Polaris BRUTUS Owner's Manual For Maintenance And Safety
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Utility Vehicle
  5. BRUTUS
  6. Owner's manual for maintenance and safety

Polaris BRUTUS Owner's Manual For Maintenance And Safety

Hide thumbs Also See for BRUTUS:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
BRUTUS™
BRUTUS™ HD
BRUTUS™ HD
PTO
Owner's Manual
for Maintenance and Safety

Advertisement

Table of Contents
loading

Related Manuals for Polaris BRUTUS

Summary of Contents for Polaris BRUTUS

  • Page 1 BRUTUS™ BRUTUS™ HD BRUTUS™ HD Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS® and BRUTUS™ are trademarks of POLARIS Industries Inc. Copyright 2014 Polaris Industries 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 discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Emission Control Systems ......72 POLARIS Products ....... . 119 Specifications .

  • Page 6: Introduction

    INTRODUCTION The BRUTUS is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
  • Page 7 Failure to follow the warnings contained in this manual can result in severe injury or death. Your POLARIS BRUTUS is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost...

  • Page 9: Safety

    A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. POLARIS recommends wearing approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE. Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes.
  • Page 10 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 11 • On paved surfaces – pavement may seriously affect handling and control. • With non-POLARIS approved accessories – they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover could cause serious injury or death.
  • Page 12 SAFETY Safety Labels and Locations Seat Switch Warning WARNING Avoid Injury Or Death • Check that seat switch is properly installed and functions correctly. • Replace switch and components if damaged or missing. 7179343 Attachment Arm Warning WARNING Avoid Serious Injury Or Death. •...
  • Page 13 No Cab: 2000 lbs. (907 kg) Includes weight of operator, passenger, Cab: 1750 lbs. (794 kg) Cab: 1750 lbs. (794 kg) cargo, attachment arm rated capacity (BRUTUS HD only), and accessories. Read Operation & Maintenance Manual for detailed loading information. 7179171...
  • Page 14 • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
  • Page 15 • Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. • Never modify this vehicle through improper installation or use of non-POLARIS- approved accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.

  • Page 16: Seat Belts

    Operator Safety WARNING Failure to operate the BRUTUS properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.
  • Page 17 SAFETY Operator Safety Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
  • Page 18 SAFETY Operator Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 19 SAFETY Operator Safety Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly).

  • Page 20: Equipment Modifications

    Rated Capacity. They are designed for secure fastening to the BRUTUS utility vehicle. The user must check with the dealer, or POLARIS literature, to determine safe loads of materials of specified densities for the vehicle - attachment combination.

  • Page 21: Features And Controls

    FEATURES AND CONTROLS Component Locations Not all models come with all features. Refer to the specifications section beginning on page 120. OPS Cab Storage Compartment Under Seats Frame Console Cargo Box Attachment Arm (Model HD and HD Only) Hip Bar Fuel Tank Cap (Model HD Only)

  • Page 22: Ignition Switch

    FEATURES AND CONTROLS Switches and Indicator Lights AWD/Differential Switch AWD/Differential Switch Power Lift Assist Switch Power Lift Assist Switch Mode Button Mode Button (If Equipped) (If Equipped) Blank Switch Openings Blank Switch Openings Light Switch Light Switch (Available For (Available For Accessories) Accessories) HVAC Switches...

  • Page 23: Light Switch

    FEATURES AND CONTROLS Switches and Indicator Lights Light Switch The ignition switch must be in the ON position to operate the headlights. HIGH Press the top of the rocker switch toward the dash to place the headlights on high beam. Move the rocker switch to the center position to place the headlights on low beam.

  • Page 24: Gear Selector

    Gear Selector Use the gear selector to shift gears. Low gear is the primary driving range for the BRUTUS. High gear is intended for use on hard-packed surfaces with light loads. To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.
  • Page 25 FEATURES AND CONTROLS Center Console (For Models HD and HD Only) Control Joystick Lever Joystick - Attachment Arm Movement of the joystick controls the lift and tilt functions of the attachment arm and the PRO-TACH attachment system. See page 42. Engine Speed (RPM) Control Lever The engine speed (RPM) control lever controls engine RPM.

