Boxer 700HDX Parts Manual

Transcription

1 BIG POWER IN ALL PLACES Phone: Sales , Parts and Service Boxer 700HDX Parts Manual SN 5082 and Higher Part No Manufactured by: Morbark, LLC S. Winn Rd., P.O. Box 1000, Winn, Michigan

2 PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: - September 5, 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... 4 Track Assembly... 8 Track Undercarriage Assembly, L/H Front Idler Assembly, L/H Track Undercarriage Assembly, R/H Tensioning Bolt Assembly Front Idler Assembly, R/H Engine Assembly, Kubota 25 HP T Engine and Pump Assembly Exhaust Assembly Intake Assembly Battery Assembly Fuel Circuit Assembly Control Panel Assembly Operator Platform Assembly Cover Assembly Door Assembly Electric Panel Assembly Hydraulic Control Assembly Boom Assembly Attachment Plate Assembly Top Panel Assembly Exhaust Cover Assembly Document Holder Assembly 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 Boxer 700HDX Maintainance Kit Outer Air Filter Element Inner Air Filter Element Fuel Filter Fuel Filter Element Fuel Filter Head Hydraulic Oil Filter Engine Oil Filter Hydraulic Oil... Chevron Rykon Premium ISO 46 or equal Seal Kit for Tilt Cylinder Seal Kit for Wheel Motor Replacement cartridge for Counterbalance valve Replacement Ignition Key

6 Top Level Assembly Item Qt 1* 1 2* 1 3* * 1 21* 2

7 Top Level Assembly ITEM QTY PART NO REV E 1* * * B A C A A A C B F C 20* * DESCRIPTION Boxer 700HDX Hydraulic Hose Kit Hydraulic Schematic Electrical Schematic Gauge Panel Track Assemblies Platform Guard Top Panel w/wrench Holder Assembly Lower Door Assembly Control Panel Exhaust Cover w/ Fasteners Boom Assembly Engine Air Intake Assembly Battery Kit Control Assembly Fuel Circuit Engine Assembly Frame & Installation Components Operator Platform Decal Kit, Boxer 700HDX Hose Guard 3

8 4 Frame Assembly Item 1 2 3* * 9* 10 11*

9 Frame Assembly ITEM QTY PART NO REV DESCRIPTION F Frame & Installation Components A Boxer 700HDX Frame Hydraulic Oil Cooler Guard 3* Serial Number Tag Control Panel Spacer Bumper A Skid Guard Dash Mount 8* Pipe Clamp, 1 3/4 9* Metal Clamp, Rubber Insulated Tank Cover 11* Ceramic Ring, Magnet Cap Oil Cooler Hydraulic Filter Assembly Hose Barb, 1 1/ Hose Barb, Hydraulic Fitting, 90 Deg, 16FORB x 16MORB Hydraulic Fitting, 90 Deg, 16FJIC x 16MJIC Bulkhead Hydraulic Fitting, 12ORFS x 8ORFS Tee Fitting, 12 x 16 x 12 SAE Fitting, 12 x 12 SAE MALE Fitting, 04 x 06 SAE MALE Hydraulic Cap Hydraulic Fitting, Throttle Nylock Nut UNF Flat Head Bolt UNF x 5/ Nut Insert - 5/16-18 UNC 30* Nylock Nut - 3/8-16 UNC Nylock Nut - 1/2-13 UNC 5

10 6 Frame Assembly, Con t Item 1 2 3* * 9* 10 11*

11 Frame Assembly ITEM QTY PART NO REV DESCRIPTION Nylock Nut - 3/8-16 UNC Nylock Nut - 3/8-16 UNC Carriage Bolt - 3/8-16 UNC x Zinc Plated Hex Bolt, ISO 4017: M6x1x16mm, GR * Hex Bolt - 5/16-18 UNC x 1 1/ Hex Bolt - 5/16-18 UNC x Hex Bolt - 1/2-13 UNC x 1 3/ Hex Bolt - 3/8-16 UNC x 1 1/ Spring Lock Washer, ISO 4017:2014-6mm ID Zinc Plated Washer, ANSI B Type A Narrow - 1/2 ID Zinc Plated Washer, ANSI B Type A Narrow - 3/8 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID Zinc Plated Washer, ANSI B Type A Narrow - 3/8 ID Zinc Plated Washer, ANSI B Type A Narrow - 1/4 ID 7

