Mertz 999-848.01 Operator'S Manual Download Page 1

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MANUFACTURING, LLC

Part No. 999-848.01

Serial No.s 1133 and Higher

526DX Operator’s Manual

BIG POWER IN ALL PLACES

Summary of Contents for 999-848.01

Page 1: ...MANUFACTURING LLC Part No 999 848 01 Serial No s 1133 and Higher 526DX Operator s Manual BIG POWER IN ALL PLACES...

Page 2: ...the Serial Number plate Record SERIAL Number here MANUFACTURED BY MANUFACTURED BY MODEL NO S N ENGINE SERIAL NO ENGINE SERIAL NO WEIGHT POWER MERTZ MANUFACTURING LLC 800 654 6433 mertzok com MERTZ MA...

Page 3: ...thorized dealer of said defect The purchaser agrees to return the defective equipment or parts to Mertz Manufacturing LLC or to an authorized dealer facility freight prepaid within fifteen 15 days aft...

Page 4: ...LLC or an authorized service facility or for any costs incurred with such removal or reinstallation CONSEQUENTIAL DAMAGES Notwithstanding any other provision of this agreement in no event shall Mertz...

Page 5: ...this form Not returning the form could result in your being denied some of your warranty entitlements To have Mertz Manufacturing LLC reset the warranty start date please complete the form below and...

Page 6: ...iv Mertz Manufacturing LLC P O Box 150 Ponca City OK 74602 Affix Stamp Here...

Page 7: ...indicated whenever you see the Safety Alert symbol no matter which signal word appears next to the Safety Alert symbol INDICATES A HAZARDOUS SITUATION THAT IF NOT AVOIDED IS VERY LIKELY TO CAUSE DEAT...

Page 8: ...vi...

Page 9: ...on and Operation 3 1 Pre Start Inspection 3 1 Daily Service Checks 3 1 Cylinder Lock Installation 3 7 Cylinder Lock Removal 3 7 Operating Instructions 3 8 Machine Start up 3 8 Machine Shut down 3 9 Tr...

Page 10: ...el 4 19 Fuse Panel 4 21 Track and Tension System Installation 4 22 Boxer 526DX Electrical Schematic 4 27 Boxer 526DX Hydraulic Interconnect Diagram 4 28 Section 5 Troubleshooting 5 1 Section 6 General...

Page 11: ...site Resume work only when the operating area is clear Keep all non operating personnel away from the machine during operation Passengers must never be allowed to ride on the machine or any attachmen...

Page 12: ...r the work area stop machine operation until the work area is clear Prior to unloading the unit and starting to work inspect the path you will travel and work site area for potential hazards Some of t...

Page 13: ...suming work Be alert to any unusual reaction to any of the controls If anything unusual is noticed shut the machine down and thoroughly inspect it to determine the cause of the problem Do not operate...

Page 14: ...or work site hazards Be sure the area has adequate light and is well ventilated NEVER operate the machine inside a closed area Clean up any oil grease mud water or snow which might cause the floor su...

Page 15: ...explosion If electrolyte is splashed into your eyes flush them immediately with clean water and seek medical attention If electrolyte is swallowed seek medical attention immediately If electrolyte is...

Page 16: ...ny hydraulic lines Hot hydraulic fluid can cause severe burns Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death When troubleshooting a hydraulic system f...

Page 17: ...e machine before beginning the fueling process Keep the fuel nozzle in constant contact with the rim of the machines fuel tank When filling a portable gas container always place it on the ground Never...

Page 18: ...1 8 Safety Precautions...

Page 19: ...ting plate 2 Tilt cylinder 3 Boom 4 Auxiliary hydraulic quick connects 5 Manual holder 6 Operating controls 7 Hand grip 8 Lift cylinder 9 Hydraulic Oil Cooler 10 Fuel filler cap 11 Fuel tank 12 Left t...

Page 20: ...hment mounting plate 2 Attachment hydraulic quick connects 3 Right track assembly 4 Operator s platform 5 Air cleaner assembly 6 Fuel tank 7 Fuel filler cap 8 Engine hour meter 9 Loader arm lift cylin...

Page 21: ...6 Ignition protective cap 7 Auxiliary attachment activation control 8 Track widen control 9 Auxiliary hydraulic cylinder control 10 Hand grip 11 Attachment tilt control 12 Right travel motor control...

Page 22: ...1 Burn Hazard 2 Cylinder Lock Installation Warning 3 Lifting Point 4 DANGER Auxiliary Valve 5 Danger Zone 6 Crush Hazard 7 Boxer Decal 8 Mertz Decal 9 ISO 46 DECAL 10 Attachment Must Be Securely Faste...

