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Summary of Contents for Mertz Boxer 999-935
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MANUFACTURING, LLC Big Power in Small Places Part No. 999-935 Serial No.s 1704 and Higher Operator’s Manual...
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Any parts of the equipment found to be defective within the warranty period shall be repaired or replaced, at Mertz Manufacturing, LLC's sole option. Repairs must be performed at Mertz Manufacturing, LLC facilities or at an authorized dealer facility.
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Mertz Manufacturing, LLC. In no event shall Mertz Manufacturing, LLC be liable for removing defective parts or for reinstalling said parts when repaired or replaced by anyone other than Mertz Manufacturing, LLC or an authorized service facility or for any costs incurred with such removal or reinstallation.
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To have Mertz Manufacturing, LLC reset the warranty start date, please complete the form below and mail or fax it back to: Mertz Manufacturing, LLC, P.O. Box 150, Ponca City, OK 74602, Fax: 580-767-8411.
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Affix Stamp Here Mertz Manufacturing, LLC P.O. Box 150 Ponca City, OK 74602...
Safety Introduction Be Prepared - Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol. Wherever it appears, either in this manual or on safety signs on the machine, you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
Table of Contents Boxer Product Warranty ..................i Safety Introduction ..................... v Be Prepared - Get to Know All Operating and Safety Instructions ...v Learn the Signal Words Used with the Safety Alert Symbol.....v Section 1 – Safety Precautions ..............1–1 GENERAL SAFETY ...................
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Section 4 – Routine Service and Maintenance ..........4–1 Daily Maintenance Procedures ..............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 Fuel Tank (Diesel)............... 4–22 Section 5 –...
• Use only original Mertz or approved replacement parts and attachments. Imitation parts may lead to unit damage and/or injury to personnel. The machines’ warranty may be voided if unauthorized parts and attachments are used.
Safety Precautions OPERATING SAFETY • Plan ahead and learn as much as possible about your job-site area before beginning any work. • Know the exact location of overhead power lines or obstructions. • Have all buried lines such as; gas, electric, water, telephone and cable TV, marked by the proper authorities.
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Safety Precautions • Never attempt to operate any attachment without first understanding proper installation and operating procedures. The center of gravity, stability, and operating characteristics of the entire machine will change with the use of different attachments. • Operate all controls slowly and smoothly and never abruptly stop any function. This can cause the machine to become unstable.
• Use only Mertz supplied or approved replacement parts and attachments. Imitation parts may lead to unit damage and/or injury to personnel. Warranty may be voided if unauthorized parts and attachments are used.
Safety Precautions Battery Hazards Before working with batteries, the following are important points about battery safety that you should be aware of: • Batteries are always surrounded by extremely explosive gases. This is especially true when the battery is being charged. To avoid explosion: –...
Safety Precautions Hydraulic System Hazards The hydraulic system is under pressure whenever the engine is running and may hold pressure even after the engine is shut off. Cycle all hydraulic controls after the loader boom is resting on the ground. Some components will retain residual or trapped pressure. Use extreme caution when removing any hydraulic component.
Safety Precautions Fueling Hazards Most fuels are highly flammable. Observe the following precautionary practices to reduce the possibility of a serious accident: • Always refuel the unit in an open, well ventilated area away from sparks or open flames. DANGER Diesel Engines: •...
Operating Controls Operating Controls 2086 Item No. Description Auxiliary attachment activation control Loader arm lift control Track widen control Attachment tilt control Travel crawl activation control Travel crawl speed control Hand grip Right travel motor control Left travel motor control Hand grip High/Low speed control switch Engine throttle...
Operating Controls Operating Controls Description 2086 1. Attachment Activation Lever – Moving this lever into the FORWARD detent position activates the hydraulically powered attachment's forward motion. Moving the control lever into the BACKWARD detent position activates the hydraulically powered attachment's reverse motion.