  • Page 26: Storage Compartments

    The Occupant Protective Structure (OPS) on this vehicle meets ANSI/OPEI B71.9-2012 occupant requirements. Always have your authorized POLARIS dealer thoroughly inspect the OPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover.

  • Page 27: Seat Belt Inspection

    3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. 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.

  • Page 28: Instrument Cluster

    If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. 1. Vehicle Speed (Speedometer) Display - Analog display of vehicle speed in MPH or km/h.
  • Page 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode. 4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the high beam position.
  • 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: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock. Units of Measurement Distance Miles (MPH)
  • Page 31 FEATURES AND CONTROLS Instrument Cluster Information Display Area Tachometer (RPM) Engine RPM can be displayed digitally. PTO RPM, when engaged, is indicated after the PTO icon. Engine Temperature Engine temperature can be displayed in °F or °C. Refer to “Units of Measurement” to change the format. Clock The clock displays the time in a 12-hour or 24-hour format.
  • Page 32 FEATURES AND CONTROLS Instrument Cluster Information Display Area Programmable Service Interval The initial factory service interval setting is 50 hours. Each time the engine is started, the engine hours are subtracted from the service interval hours. When the service interval reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started.
  • Page 33 FEATURES AND CONTROLS Instrument Cluster Information Display Area Check Engine / Trouble Code Display The diagnostic mode is accessible only when the check engine MIL has been activated. Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate.

  • Page 34: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in this owner’s manual. Break-In Period The break-in period for your new vehicle is the first 50 hours of operation.
  • Page 35 PTO (If Equipped) Inspect splines, guards, shields and hardware, ensure tightness, replace damaged parts. Brake light/tail lamp / Check operation, apply POLARIS dielectric grease when Headlamp lamp is replaced. Heater/Air Conditioning Filter Clean and replace filter as needed during heating and...
  • Page 36 NOTICE: For the best engine performance, to prevent engine damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel fuel. POLARIS recommends the following diesel fuels for use in this vehicle: • Low Sulfur • Ultra Low Sulfur #2 •...
  • Page 37 OPERATION Fuel Recommendations Bio-Diesel Fuels In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.
  • Page 38 Fuel Recommendations Bio-Diesel Fuels B6 To B20 Bio-diesel Fuel Blend Usages B6 to B20 bio-diesel is not approved for this POLARIS application. Approved Engines Only the YANMAR TNM engine series listed below may operate with bio-diesel fuel concentrations up to B5 for POLARIS applications...
  • Page 39 3. Replace a clogged fuel filter/water separator. 4. Replace old fuel. Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the following guidelines when starting the BRUTUS in cold weather conditions. Cold Starting Guidelines +20° F to +15° F +15°...
  • Page 40 OPERATION Cold Weather Operation Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle. See page 35. Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle: •...

  • Page 41: Starting The Engine

    • If the ambient temperature exceeds +104° F (+40° C), the engine may overheat and cause the engine oil to break down. • If the ambient temperature is between +5° F (-15° C) and -25° F (-32° C), POLARIS recommends the use of a block heater.

  • Page 42: Stopping The Engine

    OPERATION Stopping the Engine For maximum engine life, allow the engine to idle, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down. 1.

  • Page 43: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 33. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.
  • Page 44 OPERATION Hydraulic Controls (Models HD and HD Joystick Operation The utility vehicle engine must be running for the hydraulic system to be activated. 1. Start the engine. See page 39. 2. Allow the hydraulic system to warm to operating temperature. The utility vehicle has both a joystick lockout switch and a tilt lockout switch.
  • Page 45 OPERATION Hydraulic Controls (Models HD and HD Front Auxiliary Hydraulic Operation WARNING! Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks.
  • Page 46 OPERATION Hydraulic Controls (Models HD and HD Quick Couplers WARNING! Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks.

  • Page 47: Engaging Pto

    OPERATION Power Take-Off (PTO) (Model HD The front PTO is standard equipment on the HD model only. The PTO must be in the disengaged (OFF) position before the engine can be started. The PTO has a rated speed of 2000 RPM. WARNING! PTO Switch •...