Page 23: ...D OPERATORS MANUAL Warning Decal 5 Battery Connection Decal 6 CA PROP 65 Warning Decal 7 Diesel Fuel Decal 8 Safety Instructions Decal 9 Control Operation Instruction Decal 10 Lifting Point Decal 11 A...

Page 24: ...on Lever Operator Presence Control With your right hand squeeze the AUXILIARY attachment control lever towards the hand hold to activate the attachment in the FORWARD motion NOTE The lever is spring l...

Page 25: ...ng the attachment Pulling the lever backwards tilts the attachment plate backwards raising the attachment 11 Right Travel Motor Control Pushing the lever forward rotates the right side wheels for forw...

Page 26: ...2 8 Operating Controls...

Page 27: ...ks Check hydraulic lines and hoses for signs of damage or leaks Inspect the machine for any signs of damage or loose fasteners Check fluid levels and any signs of leaking fluids Do all Daily Service C...

Page 28: ...oil lines Item 1 Figure 3 1 indicated by the letters F and A The correct oil level is between those two lines Figure 3 1 Engine Oil Level Check If the engine oil level is below the add line indicated...

Page 29: ...e fuel tanks Item 1 Figure 3 3 Each of the tanks has a fuel gauge located in the filler cap Item 2 Figure 3 3 Remove cap and visually inspect fuel level to make sure that the indicator is showing the...

Page 30: ...machine until repairs have been made Some examples of common hydraulic hose damage are shown in Figure 3 4 Figure 3 4 Hydraulic Hose Damage 1 End fittings damaged or leaking 2 Outer covering chafed or...

Page 31: ...returns to the Neutral position Move all hydraulic control levers rearward and release the lever Make sure that each lever automatically returns to the Neutral position The Auxiliary Control Lever wil...

Page 32: ...3 5 Lubrication Points NOTE Extremely dusty or dirty working conditions may require more frequent service replacement Make sure to install the cylinder lock before performing any service work undernea...

Page 33: ...g the cylinder lock Item 5 Figure 3 6 in the support position NOTE Make sure that the safety lock pin goes behind the loader arm cylinder 7 Lower the loader arm assembly until it is supported by the c...

Page 34: ...Stand on the operator s platform Item 1 Figure 3 7 Figure 3 7 Operator s Platform 2 Rotate the ignition key switch to the HEAT position 1 Figure 3 8 for about 10 seconds 3 Move the throttle lever Item...

Page 35: ...f the main hydraulic controls to cycle warmed hydraulic oil through the hydraulic lines into the cylinders and hydraulic motors Allow the engine to idle for another 5 minutes before beginning any mach...

Page 36: ...hment the operator becomes the load Figure 3 10 Transport Position on Trailer 3 When the machine is positioned on the trailer properly lower the attachment to the trailer deck 4 Shut the engine off an...

Page 37: ...ting eyes Item 2 Figure 3 12 located at the top of the boom arms 4 Make sure that the length of chain on each side of the lifting point is the same Item 3 A Figure 3 12 is the same as Item 3 B Figure...

Page 38: ...ogging condition is most likely to occur while operating in a reverse direction pulling a heavy load and during the first 50 hours of track usage It is caused by the tension spring being fully compres...

Page 39: ...arther forward the right control is moved the faster the left turn will be made See Figure 3 16 2220 Figure 3 16 Left Hand Turn in Forward Right Turn During Reverse Travel Left Turn During Reverse Tra...

Page 40: ...ve the travel control levers in opposite directions to spin the machine on it axis To spin left move the right control lever forward while pulling the left control lever backwards to spin turn to the...

Page 41: ...machine Keep attachments as low as possible when traveling on slopes or rough terrain Figure 3 20 Slide Slope Travel Keep the heavy end of the machine towards the uphill direction when traveling up or...

Page 42: ...securing the attachment to the machine If the lock pin does not drop into the locked position start the engine and tilt the attachment slightly forwards or backwards until the lock pins snap into plac...

Page 43: ...attachment mounting plate to remove any debris that might interfere with the attachment installation 2 Start the machines engine lower the loader arm and tilt the mounting plate forwards NOTE Make sur...

Page 44: ...e engine off 6 Rotate the attachment lock pins Item 1 Figure 3 25 and Item 1 Figure 3 26 into the locked position securing the attachment to the machine Figure 3 26 Attachment Locks in Locked Position...

