if applicable, of the
competent inspection authorities.
The manufacturer accepts no liability for damage caused by using non-original parts and accessories that have not been
approved.
Caution
This machine is not equipped with a FOPS or ROPS protective structure.
Dropping a load or the loader overturning with the vehicle operator’s (driver’s) position impacted
as a result can be fatal. Potential danger to life!
Caution
The installation and use of such products may have a negative effect on the design characteristics
of the loader and thus also compromise passive driving safety.
!
!
6.3.5 LOADER DEFECTS AND DAMAGE, INCORRECT USE OF SAFETY DEVICES
Damage and other faults of the loader or its attachment must be reported to the operator immediately so that the fault can
be rectified by the same.
Loaders and attachments that are not safe or functional must not be used until properly repaired.
Do not remove, disable or turn off safety devices or switches!
Predefined settings may only be changed with the manufacturer’s consent.
Works on the electronic system (such as connecting radio, additional headlights etc.) are only permitted with the
manufacturer’s written consent. All interventions in the electrical system must be properly documented!
6.3.6 RISK TO STABILITY
To ensure stability, the following rules must be observed:
only use tracks with the same allowable level of wear;
only use tracks approved by the manufacturer;
only use high-quality products.
Tracks approved by the manufacturer can be found in the spare parts list. If you want to use other tracks, you must first
obtain the manufacturer’s consent!
When replacing tracks, always make sure that the loader is never tilted to one side. More detailed information on these
topics can be obtained from an authorized service centre.
6.3.7 MEDICAL DEVICES
Only use devices that are sufficiently protected against electromagnetic interference. Medical devices such as pacemakers
or hearing aids may not function properly during the operation of the loader.
Check with your doctor or the manufacturer of your medical device to make sure that it is sufficiently protected against
electromagnetic interference.
Caution
A failure to follow these instructions and information may result in compromised stability. The
loader may overturn; there is a risk of an accident.
Caution
Electromagnetic interference with medical devices may occur.

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!
!
6.4 INSULATION TEST
The insulation of the loader must provide sufficient insulation resistance. Consequently, as part of the tests under the FEM
standard, the insulation resistance must be checked at least once a year in accordance with ČSN EN 1175, DIN 43539, VDE
0117 and VDE 0510. The results of the insulation tests must meet at least the test values given in the two tables below.
Contact an authorized service centre if you want to carry out insulation tests!
6.5 SAFETY INSTRUCTIONS FOR HANDLING CONSUMABLES
6.5.1 ALLOWABLE CONSUMABLES
Non-compliance with the safety regulations applicable to consumables may result in injury, death or damage to the
environment.
Observe the safety regulations when handling such materials.
Allowable materials necessary for operation are listed in the maintenance data table.
6.5.2 OILS
Test values for the traction battery and the complete loader:
Caution
The electrical system of the loader and the traction battery must be checked separately!
Caution
Oils are flammable!
COMPONENT RECOMMENDED TEST
VOLTAGE MEASUREMENT RATED VOLTAGE UBAT TEST VALUES
Battery
50 V DC
Batt. + Batt. -
Battery
compart-
ment
24 V > 1200
100 V DC 48 V > 2 400
100 V DC 48 V > 2 400
RATED VOLTAGE TEST VOLTAGE
TEST
VALUES
FOR NEW
LOADERS
MINIMUM VALUES DURING SERVICE LIFE
24 V 50 V DC At least 50 k > 24 k
48 V 100 V DC At least 100 k > 48 k
80 V 100 V DC At least 200 k > 80 k
!
!
!
Smoking and access with fire or an open flame is prohibited! Observe the legal regulations of the country of operation!
Make sure that oils do not come into contact with hot machine parts!
When gases or vapours have been inhaled, get into the fresh air immediately!
If your eyes are affected, rinse with plenty of water (for at least ten minutes), then seek an ophthalmologist!
If swallowed, do not induce vomiting. Seek medical attention immediately!
Prolonged intensive contact with the skin may cause skin dryness and irritation!
Wear protective gloves.
If the substance comes into contact with the skin, wash the skin with soap and water, and then apply skin care products.
Change contaminated clothing and shoes immediately.
Danger
Oils are toxic! Avoid contact with and ingestion of oil.
Caution
There is a risk of slipping on spilled oil, in particular in combination with water.
Caution
Spilled oil must be removed immediately using oil absorbents and disposed of in accordance
with regulations.
