Polaris BRUTUS Owner's Manual
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Polaris BRUTUS Owner's Manual

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Summary of Contents for Polaris BRUTUS

  • Page 1 BRUTUS™ BRUTUS™ HD BRUTUS™ HD Owner's Manual for Maintenance and Safety...
  • Page 2 Manual and should be performed only by a Factory Certified Master Service Dealer® (MSD) Technician. Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
  • Page 3 POLARIS is registered trademark of and BRUTUS is a trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor dis- crepancies may result between the actual vehicle and the information presented in this publication.

  • Page 4: Table Of Contents

    Specifications ..... 125 Polaris Products ....128 Troubleshooting .

  • Page 5: Introduction

    Your safety and the safety of others is involved when these words and symbols are used. Become familiar with A POLARIS BRUTUS is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as their meanings before reading the manual.

  • Page 6: Vehicle Identification Numbers

    Vehicle Identification Numbers Record your vehicle's identification numbers and key number a POLARIS key blank (using your key number) and mating it in the spaces provided. Remove the spare key and store it in a with one of your existing keys. The ignition switch must be safe place.

  • Page 7: Safety

    POLARIS dealer to purchase a replacement. Replacement vehicle carefully. If any of the labels depicted in this manual safety labels are provided by POLARIS at no charge. The part differ from the labels on your vehicle, always read and follow number is printed on the label.
  • Page 8 SAFETY Safety Labels and Locations Age 16 Warning Discretionary Warning WARNING WARNING NO OPERATOR UNDER 16 Improper vehicle use can result in Serious Injury or Death. Operating this vehicle if you are under the age of 16 increases your NEVER Operate: chance of severe injury or death.
  • Page 9 SAFETY Safety Labels and Locations Attachment Arm Warning Rotating Fan Warning WARNING WARNING Avoid Serious Injury Or Death. Avoid Serious Injury Or Death. Do not operate with shields removed. • Do not exceed attachment arm rated capacity. Do not modify. •...
  • Page 10 Center and secure loads as low as possible in box. • Reduce speed and cargo on rough or hilly terrain. • Check for proper tire pressure. BRUTUS BRUTUS HD BRUTUS HD MAXIMUM CARGO BOX LOAD 1250 lbs. 1250 lbs.
  • Page 11 Eye Protection Boots Do not depend on eyeglasses or sunglasses for eye protection. Wear sturdy over-the-ankle boots. Do not ride a POLARIS Whenever riding a POLARIS vehicle, always wear shatter- vehicle with bare feet. proof goggles. POLARIS recommends wearing approved Per-...
  • Page 12 • Always have this vehicle checked by an authorized • Never permit a guest to operate this vehicle unless the guest POLARIS dealer if it has been involved in an accident. has read this manual and all product labels. • Never operate this vehicle on hills too steep for the vehicle •...
  • Page 13 If necessary, apply them lightly several times to let FOR MORE INFORMATION ABOUT SAFETY, call friction dry out the pads. POLARIS at 1-800-342-3764. • Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed...
  • Page 14 WARNING terrain. Failure to operate the BRUTUS properly can result in a collision, loss All operators must read and of control, accident or overturn, which may result in serious injury or understand the Owner's Manual death.
  • Page 15 SAFETY Operator Safety Using Alcohol or Drugs Protective Eyewear Riding in this vehicle without wearing protective eye wear increases Operating the vehicle after the risk of a serious injuries in the event of an accident. consuming alcohol or drugs could adversely affect operator judgment, Operator and all passengers must always wear approved eye reaction time, balance and...
  • Page 16 Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Always inspect your BRUTUS before each use to make sure it's in Practice turning at slow speeds before attempting to turn at faster safe operating condition.
  • Page 17 SAFETY Operator Safety Operating on Public Roads Improper Hill Climbing Operating this vehicle on public streets, roads or highways could Climbing hills improperly can cause loss of control or vehicle overturn. result in a collision with another vehicle. Always follow proper procedures for climbing hills as described in the owner's manual.
  • Page 18 Rated Capacity. They are designed for secure fastening to the BRUTUS utility vehicle. The user must Operating on Frozen Bodies of Water check with the dealer, or POLARIS literature, to determine safe loads...

