Boxer 120 Parts Manual

Transcription

1 BIG POWER IN ALL PLACES Boxer Parts Manual Serial No.s 4 & Higher Part No. 45- Phone: Sales , Parts and Service Morbark, Inc. 50 S. Winn Rd., P.O. Box 00, Winn, Michigan 49

2 PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: Description of Changes: - Feb 0, 04 All Initial Release A Oct, Added Hose Clamp B Jan, 0.5 Item Replacement sprocket Routine Maintenance Replacement Parts The following parts should be considered as normal stock part items in your location. Keeping a supply of these will enable you to keep the Boxer in full service. Part Name Part Number Maintenance Kit Idler Wheel Repair Kit Mid - Wheel Repair Kit Air Filter Element Air Filter Pre-cleaner Air Filter Bonnet Fuel Filter (In-Line) Hydraulic Oil Filter...- Engine Oil Filter Hydraulic Oil...Chevron Rykon Premium ISO 4 or equal Seal Kit for Tilt Cylinder Seal Kit for Wheel Motor Replacement Ignition Key

3 Parts List and Illustrations Page Number Parts Manual Revision Log... Routine Maintenance Replacement Parts... Trencher Guard Assembly.... Trencher Assembly....4 Safety & Identification Decals Group.... Access Cover Group.... Battery Group....9 Travel Drive Group.... Idler Wheel and Spring Assembly.... Mid-Wheel Assembly.... Hydraulic Control Group....4 Rear Frame Parts.... Hydraulic Filter and Tank Group....0 Muffler Parts Group.... Hydraulic Pump Group.... Fuel System Parts....4 Air Filter Assembly.... Hydraulic Schematic.... Electrical Schematic.... Write your machines Serial Number in the space below for future reference. The serial number is located on the metal tag on the left side of the machine. MANUFACTURED BY: WINN, MICHIGAN, USA DATE OF MANUFACTURE MODEL NO. ENGINE SERIAL NO. WEIGHT POWER LB HP S.N. MORBARK, INC Sales (00) -004 Parts and Service (00) KG KW Record SERIAL NUMBER here.

4 Trencher Guard Assembly

5 Trencher Guard Assembly Item No. Description Quantity Part Number BOOM, 40 BOOM, 4 40 BOOM BUSHING 5 SPRING 5 4 BOOM END 5 SQUARE PIN.5 UNC X.5 NYLOC CAPSCREW 54 IDLER SPACER 9* IDLER BEARING HUB 59* IDLER WHEEL * IDLER BEARING 05* 9 CHAIN, 9 TOOTH REPLACEMENT KIT 54 CHAIN, 4 4 TOOTH REPLACEMENT KIT 5 CRUMBER BAR/PERSONAL RESTRAINT BAR 45 CRUMBER END 9 LEVER ARM 4.50 UNC X 4.50 HEX CAPSCREW HARD FLAT WASHER UNC DEFORMED LOCK NUT - GRADE 4 4 CRUMBER SHOE UNC X.5 HEX CAPSCREW 44. FLAT WASHER LOCKWASHER UNC HEX NUT RETAINING PLATE 0 CRUMBER BOOM UNC X.00 HEX CAPSCREW - GRADE UNC JAM NUT 4 5 RUBBER FLAP 4 COVER PLATE 00. UNC X.5 HEX CAPSCREW 4. UNC DEFORMED LOCK NUT 4 94 * = IDLER ROLLER REPAIR KIT 5.