Caution
Oil is a water pollutant.
Always store oils in containers that comply with the pertinent legal regulations.
Avoid spilling oil.
Spilled oil must be removed immediately with oil absorbents and disposed of
in accordance with regulations.
Dispose of used oils in compliance with the applicable directives.

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!
!
!
6.5.3 HYDRAULIC FLUID
6.5.4 BATTERY ACID
Observe the legal regulations of the country of operation when handling liquids.
Make sure that these liquids do not come into contact with hot parts of the machine and the environment.
Avoid contact of these liquids with the skin.
Do not inhale spray liquid.
Leakage of compressed fluids escaping under high pressure from the hydraulic system is extremely dangerous. In the
event of such an injury, seek medical attention immediately.
To prevent injuries, use appropriate personal protective equipment (such as protective gloves, goggles, skin protection and
skin care products)!
When handling battery acid, use appropriate protective equipment (rubber gloves, apron, goggles). Never wear watches or
jewellery when handling battery acid!
Avoid contact of the acid with the clothing, eyes and skin. In the event of contact, rinse the affected area immediately with
plenty of clean water. In the event of injury, seek medical attention immediately!
Rinse spilled battery acid immediately with plenty of water. Observe the legal regulations.
Caution
These fluids are exposed to high pressures in the operation of the loader and pose a potential
health hazard.
Caution
Battery acid contains diluted sulphuric acid. This acid is toxic and corrosive. Never touch or
swallow battery acid! In the event of injury, seek medical attention immediately!
Caution
Hydraulic fluid is a water pollutant, and so the following instructions must be observed:
always store hydraulic fluid in containers that comply with the national regulations of the
country concerned;
avoid spilling the fluid;
spilled hydraulic fluid must be removed immediately using absorbents that soak up oil
and disposed of in accordance with regulations;
dispose of used hydraulic fluid in compliance with regulations.
!
!
6.6 EMISSIONS
6.6.1 BATTERY
Always ensure that completely or partially enclosed workplaces are well ventilated.
Keep a safe distance from open flames and flying sparks.
Do not smoke.
Observe the safety regulations when handling the battery.
6.7 FIRE SAFETY
The loader has several components that heat up significantly under normal operating conditions – such as the electric
motor. If the electrical system is damaged or poorly maintained, it can produce electricity arcs or sparks.
The manufacturer recommends equipping the loader with a suitable fire extinguisher to be at hand during operation in
accordance with the relevant national regulations.
Flammable litter (such as dry leaves or straw) must be disposed of regularly. If such waste accumulates, it will increase the
risk of fire. The loader must be cleaned as needed to prevent such buildup.
6.5.5 DISPOSAL OF CONSUMABLES
Danger of explosion!
When charging, the battery releases a mixture of oxygen and hydrogen (oxygen-hydrogen
mixture). This gas mixture is volatile and must not ignite.
Caution
Dispose of used battery acid in accordance with the applicable regulations.
Caution
Materials that accumulate during repairs, maintenance and cleaning must be properly collected
and disposed of in accordance with the national regulations of the country in which the loader is
used. Such work tasks may only be carried out in designated areas. Any negative impacts on the
environment must be minimized to the extent that is possible.
All spilled fluids, such as hydraulic or transmission oil, must be contained immediately
using an absorbent that binds oils.
Neutralize spilled battery acid immediately.
Always follow the national regulations governing the disposal of used oil.

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Do not use the loader in places where electric arcs, sparks or hot parts may come into contact with flammable substances
or explosive atmospheres.
Inspect all electrical wires and connections for damage. Keep the battery terminals clean and screwed tight. Repair or
replace any damaged component.
Inspect hydraulic pipes, hoses and terminals for damage or leaks. Never use open flames or exposed skin to check for fluid
leaks. Tighten or replace any leaking components. Always clean liquid stains. For cleaning the components, do not use
petrol or diesel. Use commercial non-flammable solvents.
Do not use the loader in an explosive atmosphere.
Do not connect the battery improperly. It needs to be connected by a professional.
Keep batteries clean, and lubricate the pole terminals with grease.
When welding, disconnect the batteries, provide ventilation and have a fire extinguisher at the ready near the loader.
6.8 SAFETY RULES WHEN WORKING
Before commencing work, the driver has to perform daily maintenance.
Crushing and loading other types of rocks than those specified in the operating manual is prohibited!