  • Page 19: Features And Controls

    FEATURES AND CONTROLS Component Locations Not all models come with all features. Refer to the specifications section on page 125. Storage Compartment ROPS / OPS Attachment Arm Under Seats Cab Frame (Model HD and HD Only) Console Headlights Cargo Box Radiator Front Bumper/ Brush Guard...
  • Page 20 FEATURES AND CONTROLS Switches and Indicator Lights AWD/Differential Switch Power Lift Assist Switch (If Equipped) Blank Switch Openings - Available For Accessories Light Switch HVAC Switches (If Equipped) Ignition Switch Ignition Switch START The ignition switch is a three-position, key-operated switch. The key can be removed from the switch in the OFF position.
  • Page 21 Switches and Indicator Lights Light Switch HVAC Switches (If Equipped) The ignition switch must be in the ON If equipped with a Cab with Temp position to operate the headlights. HVAC (Heat and Air Condi- HIGH On-Off Control tioning): Press the top of the rocker switch •...
  • Page 22 Use the gear selector to shift gears. Low gear is the primary The 12-volt receptacles have spade connections on the back driving range for the BRUTUS. High gear is intended for use that may be used to power an auxiliary light or other optional on hard-packed surfaces with light loads.
  • Page 23 FEATURES AND CONTROLS Console Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
  • Page 24 FEATURES AND CONTROLS Center Console (For Models HD and Joystick Lock Switch Only) The joystick lockout switch (Item 4) is used to active or lock- out the joystick functions. The joystick should be lockout Joystick - Attachment when no attachments are installed. This will keep the joystick from accidentally being activated.

  • Page 25: Trailer Hitch Bracket

    ANSI/OPEI B71.9-2012 occu- Travel Control pant requirements. Always have Pedal your authorized POLARIS dealer thoroughly inspect the The travel control pedal is ROPS / OPS if it ever becomes used to control the forward damaged in any way.
  • Page 26 Always make sure the seat Buckle belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the BRUTUS.
  • Page 27 If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.

  • Page 28: Instrument Cluster

    If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1. Vehicle Speed Display - Analog display of vehicle speed in MPH or km/h.
  • Page 29 FEATURES AND CONTROLS Instrument Cluster 12. Low Oil Pressure Indicator - LED icon illuminates low engine oil or hydraulic fluid pressure is sensed. 3. MPH / KM/H Display - MPH is displayed when the 13. Gear Position Indicator - Displays gear selector position. instrument cluster is in the Standard mode.
  • Page 30 FEATURES AND CONTROLS Instrument Cluster Information Display Area The LCD portion of the instrument cluster is the information display area which displays the following information: odome- ter, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock.
  • Page 31 FEATURES AND CONTROLS Instrument Cluster Odometer Engine Hours The odometer records and displays the total distance traveled Engine hours are logged anytime the engine is running. Total by the vehicle. The odometer can not be reset. hours can not be reset. Trip Meter Tachometer (RPM) The trip meter records the miles traveled by the vehicle on...
  • Page 32 FEATURES AND CONTROLS Instrument Cluster Engine Temperature Clock The clock displays the time in a 12-hour or 24-hour format. Engine temperature can be displayed in F° or ° C. Refer to “Units of Measurement” to change the format. Refer to “Units of Measurement” to change the format (Stan- dard 12-hour / Metric-24 hour).
  • Page 33 FEATURES AND CONTROLS Instrument Cluster Battery Under / Over Voltage If battery voltage rises above 15 volts, a warning screen will display “OV” and provide the present battery voltage. If volt- This warning usually indicates that the vehicle is operating at age rises above 16.5 volts, LCD backlighting and icons will an RPM too low to keep the battery charged.
  • Page 34 FEATURES AND CONTROLS Instrument Cluster Check Hydraulic 1. If the trouble codes are not displayed, use the MODE but- ton to toggle until “CK ENG” displays on the information display area. 2. Press and hold the MODE button to enter the diagnostics code menu.