6 Trencher Assembly

7 Trencher Assembly Item No. Description Quantity Part Number TRENCHER, COMPLETE (FOR ) 945 TRENCHER, 4 COMPLETE (FOR ) 944 TRENCHER, MODEL 5 COMPLETE ( - GPM) 9 PLANETARY DRIVE ASSEMBLY 9 REPLACEMENT SEAL PROTECTOR 99 REPLACEMENT SPROCKET 59 4 REPLACEMENT LOCK COLLAR 4 REPLACEMENT SET SCREW 0 5 AUGER 004 HEX CAPSCREW 9 HARD FLAT WASHER 50 UNC DEFORMED LOCK NUT HEX CAPSCREW - GRADE 00 HEX CAPSCREW - GRADE 0 HARD FLAT WASHER DEFORMED LOCK NUT 9 HEX CAPSCREW - GRADE HEX CAPSCREW - GRADE 4 5 HARD FLAT WASHER 4 MAINFRAME GASKET 0 MOTOR, HYDRAULIC 95 9 SOCKETHEAD CAPSCREW 90 0 HARD FLAT WASHER 505 MOUNT, BOXER 99 CYLINDER, HYDRAULIC 999 PIN, CYLINDER END 4 4 PIN, RAM END HEX CAPSCREW - GRADE 4 LOCK WASHER 50 HARD FLAT WASHER 0 BUSHING PIN, RAM END 0 GREASE ZERK ADJUSTMENT BRACKET 5 PLATE HEX CAPSCREW - GRADE HARD FLAT WASHER ADJUSTMENT BOLT 5 JAM NUT 44 HEX NUT 0.5

8 Safety and Identification Decals Group 9,

9 Safety and Identification Decals Group Item No. Description Quantity Part Number DECAL, LIFT POINT/TIE DOWN DECAL, BOXER 95-5 PLACARD, WEIGHT/POWER 95-4 PLACARD, SERIAL NUMBER DECAL, OPERATION 95-0 DECAL, CALL BEFORE YOU DIG DECAL, DECAL, LOGO, MORBARK WHITE LETTER DECAL, GASOLINE/PETROL ONLY DECAL, CAUTION, BURN HAZARD, SYS CONNECTOR DECAL, CAUTION, CLOSE FUEL SHUT-OFF DECAL, CAUTION, BURN HAZARD, DO NOT TOUCH DECAL, WARNING, REFUELING WARNING DECAL, WARNING, BATTERY GROUND (SYM) DECAL, WARNING, STAY BACK, SYS DANGER DECAL, WARNING, CALIFORNIA PROPOSITION DECAL, WARNING, SPARK HAZARD DECAL, WARNING, AUXILIARY VALVE DECAL, WARNING, ABRUPT SPEED CHANGE 95-0 DECAL, WARNING, READ MANUAL/SYM WARNING DECAL, WARNING, HIGH PRESSURE FLUID 95-5 DECAL, DANGER, CRUSH HAZARD, TRACK NS DECAL, HYDRAULIC OIL, ISO PREMIUM 4 (LOCATED ON FILTER CAP) 95- NS DECAL, SERIAL NUMBER (SMALL) NS DECAL, MANUFACTURING PLACARD 95- NS DECAL, LOW OIL 95- DECAL KIT

10 Access Cover Group Item No. Description Quantity Part Number COVER, OIL COOLER 0-0 MOUNT, OIL COOLER PANEL, TOP COVER PANEL, BOTTOM COVER HOLDER, MANUAL 94- BOLT 9-00 FLAT WASHER -9 BOLT LOCK WASHER -9 FLAT WASHER -5.

11 Battery Group Item No. Description Quantity Part Number BATTERY 95-0 ADJUSTABLE BATTERY HOLD DOWN - Includes Wingnuts, Flat 95-0 Washers And Threaded J-Hooks POSITIVE CABLE, COMPLETE RED BATTERY TERMINAL INSULATOR RED BATTERY TERMINAL INSULATOR - STARTER END NEGATIVE CABLE, COMPLETE BLACK BATTERY TERMINAL INSULATOR BOLT FLAT WASHER 4-0 NUT -04.9

12 Travel Drive Group ,,

13 Travel Drive Group Item No. Description Quantity Part Number BOLT 9-5 FRONT IDLER ASSEMBLY See Page FITTING WHEEL MOTOR WOODRUFF KEY 5-0 OUTPUT SHAFT 5-0 WHEEL MOTOR SEAL KIT (NOT SHOWN) 5-0 TRACK DRIVE HUB 0-0 COTTER PIN -0 SPROCKET 09-0 FLAT WASHER -4 BOLT CASTLE NUT MID-WHEEL SPOOL ASSEMBLY See Page BOLT 9- WASHER -55 WASHER, LOCK WASHER, LOCK -4 0 HOSE ASSY, LEFT WHEEL MOTOR, FRONT PORT 5- HOSE ASSY, LEFT WHEEL MOTOR, REAR PORT 5- HOSE ASSY, RIGHT WHEEL MOTOR, FRONT PORT 5- HOSE ASSY, RIGHT WHEEL MOTOR, REAR PORT 5-.