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Operating Controls Operating Controls Description (Continued) 10.Left Hand Grip. 11.High/Low Speed Range Selector Switch – Selects the travel speed range. 12.Engine Throttle – Moving the control lever upwards increases the engine speed and moving the lever downwards slows the engine to idle speed. 13.Engine Glow Plug Indicator Light.
Section 3 – Pre-Start Inspection and Operation DANGER IMPROPER USE OF THE COMPACT UTILITY LOADER COULD CAUSE SERIOUS INJURY OR DEATH. BEFORE OPERATING THE MACHINE, OR PERFORMING MAINTENANCE, THE OPERATOR MUST READ AND UNDERSTAND THE ENTIRE OPERATOR'S MANUAL, REVIEW MACHINE CONTROLS, LOCATE AND REVIEW ALL WARNINGS AND SAFETY PLACARDS AND RELEVANT OPERATOR SAFETY MATERIALS INCLUDING WRITTEN, VISUAL, VIDEO OR VERBAL INSTRUCTIONS.
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Pre-Start Inspection and Operation Do the following pre-start service checks: 1. Check condition of all warning and instructional decals. Replace any damaged decals with genuine Mertz replacement decals. 2. Check engine oil - • Make sure that the engine is OFF.
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Pre-Start Inspection and Operation Extremely dusty or dirty working conditions may require more frequent checking, NOTE: filling and/or changing of engine oil. • After filling the oil, wait a few minutes and check the oil level again. IMPORTANT Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine. Check engine fuel and fill as needed - be sure engine is OFF 3.
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Pre-Start Inspection and Operation 4. Check all hydraulic hoses, lines and fittings. WARNING Hydraulic oil under pressure can penetrate body 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 hydraulic oil or any other fluids, immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries.
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Pre-Start Inspection and Operation 8. Grease pivot shafts with proper type of grease. There are 14 grease points on this machine, Figure 3–5. CAUTION Before starting the engine: • Move all hydraulic control levers forward and release the lever. Make sure that each lever automatically returns to the Neutral position.
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Pre-Start Inspection and Operation 2088 Figure 3–5 Lubrication Points Extremely dusty or dirty working conditions may require more frequent service/ NOTE: replacement. CAUTION Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly.
Pre-Start Inspection and Operation Cylinder Lock Installation 1. Start the engine. (See Machine Start-up in this section for engine starting instructions. 2. Fully raise the loader arm. 3. Shut off the engine. 4. While holding the cylinder lock (Item 2, Figure 3–6), pull the safety lock pin (Item 1, Figure 3-6) outwards, releasing the cylinder lock.
Pre-Start Inspection and Operation Operating Instructions Machine Start-up To start the machine, the operator must: 1. Stand on the operator's platform (Item 1, Figure 3–7). 2091 Figure 3–7 Operator's Platform 2. Rotate the ignition key switch to the HEAT position (1, Figure 3–8) for about 10 seconds.
Pre-Start Inspection and Operation 4. Rotate and hold the starter switch in the START (Item 4, Figure 3–8) position until the engine starts. 2093 Figure 3–9 Throttle Settings 5. As soon as the engine starts, release the starter key. The key will automatically return to the RUN position.
Pre-Start Inspection and Operation Transportation 1. Move the throttle control lever to the mid-range engine speed and set the transport speed to the LOW range. Raise the attachment so that it will clear the ramp of the transport trailer. The longer the attachment, like the trencher, the more the attachment needs to either NOTE: be tilted or raised.
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Pre-Start Inspection and Operation Due to the spring tension system built into the track drive system as a safety NOTE: mechanism, the machine can be put into an extreme situation during which the drive sprocket will bypass the rubber track guide holes causing a popping noise, called “cogging”. This situation is part of the track drive systems safety design, and indicates that this portion of the safety system is functioning properly.
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Pre-Start Inspection and Operation Right Turn During Forward Travel Left Turn During Forward Travel To turn to the To turn to the left, right, move the left move the right hand control lever hand control lever farther forward farther forward than the right than the left control lever.