12 Track Assembly

13 Track Assembly ITEM QTY PART NO REV DESCRIPTION Track Assemblies B Track Undercarriage Assembly, Right Side B Track Undercarriage Assembly, Left Side A Short Pivot Pin Pivot Pin Fork Hydraulic Cylinder, 2 1/ Hydraulic Fitting, O-Ring Seal, 90 Degree 04 x 04, SAE, Male Cup Point Set Screw, 1/4-28 x 1/ Nylock Nut - 5/8-11 UNC Hex Bolt - 3/8-16 UNC x 3/ Zinc Plated Flange Bolt - 5/8-11 UNC x 7 1/ Spring Lock Washer, ANSI B /8 ID 9

14 Track Undercarriage Assembly, L/H

15 Track Undercarriage Assembly, L/H ITEM QTY PART NO REV DESCRIPTION B Track Undercarriage Assembly, Left Side Track Module,Left Guide Rod, Left C Track Tensioning Assembly D Track Idler Assembly, Right A Drive Sprocket, 72mm, 15 Teeth A Drive Hub Tension Lock Plate Mid-track Wheel Assembly Rubber Track, 230 x 39 x Hydraulic Motor Hydraulic Fitting, 90 Degree, #8 O-Ring Seal x #10 SAE Male Zinc Plated Hex Bolt - 1/2-20 UNF x 1 1/ Nylock Nut, 3/ Stover Nut, 5/8-11 UNC Hex Bolt - 3/8-16 UNC x 1 1/ Point Bolt - 1/2-13 UNC x 1 1/ Point Bolt - 1/2-13 UNC x Spring Lock Washer, ANSI B /2 ID Zinc Plated Washer, ANSI B Type A Nar - 3/8 ID Zinc Plated Washer, ANSI B Type A Nar - 9/16 ID Washer, ANSI B Type A Nar - 1/2 ID 11

16 Front Idler Assembly, L/H

17 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 35 x 6 mm Idler Bearing C Idler Wheel Snap Ring, 62 mm Hex Bolt - 1/2-13 UNC x Spring Lock Washer, ANSI B /2 ID 13

18 Track Undercarriage Assembly, R/H

19 Track Undercarriage Assembly, R/H ITEM QTY PART NO REV DESCRIPTION B Track Undercarriage Assembly, Right Side Track Module, Right D Idler Assembly, Left Guide Rod, Right C Track Tensioning Assembly A Drive Sprocket, 72mm, 15 Teeth A Drive Hub Tension Lock Plate Mid-track Wheel Assembly Rubber Track, 230 x 39 x Hydraulic Motor Hydraulic Fitting, 90 Degree, #8 O-Ring Seal x #10 SAE Male Zinc Plated Hex Bolt - 1/2-20 UNF x 1 1/ Nylock Nut, 3/ Stover Nut, 5/8-11 UNC Hex Bolt - 3/8-16 UNC x 1 1/ Point Bolt - 1/2-13 UNC x 1 1/ Point Bolt - 1/2-13 UNC x Spring Lock Washer, ANSI B /2 ID Zinc Plated Washer, ANSI B Type A Nar - 3/8 ID Zinc Plated Washer, ANSI B Type A Nar - 9/16 ID Washer, ANSI B Type A Nar - 1/2 ID 15

