Boxer 600HD Parts Manual

Transcription

1 Phone: Sales , Parts and Service BIG POWER IN ALL PLACES Boxer 600HD Parts Manual SN 1 and Higher Part No Manufactured by: Morbark, LLC. 807 S. Winn Rd., P.O. Box 1000, Winn, Michigan

2 PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: - September, 2017 All Initial Release Description of Changes: 2

3 Page Intentionally Left Blank iii

4 Table of Contents Parts List and Illustrations Page Number Routine Maintenance Replacement Parts... 1 Top Level Assembly... 2 Frame Assembly... Front Idler Assembly, L/H... 8 Tensioning Bolt Assembly Front Idler Assembly, R/H Engine Assembly, Kubota D HP T... 1 Engine and Pump Assembly Exhaust Assembly Intake Assembly Battery Assembly Fuel System Assembly... 2 Operator Platform Assembly Upper Dash Assembly Lower Dash Assembly... 0 Hydraulic Control Assembly... 2 Boom Assembly... Attachment Plate Assembly... 6 Shroud Assembly... 8 iv

5 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 Engine Air Filter Elements Outer Inner Fuel Filter Hydraulic Filter Engine Oil Filter Hydraulic Filter Head Hydraulic Oil... Chevron Rykon Premium ISO 6 or equal Seal Kit for Tilt Cylinder Seal Kit for Lilt Cylinder Seal Kit for Wheel Motor Replacement Ignition Key Replacement Dash Panel Key

6 Top Level Assembly Item 1* 2* * 16*

7 Top Level Assembly ITEM QTY PART NO REV DESCRIPTION C Boxer 600HD 1* Electrical Harness, Controls 2* Electrical Harness, Main B Hydraulic Control Assembly Engine Shroud Dash Panel, Lower A Joystick Guard B Fuel System Battery Kit A Air Cleaner A Exhaust Assembly A Engine Package C Boom Assembly A Boxer Frame * * Operator Platform - Decal Kit, Boxer 600HD - Hose Guard

8 Frame Assembly DETAIL A A B 2 DETAIL B Item Q *

9 Frame Assembly ITEM QTY PART NO REV DESCRIPTION A Boxer Frame A Frame Weldment B Hydraulic Dipstick D Idler Assembly, Left C Track Tensioning Assembly D Track Idler, Right Key Ring Document Holder Control Panel Spacer Bumper Key Plate A Drive Sprocket, 72mm, 1 Teeth A Drive Hub Tension Lock Plate Rubber Track Mid-track Wheel Assembly Digital Hour Meter, 12 V Breather Cap 18* Ceramic Ring, Magnet Oil Cooler Hydraulic Motor, 22.2 cubic inch Hydraulic Fitting, Tee, #9 MSAE x #9 FSAE x #9 FSAE Drain Plug Hydraulic Fitting, # MORS x #6 MSAE Hydraulic Fitting, 90 degree, #10 MSAE x #12MSAE Hydraulic Fitting, degree, #10 ORS x #10 MSAE Throttle 27* Nylock Nut UNF Zinc Plated Hex Bolt - 1/2-20 UNF x 1 1/ Fillister Head Screw - #10-2 x / Flat Head Bolt UNF x / Nut Insert - /16-18 UNC

10 Frame Assembly, Con t DETAIL A A B 2 DETAIL B Item Q *

11 Frame Assembly ITEM QTY PART NO REV DESCRIPTION Nut Insert UNF Stover Nut, /8-11 UNC Nylock Nut - 1/2-1 UNC Hex Bolt - /8-16 UNC x 7/ Hex Bolt - 1/2-1 UNC x 2 1/ Hex Bolt - 1/2-1 UNC x 1 / Hex Bolt - /8-16 UNC x / Spring Lock Washer, ANSI B /2 ID Spring Lock Washer, ANSI B /8 ID Spring Lock Washer, ANSI B #10 ID Zinc Plated Washer, ANSI B Type A Narrow - 1/2 ID Zinc Plated Washer, ANSI B Type A Nar - 9/16 ID Washer, ANSI B Type A Nar - /8 ID Cotter Pin, 1/8 x 1 1/ Aluminum Rivet, 1/ x / 7