  • Page 35: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of New Engine Break-In control, accident or overturn, which may result in serious injury or 1. Fill the fuel tank with the recommended fuel. See page 36. death.
  • Page 36 PTO (If Equipped) Inspect splines, guards, shields and hardware, ensure tightness, replace damaged parts. Brake light/tail lamp /Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced. 102, 114 Heater/Air Conditioning Filter Clean and replace filter as needed during heating and cooling season.
  • Page 37 • The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Especially in the U.S.A. and Canada, POLARIS recommends the following diesel fuels for use in Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low Sulfur this vehicle: fuel should be used.
  • Page 38 OPERATION Fuel Recommendations Bio-Diesel Fuels Precautions and concerns regarding the use of bio-fuels: 1. Free methanol in FAME may result in corrosion of alumi- In Europe and in the United States, as well as some other coun- num and zinc FIE components. tries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), 2.
  • Page 39 Engine Warranty B6 To B20 Bio-diesel Fuel Blend Usages Damages, performance or service concerns determined to be B6 to B20 bio-diesel is not approved for this POLARIS appli- caused by the use of bio-diesel fuel not meeting the specifica- cation.
  • Page 40 OPERATION Fuel Recommendations Refueling Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than The fuel tank filler cap is located on 5% bio-diesel in this vehicle. See page 37. the outside left side of the vehicle near the operator seat. Remove the Bio-diesel blended fuel has unique qualities that should be cap and add the recommended fuel considered before using it in this vehicle:...
  • Page 41 • If the ambient temperature is between +5° F (-15° C) and - NOTICE: Bio-diesel blended fuel does not have long term stability 25° F (-32° C), POLARIS recommends the use of a block and should not be stored for more than three months.

  • Page 42: Starting The Engine

    OPERATION Starting the Engine NOTICE: NEVER use an engine 8. Allow the engine to warm to operating temperature. (For starting aid such as ether. Models HD and HD ; Vary the engine RPM slightly Engine damage will result. with the engine speed control lever to aid in warm up until Before operating this vehicle in the engine idles smoothly.) cold weather, review the cold...
  • Page 43 OPERATION Braking 4. Start the engine and allow it to warm up. 5. For Model HD; Raise the attachment arm. See page 44. 1. Release the travel control pedal completely. 6. Apply the service brakes and shift the transmission into 2.

  • Page 44: Driving With A Passenger

    3. Make sure all passengers are wearing eye protection. 4. Make sure all passengers secure their seat belt. 5. Do not carry more than two passengers in the BRUTUS utility vehicle. Do not carry more than one passenger in models HD and HD 6.
  • Page 45 OPERATION Hydraulic Controls (Models HD and Attachment Arm Operation Movement of the joystick controls the hydraulic cyl- Joystick Operation inders for the lift and tilt Start the engine. See page 41. functions. Allow the hydraulic system to warm to operating temperature. Pull the joystick backward to raise the attachment arm Tip: The utility vehicle has both a joystick lockout switch (Item 1) and...
  • Page 46 OPERATION Hydraulic Controls (Models HD and Press the left side of the auxiliary hydraulic switch (Item 2) to pressurize the Front Auxiliary Hydraulic Operation female coupler. WARNING! Press the right side of the auxiliary hydraulic switch Avoid Injury Or Death. (Item 3) to pressurize the Diesel fuel or hydraulic fluid under male coupler.
  • Page 47 OPERATION Hydraulic Controls (Models HD and Relieve Hydraulic Pressure (Utility Vehicle And Attachment) Utility Vehicle Quick Couplers • Lower the attachment WARNING! arm fully and put the Avoid Injury Or Death. attachment flat on the Diesel fuel or hydraulic fluid under pressure can penetrate skin or ground.
  • Page 48 OPERATION Power Take-Off (PTO) (Model HD The operator must be in the oper- ator seat to engage the PTO sys- Description tem. (If the operator exits the The front PTO is standard equipment on the HD model machine with the PTO engaged, only.
  • Page 49 • Loss of stability WARNING! Avoid Injury or Death. Never use attachments or buckets which are not approved by Polaris. Buckets and attachments for safe • Reduced utility vehicle life loads of specific densities are approved for each model. Unapproved attachments can cause injury or death.
  • Page 50 OPERATION Attachments (Models HD and HD Installing And Removing Attachments The PRO-TACH attachment system is used for fast changing 7. Install the two pins of buckets and other attachments. See the appropriate (Item 1) and retainers Attachment Owner’s Manual to install other attachments. (Item 2) (both sides).
  • Page 51 OPERATION Attachments (Models HD and HD 7. Install the two pins (Item 3) and retainers Installing And Removing Attachments (Item 4) into the stor- Removing: age position. Tip: In muddy conditions or to prevent the attachment from freezing to 8. Start the engine. See the ground, put the attachment on planks or blocks before page 41.
  • Page 52 Rotating Parts Can Cause Serious Injury Or Death Installing And Removing The PTO • Disengage the PTO, put the gear selector in PARk, stop the engine The BRUTUS Model HD is factory equipped with a PTO. and make sure all rotating components are completely stopped The PTO has a rated speed of 2000 RPM.
  • Page 53 OPERATION Power take-Off (PTO) (Models HD Removing Installing And Removing The PTO Stop the engine and exit the utility vehicle. See Installing (Con’d) page 41. Each attachment has a spe- cific length PTO drive Make sure the PTO drive- shaft that is affixed to the line and all rotating com- attachment.