20 Tensioning Bolt Assembly

21 Tensioning Bolt Assembly ITEM QTY PART NO REV DESCRIPTION C Track Tensioning Assembly A Track Adjusting Bolt A Spring Tension Nut Track Tension Spring 17

22 Front Idler Assembly, R/H

23 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 35 x 6 mm Idler Bearing C Idler Wheel Snap Ring, 62 mm Hex Bolt - 1/2-13 UNC x Spring Lock Washer, ANSI B /2 ID 19

24 Engine Assembly, Kubota, 25 HP, T A DETAIL A Item Qty 401 P 1*

25 Engine Assembly, Kubota, 25 HP, T4 ITEM QTY PART NO REV DESCRIPTION A Engine Assembly 1* Main Electrical Harness, Kubota D Exhaust Assembly Pump Support Bracket G Kubota Engine Assembly, 25 HP Radiator Overflow Hose A Radiator Upper Mount, Kubota 25 HP Radiator Side Mount, Kubota 25 HP Radiator Overflow Bottle Rubber Engine Isolator Rubber Isolator Stover Nut - 3/8-16 UNC Nylock Nut - 3/8-16 UNC Zinc Plated Hex Bolt, ISO 4017: M12 x 1.75 x 40mm, GR Zinc Plated Hex Bolt, ISO 4017: M6 x 1 x 16mm, GR Hex Bolt - 3/8-16 UNC x 1 3/ Hex Bolt - 3/8-16 UNC x 1/ Hex Bolt - 3/8-16 UNC x 3/ Hex Bolt - 5/16-18 UNC x Hex Bolt - 1/4-20 UNC x 3/ Spring Lock Washer, ANSI B /4 ID Washer, ANSI B Type A Narrow - 1/4 ID Washer, ANSI B Fender - 1/2 ID Zinc Plated Washer, ANSI B Type A Narrow - 1/2 ID Zinc Plated Washer, ANSI B Type A Narrow - 3/8 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 21

26 Engine and Pump Assembly Item Qty

27 Engine and Pump Assembly ITEM QTY PART NO REV DESCRIPTION G Kubota Engine Assembly, 25 HP Electrical Power Cable, Brute K Oil Fill Adaptor A Engine Mount, Left A Engine Mount, Right B Throttle Cable Bracket Water Temperature Sensor Oil Pressure Sensor Throttle Clamp Face Gasket, SAE A Kubota D1105, 25HP Engine Hydraulic Double Pump, Poclain PM10B14 & PM10A Hydraulic Double Pump, Casappa PLP20.14 & PLP Hydraulic Fitting, 45 Degree, 1 Barb x #12 O-Ring Seal Hydraulic Fitting, #4 O-Ring Seal x #4 SAE Male Hydraulic Fitting, Straight, #4 O-Ring Seal x #4 SAE Male Hydraulic Fitting, 90 Degree, #12 O-Ring Seal x #10 SAE Male Hydraulic Fitting, 90 Degree Long, #8 MORB x #8 MOFS Hydraulic Fitting, 90 Degree, #8 O-Ring Seal x #10 SAE Male Hydraulic Fitting, 45 Degree, #8 O-Ring Seal x #8 SAE Male Hydraulic Fitting, 90 Degree, 1/8 NPT Nylock Nut - # Lock Nut, ISO 8992: M6, Class Zinc Plated Nylock Nut, ANSI B /16-18 UNC, GR Zinc Plated Hex Bolt - M10 x 1.25 x 16mm Zinc Plated Hex Bolt, ISO 4017: M10 x 1.25 x 16mm Zinc Plated Hex Bolt - 1/2-13 UNC x 1 1/ Zinc Plated Hex Bolt - 5/16-18 UNC x 1 1/ Zinc Plated Hex Bolt, ISO 4017: M10 x 1.25 x 30mm Zinc Plated Self Drilling Hex Screw - #10-32 UNF x 3/ Spring Lock Washer, ISO 4017: mm ID Spring Lock Washer, ISO 4017:2014-6mm ID 23