  • Page 48: Choosing The Correct Attachment

    Choosing The Correct Attachment WARNING! Avoid Injury or Death. Never use attachments or buckets which are not approved by POLARIS. Buckets and attachments for safe loads of specific densities are approved for each model. Unapproved attachments can cause injury or death.
  • Page 49 OPERATION Attachments (Models HD and HD Installing And Removing Attachments The PRO-TACH attachment system is used for fast changing of buckets and other attachments. See the appropriate Attachment Owner’s Manual to install other attachments. Installing: 1. Remove the two retainers and pins from the storage position.
  • Page 50 OPERATION Attachments (Models HD and HD Installing And Removing Attachments Removing Tip: In muddy conditions or to prevent the attachment from freezing to the ground, put the attachment on planks or blocks before removing the attachment from the vehicle. 1. Lower the attachment arm and put the attachment flat on the ground.
  • Page 51 OPERATION Power Take-Off (PTO) (Models HD Installing And Removing The PTO The BRUTUS Model HD is factory equipped with a PTO. The PTO has a rated speed of 2000 RPM. WARNING! • Do Not exceed the rated attachment PTO speed.
  • Page 52 OPERATION Power take-Off (PTO) (Models HD Installing And Removing The PTO Each attachment has a specific length PTO drive shaft that is affixed to the attachment. Do not intermix or replace drive shafts or components between different attachment types. Connect the PTO driveline to the PTO shaft of the utility vehicle.

  • Page 53: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). For model HD and HD : Keep the heavy end of the vehicle uphill. See page 58. 3. Keep both feet on the floor. 4.

  • Page 54: Driving Downhill

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

  • Page 55: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

  • Page 56: Driving Through Water

    OPERATION Driving Through Water Your POLARIS BRUTUS can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Driving through water deeper than the floorboards will cause engine damage and will also void the engine warranty.

  • Page 57: 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 58 D - Maximum Trailer Hitch Tongue Weight = 150 lbs. (68 kg) E - Tow Weight (Level Ground) = 2000 lbs. (907 kg) (includes weight of trailer) Vehicle Rated Capacity = A plus B plus C plus D = (BRUTUS and BRUTUS HD ) 1750 lbs.

  • Page 59: 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.. Towing a trailer increases braking distance.
  • Page 60 OPERATION Operating With A Full Bucket And Empty Cargo Box Loaded Bucket And Empty Cargo Box Going Up Slope Going Down Slope With a loaded bucket and an empty cargo box, go up or down the slope with the heavy end toward the top of the slope.
  • Page 61 OPERATION Filling And Emptying The Bucket Filling 1. Lower the attachment arm all the way (A) and tilt the bucket forward (D) until the cutting edge is on the ground. 2. Drive slowly forward to push the bucket slightly into the material. 3.
  • Page 62 OPERATION Leveling The Ground Using Float 1. Raise the attachment arm (B) and tilt the bucket forward (D). 2. Push the joystick all the way forward (AA) to activate float. NOTICE: Never drive forward when the attachment arm is in the float position. 3.

  • Page 63: Engaging Awd

    OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction.
  • Page 64 OPERATION PTO Safety (if equipped) WARNING! • Do Not exceed the rated attachment PTO speed. • Stay clear of rotating driveline. • Keep bystanders away. • Keep hands, feet, clothing and long hair away. • Keep PTO shields and all guards in place. •...
  • Page 65 OPERATION Operating The PTO (HD The BRUTUS HD utility vehicle is factory equipped with a PTO. The PTO has a rated speed of 2000 RPM. Read and understand the attachment Owner’s Manual and the utility vehicle Owner’s Manual prior to installing or using any attachment.
  • Page 66 OPERATION Operating The PTO (HD See the attachment Owner’s Manual for the correct operating procedure for your attachment. Install the attachment on the utility vehicle. See pages 47-48. Engaging PTO PTO Switch 1. Start the engine. See page 39. 2. Reduce the engine speed. Tip: Do not engage the PTO system at higher engine RPM with the attachment under load.