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Pre-Start Inspection and Operation Spin Turn CAUTION Make sure to use the machine hand holds while doing a spin turn to maintain your balance. Move 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;...
Pre-Start Inspection and Operation Attachment Installation and Removal Attachment Lock Pins The mounting plate located at the front of the machine provides for the easy installation and safe use of the wide variety of available attachments. This system is very easy to use, but requires the proper use of the attachment lock pins.
Pre-Start Inspection and Operation CAUTION Make sure to keep your hands and feet away from the attachment during the unlocking process. As the attachment becomes free from the machine, it may move. Pins Unlocked 2021 Figure 3–19 Attachment Locks in Unlocked Position Installation of Non-Hydraulically Powered Attachments There are many available attachments that are very easy to install.
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Pre-Start Inspection and Operation 4. When the machines mounting plates top edge is seated in the attachment mounting plate, curl the machines mounting plate backwards slightly to allow the lower edge of the machines mounting plate to slide into position. See Figure 3–21.
Pre-Start Inspection and Operation Removal of Attachment 1. Lower the attachment onto a firm, level surface. 2. Shut off the machine engine. 3. Rotate the attachment lock pins to the UNLOCKED position (Item 1, Figure 3–23). Pins Unlocked 2021 Figure 3–23 Attachment Locks in Unlocked Position 4.
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Pre-Start Inspection and Operation 3. Slowly drive towards the attachment and align the top edge of the male mounting plate (Item 1, Figure 3–25) and the upper lip of the female attachment mounting plate (Item 2, Figure 3–25). Make sure to position the attachments hydraulic hoses (Item 4, Figure 3–25) so that NOTE:...
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Pre-Start Inspection and Operation 5. Shut the engine off. 6. Rotate the attachment lock pins (Item 1, Figure 3–26, Item 1, Figure 3–27) into the locked position securing the attachment to the machine. Pins Locked 2022 Figure 3–27 Attachment Locks in Locked Position 7.
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Pre-Start Inspection and Operation b. Remove the protective covers (Items 2, 6, Figure 3–29) from the attachment quick connectors. c. Wipe off the end of each of the connectors (Items1, 3, Figure 3–29) to remove any dirt or debris. 2116 Figure 3–29 Auxiliary Hydraulic Quick Connects d.
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Pre-Start Inspection and Operation 11.Make sure that the hydraulic hoses are routed so that they will not be in the way or damaged during machine operation. Figure 3–30 shows how the hoses might be routed to keep them out of the way during operation and prevent them from being damaged. 2117 Figure 3–30 Attachment Hydraulic Hose Routing 12.The attachment is now ready to use.
Pre-Start Inspection and Operation Operating Instructions for a Hydraulic Attachment 1. Move the engine throttle to the full speed setting. Raise the attachment off the ground and position it for use. CAUTION Make sure that you are standing on the operator's platform. DO NOT step off of the platform when the auxiliary attachment’s power is engaged.
Pre-Start Inspection and Operation Travel Crawl Control The travel system on the machine can be adjusted to make the attachment more effective in tough digging situations. The travel “crawl” control allows the travel speed to be adjusted from full speed forward or reverse to no movement at all. To adjust the travel speed using the crawl control, move the engine throttle lever to the maximum engine speed and: Make sure that the High/Low travel speed switch (Item 2, Figure...
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Pre-Start Inspection and Operation a. Rotate the CRAWL control lever (Item 1, Figure 3–34) to adjust the travel speed as needed. 2102 Figure 3–34 Crawl Speed Adjust Control b. Rotate the CRAWL control lever fully clockwise to the turtle, or NO TRAVEL position. Full hydraulic power will be directed to the attachment and the machine will not move.