  • Page 54: Driving Uphill

    Whenever traveling uphill, follow these precautions: Stalling or rolling backwards while climbing a hill could cause overturn. Always maintain a steady speed when climbing hills. 1. Always travel straight BRUTUS uphill. If All Forward Speed Is Lost: 2. Avoid steep hills (15°...

  • Page 55: Driving Downhill

    OPERATION Driving Downhill When driving down- BRUTUS hill, follow these pre- cautions: 1. Avoid steep hills (15° maximum). 2. Drive straight downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean 15° maximum sharply to one side.

  • Page 56: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

  • Page 57: Driving Over Obstacles

    OPERATION Driving Over Obstacles Driving in Reverse Follow these pre- BRUTUS cautions when oper- Follow these precau- ating over obstacles: tions when operating in 1. Always check reverse: for obstacles 1. Always check for before operat- obstacles or people ing in a new behind the vehicle.

  • Page 58: Driving Through Water

    WARNING! The large tires on your BRUTUS may cause the vehicle to float in deep or fast-flowing water, which could result in loss of NOTICE: Immersion can result in major damage if the vehicle isn't control and lead to serious injury or death.

  • Page 59: Parking On An Incline

    OPERATION Parking the Vehicle Parking on an Incline 1. Press the brake pedal until the utility vehicle comes to a complete stop. Stop the vehicle on a level surface. Avoid parking on an incline if pos- 2. When parking inside a garage or other structure, be sure sible.

  • Page 60: Hauling Cargo

    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the vehicle rated capacity or the total rated capacity. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, attachments (models HD and HD Only), loads in the box and the load on the trailer tongue.
  • Page 61 Hauling Cargo The BRUTUS has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. The total load (operator, passenger, attachments, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

  • Page 62: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68 kg) tongue weight on the towing bracket. 2. Use low range. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 61. Towing a trailer increases braking distance.

  • Page 63: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump WARNING! Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause the cargo box. Do not injury to the driver or passenger. The rear tires will also catch the rear attempt to dump or unload of a raised box, damaging the vehicle and creating hazardous driving the vehicle while parked...
  • Page 64 OPERATION Operating With A Full Bucket And Empty Operating With An Empty Bucket And Cargo Box Loaded Cargo Box Loaded Bucket And Empty Cargo Box Loaded Bucket And Empty Cargo Box Going Down Slope Going Up Slope Going Up Slope Going Down Slope With an empty bucket and a loaded cargo box, go up or down With a loaded bucket and an empty cargo box, go up or down...
  • Page 65 OPERATION Filling And Emptying The Bucket WARNING! Avoid serious Injury Or Death Filling Load, unload and turn on flat level ground. Do not exceed vehicle load capacity shown on sign (decal) in cargo box. Failure to obey warnings can cause vehicle rollover and can cause serious injury or death.
  • Page 66 OPERATION Leveling The Ground Using Float Backfilling Lower the attachment arm (Item A) and put the cutting edge of the bucket on the ground (Item D). Drive forward to the edge Raise the attachment arm (Item B) and tilt the bucket forward of the hole to push the material into the hole.
  • Page 67 OPERATION All Wheel Drive (AWD) Engaging AWD increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gearcase. Press the top of the rocker switch to engage 1. Stop the vehicle. Operate in reverse for at least 10 feet (3 All Wheel Drive (AWD).
  • Page 68 OPERATION Safety Rules For PTO Operation (HD • Keep all shields in place. Replace damaged or missing shields before operating • Follow warnings and instructions on machine signs (decals). WARNING! Replace damaged or missing decals. Avoid Injury Or Death • Do not wear loose or bulky clothing around the PTO or other mov- ing parts.
  • Page 69 OPERATION Operating The PTO (HD The BRUTUS HD utility vehicle is factory equipped with Look for drop-offs or rough terrain. Have underground utility a PTO. lines (gas, water, sewer, irrigation, etc.) located and marked. The PTO has a rated speed of 2000 RPM.
  • Page 70 OPERATION Operating The PTO (HD 5. Increase the engine speed to the desired rpm specified for your attachment. See the attachment Owner’s Manual for See the attachment Owner’s Manual for the correct operating the correct attachment operating RPM. (With engine RPM procedure for your attachment.