12 Front Idler Assembly, L/H

13 Front Idler Assembly, L/H ITEM QTY PART NO REV DESCRIPTION D Idler Assembly, Left A Track Fork Weldment A Idler Wheel Shaft A Clip Washer, ANSI B , 1/2 ID E Idler Bushing Seal, 62 x x 6 mm Idler Bearing C Idler Wheel Snap Ring, 62 mm Hex Bolt - 1/2-1 UNC x Spring Lock Washer, ANSI B /2 ID 9

14 Tensioning Bolt Assembly

15 Tensioning Bolt Assembly ITEM QTY PART NO REV DESCRIPTION C Track Tensioning Assembly A Track Adjusting Bolt A Spring Tension Nut Track Tension Spring 11

16 Front Idler Assembly, R/H

17 Front Idler Assembly, R/H ITEM QTY PART NO REV DESCRIPTION D Track Idler Assembly, Right A Track Fork Weldment A Idler Wheel Shaft A Clip Washer, ANSI B , 1/2 ID E Idler Bushing Seal, 62 x x 6 mm Idler Bearing C Idler Wheel Snap Ring, 62 mm Hex Bolt - 1/2-1 UNC x Spring Lock Washer, ANSI B /2 ID 1

18 Engine Assembly, Kubota, D HP, T

19 Engine Assembly, Kubota, D HP, T ITEM QTY PART NO REV DESCRIPTION A Engine Package Pump Mount B Engine Assembly, Kubota D hp Radiator Tube, Degree * Vacuum Tube Hose, 7/8 OD x Heater Tube A Coolant Tube * * Overflow Tank - Radiator - Hydraulic Fitting, 90 Degree, #12 MSAE x /8 Hose Barb - Hose Clamp, 1 1/2 - Hose Clamp, /8 - Hose Clamp, 1 - Rubber Engine Isolator - Zinc Plated Nylock Nut - 1/2-1 UNC - Bolt, Carriage - 1/-20 x / - Zinc Plated Hex Bolt, ISO 017:201 - M12 x 1.7 x 0mm, GR Hex Bolt - 1/2-1 UNC x 1 1/2 - Hex Bolt, ANSI B /8-16 UNC x /8, GR-8 - Spring Lock Washer, ANSI B /2 ID - Washer, ANSI B Fender - 1/2 ID - Black Oxide Washer, ANSI B Type A Narrow - 1/2 ID - Zinc Plated Washer, ANSI B Type A Narrow - /8 ID - Washer, ANSI B Type A Nar - 1/ ID - Wire Loom, 1 1/2 1

20 Engine and Pump Assembly A DETAIL A 26 Item Qty 010 Pa

21 Engine and Pump Assembly ITEM QTY PART NO REV DESCRIPTION B Engine Assembly, Kubota D hp Belt Guard A Engine Mount, Left A Engine Mount, Right Oil Filter Bracket Throttle Throttle Clamp Face Gasket, SAE A Kubota DH Tier, 2.8 hp Hydraulic Filter Assembly Hydraulic Pump, Poclain PM10 Double Hydraulic Pump, Cassapa PLP20.11/ Hydraulic Fitting, 90 Degree, #12 MSAE x /8 Hose Barb Hydraulic Fitting, Degree, #12 MSAE x 1 1/ Hose Barb Hydraulic Fitting, Tee, #12 MSAE x #12 FSAE x #12 FSAE Hydraulic Fitting, Tee, #10 MORS x #12 MSAE x #10 MORS Hydraulic Fitting, # O-Ring Seal x # SAE Male Hydraulic Fitting, 90 Degree Long, #8 MORB x #8 MOFS Hydraulic Fitting, 90 Degree, #10 MSAE x #10 MSAE Hydraulic Fitting, O-Ring Seal, 90 Degree 0 x 0, SAE, Male Hydraulic Fitting, #16 MSAE x #12 FSAE Stover Nut - /8-16 UNC Zinc Plated Hex Bolt - M10 x 1. x 16mm Hex Bolt - /8-16 UNC x 1 1/ Hex Bolt - /16-18 UNC x Hex Bolt - /16-18 UNC x / Zinc Plated Self Drilling Hex Screw - #10-2 UNF x / Spring Lock Washer, ANSI B /8 ID Lock Washer, ANSI B /16 ID 17