Pre-Start Inspection and Operation Removal of Hydraulically Powered Attachments CAUTION After use, the quick couples and hydraulic fluid will be very hot. Wear gloves when disconnecting the auxiliary hydraulic lines. To remove a hydraulically powered attachment; 1. Lower the attachment to the ground and shut off the engine. 2.
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Pre-Start Inspection and Operation 3-26...
Section 4 – Routine Service and Maintenance The following information presents the routine service and maintenance required to make sure that the machine functions safely and properly. More detailed service information is contained in the Service Manual. Table 1: Service Cycle Table Daily Machine Weekly...
Routine Service and Maintenance Daily Maintenance Procedures Do the following procedures daily or every 10 operating hours: 1. Check condition of all warning and instructional decals. Before operating the machine, replace any missing or damaged decals. Make sure to read and understand all WARNING and SAFETY decals before NOTE: operating the machine.
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Routine Service and Maintenance 3. Check engine oil - a. Make sure that the engine is OFF. b. Pull out the dipstick (Item 1, Figure 4–2) and look for the “FULL” line. 2110 Figure 4–2 Oil Level Check c. If the engine oil level is below the add line, indicated by the letter “A” on the dipstick, carefully add the proper amount of oil through the engine oil filler (Item 1, Figure 4–2).
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Routine Service and Maintenance IMPORTANT Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine. 4. Release 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.
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Routine Service and Maintenance 2118 Figure 4–5 Air Filter Restriction Indicator 6. Check hydraulic oil level, fill as needed with the proper hydraulic oil - be sure engine is OFF a. The hydraulic oil dipstick can be reached through the opening in the front cover. b.
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Routine Service and Maintenance 2104 Figure 4–6 Hydraulic Fluid Level Dip Stick 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. IMPORTANT Do not over fill the hydraulic system.
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Routine Service and Maintenance 7. Check hydraulic hoses. WARNING Hydraulic oil under pressure can penetrate body 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 hydraulic oil or any other fluids, immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries.
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Routine Service and Maintenance 2119 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.
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Routine Service and Maintenance d. Some examples of common hydraulic hose damage are shown in Figure 4–8: 1034 Figure 4–8 Hydraulic Hose Damage 1. End fittings damaged or leaking. 2. Outer covering chafed or cut, and wire reinforcing is exposed. 3.
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Routine Service and Maintenance Extremely dusty or dirty working conditions may require more frequent service/ NOTE: replacement. 10.Check both track assemblies for: a. The proper tension. Too little or too much tension can cause premature track wear and travel motor damage. b.
Routine Service and Maintenance 2147 Figure 4–10 Track Deflection Measurement and Adjustment New Machine 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 left side of the engine - see engine manual and (Item 1, Figure 4–11).
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Routine Service and Maintenance 3. Change the hydraulic filter. See Service Manual and Figure 4–12. a. Remove the front cover (Item 10, Figure 4–12) to enable access to the filter assembly (Item 9, Figure 4–12). b. Remove the three bolts (Item 1, Figure 4–12) holding the filter cover (Item 2, Figure...
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Routine Service and Maintenance 4. Rotate the track until the plugs (Items 1 and 2, Figure 4–13) on the side of the final drive cover plate are at the 12:00 and 3:00 position and turn off the engine. a. Using an allen wrench, remove the plug (Item 2, Figure 4–13) that is in the 3:00 position.
Routine Service and Maintenance Weekly Maintenance Procedures Do the following procedures weekly or every 50 operating hours: 1. Do all Daily maintenance procedures 2. Check the battery (Item 1, Figure 4–14) and cable connections (Items 2 and 3, Figure 4–14) for signs of leaking, corrosion or damage.
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Routine Service and Maintenance a. Unhook the two retaining clips and remove the end cap (Item 2, Figure 4–15) from the air cleaner housing (Item 1, Figure 4–15). b. Pull the air cleaner element (Item 3, Figure 4–15) out of the housing and inspect. c.
