Mertz Boxer 999-935 Operator'S Manual Download Page 10

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Section 4 – Routine Service and Maintenance ............................................. 4–1

Draining Fuel Tank (Diesel) ............................................................... 4–22

Section 5 – Troubleshooting .......................................................................... 5–1

General Specifications ............................................................................... 5–4

Summary of Contents for Boxer 999-935

Page 1: ...MANUFACTURING LLC Big Power in Small Places Part No 999 935 Serial No s 1704 and Higher Operator s Manual...

Page 2: ......

Page 3: ...horized 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 afte...

Page 4: ...LLC or anauthorized 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: ...1 Right Rear View 2 2 Operating Controls 2 3 Safety Decals 2 4 Operating Controls Description 2 6 Section 3 Pre Start Inspection and Operation 3 1 Pre Start Inspection 3 1 Daily Service Checks 3 1 Cy...

Page 10: ...res 4 2 New Machine Brake in Maintenance Procedures 4 11 Weekly Maintenance Procedures 4 14 Monthly Maintenance Procedures 4 14 Annual Maintenance Procedures 4 18 General Maintenance 4 22 Draining Fue...

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: ...the work area stop machine operation until the work area is clear Prior to unloading the unit and starting to work in spect 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 thecontrols If anything unusual is noticed shut the machine down and thoroughly inspect it to determine the cause of the problem Do not operate t...

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: ...shed into youreyes flush them immediately with clean water and seek medical attention If electrolyte is swallowed seek medical attention immediately If electrolyte is splashed onto exposed skin or clo...

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: ...unting plate 2 Tilt cylinder 3 Loader Arms 4 Operating controls 5 Hand grip 6 Manual holder 7 Lift cylinder 8 Fuel filler cap 9 Fuel tank 10 Battery 11 Left track assembly 12 Hydraulic level check 13...

Page 20: ...Lift cylinder 3 Attachment hydraulic quick connects 4 Lift cylinder safety lock 5 Loader arm lift cylinder 6 Right track assembly 7 Hydraulic oil cooler 8 Fuel primer pump 9 Operator s platform 10 Fue...

Page 21: ...trol 4 Attachment tilt control 5 Travel crawl activation control 6 Travel crawl speed control 7 Hand grip 8 Right travel motor control 9 Left travel motor control 10 Hand grip 11 High Low speed contro...

Page 22: ...ontrols Safety Decals Item No Description 1 Pinch Point Warning 2 Made in USA Decal 3 Boxer Decal 4 Track Widening Caution Decal 5 Mertz Decal 6 ISO 32 DECAL 7 Cylinder Lock Installation Warning 1 1 2...

Page 23: ...iring Control Decal 4 Crawl Valve OFF ON Control Decal 5 Crawl Speed Control Decal 6 Track Boom Bucket Control Decal 7 Two Speed Control Decal 8 Auxiliary Power Caution Decal 9 Engine Throttle Decal 1...

Page 24: ...owly forward or slowly backward 4 Attachment Tilt Pushing the lever forwards tilts the male mounting plate forwards lowering the attachment Pulling the lever backwards tilts the male mounting plate ba...

Page 25: ...ne to idle speed 13 Engine Glow Plug Indicator Light 14 Ignition Switch Rotating the key switch to the left activates the engine glow plug Rotating the key switch one position to th e right turns on t...

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

Page 27: ...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 Chec...

Page 28: ...nes 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 by the...

Page 29: ...e is OFF 3 The Boxer has two saddle 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...

Page 30: ...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 cut and wire reinforcing is exposed...

Page 31: ...s 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 will rema...

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: ...igure 3 6 securing the cylinder lock 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 cy...

Page 34: ...must 1 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 le...

Page 35: ...of 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 mac...

Page 36: ...ition on Trailer 3 When the machine is positioned on the trailer properly lower the attachment to the trailer deck 4 Shut the engine off and remove the key 5 Secure the unit to the transport vehicle w...

Page 37: ...load If a cogging condition occurs immediately stop machine travel and auxiliary functions and reverse travel direction slightly to de compress track tension Continued cogging will cause the track dri...

Page 38: ...arther forward the right control is moved the faster the left turn will be made See Figure 3 14 2097 Figure 3 14 Left Hand Turn in Forward Right Turn During Reverse Travel Left Turn During Reverse Tra...

Page 39: ...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 40: ...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 41: ...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 42: ...ure 3 21 Figure 3 21 Attachment Installed 5 Shut the engine off 6 Rotate the attachment lock pins Item 1 Figure 3 21 and Item 1 Figure 3 22 into the locked position securing the attachment to the mach...

Page 43: ...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 44: ...e not damaged during the installation process Tuck the upper edge of the male mounting plate into the upper lip of the female attachment mounting plate Figure 3 25 Hydraulically Powered Attachment Ins...

Page 45: ...XILIARY control lever Item 1 Figure 3 28 into either the FORWARD or BACKWARD detent position This will release the hydraulic pressure locked in the auxil iary hydraulic lines Leave the control lever i...

Page 46: ...male coupling Item 3 Figure 3 29 into the female bulkhead quick connect coupling Item 1 Figure 3 29 on the machine and push until the connector locks into position e Repeat the above process to connec...

Page 47: ...keep them out of the way during operation and prevent them from being damaged Figure 3 30 Attachment Hydraulic Hose Routing 12 The attachment is now ready to use Before starting the engine make sure t...