28 Engine and Pump Assembly, Con t Item Qty

29 Engine and Pump Assembly ITEM QTY PART NO REV DESCRIPTION Spring Lock Washer, ANSI B /8 ID Zinc Plated Washer, ANSI B Type A Nar - 1/2 ID Zinc Plated Washer, ANSI B Type A Nar - 3/8 ID Washer, ANSI B Type A Narrow - 5/16 ID 25

30 Exhaust Assembly

31 Exhaust Assembly ITEM QTY PART NO REV DESCRIPTION Exhaust Assembly Exhaust Pipe Muffler 27

32 Intake Assembly

33 Intake Assembly ITEM QTY PART NO REV DESCRIPTION A Engine Air Intake Assembly Air Intake Hose Air Intake Tube Air Intake Tube Rubber Tube Reducer, 2 to 1 3/ Rubber Tube, 90 Degree, 2 Diameter Air Cleaner Air Cleaner Mount Rubber Tube, 90 Degree, 2 Diameter Hose Clamp, 2 1/ Nylock Nut - 3/8-16 UNC Carriage Bolt - 5/16-18 UNC x Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 29

34 Battery Assembly Ite

35 Battery Assembly ITEM QTY PART NO REV DESCRIPTION Battery Kit Negative Battery Cable, A Positive Battery Cable, Adjustable Battery Hold Down V Battery Wing Nut, 1/4-20 UNC Washer, ANSI B Type A Nar - 1/4 ID 31

36 Fuel Circuit Assembly A DETAIL A Item Qty 401 P

37 Fuel Circuit Assembly ITEM QTY PART NO REV DESCRIPTION Fuel Circuit Fuel Tank Fuel Tank w/ Fuel Gage Port A Fuel Hose, 1/8 x Fuel Hose, 5/16 x Fuel Hose, 3/16 x Fuel Hose, 1/8 x Fuel Hose, 1/4 x Fuel Hose, 1/4 x Fuel Hose, 1/4 x Fuel Tank Mount, Left Fuel Tank Mount, Right Fuel Shutoff Valve, 1/8 NPT x 1/4 Hose Barb Fuel Filter Assembly, KU 05 Series Hose Clamp, Rubber Insulated, 1/ Tank Cap, Kelch Grease Zerk, 1/8 NPT Straight Guage, Oil/Fuel Hose Clamp Hose Clamp Fitting, Tee, 1/4 Hose Barb x 1/4 Hose Barb x 5/16 Hose Barb Fitting, Tee, 1/8 NPT x 1/8 Hose Barb x 1/8 Hose Barb Fitting, 1/8 Hose Barb x 1/8 Female NPT Fitting, 90 Degree, 1/8 NPT x 1/8 Hose Barb Fitting, 3/16 Hose Barb x 1/8 Male NPT Fitting, 1/4 NPT x 1/8 NPT Zinc Plated Nylock Nut - 5/16-18 UNC Zinc Plated Nylock Nut - 1/2-13 UNC Zinc Plated Hex Bolt - 1/4-20 UNC x Hex Bolt - 5/16-18 UNC x Self Drilling Hex Head Screw, #8 x 1/ Washer, ANSI B Type A Nar - 5/16 ID Washer, ANSI B Type A Nar - 1/4 ID 33

38 Control Panel Assembly

39 Control Panel Assembly ITEM QTY PART NO REV DESCRIPTION C Control Panel Joystick Guard B Control Panel Zinc Plated Hex Bolt - 3/8-16 UNC x Hex Bolt - 5/16-18 UNC x Spring Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - 3/8 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 35