22 Exhaust Assembly Item Qty

23 Exhaust Assembly ITEM QTY PART NO REV DESCRIPTION A Exhaust Assembly Muffler Mount Flex Joint Gasket Kubota D902 Muffler Nylock Nut - /8-16 UNC Zinc Plated Nylock Nut - /16-18 UNC Zinc Plated Hex Bolt - M8 x 1.2 x 20 mm Hex Bolt, ANSI B /8-16 UNC x 1, GR Hex Bolt - /16-18 UNC x Lock Washer, ANSI B /16 ID Washer, ANSI B Type A Nar - /8 ID 19

24 Intake Assembly

25 Intake Assembly ITEM QTY PART NO REV DESCRIPTION A Air Cleaner Rubber Elbow, 90 Degree, Air Cleaner Cap Air Cleaner Assembly (Includes: , , ) Air Cleaner Mount Reducer Fitting, 2 x 1 1/2 OD 6* Air Filter Canister 7* Kohler Air Filter Element * Kohler Air Filter Element Hose Clamp, 2 1/ Zinc Plated Nylock Nut - /16-18 UNC Hex Bolt - /16-18 UNC x Zinc Plated Washer, ANSI B Type A Narrow - 1/ ID 21

26 Battery Assembly Item

27 Battery Assembly ITEM QTY PART NO REV DESCRIPTION Battery Kit Negative Battery Cable, 20, Black Positive Battery Cable, 20, Red Brute K27 Power Cable, Red Adjustable Battery Hold Down V Battery Zinc Plated Nylock Nut - 1/2-1 UNC Wing Nut, 1/-20 UNC Washer, ANSI B Type A Nar - 1/ ID 2

28 Fuel System Assembly A DETAIL A Item Qty Part *

29 Fuel System Assembly ITEM QTY PART NO REV DESCRIPTION B Fuel System Rubber Tank Insert Bushing Fuel Tank A Fuel Hose, 18 / Fuel Hose, A Fuel Hose, Fuel Cap Guage, Oil/Fuel, Fitting, 90 Degree, 1/ Hose Barb x 1/ NPT Hose Clamp, / Hose Clamp, / Tank Fitting, Hose Barb 12* Rubber Grommet Hex Bolt - /16-18 UNC x / Lock Washer, ANSI B /16 ID Washer, ANSI B Type A Nar - /16 ID 2

30 Operator Platform Assembly

31 Operator Platform Assembly ITEM QTY PART NO REV DESCRIPTION Operator Platform C Platform Weldment B Rubber Mat A Platform Stop A Bushing Compression Spring, 1 1/2 Dia x 1/ Zinc Plate Nylock Nut - /8-11 UNC Zinc Plated Hex Bolt - /8-11 UNC x 2 / Zinc Plated Flat Washer, ANSI B Type A Wide, /8 ID 27

32 Upper Dash Panel Assembly

33 Upper Dash Panel Assembly ITEM QTY PART NO REV DESCRIPTION A Joystick Guard Joystick Guard B Dash Panel, Upper Indicator Light Zinc Plated Hex Bolt - /8-16 UNC x Zinc Plated Hex Bolt - /16-18 UNC x 1 1/ Hex Bolt - /16-18 UNC x Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - /8 ID Washer, ANSI B Type A Nar - /16 ID 29

34 Lower Dash Panel Assembly Item Qty

35 Lower Dash Panel Assembly ITEM QTY PART NO REV DESCRIPTION Dash Panel, Lower Dash Panel, Lower Front Pad Assembly Boxer Track Wrench Lockable Pushbutton Rubber Grommet, 1/ ID Zinc Plated Wing Nut, /8-16 UNC Bolt - 1/-20 x 1/ Zinc Plated Washer, ANSI B Type A Narrow - 1/ ID 1