Page 45: ...Installation of Hydraulically Powered Attachments There are many hydraulically powered attachments available that are very easy to install To install any of these attachments 1 Position the attachment...

Page 46: ...unting plate into the upper lip of the female attachment mounting plate Figure 3 29 Hydraulically Powered Attachment Installation 4 When the machines mounting plates top edge is seated in the attachme...

Page 47: ...e 10 Attach the hydraulic hoses to the quick connects See Figure 3 33 There are two hydraulic hoses that need to be connected The quick connect system prevents you from incorrectly connecting the hydr...

Page 48: ...e coupling Item 3 Figure 3 33 into the female bulkhead quick connect coupling Item 2 Figure 3 33 on the machine and push until the connector locks into position e Repeat the above process to connect t...

Page 49: ...keep them out of the way during operation and prevent them from being damaged Figure 3 34 Attachment Hydraulic Hose Routing 12 The attachment is now ready to use Before starting the engine make sure t...

Page 50: ...lever is spring loaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping the attachments motion The engine will continue to run Figure 3 35 Auxiliary Attac...

Page 51: ...ch Item 3 Figure 3 36 is in the HIGH position 1 With the attachment raised off the ground move the AUXILIARY control lever Items 1 2 Figure 3 36 to either the FORWARD or REVERSE position Figure 3 36 A...

Page 52: ...hine travels more hydraulic power will be directed to the hydraulic attachment e When the crawl travel speed has been set properly steering and direction control can be adjusted by using either or bot...

Page 53: ...connect Item 1 Figure 3 38 to align the notch on the collar with the lock button Item 2 Figure 3 38 4 Slide the collar backwards on the female quick connect Item 4 Figure 3 38 until it stops against t...

Page 54: ...3 28 Pre Start Inspection and Operation...

Page 55: ...dirty working conditions may require more frequent service replacement Under very wet and muddy conditions more frequent lubrication may be required Activity Daily 10 Hours New Machine 20 Hours Weekl...

Page 56: ...The Boxer has a saddle tank Item 1 Figure 4 1 on each side of the machine Figure 4 1 Fuel Level Check b Each of the tanks has a fuel gauge located in the filler cap Item 2 Figure 4 1 Remove cap and v...

Page 57: ...ect SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature during operation The engine is filled at the factory wit...

Page 58: ...lease dirt from separator tube at the bottom of the air filter by squeezing the rubber dust ejector valve Item 1 Figure 4 4 underneath the air filter Figure 4 4 Air Filter Dirt Release 5 Check the Air...

Page 59: ...ick can be reached through the opening in the front cover b Unscrew the dipstick assembly and remove from the machine 1 Figure 4 6 c Make sure that the hydraulic fluid is between the marker holes in t...

Page 60: ...tissue causing serious injury and possible death When troubleshooting a hydraulic system for leaks always use cardboard or wood as a detector DO NOT USE YOUR BARE HANDS If you are injected with hydra...

Page 61: ...ir hydraulic connections NOTE Item 3 is the track extension cylinder located underneath the machine but protected by the belly pan If any leakage from underneath the machine is noticed do not use the...

Page 62: ...Damage 1 End fittings damaged or leaking 2 Outer covering chafed or cut and wire reinforcing is exposed 3 Hose shows signs of kinking or crushing 4 Outer covering ballooning 8 Grease pivot shafts with...

Page 63: ...10 or suggested location of the support devices b Tilt the bucket downwards until the cutting edge is touching the ground See Figure 4 10 c Lower the loader arm assembly pushing the front of the machi...

Page 64: ...in Maintenance Procedures Do the following after the first 20 operating hours for a new machine only 1 Change engine oil see engine manual 2 Change engine oil filter which is located on the left side...

Page 65: ...r and spring Item 4 Figure 4 12 d Remove the filter element Item 5 Figure 4 12 and replace with a new filter element e Inspect the filter cover O ring Item 3 Figure 4 12 for any signs of wear or damag...

Page 66: ...1 Do all Daily maintenance procedures 2 Check the battery Item 1 Figure 4 13 and cable connections Items 2 and 3 Figure 4 13 for signs of leaking corrosion or damage Some items have been removed for c...

Page 67: ...e the end cap Item 3 Figure 4 14 from the air cleaner housing Item 1 Figure 4 14 b Pull the air cleaner element Item 4 Figure 4 14 out of the housing and inspect c Do not wash the filter element or us...

Page 68: ...Item 1 Figure 4 16 a Locate fuel filter assembly Item 1 Figure 4 16 through the opening in the frame along the right side of the machine b Unscrew the filter canister Item 2 Figure 4 16 NOTE The fuel...