14 Idler Wheel and Spring Assembly Item No. Description Quantity Part Number IDLER ASSY, FRONT, RH IDLER ASSY, FRONT, LH TENSION LOCK PLATE 00-0 JACKING BOLT WELDMENT SPRING TENSIONER WELDMENT SPRING TRACK FORK WELDMENT WHEEL ASSEMBLY BEARING 95-4 IDLER SPACER TUBE IDLER PIN SEAL 95-4 SNAP RING FRONT IDLER WHEEL LOCK WASHER -4 4 BOLT - 5 FLAT WASHER -90.

15 Mid Wheel Assembly Item No. Description Quantity Part Number NUT -4 WASHER - SEAL SNAP RING BEARING MIDWHEEL 0-0 MIDWHEEL AXLE MID WHEEL, COMPLETE

16 Hydraulic Control Group

17 Hydraulic Control Group Item No. Description Quantity Part Number VALVE, SD5/ - SPACER PLATE 00-0 BOLT, 5/- X / NUT, 5/ TRENCHER CONTROL LEVER 0-0 WASHER, 5/ -5 NUT - M X.5-0 FITTING, UNION ADAPTER FITTING, TEE HB X HB X SAE CLAMP FITTING, HB X SAE ORING HOSE, TO COUNTER BALANCE VALVE HOSE, TO ENGINE COOLER FITTING HOSE, TO BULKHEAD 5- HOSE, TO BULKHEAD 5- SOLENOID -40 BOLT WASHER -0 0 FITTING 5- HOSE 5- FITTING 5- HOSE, TO ENGINE PUMP FITTING, ORS TEE 0 X 0SAE X 0ORS FITTING, NIPPLE 5-45 TEST PORT DUST CAP 5-4.5

18 Hydraulic Control Group

19 Hydraulic Control Group Item No. Description Quantity Part Number VALVE, SD5/ -4 BOLT, 5/- X / 5-0 NUT, NYLOC, 5/ CAST HANDLE TRAVEL CONTROL LEVER NUT, M-.5-0 MOLDED HANDLE TRAVEL CONTROL LEVER NUT - M X.5 ZC 4 - ADAPTOR, UNION FITTING -54 FITTING ASSEMBLY, HOSE FITTING, ORS 0 X 0 SAE MALE STR ASSEMBLY, HOSE, PISTON TO BANK - FITTING 5-0 FITTING, ORS TEE 0 X 0SAE X 0ORS 5- ASSEMBLY, HOSE, PUMP TO BANK FITTING ASSEMBLY, HOSE, PISTON TO BANK -9 VALVE, SOLENOID - FITTING, ORS TEE 0 X ASSEMBLY, HOSE, COUNTERBALANCE VALVE TO VB PSI FITTING TEST PORT DUST CAP 5-4 TEST PORT FITTING 5-44 FITTING 5- FITTING 5-59 NS SPACER PLATE 00-0.

20 Rear Frame Parts

21 Rear Frame Parts Item No. Description Quantity Part Number CONTROL PANEL TEXTURED GRIP SUB PANEL BOLT BOLT 9-05 BOLT, CARRIAGE 4-0 LOCK WASHER 4-9 FLAT WASHER NUT 4-45 CONTROL THROTTLE 4-00 HOUR METER 9-9 IGNITION W/KEY NS KEY KEY CHAIN TERMINAL, REMOTE MOUNT JUMPER 4-40 NS RUBBER MATT

22 Hydraulic Filter and Tank Group

23 Hydraulic Filter and Tank Group Item No. Description Quantity Part Number HYDRAULIC FILTER ASSEMBLY -90 NS HEX HEAD BOLT -9 NS HYDRAULIC FILTER TOP COVER PLATE -0 NS O-RING SEAL KIT - NS HYDRAULIC FILTER PRESSURE SPRING - NS HYDRAULIC FILTER ELEMENT - NS FILTER HOLDER BASKET - NS BOLT - NS WASHER - NS FILTER HEAD - FITTING 5-4 CLAMP, HOSE HOSE DIPSTICK HOSE 5-5 HYDRAULIC TANK CLEAN-OUT COVER HYDRAULIC TANK CLEAN-OUT COVER GASKET, COMES W/# FITTING 5-4 HOSE 4-90 FITTING 5- MOUNT, BREATHER FITTING, BREATHER BREATHER BOLT 5-00 WASHER, FLAT 4-9 COOLER, HYDRAULIC 44- CLAMP, HOSE -5 9 BOLT, CLAMP, HOSE -4.