36 Hydraulic Control Assembly Item Qty 1* *

37 Hydraulic Control Assembly ITEM QTY PART NO REV DESCRIPTION B Hydraulic Control Assembly 1* Hydraulic Hose Kit A Joystick Mount A Joystick Adapter * Hydraulic Valve Assembly - Joystick Handle w/ Switch - Hydraulic Valve Assembly w/ Joystick - Hydraulic Valve Assembly - Plug, /-16 - Hydraulic Fitting, #8 O-Ring Seal Male x #8 SAE Male - Hydraulic Fitting, #8 O-Ring Seal Male x #10 SAE Male - Hydraulic Fitting, #6 ORS x #8 ORB - Hydraulic Fitting, # O-Ring Seal x # SAE Male - Hydraulic Fitting, 90 Degree, #8 SAE Male x #10 ORFS Male - Hydraulic Fitting, 90 Degree, #8 O-Ring Seal Male x #8 SAE Male - Hydraulic Fitting, Degree, #8 O-Ring Seal x #8 SAE Male - Nut Insert - /16-18 UNC - Zinc Plated Nylock Nut - /16-18 UNC - Nylock Nut - /8-16 UNC - Nylock Nut - 1/-20 UNC - Carriage Bolt - /8-16 UNC x 1 - Hex Bolt - /16-18 UNC x 2 1/ - Hex Bolt - /8-16 UNC x 1 1/ - Hex Bolt - 1/-20 UNC x 1 1/ - Hex Bolt - /16-18 UNC x 2 1/2 - Zinc Plated Washer, ANSI B Type A Narrow - 1/ ID - Zinc Plated Washer, ANSI B Type A Narrow - /8 ID - Zinc Plated Washer, ANSI B Type A Narrow - /16 ID - Zinc Plated Washer, ANSI B Type A Narrow - 1/ ID - Zinc Plated Washer, ANSI B Type A Narrow - /16 ID - Washer, ANSI B Type A Nar - /8 ID

38 Boom Assembly Item Qty

39 Boom Assembly ITEM QTY PART NO REV DESCRIPTION C Boom Assembly Pin, Greasable Teardrop Pin, Greasable Teardrop A Pin, Greasable Teardrop Boom Weldment A Attachment Plate Boom Lock Knob Grease Zerk, 1/-28 UNF Hydraulic Cylinder, 2 Bore, 12 Stroke Hydraulic Cylinder, 2 1/2 Bore, 10 Stroke Pressule Release Manifold Hydraulic Fitting, #1 MORFS x #9 FORFS Hydraulic Fitting, #7 MORS x #7 MSAE Hydraulic Fitting, # O-Ring Seal x # SAE Male Hydraulic Fitting, 90 Degree, #8 MSAE x # MSAE Hydraulic Fitting, O-Ring Seal, 90 Degree 0 x 0, SAE, Male Hydraulic Fitting, O-Ring Seal, Tee 0 x 0 x 0S Hex Bolt - /8-16 UNC x / Socket Head Bolt - 1/-20 UNC x 1 1/ Spring Lock Washer, ANSI B /8 ID

40 Attachment Plate Assembly

41 Attachment Plate Assembly ITEM QTY PART NO REV DESCRIPTION A Attachment Plate D Attachment Plate Weldment C Latch Pin Latch Stop Coupler Grease Zerk, 1/-28 UNF Compression Spring, 1/16 OD x.080 x 1 / Split Steel Bushing Spring Roll Pin 7

42 Shroud Assembly Item Qty 0 P

43 Shroud Assembly ITEM QTY PART NO REV DESCRIPTION Engine Shroud Shroud, Right Shroud, Left Shroud, Top Radiator Guard Nut Insert - /16-18 UNC Hex Bolt - /16-18 UNC x Spring Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - /16 ID 9

44 BIG POWER IN ALL PLACES Manufactured by: Phone: Sales , Parts and Service Morbark, LLC. 807 S. Winn Rd., P.O. Box 1000, Winn, Michigan