  • Page 67: Attachment Arm

    ATTACHMENT ARM Removing And Installing (Models HD and HD When the PRO-TACH attachment system is not being used, it can be removed from the vehicle. Tip: Remove the bucket or attachment before removing the attachment arm from the vehicle. Removing 1.
  • Page 68 ATTACHMENT ARM Removing And Installing (Models HD and HD The PRO-TACH attachment system is used for fast changing of buckets and other attachments. See the appropriate attachment Owner’s Manual to install other attachments. 11. Rotate the tilt cylinder up and into the storage position. A heavy tie strap can be used to secure the cylinder to the grille in the storage position.
  • Page 69 ATTACHMENT ARM Removing And Installing (Models HD and HD Installing WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm. 1. Position the utility vehicle so it is centered in front of the attachment arm. 2.
  • Page 70 ATTACHMENT ARM Removing And Installing (Models HD and HD 6. Start the engine. See page 39. Press the bottom of the joystick lockout switch to enable the joystick. WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm.

  • Page 71: Pto System

    PTO SYSTEM Removing And Installing PTO Shafts (Models HD If the utility vehicle will not be used for PTO driven attachments for extended periods of time, it is possible to remove the PTO drive shaft assembly from the PTO clutch. This will prevent damage to the PTO system if the utility vehicle will be used off road or if additional ground clearance is desired.
  • Page 72 PTO SYSTEM Removing And Installing PTO Shafts (Models HD 6. Remove the four bolts and nuts and remove the guard. Bolt Installation Torque: 32-35 ft-lbs (43-47 Nm) Guard Bolts and Nuts 7. Remove the four bolts and nuts and remove the PTO Shaft Carrier Assembly PTO shaft carrier assembly.
  • Page 73 PTO SYSTEM Removing And Installing PTO Shafts (Models HD Installing 1. Stop the engine and exit the vehicle. See page 40. 2. Make sure the PTO driveline and all rotating components have come to a complete stop before exiting the utility vehicle. 3.

  • Page 74: Emission Control Systems

    Operation on Public Lands in the U.S.A. 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 75: Periodic Maintenance Chart

    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 76 Engine intake pre-filter Daily Inspect; clean often screen (left 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 77 (HD/ lbs (129 Nm) Brake pad wear Initial fluid level inspection; add lubricant if (400) 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 78 Travel Control And 100 H 1000 Inspect for proper operation and adjust if Engine Speed Control (1600) 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 79 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 80 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 81: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 73, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method...
  • Page 82 MAINTENANCE PTO Interlock System (Model HD The utility vehicle is equipped with a PTO Interlock System. The operator must be seated in the operators seat before the PTO can be engaged. Inspection To check the function of the PTO Interlock System: 1.
  • Page 83 Never start or operate this vehicle if it has a sticking or improperly operating treadle pedal. Immediately contact your dealer for service if travel control problems arise. Inspection And Maintenance (For BRUTUS HD And HD Models Only) Position the utility vehicle on a flat level surface. Put the gear selector in PARK and stop the engine.

  • Page 84: Engine Oil

    Oil Recommendations NOTICE: Use of a non-recommended engine oil may cause serious engine damage. POLARIS recommends the use of POLARIS Diesel Oil (SAE CI-4) for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation.
  • Page 85 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.

  • Page 86: Gearcase Specification Chart

    Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 119 for the part numbers of POLARIS products. Oil Check Fill Level Fill Plug The fill plug is located on the right side of the transmission.
  • Page 87 Maintenance Chart beginning on page 73. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 84 for recommended lubricants, capacities and torque specifications. See page 119 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.

  • Page 88: Cooling System

    NOTICE: Do not mix different types of coolant in the cooling system when adding coolant. Mixing types can result in damage to the cooling system. POLARIS recommends the use of POLARIS Antifreeze 60/40 Premix or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS antifreeze 60/40 is already premixed and ready to use.
  • Page 89 Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Maximum Minimum Have the cooling system inspected by your POLARIS dealer. Radiator Coolant Level Pressure Cap 1. Lift the hood.