  • Page 71: Attachment Arm

    Tilt Cylinder Stow Kit. The stow kit will secure the tilt cylinder interface flat on the ground. in the storage position when the attachment arm is removed. See your Polaris dealer for parts. 5. Remove the retainer pin (Item 3) and pin 1.
  • Page 72 Tip: The utility vehicle is (Item 5) and lower the shown equipped with the optional cylinder Stow Kit attachment arm fully. (Item 1). See your Polaris Reinstall the pins (Item 5) dealer for parts. and the retainer pins (Item Rotate the tilt cylinder up...
  • Page 73 ATTACHMENT ARM Removing And Installing (Models HD and 4. Remove the lift cylin- der retainer pin (Item 3) and the pin (Item 4). Installing: WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm.
  • Page 74 ATTACHMENT ARM Removing And Installing (Models HD and 11. Rotate the interface upward until it is aligned with the rod end of the tilt cylinder. Installing (Cont’d): Install the pin (Item 3) 6. Start the engine. See page 41. Press the bottom of the joy- and retainer pin (Item stick lockout switch to enable the joystick.

  • Page 75: Pto System

    PTO SYSTEM Removing And Installing PTO Shafts 5. Remove the eight bolts (Item (Models HD 3) and remove Description the belly pan (Item 4). If the utility vehicle will not be used for PTO driven attach- ments for extended periods of time, it is possible to remove the PTO drive shaft assembly from the PTO clutch.
  • Page 76 PTO SYSTEM Removing And Installing PTO Shafts 9. Reinstall the belly pan after the PTO shaft has been removed. (Models HD 10. Place all the parts in a secure, dry area for installation at a Removing (Cont’d): later date. 7. Remove the 11.

  • Page 77: Emission Control Systems

    Operation on Public Lands in the U.S.A. standards that apply to this vehicle. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 78: Maintenance

    Tip: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

  • Page 79: Periodic Maintenance Chart

    Engine intake pre-filter screen (LH Daily Inspect; clean often side) Frame fasteners Daily Inspect and ensure tightness ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 80 Re torque the lower mounting bolts to 95 ft-lbs ►D Brake pad wear 250 (400) Initial fluid level inspection; add lubricant if needed ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 81 D,E Travel Control And Engine Speed Control 100 H 1000 (1600) Inspect for proper operation and adjust if necessary System ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 82 Fuel filter/water separator 150 H 12 M Replace fuel filter / water separator ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 83 Replace rubberized fuel hoses ► Cooling hoses 2000 H 24 M Replace coolant hoses Headlight aim Adjust as needed ► Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 84: Lubrication Recommendations

    Front Gearcase Oil Demand Drive PLUS Fluid See page 90. Front Prop Shaft Yoke and PTO shaft POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120. Front and rear suspension POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120.
  • Page 85 MAINTENANCE Start Interlock System Description 2. With the travel control pedal (Item 3) in neutral and the gear selector lever (Item 1) in PARK, move the PTO (Item The utility vehicle is 2) to the ON position, the engine must not start. equipped with a Start Inter- lock System.
  • Page 86 Use the engine speed control lever (Item 2) and check the high idle. Inspection And Maintenance (For BRUTUS HD And HD Models Only) When on flat level ground, the gear selector lever in Park, move the engine speed control lever (Item 2) to high idle.
  • Page 87 MAINTENANCE Horse Power Management Inspection and Maintenance Test conditions: Air Con- Description ditioning off, no weight in Horsepower management automatically increases or decreases cargo box, operator only. pressure to the hydrostatic transmission to sustain engine rpm no attachment, no signifi- and maintain optimum drive performance.

  • Page 88: Engine Oil

    NOTICE: Use of a non-recommended engine oil may cause serious engine damage. 2. Stop the engine. Check Level POLARIS recommends the use of POLARIS Diesel Oil (SAE on Top Side 3. Tilt the rear cargo CI-4) for this vehicle. Always use the correct viscosity grade box to access the based on the ambient temperature expected during operation.
  • Page 89 MAINTENANCE Engine Oil Oil and Filter Change 11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 Always change the oil and filter at the intervals outlined in the turn.
  • Page 90 See Drain Plug tion. page 128 for the part numbers of POLARIS products. 5. Add the recommended oil. 6. Reinstall the fill plug. Torque to specification. 7. Check for leaks. Dispose of used oil properly.
  • Page 91 Refer to the Gearcase Specifications Chart on page 89 for rec- on the bottom of the ommended lubricants, capacities and torque specifications. gearcase. See page 128 for the part numbers of POLARIS products. 4. Remove the drain Oil Check plug. Allow the oil to drain completely.