Page 48: ...iary Attachment Controls 3 Lower the attachment to begin work CAUTION ON OFF CRAWL VALVE CRAWL VALVE LOW LOW FLOAT DOWN BOOM UP LEFT RIGHT DUMP BUCKET CURL CRAWL SPEED CRAWL SPEED T H R O T T L E A U...

Page 49: ...NE READ AND UNDERSTAND THE OPERATOR S MANUAL BEFORE OPERATING THIS MACHINE CAUTION CAUTION BE SURE AUXILIARY POWER IS IN THE NEUTRAL POSITION BEFORE STARTING ENGINE BE SURE AUXILIARY POWER IS IN THE N...

Page 50: ...he faster the machine travels the less hydraulic power will be directed to the attachment The slower the machine travels more hydraulic power will be directed to the hydraulic attachment e EXAMPLE Whe...

Page 51: ...connect Item 1 Figure 3 35 to align the notch on the collar with the lock button Item 2 Figure 3 35 4 Slide the collar backwards on the female quick connect Item 4 Figure 3 35 until it stops against t...

Page 52: ...3 26 Pre Start Inspection and Operation...

Page 53: ...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 Weekly 50 Hours Monthly 200 Hours A...

Page 54: ...OFF a 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...

Page 55: ...refully add the proper amount of oil through the engine oil filler Item 1 Figure 4 2 It is important to add the correct type of engine oil as stated in the engine manual NOTE Make sure to reinstall an...

Page 56: ...r valve Item 1 Figure 4 4 underneath the air filter Figure 4 4 Air Filter Dirt Release 5 Check the Air Restriction Indicator Item 1 Figure 4 4 located underneath the left side of the air filter If the...

Page 57: ...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 58: ...tick d Add the proper hydraulic fluid Chevron Rykon Premium ISO 46 hydraulic fluid or equivalent until the fluid level is at but not above the upper marker hole in the dipstick Do not over fill the hy...

Page 59: ...g hydraulic fluid wear or damage Carefully inspect the quick couples Item 3 Figure 4 7 to make sure that they are not damaged or leaking 8 Follow all of the hoses line and tubes from the control valve...

Page 60: ...4 8 Routine Service and Maintenance Figure 4 7 Inspect Hydraulic Lines and Fittings c If any signs of damage are visible do not operate the machine until repairs have been made 2119 1 1 1 6 4 5 4 2 3...

Page 61: ...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 9 Grease pivot shafts with...

Page 62: ...4 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 ma...

Page 63: ...Brake 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 lef...

Page 64: ...ing c Remove the filter cover and spring Item 3 Figure 4 12 d Remove the filter element Item 3 Figure 4 12 and replace with a new filter element e Inspect the filter cover O ring Item 5 Figure 4 12 fo...

Page 65: ...t below the plug opening c If oil needs to be added remove the oil fill plug Item 1 Figure 4 13 and add the proper oil through the upper plug opening until oil begins to run out of the oil level check...

Page 66: ...Figure 4 14 for signs of leaking corrosion or damage Some items have been removed for clarity Figure 4 14 Battery and Cable Connections Monthly Maintenance Procedures Do the following procedures mont...

Page 67: ...the two retaining clips In extremely dusty or dirty operating conditions this service cycle may need to be shortened 4 Reset air filter restriction indicator Item 1 Figure 4 16 by pressing upwards on...

Page 68: ...n any air bubbles g Tighten the air bleed bolt h Start the engine and allow it to idlefor several minutes to make surethat all air bubbles are out of the fuel system Make sure to clean up any spilled...

Page 69: ...the leaking fluid can cause respiratory problems Check both of the battery cables Items 2 and 3 Figure 4 19 for signs of damage or cor rosion Loosen the cable clamps and remove the cable from the batt...

Page 70: ...ngine idle speed Refer to engine manual 4 Replace hydraulic fluid a Place a suitable sized container at the left front corner of the Boxer b Remove the hydraulic tank drain plug Item 1 Figure 4 20 and...

Page 71: ...filter See page 4 12 Step 3 NOTE The hydraulic oil dipstick can be reached through the opening in the front cover e Unscrew the dipstick assembly and remove from the machine 1 Figure 4 21 and fill the...

Page 72: ...e 3 00 and 6 00 position and shut off the engine b Position a drain pan under the final drive c Using an allen wrench remove the lower plug Item 1 Figure 4 22 and allow the oil to drain from the final...

Page 73: ...e final drive Make sure not to over tighten while reinstalling check plugs damage to the aluminum hous ing cover plug holes can occur f Reinstall and secure both oil level check plugs g Repeat this pr...

Page 74: ...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 75: ...and allow the fuel to drain into the drain pan 8 Install a new spin on fuel filter Item 4 Figure 4 25 as described earlier in this section 9 Install the fuel line onto the fuel feed pump 10 Slide the...

Page 76: ...6 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 spilled fuel from in and around the engine compartmen...

Page 77: ...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 78: ...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 79: ...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 80: ...ment Tilt Three position spring centered lever control Extend neutral and curl Auxiliary Attachment Control Three position detent lever control Wheel Track Options 9 Wide Track 7 track available Track...

Page 81: ...ooting Tip Capacity 1700 lb 771 kg Operating Capacity 35 of tip load 595 lb 270 kg Operating Capacity 50 of tip load 850 lb 386 kg Weight without Bucket w Bucket 2300 lb 1043 kg Ground Pressure 3 8 ps...

Page 82: ...5 6 Troubleshooting...

Page 83: ......

Page 84: ...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 999 851...

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