  • Page 90: Vehicle Immersion

    NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. 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.
  • Page 91 MAINTENANCE Fuel Filter/Water Separator The fuel filter/water separator is located under the cargo box on the left side of the vehicle. Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Service the separator more frequently if the vehicle is operated with poor quality fuel.

  • Page 92: Air Pre-Filter

    MAINTENANCE Air Pre-Filter Always clean the pre-filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Service the pre-filter more frequently if the vehicle is operated in wet or dusty conditions or at high engine RPM for extended periods. The intake air pre-filter is located in the access panel on the left rear OPS post.

  • Page 93: Air Filter

    MAINTENANCE Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Service the air filter more frequently if the vehicle is operated in wet or dusty conditions or at high engine RPM for extended periods.

  • Page 94: Cleaning Intake Water Drain Valve

    5. Check the fluid level in the sight gauge. The fluid level is correct when at the center of the sight gauge. 6. Use only recommended POLARIS hydraulic fluid when adding or changing the hydraulic fluid. See Sight Gauge Fill Cap page 119.
  • Page 95 MAINTENANCE Hydraulic/Hydrostatic System Removing And Replacing Hydraulic/Hydrostatic Filter Change the hydraulic/hydrostatic filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. 1. Park the utility vehicle on a flat level surface, lower the attachment arm and put the attachment flat on the ground.
  • Page 96 MAINTENANCE Hydraulic/Hydrostatic System Removing And Replacing Hydraulic/Hydrostatic Fluid Change the hydraulic/hydrostatic fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Replace the fluid if it becomes contaminated or after major repair. Always replace the hydraulic / hydrostatic filters whenever the hydraulic fluid is replaced.

  • Page 97: Spark Arrester

    MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area.

  • Page 98: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 24. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.

  • Page 99: Shift Cable Adjustment

    MAINTENANCE Shift Cable Adjustment Inspection Top Shift Slot Lever Shift cable adjustment is necessary when any of the following is noticed: • Noise on deceleration. • Inability to engage a gear. • Excessive gear clash (noise). • Gear selector is moving out of desired range. Inspect the shift cable, clevis pins, and pivot bushings and replace if worn or damaged.

  • Page 100: Steering Wheel Inspection

    Rear Suspension Shown Adjustment is similar for Front Suspension Place the vehicle on jack stands. See page 107. Adjust the front (BRUTUS only) and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension.
  • Page 101 MAINTENANCE Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle.
  • Page 102 MAINTENANCE Alternator Belt Belt Replacement 1. Loosen the mounting and adjustment bolts and move the alternator toward the engine. 2. Remove the belt. 3. Install the new belt and adjust as shown under Belt Adjustment. Air Conditioning (if equipped) Belt Adjustment Check the air conditioning belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73.
  • Page 103 MAINTENANCE Air Conditioning (if equipped) Belt Adjustment 5. If the belt tension is not correct, loosen the Adjustment Bolt mounting bolt and adjustment bolt. 6. Move the top of the compressor to tighten the belt. 7. Tighten the mounting bolt to 15 ft-lbs (20 Nm). 8.

  • Page 104: Condenser Cleaning

    MAINTENANCE Air Conditioning (if equipped) Condenser Cleaning If equipped with air conditioning, the condenser should be cleaned at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73. 1. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle.

  • Page 105: Adjusting The Pto Clutch Brake

    MAINTENANCE PTO Clutch (If Applicable) The PTO system is activated by engaging an electric clutch. When the clutch is engaged, the PTO driveline will rotate. When disengaged, a PTO brake is applied. The PTO clutch brake must be checked and adjusted periodically as outlined in the Periodic Maintenance Chart beginning on page 73.
  • Page 106 MAINTENANCE PTO Drive Belt (If Applicable) Belt Inspection Check the PTO drive belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73. The PTO drive belt has a constant tension idler to keep the correct tension on the belt. 1.
  • Page 107 MAINTENANCE PTO Gearbox (If Applicable) Checking PTO Gearbox Fluid 3. To check the fluid level, use the T40 wrench that is included in the tool kit (or an equivalent tool) and a piece of tubing that fits snuggly over the tool. 4.
  • Page 108 MAINTENANCE PTO Gearbox (If Applicable) Removing And Replacing PTO Gearbox Fluid Replace the PTO gear fluid at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73. 1. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle.
  • Page 109 MAINTENANCE Supporting Utility Vehicle On Jack Stands For service work under the utility vehicle, or to remove the wheels, always support the utility vehicle with jack stands or blocks of adequate capacity for weight of utility vehicle. See specifications page 120. Always park the utility vehicle on a flat level surface.