  • Page 92: Cooling System

    POLARIS recommends the use of POLARIS Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality alumi- num compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use. Do not dilute with water.
  • Page 93 Tip: If coolant must be added often, or if the overflow bottle runs com- cap will not allow the recovery system to function prop- pletely dry, there may be a leak in the system. Have the cooling erly. See your dealer for the correct replacement part. system inspected by your POLARIS dealer.

  • Page 94: Vehicle Immersion

    Take the vehicle to your dealer before starting the engine. If it's impossible to take your BRUTUS to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land or at the very least, to water below the floorboards.
  • Page 95 MAINTENANCE Fuel Filter/Water Separator The fuel filter/water 5. When fluids stop drain- Tighten separator is located ing from the valve, under the cargo box tighten the valve firmly on the left side of the (by hand only). Tighten vehicle. the bleed screw. Inspect the separator 6.

  • Page 96: Cleaning Intake Water Drain Valve

    MAINTENANCE Air Pre-Filter Always clean the pre-filter 3. DO NOT use compressed at the intervals outlined in air to clean the pre-filter the Periodic Maintenance open. Use a damp cloth Chart beginning on page and clean the inside of the 78.

  • Page 97: Air Filter

    MAINTENANCE Air Filter Always change the air fil- NOTICE: Operating a diesel engine with a soiled or damaged air filter can result in engine damage. Do not attempt to wash ter at the intervals out- the filter. Always replace a soiled or damaged filter with a lined in the Periodic new filter.
  • Page 98 Check the fluid level in Sight Gauge Fill Cap the sight gauge. The fluid level is correct when at the center of the sight gauge. Use only recommended Polaris hydraulic fluid when adding or changing the hydraulic fluid. See page 128.
  • Page 99 MAINTENANCE Hydraulic/Hydrostatic System Removing And Replacing Hydraulic/Hydrostatic Place a container under Filter the filter. Recycle or dis- pose of used oil in an Change the hydraulic/hydrostatic filter at the intervals outlined environmentally safe in the Periodic Maintenance Chart beginning on page 78. manner.
  • Page 100 MAINTENANCE Hydraulic/Hydrostatic System Remove and clean the hydraulic fill screen. Use Removing And Replacing Hydraulic/Hydrostatic low air pressure to clean Fluid the screen. Change the hydraulic/hydrostatic fluid at the intervals outlined Remove the hydraulic fil- in the Periodic Maintenance Chart beginning on page 78. ter.

  • Page 101: Spark Arrester

    MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark 3. Press the brake pedal and then press the travel control arrester could result in serious injury or death. pedal to increase engine RPM. Purge accumulated carbon Do not perform service on the spark arrester while the system is hot.
  • Page 102 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes acti- 4. If the fluid level is lower than the upper level line, add vated by the brake pedal. See page 24. brake fluid to the upper (MAX) line. 5.

  • Page 103: Shift Cable Adjustment

    MAINTENANCE Shift Cable Adjustment If there is any contact at either the bottom (Item 2) or the top (Item 4) of the gear selector shift slot, the shift cable will need Inspection to be adjusted. Do the following: Shift cable adjustment is necessary when any of the following Adjustment is noticed: 1.