24 Muffler Parts Group Item No. Description Quantity Part Number ENGINE, KOHLER CH4I (0.5 HP) 95-0 GASKET, AIR BREATHER W/ENGINE ELBOW, AIR BREATHER W/ENGINE 4 BOLTS,ELBOW, AIR BREATHER W/ENGINE 5 FITTING HOSE, DRAIN, ENGINE 95- PLUG, HOSE 54-4 BOLT, ENGINE WASHER, LOCK, ENGINE 4-9 WASHER, FLAT, ENGINE 4-5 MUFFLER 95- NS MUFFLER GASKET 95- GUARD, MUFFLER 95-9 END CAP, MUFFLER (COMES WITH ENGINE) SHEET METAL SCREW -00.

25 Hydraulic Pump Group Item No. Description Quantity Part Number PUMP, HYDRAULIC -055 BOLT 5- FLAT WASHER FITTING FITTING 5- HOSE HOSE 5-5 CLAMP, HOSE HOSE 5-50 FITTING 5-45.

26 Fuel System Parts

27 Fuel System Parts Item No. Description Quantity Part Number FUEL TANK 9-40 FUEL TANK CAP 49- BOLT LOCK WASHER -9 5 FLAT WASHER - BUSHING, STEEL 5-00 VALVE, SHUT OFF HOSE CLAMP FUEL HOSE 9-90 FUEL FILTER 95-0 FUEL HOSE 0-90 FITTING, BARBED 5-0 FUEL, SHUT OFF, ELECTRIC BOLT NUT -45 GROMMET 4-9 FUEL LINE

28 Air Filter Assembly Item No. Description Quantity Part Number AIR CLEANER ASSEMBLY 995- HOSE CLAMP FILTER MOUNTING BAND BOLT FLAT WASHER -5 NYLOC NUT -45 AIR FILTER ELEMENT - INNER 95- AIR FILTER ELEMENT - OUTER 95-9 RUBBER ELBOW, STEEL TUBE, RUBBER HOSE -90.

29 Hydraulic Schematic TRENCHER MOTOR LIFT CYLINDER LEFT TRACK 5-00 RIGHT TRACK 5-00 COUNTER BALANCE VALVE - TRENCHER VALVE - VALVE BANK -4 PUMP -055 COOLER 44- FILTER ASSEMBLY -90.

30 Electric Schematic HOUR METER BLUE GA RED 4 GA RED/WHITE GA BLACK GA BLACK GA RED/WHITE 4 GA RED GA 5 BLACK GA OIL COOLER FAN WHITE GA GREEN GA BLACK 4 GA OIL IGNITION SWITCH PRESSURE ALARM RED GA GREEN GA BLACK GA BATTERY CABLE RED GA BATTERY CABLE RED GA POSITIVE JUMPER POST RED 4 GA BLUE GA RED/ WHITE 4 GA WHITE GA 0A FUSE SEE KOHLER COMMAND CH-45 ENGINE SCHEMATICS FOR MORE DETAILS GROUND RED GA STARTER SOLENOID BLUE GA BLUE RED WHITE YELLOW RED.

31 Electrical Schematic DT RECEP # EYELET # G FUEL SHUTDOWN RED (SWITCHED VOLTAGE) -- BLACK (GROUND) -- RED (CONSTANT VOLTAGE) -- TELEMATIC DEVICE F TOGGLE SWITCH SPLICE RED -- BLACK -- A RED -- BLACK -- JUMPER POST C EYELET # E SOLENOID VALVE RED -- BLACK -- B DT PLUG # CONNECTOR FROM MAIN HARNESS CHASSIS GROUND DT PLUG # D EYELET # RED (SWITCHED VOLTAGE) BLACK (GROUND) DT RECEP #

32 BIG POWER IN ALL PLACES Phone: Sales , Parts and Service Morbark, Inc. 50 S. Winn Rd., P.O. Box 00, Winn, Michigan 49