  • Page 110: Wheel Removal

    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 111: Headlight Lamp Replacement

    MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
  • Page 112 Locate and correct any short circuits that may have caused a blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.

  • Page 113: Battery Removal

    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Your vehicle is equipped with a sealed battery, which requires little maintenance.

  • Page 114: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge.

  • Page 115: Wheel Toe Alignment

    MAINTENANCE Wheel Toe Alignment Inspection The wheel toe alignment requires regular inspection and maintenance at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 73. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle.
  • Page 116 MAINTENANCE Lubricating The Utility Vehicle Lubrication Location Lubricate as outlined in the Periodic Maintenance Chart beginning on page 73. Always use a good quality lithium based multi-purpose grease. Lubricate the following: 1. Lower A Arms (both sides) 2. Upper A Arms (both sides) 3.
  • Page 117 MAINTENANCE Lubricating The Utility Vehicle Lubrication Location 6. Drive Shaft (in front of transmission 7. Lift Cylinder Base End 8. Lift Cylinder Rod End 9. Tilt Cylinder Base End 10. Tilt Cylinder Rod End (bottom side of cylinder rod) 11. Attachment Arm Pivot - Rear (both sides) 12.

  • Page 118: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 119: Polishing The Vehicle

    • Coolant (test strength/fill) Storage Area/Covers Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

  • Page 120: 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 121: Polaris Products

    Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug Coolant 2871323 POLARIS Antifreeze 60/40 Premix (gal./3.8 l) 2871534 POLARIS Antifreeze 60/40 Premix (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 122: Specifications

    SPECIFICATIONS BRUTUS BRUTUS 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 (without Cab) 1634 lbs. (741 kg) 1808 lbs.
  • Page 123 SPECIFICATIONS BRUTUS BRUTUS BRUTUS HD Engine YANMAR 3-Cylinder Inline Diesel Displacement 55.1 in. (904 cc) Bore x Stroke 2.83 in. x 2.91 in. (72mm x 74mm) Lubrication System Pressurized Wet Sump High Idle 3700 +/- 100 RPM Low Idle 1350 +/- 100 RPM...

  • Page 124: Troubleshooting

    Drain the fuel system and refuel, replace fuel filter/ water separator Old or non-recommended fuel Replace with fresh recommended fuel Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer...

  • Page 125: Warranty

    WARRANTY for all components, except the diesel engine and spark arrestor, of your POLARIS diesel vehicle against defects in material or workmanship. POLARIS gives a 12 month or 1,000 hours of engine operation (whichever occurs first) LIMITED WARRANTY on all components of the diesel engine against defects in material or workmanship.

  • Page 126: Lubricants And Fluids

    The exclusive remedy for breach of this warranty shall be, at POLARIS’ option, repair or replacement of any defective materials, components, or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 127 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 128 This EPA emissions warranty period is extended for at least as long as the standard factory warranty that POLARIS provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension.
  • Page 129 WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

  • Page 130: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 131 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 132: Index

    Index Accessory Outlets ......22 Cab Frame ....... 24 Adding Hydraulic Fluid.
  • Page 133 Index Fan, Cooling ......86 Ignition Switch ......20 Filling And Emptying The Bucket .
  • Page 134 Index Obstacles ....... 53 PTO Drive Belt ......104 Occupant Protective Structure .
  • Page 135 Index Shifter ........22 Tachometer ......29 Shifting Gears .
  • Page 136 • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death.

This manual is also suitable for:

Brutus hdBrutus hdpto

Table of Contents