Page 69: ...n any air bubbles g Tighten the air bleed bolt h Start the engine and allow it to idle for several minutes to make sure that all air bubbles are out of the fuel system Make sure to clean up any spille...

Page 70: ...otectent and sealer onto both terminals and cable clamps after cables are installed The electrical system on this machine is a NEGATIVE ground system Check both of the battery cables Items 1 and 3 Fig...

Page 71: ...he O ring Item 2 Figure 4 19 on the drain plug Replace the O ring if any signs of damage are noted Figure 4 19 Hydraulic Tank Drain Plug c When all of the hydraulic fluid has drained out of the tank r...

Page 72: ...um ISO 46 or equivalent until the fluid level is at but not above the upper marker hole in the dipstick Figure 4 20 Hydraulic Fluid Level Dip Stick Do not over fill the hydraulic system Damage to the...

Page 73: ...HE ENGINE IS COLD 4 FUEL TANKS SHOULD ONLY BE DRAINED IN AN AREA THAT IS WELL VENTILATED 5 WIPE UP ANY DIESEL FUEL THAT SPILLS 1 Park the machine on a level surface to ensure that the fuel tank is com...

Page 74: ...er Dispose of the used fuel filter in an appropriate manner and according to State and Local regulations 9 Install the fuel line onto the fuel feed pump 10 Slide the hose clamp close to the fuel feed...

Page 75: ...with matching the amperage rating shown on the top of the blown fuse All fuses and their locations are shown in illustration Figure 4 23 Figure 4 23 Fuse Panel Fuse Circuit Amp Rating 1 Fuel Solenoid...

Page 76: ...assembly when the track came off of the machine proceed to Step 2 If not skip to Step 7 2 Fully extend the track assemblies 3 Shut off the engine 4 Install tension bolt and thrust washer Item 1 Figure...

Page 77: ...k Plate 8 Remove track tension lock plate bolt Item 1 Figure 4 26 using a 9 16 wrench 9 Remove lock plate Item 2 Figure 3 10 Loosen track tension by rotating the tension bolt Item 3 Figure 4 26 CLOCKW...

Page 78: ...4 securing the drive sprocket Item 3 Figure 4 27 to the drive motor Figure 4 27 Remove Drive Sprocket 12 Slide the track Item 2 Figure 4 28 on the front idler wheel Item 1 Figure 4 28 making sure that...

Page 79: ...9 Insert Drive Sprocket into Track 14 Position the drive sprocket and the track onto the drive motor 15 Rotate the drive sprocket Item 1 Figure 4 30 and track to align the bolt holes Figure 4 30 Insta...

Page 80: ...ensionStart the engine and slowly rotate the track forward and backward to make sure that the track is properly seated on the drive sprocket 19 Fully rotate the track forward and backward several time...

Page 81: ...4 27 Routine Service and Maintenance Boxer 526DX Electrical Schematic Figure 4 32 Boxer 526DX Electrical Schematic 2243...

Page 82: ...4 28 Routine Service and Maintenance Boxer 526DX Hydraulic Interconnect Diagram Figure 4 33 Boxer 526DX Hydraulic Interconnect Diagram 2244...

Page 83: ...ever to neutral position Battery is dead Charge the battery If battery does not hold a charge replace the battery Electrical connections are corroded or loose Check electrical connections for good con...

Page 84: ...ir bleed instructions Dirty or contaminated fuel filter Replace fuel filter Dirt water or stale fuel is in fuel system Drain fuel in tanks into an appropriate storage container and dispose of bad fuel...

Page 85: ...els and with the type of coolant indicated in the engine manual Dirty or plugged radiator Clean the radiator Abnormalenginevibration Engine mounting bolts are loose Tighten engine mounting bolts With...

Page 86: ...5 4 Troubleshooting...

Page 87: ...eutral down and float Bucket Attachment Tilt Three position spring centered lever control Extend neutral and curl Auxiliary Attachment Control Three position detent lever control Wheel Track Options 9...

Page 88: ...4 EC in addition to ISO 3744 and ISO 6395 Engine rpm was set 2600 rpm The noise measurements were made with the operator present The declared value for the operator is 86dB LPA The Guaranteed SWL valu...

Page 89: ...S A 15 DEGRE E SLOPE DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES To avoid serious injury operate your unit u...

Page 90: ...MANUFACTURING LLC Mertz Manufacturing 1701 N Waverly St Ponca City OK 74601 Phone 800 654 6433 Fax 580 767 8411 Web Site www mertzok com Part Number 999 848 01...

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