It is allowed to work with the machine on slopes with a transverse and longitudinal inclination of up to five degrees
without restrictions.
If it is necessary to work at night or in otherwise reduced visibility, the workplace must be lit by local light sources.
The loader is not equipped to operate in reduced visibility!
The loader must not operate on public roads. The loader must not endanger the safety of other users.
Because of the possibility of overloading the loader, it is necessary to adjust the driving speed and working
movements with a loaded bucket to the effective load. Overloading the machine will characteristically manifest
itself when lifting the work device by lightening the load on the rear part of the machine.
!Caution
The maximum load capacity of the machine (400 kg) can only be used on a paved and level
surface.
While the boom is raised and not secured, any maintenance of the hydraulic system and any maintenance works
under it are prohibited. During maintenance and repairs, it is necessary to secure the raised boom in its position
with the safety strut that forms part of it.
Any interventions during maintenance of the hydraulic transmission may only be carried out with the engine stopped, when
there is zero pressure in pipes and hoses.
After an attachment has been mounted, its operation needs to be checked without a load.
Itisnotallowed touseanylubricants otherthanthosespecified inthismaintenancemanual. Mixingindividuallubricants
is prohibited.
Contact an authorized service centre to have more complex repairs carried out by them.
Danger
When working on a slope, there is a risk of the loader tipping over.
6.10 SECURITY RULES FOR TRAVELLING ON PUBLIC ROADS
Moving on public roads is prohibited.
When driving, the boom must be fully lowered to the lowest position, with the bucket tilted towards the boom to the
maximum extent possible, and with the cutting edge of the bucket covered with a protective cap.
6.11 LOADING, CLAMPING WHEN LOADING
For moving the loader with a crane, use a lifting device with a load capacity of at least 1.5 tons. A steel rope or a textile belt
with a load capacity of at least 1.5 tons can be used for binding. The attachment points are located at the front on the boom
arms and at the rear on the inside of the cross-member of the frame, and are marked with the "HOOK" symbol.
6.9 SAFETY RULES FOR MAINTENANCE
The personnel operating the loader have to perform maintenance and lubrication at intervals according to the
operating hours worked in accordance with the operating and maintenance manual for the machine. Each
maintenance and lubrication must be recorded in the machine warranty book issued by the operator in accordance
with the national regulations of the country concerned.
For maintenance and any repairs to the loader, always use the tools and equipment designed for the type of task
at hand.
Cotter pins, bolts and nuts must not be used again after disassembly, but have to be replaced with new ones.
The hydraulic circuit is protected by relief valves. Only a trained person and, during the warranty period, only
the warranty service may readjust the relief valves.
Figure 3: Loading

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!Caution
When loading, the boom must be locked in the lower position!
6.12 IT IS PROHIBITED:
to use the loader without training and without following the operating manual;
to leave the loader with the engine running or the boom raised; when parking, the boom must be lowered all the
way down and the bucket be resting on the ground;
to exceed the loader’s carrying capacity;
to let persons into the loader’s work zone and to transport persons with the loader;
to use the loader for any work other than specified in the operating manual;
to otherwise modify attachments and use any equipment other than specified by the manufacturer for the approved
version of the loader;
to turn with and drive the loader with the boom raised and the bucket filled.
7.1 LAYOUT OF AGGREGATES
The frame (1) of the loader carries the aggregates, which are concentrated in larger assembly units. The batteries (2) are
stored in a section of the frame. Hydraulic tank (3) and hydraulic distributor (5). Electric motors with a gearbox (7) for travel
are located in the rear part of the frame. Tilting platform to stand on (12).
The work device (9) on which the work tool (10) is mounted is attached to the rear part of the frame. The track chassis (8) is
attached to the bottom part of the frame. In the front part of the frame there is an electric motor with a gear pump (4). The
hydraulic oil is filtered through a filter (6). In the rear upper part of the frame there is a space for storing the remote control
(11).
Danger
Before putting the machine into operation, the operating personnel must receive the respective instruction!
Untrained operating personnel may cause injury or death.
There is a risk of falling when working on high parts of the loader.
7. TECHNICAL DESCRIPTION
The MiniZ 400 universal front loader 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 733050,
using specifically designated attachments. An extract from the ČSN 733050 standard can be found on page 73 of this
operating manual.
The loader is driven by electrical units. The transmission mechanism consists of two separate gearboxes and two crawler
undercarriages.