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Routine Service and Maintenance f. Using the rubber fuel feed squeeze bulb (Item 1, Figure 4–18) pump fuel into the fuel filter assembly until the fuel escaping from the air bleed bolt does not contain any air bubbles. g. Tighten the air bleed bolt. h.
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Routine Service and Maintenance 6. Check battery signs of leakage or for corrosion on the battery cables. • On a monthly basis, check the battery (Item 1, Figure 4–19) for signs of leaking electro- lyte. If any signs of damage are visible, remove and replace the battery. CAUTION Wear the proper protective clothing when handling the battery.
Routine Service and Maintenance Annual Maintenance Procedures Do the following procedures annually: 1. Do all Daily, Weekly and Monthly maintenance procedures 2. Replace air filter** See page 4-14, Step 3. 3. Check engine idle speed (Refer to engine manual) 4. Replace hydraulic fluid**. a.
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Routine Service and Maintenance c. When all of the hydraulic fluid has drained out of the tank, reinstall and secure the drain plug. IMPORTANT Make sure to dispose of the used hydraulic fluid in an appropriate manner. d. Replace hydraulic filter. See page 4-12, Step 3. The hydraulic oil dipstick can be reached through the opening in the front cover.
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Routine Service and Maintenance IMPORTANT Do not over fill the hydraulic system. Damage to the hydraulic system might result. f. Start the machine and run the engine at low idle for several minutes. Shut off the engine. g. Recheck the hydraulic fluid level as described above. 5.
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Routine Service and Maintenance IMPORTANT • Use only a quality non-leaded SAE 150 lubricant in the final drive. • Make sure not to over tighten while reinstalling check plugs, damage to the aluminum hous- ing cover plug holes can occur. f.
Routine Service and Maintenance General Maintenance Draining Fuel Tank (Diesel) DANGER 1. DIESEL FUEL IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE. 2. A FIRE OR EXPLOSION FROM DIESEL FUEL CAN BURN YOU OR OTHERS AND CAUSE PROPERTY DAMAGE. 3. DRAIN FUEL FROM TANKS WHEN THE ENGINE IS COLD. 4.
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Routine Service and Maintenance 5. Loosen the intake hose hose clamp (Item 2, Figure 4–25) at the fuel feed pump (Item 1, Figure 4–25). Slide the clamp along the fuel line (Item 3, Figure 4–25), away from the fuel feed pump. 2125 Figure 4–25 Fuel Filter 6.
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Routine Service and Maintenance 15. Tighten the air bleed bolt. 16. Start the engine and allow it to idle for several minutes to make sure that all air bubbles are out of the fuel system. CAUTION Make sure to clean up any spilled fuel from in and around the engine compartment of the machine.
Section 5 – Troubleshooting The following procedures will assist you in determining the potential cause of a machine operating problem. IMPORTANT Make sure to follow all safety precautions stated in this manual when doing any work on the machine. Problem Possible Causes Corrective Action Starter does not turn the...
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Troubleshooting Problem Possible Causes Corrective Action Engine will not start, • Auxiliary hydraulics lever is not • Move lever to neutral starts hard, or fails to in neutral position with a position. keep running. hydraulically powered attachment installed. • Fuel tanks are empty. •...
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Troubleshooting Problem Possible Causes Corrective Action • Dirty or contaminated fuel filter. • Replace fuel filter. • Dirt, water, or stale fuel is in fuel • Drain fuel in tanks into an system. appropriate storage container and dispose of bad fuel properly.
Troubleshooting General Specifications Engine System Type Perkins 403C11 Cooling System Liquid Cooled 26.1 Fuel Tank 8.6 Gallons Air Cleaner Heavy-Duty Air Cleaner Hydraulic System Oil Cooling System Air to oil cooler with electric fan Pressure (Auxiliary/Boom & Tilt 3000 psi system relief Cylinder Circuit) Pressure Ground Drive Circuit 2600 psi system relief...
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Troubleshooting 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 3.8 psi Ground Pressure 1.7 kg/cm...
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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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