40 Operator Platform Assembly

41 Operator Platform Assembly ITEM QTY PART NO REV DESCRIPTION C Operator Platform D Operator Platform Weldment Rubber Mat, 16 x 16 1/ Operator Platform Stop Compression Spring, 1 1/2 Dia x 3 1/ Stover Nut, 3/4-10 UNC Zinc Plated Hex Bolt - 1/2-13 UNC x 1 1/ Zinc Plated Hex Bolt, ANSI B /4-10 UNC x 4, GR Spring Lock Washer, ANSI B /2 ID Zinc Plated Washer, ANSI B Type A Narrow - 3/4 ID 37

42 Cover Assembly

43 Cover Assembly ITEM QTY PART NO REV DESCRIPTION Platform Guard Operator Platform Guard Hex Bolt - 5/16-18 UNC x Spring Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 39

44 Door Assembly

45 Door Assembly ITEM QTY PART NO REV DESCRIPTION A Lower Door Assembly Lower Door Weldment Front Pad Assembly Lockable Pushbutton Hex Bolt - 1/4-20 UNC x Zinc Plated Washer, ANSI B Type A Narrow - 1/4 ID 41

46 Electric Panel Assembly Item Qty 1* 1 2* * 2 10*

47 Electric Panel Assembly ITEM QTY PART NO REV DESCRIPTION Gauge Panel 1* Joystick Harness 2* Main Harness Gauge Panel Weldment Oil Pressure Gauge Digital Hour Meter, 12 V Water Temperature Gauge Fuse Panel Blade Type Fuse, 15 A 9* Blade Type Fuse, 3 A 10* Blade Type Fuse, 1 A Dash Plug, 1 3/ Dash Plug, Dash Plug, 3/ Dash Plug, 1/ Nylock Nut UNF Pan Head Machine Screw, #10-32 UNF x 1 1/ Hex Bolt - 5/16-18 UNC x 3/ Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 43

48 Hydraulic Control Assembly Item Qty

49 Hydraulic Control Assembly ITEM QTY PART NO REV DESCRIPTION C Control Assembly A Control Panel Valve Lever A Joystick Adapter Valve Handle Hydraulic Valve Assembly Joystick Handle w/ Switch Hydraulic Valve Assembly w/ Joystick Hydraulic Valve Assembly Hydraulic Valve Assembly Hydraulic Fitting, #8 O-Ring Seal Male x #8 O-Ring Seal Male x #8 SAE Male Hydraulic Fitting, #8 O-Ring Seal Male x #8 SAE Male Hydraulic Fitting, #6 JIC Male x #6 SAE Male Hydraulic Fitting, #8 O-Ring Seal Male, #8 SAE Male Hydraulic Fitting, #8 O-Ring Seal Male x #10 SAE Male Hydraulic Fitting, #4 O-Ring Seal x #4 SAE Male Hydraulic Fitting, 90 Degree, #12 O-Ring Seal x #10 SAE Male Hydraulic Fitting, 90 Degree, #8 O-Ring Seal Male x #8 SAE Male Hydraulic Fitting, 45 Degree, #4 O-Ring Seal Male x #4 O-Ring Seal Female Hydraulic Fitting, #6 SAE Male x #4 SAE Male Nut Insert - 5/16-18 UNC Nylock Nut - 3/8-16 UNC Nylock Nut - 3/8-16 UNC Nylock Nut - 1/4-20 UNC Carriage Bolt - 3/8-16 UNC x Hex Bolt - 3/8-16 UNC x 1 1/ Hex Bolt - 5/16-18 UNC x 2 1/ Hex Bolt - 5/16-18 UNC x 2 1/ Hex Bolt - 1/4-20 UNC x 1 1/ Zinc Plated Washer, ANSI B Type A Narrow - 3/8 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID Zinc Plated Washer, ANSI B Type A Narrow - 1/4 ID Washer, ANSI B Type A Nar - 3/8 ID 45