The loader control and control of the work device is channelled into two control levers, which control all the operating
functions.
The turning of the loader is facilitated by the different revolution speeds of the individual tracks. The basic shovel is
toothless. In addition to the basic shovel, other attachments can be mounted on the machine as well using quick clamps.
The following sections of this operating and maintenance manual provide instructions for controlling, using and maintaining
the loader. You must familiarize yourself with the content of these instructions before starting any work.
In the basic version, the loader can work in the WT climate zone according to ČSN 038900, with the range of working
temperatures adjusted to -15 to + 35 °C according to ČSN ISO 7131 (Earth-moving machines – Loaders). For working in other
climate zones, the loader must be modified in a manner that is subject to arrangement with the manufacturer.
7.2 ELECTRIC MOTOR
The loader is driven by two three-phase electric motors with a total output of 2 x 2.7 kW.
Figure 4
Figure 5

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Figure 6: Released quick clamp
1 locking lever
2 retractable clamping pin
3 fixed clamping pins
Figure 7: Quick clamp in secured position
1 locking lever
2 retractable clamping pin
3 fixed clamping pins
7.3 HYDRAULIC SYSTEM
The loader’s hydraulic system is used to control the work device. The system consists of an electric motor, hydraulic pump
and distributor.
The entire hydraulic system is protected by relief valves. Pressure adjustment on the relief valves during the warranty
period may only be performed by a service technician, and after the warranty period by a trained worker. For attachments,
connections with quick couplings are routed via the boom to its front part.
7.4 BRAKE SYSTEM
The service and parking brakes are activated via controls (by setting these to the neutral position).
7.5 WORK DEVICE
The work device consists of a boom, clamp and hydraulic cylinders.
It is pivotally attached via pins to the rear of the frame. The basic work tool is mounted on the front part of the boom using
the clamp. The boom is raised and lowered by a pair of hydraulic cylinders.
Another pair of hydraulic cylinders ensures the picking up and dumping of soil from the work tool (bucket).
7.6 CLAMPING ON ATTACHMENT
7.6.1 THE "MINIZ" QUICK CLAMP
1. Before clamping, the clamping surfaces on the attachment and on the quick clamp must be cleaned of any dirt.
2. The attachment to be clamped on must be placed with the bottom and the cutting edge on the ground so that the
cutting edge faces away from the machine.
3. By flipping the lever (position 1 in Figure 6: Released quick clamp) into a vertical position, insert the quick clamp by its
pins (2).
4. By handling the loader and the quick clamp, fit the clamping pins (3) of the quick coupler into the beds on the attachment.
5. Adjust the attachment by tilting the quick clamp so that the holes on the work tool are opposite the pins (2) on the quick
clamp.
6. Secure the attachment by sliding the pins (2) out and into the hole on the work tool, and flip the levers (1) back to their
original (horizontal) position (Figure 7: Quick clamp in secured position).
!
7.7 ELECTRICAL INSTALLATIONS
The electric drive of the loader is provided with a voltage of 48 V; some appliances are in the 12 V version. The power
source is batteries located in the rear part of the frame. The display operating unit, which is installed in the frame of the
machine, is used to check the operating data. The machine is controlled by means of the remote control. The remote
control compartment is in the rear part of the machine.
7.8 TREADING PLATFORM
The treading platform is used for occasional transport of the operating personnel of the machine when moving with the
loader from its parking place to the place of work. It is forbidden to stand on the treading platform while working with the
machine.
Danger
Improper clamping of the work tool may cause injury or death. When the work tool touches the
ground, it may shift away from the clamp. Make sure that the work tool does not touch the ground
until the clamping pins are fully inserted.
Danger
By releasing the clamping pins of the mechanism, the technician loses control over the work tool.
Disconnecting the work tool when in an unstable position or when carrying a load can result in a
serious or fatal injury. Place the work tool in a safe position before releasing the clamping pins.
Caution
During service where the boom needs to be raised, the boom must be supported by a safety
strut.

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8. VIEWS
8.1 OUTSIDE VIEW OF THE LOADER
Track chassis
Frame
Boom
Bonnet
Basic shovel
Remote control
Platform
Bucket cylinder
Boom cylinder
Figure 8
1
2
3
4
5
6
7
8
9
8.2 OVERVIEW OF THE DRIVER’S PLACE
Remote control
Holding bar for operator
Remote control holder
Operator’s platform
Figure 9
1
2
3
4