  • Page 104: Steering Wheel Inspection

    Rear Suspension Shown Adjustment is similar for Front Suspension For the BRUTUS model: Adjust the rear and front shock Place the vehicle on jack stands. See page 111. Adjust the front absorber springs by rotating the adjustment cam either clock-...
  • Page 105 MAINTENANCE Alternator Belt Belt Adjustment 4. If the belt tension is not correct, loosen the Check the alternator belt at the correct service interval as out- mounting bolt (Item 4) lined in the Periodic Maintenance Chart beginning on page 78. and adjustment bolt Stop the machine on a flat level surface.
  • Page 106 MAINTENANCE Air Conditioning (If Applicable) Belt Adjustment 5. If the belt tension is not correct, loosen the Check the air conditioning belt at the correct service interval mounting bolt (Item 4) as outlined in the Periodic Maintenance Chart beginning on and adjustment bolt page 78.
  • Page 107 MAINTENANCE Air Conditioning (If Applicable) Condenser Cleaning Filter Cleaning If equipped with air conditioning, the condenser should be The air conditioning filter is cleaned at the correct service interval as outlined in the Peri- located below the dash. odic Maintenance Chart beginning on page 78. 1.
  • Page 108 MAINTENANCE PTO Clutch (If Applicable) Description on the clutch pack. The correct clearance is The PTO system is activated by engaging an electric clutch. 0.014 in (0.35 mm). When the clutch is engaged, the PTO driveline will rotate. 0.31 in. When disengaged, a PTO brake is applied.
  • Page 109 MAINTENANCE PTO Drive Belt (If Applicable) Belt Inspection Check the PTO drive belt at the correct service interval as out- lined in the Periodic Maintenance Chart beginning on page 78. The PTO drive belt has a constant tension idler to keep the cor- rect tension on the belt.
  • Page 110 MAINTENANCE PTO Gear Box (If Applicable) Checking PTO Gear Box Fluid To check the fluid level, use the T40 wrench (Item 2) that is included in the Tip: Periodic inspection of the gearbox fluid is not needed. Visually tool kit (or an equivalent tool) and a inspect the gearbox for fluid leaks.
  • Page 111 MAINTENANCE PTO Gear Box (If Applicable) Adding PTO Gear Box Fluid 6. Thoroughly clean the area around the breather The PTO gear box should not require adding fluid. If the fluid tube fitting (Item 2) and level drops, it would indicate a leak. See your dealer for remove the fitting.
  • Page 112 MAINTENANCE Place the jack stands under Supporting Utility Vehicle On Jack the frame at the front of the Stands utility vehicle (both sides). Procedure Tip: When lifting the utility vehi- cle, place jack under front For service work under the utility vehicle, or to remove the frame.
  • Page 113 MAINTENANCE Tires WARNING Operating your vehicle with worn tires, improperly inflated tires, non- Axle and Wheel Nut Torque Specifications standard tires or improperly installed tires will affect vehicle handling Inspect the following items occasionally for tightness, and if and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this they've been loosened for maintenance service.
  • Page 114 Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 4. Attach the wheel nuts and washers and finger tighten.
  • Page 115 MAINTENANCE Lights Headlight Lamp Replacement Headlight Beam Adjustment 1. Open the hood. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 2. Unplug the headlamp from the wiring harness. Be sure to 8" (20 cm) pull on the connector, not on the wiring.
  • Page 116 If you suspect that a fuse or relay may not be working prop- erly, please see your POLARIS dealer. The fuse panel is located below the seat between the operator and passenger. For the BRUTUS model, remove the seat. For HD and HD models, the center console will need to be removed.
  • Page 117 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in Battery Removal an explosion and cause serious injury or death. When removing the 1. Remove the seat. The battery is located under the passen- battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
  • Page 118 Check battery voltage each month during storage and recharge 3. When using an automatic charger, refer to the charger as needed to maintain a full charge. POLARIS recommends manufacturer's instructions for recharging. When using a maintaining battery charge by using a POLARIS Battery Ten-...
  • Page 119 MAINTENANCE Wheel Toe Alignment Inspection Toe Adjustment The wheel toe alignment requires regular inspection and main- Tip: Be sure the steer- tenance at the correct service interval as outlined in the Peri- ing wheel is odic Maintenance Chart beginning on page 78. straight ahead before determin- Stop the machine on a flat level surface.
  • Page 120 MAINTENANCE Lubricating The Utility Vehicle Lubrication Location 4. Trailing Arm - Front Pivot (both sides) Lubricate as outlined in the Periodic Maintenance Chart begin- ning on page 78. Always use a good quality lithium based multi-purpose grease. Lubricate the following: 1.
  • Page 121 MAINTENANCE Lubricating The Utility Vehicle Lubrication Location 7. Lift Cylinder Base End 8. Lift Cylinder Rod End 9. Tilt Cylinder Base End 6. Drive Shaft (in front of transmission 10. Tilt Cylinder Rod End (bottom side of cylinder rod) 11. Attachment Arm Pivot - Rear (both sides) 12.