50 Boom Assembly A DETAIL A DETAIL B B Item Qty 401 P

51 Boom Assembly ITEM QTY PART NO REV DESCRIPTION A Boom Assembly Pin, Greasable Teardrop Pin, Greasable Teardrop A Pin, Greasable Teardrop D Boom Arm Assembly Weldment Attachment Coupler Assembly Hose Sleeve, Hose Sleeve, A Boom Lock Knob Hydraulic Hose, 8C2AT-8ORFS-8ORFS Hydraulic Hose, 8C2AT-6ORFS-8ORFS Hydraulic Hose, 8C2AT-6ORFS-8ORFS Hydraulic Hose, 4CIT-4ORFS Hydraulic Hose, 6C2AT-8ORFS Hydraulic Hose, 6C2AT-8ORFS-8ORFS Grease Zerk, 1/4-28 UNF, 90 Deg Grease Zerk, 1/4-28 UNF Hydraulic Cylinder, Loader Lift Hydraulic Cylinder, Bucket Tilt Pressure Release Manifold Hydraulic Fitting, Coupler, Nipple, SAE # Hydraulic Fitting, Quick Disconnect, PIN, FEM-502-8FO Hydraulic Fitting, Quick Disconnect, Socket, FEM-501-8F Hydraulic Fitting, Tee, Male SAE #4 x Female SAE #4 x Female SAE # Hydraulic Fitting, Adapter, Female 04 x Male Hydraulic Fitting, O-Ring Seal, Bulkhead 08 x Hydraulic Fitting, O-Ring Seal, Straight F50L Hydraulic Fitting, #4 O-Ring Seal x #4 SAE Male Hydraulic Fitting, O-Ring Seal, 90 Degree 06 x 04, SAE, Male Hydraulic Fitting, O-Ring Seal, 90 Degree 04 x 04, SAE, Male Hydraulic Fitting, O-Ring Seal, Tee 04 x 04 x 04S 47

52 Boom Assembly, Con t A DETAIL A DETAIL B B Item Qty 401 P

53 Boom Assembly ITEM QTY PART NO REV DESCRIPTION Hydraulic Hose, 8C2AT-8ORFS Hydraulic Hose, 4C2AT-4ORFS Hydraulic Hose, 4C2IT-4ORFS-4ORFS90S Nut Insert - 5/16-18 UNC Hex Bolt - 3/8-16 UNC x 3/ Socket Head Bolt - 1/4-20 UNC x 1 1/ Spring Lock Washer, ANSI B /8 ID Detent Pin 49

54 Attachment Plate Assembly

55 Attachment Plate Assembly ITEM QTY PART NO REV DESCRIPTION A Attachment Plate D Attachment Plate Weldment C Latch Pin Latch Stop Coupler Grease Zerk, 1/4-28 UNF Compression Spring, 15/16 OD x.080 x 1 5/ Split Steel Bushing Spring Roll Pin 51

56 Top Panel Assembly Item Qty

57 Top Panel Assembly ITEM QTY PART NO REV DESCRIPTION B Top Panel w/wrench B Louvered Panel Boxer Track Wrench Rubber Grommet, 1/4 ID Zinc Plated Wing Nut, 3/8-16 UNC Zinc Plated Hex Bolt - 5/16-18 UNC x 1 1/ Hex Bolt - 5/16-18 UNC x Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 53

58 Exhaust Cover Assembly

59 Exhaust Cover Assembly ITEM QTY PART NO REV DESCRIPTION A Exhaust Cover w/ Fasteners Muffler Guard Nut Insert - 5/16-18 UNC Hex Bolt - 5/16-18 UNC x Hex Bolt - 5/16-18 UNC x 3/ Lock Washer, ANSI B /16 ID Zinc Plated Washer, ANSI B Type A Narrow - 1/2 ID Zinc Plated Washer, ANSI B Type A Narrow - 5/16 ID 55

60 Document Holder Assembly

61 Document Holder Assembly ITEM QTY PART NO REV DESCRIPTION Holder Assembly Document Holder Aluminum Rivet, 1/4 x 3/4 57

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