  • Page 122: Cleaning And Storage

    If an informational or graphic label becomes illegible or comes The best and safest way to clean your POLARIS vehicle is off, contact your POLARIS dealer to purchase a replacement. with a garden hose and a pail of mild soap and water.
  • Page 123 Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
  • Page 124 2. Clean the air box, including sediment plugs. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated Inspect and Lubricate materials. They do not allow enough ventilation to prevent Inspect all cables and lubricate all areas of the vehicle as rec- condensation, and may promote corrosion and oxidation.

  • Page 125: Removal From Storage

    3. Place the transmission in PARK. 4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the BRUTUS to the transporting unit securely with suitable straps or chains. Do not attach tie straps to the front A-arm bolt pockets.

  • Page 126: Specifications

    SPECIFICATIONS BRUTUS BRUTUS HD BRUTUS HD Vehicle Rated Capacity 1750 lbs. (794 kg) 2000 lbs. (907 kg) 1750 lbs. (794 kg) (includes weight of operator, passenger, cargo, accessories, and attachment arm [if equipped]) Dry Weight 1634 lbs. (741 kg) 1808 lbs. (820 kg) 2120 lbs.
  • Page 127 SPECIFICATIONS BRUTUS BRUTUS HD BRUTUS HD Overall Length 122.2 in. (310.4 cm) 158 in. (401.1 cm) (with bucket installed) Overall Width (tires) 63.2 in. (160.6 cm) Overall Height 72.9 in. (185 cm) Wheelbase 84 in. (213.4 cm) Cargo Box Dimensions (Inside) 43.5 x 54 x 11.5 in.
  • Page 128 SPECIFICATIONS BRUTUS BRUTUS HD BRUTUS HD Travel Control Pedal Drive Hydrostatic Drive Forward/Reverse Driving System Type Hydrostatic driven, 4-wheel independent shaft, lockable differential Shift Type Single Lever (H/L/N/P) Gear Reduction - Low 4.41:1 Gear Reduction - High 1.99:1 Drive Ratio - Front: 3.82:1...

  • Page 129: Polaris Products

    Demand Drive Plus Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871323 60/40 Coolant (gal./3.8 l) 2871534 60/40 Coolant (qt./.95 l) Hydraulic Fluid 2879746 Polaris Hydraulic Fluid (gal./3.8 l) PTO Gearbox Oil 2879748 Synthetic PTO Gearbox Oil (6 oz./17.7 ml)
  • Page 130 Premium All Season Grease (14 oz./414 ml cartridge) 2871460 Starter Drive Grease 2871515 Premium U-Joint Lube (3 oz./89 ml cartridge) 2871551 Premium U-Joint Lube (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel Miscellaneous 2872189 DOT 4 Brake Fluid 2859044 POLARIS Battery Charger Yuasa 1.5A...

  • Page 131: Troubleshooting

    Clogged air filter Replace fuel Water present in fuel Replace with new fuel Water or fuel in crankcase Immediately see your POLARIS Kinked or plugged fuel tank vent Inspect and replace dealer line Low battery voltage Recharge the battery to 12.8 VDC...
  • Page 132 POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12-month LIMITED WARRANTY for all components, except the This POLARIS limited warranty excludes any failures that are not caused by diesel engine and spark arrestor, of your POLARIS diesel vehicle against a defect in material or workmanship.

  • Page 133: Warranties

    If you purchase from a private party: THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLU- If you purchase a POLARIS product from a private party, to be kept and SION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAM- used outside of the country in which the product was originally purchased, AGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED all warranty coverage will be denied.
  • Page 134 UCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Deal- ers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have...
  • Page 135 Polaris provides on the vehicle as a whole. The EPA exclusive option of POLARIS, repair or replacement of any defective mate- emissions warranty period does not further extend if you purchase additional rials, components or products.
  • Page 136 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 137: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 138: Index

    Index Block Heater ......39 Boots....... . . 10 Accessory Outlets .
  • Page 139 Index Fan, Cooling ......91 Gear Selector......21 Joystick Lock Switch .
  • Page 140 Switches ......19 Polaris Products ..... . 128 Safety Rules Fof PTO.
  • Page 141 Index Tachometer ......30 Warning Symbols ..... . . 4 Throttle Freeplay Inspection .
  • Page 142 With unapproved accessories - they may seriously affect stability. Watch for branches or other hazards that could enter vehicle. READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc. 2100 Hwy. 55...

This manual is also suitable for:

Brutus hdBrutus hdpto

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