Boxer 532DX Parts Manual

Transcription

1 BIG POWER IN ALL PLACES Boxer 5DX Parts Manual SN and Higher Part No. 5- Phone: Sales , Parts and Service Manufactured by: Morbark, Inc. 50 S. Winn Rd., P.O. Box 00, Winn, Michigan

2 PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: Description of Changes: - Oct, 0 All Initial Release A May, Item : Update part number. 0 B June, 0 Item 5: Updated Description

3 Table of Contents Parts List and Illustrations Page Number Routine Maintenance Replacement Parts...iv Creep Valve Group... Universal Mounting Plate and Loader Arm Group... Loader Arm Group... Decals Group... Hydraulic Cooler Group... Travel Drive Group... Idler Wheel and Spring Group... Mid-Wheel Group... 5 Way Diverter Valve Group... Main Control Valve Group... Electrical Panel Parts Group... 0 Rear Frame Group... Hydraulic Filter and Engine Shroud Group... Muffler and Exhaust Group... Engine and Radiator Group... Diesel Fuel Supply and Filter Group... 0 Battery Group... Pump Drive Mounting Kit Group... Pump and Radiator Group... Hydraulic Schematics... Electrical Schematic... iii

4 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 Outer Air Filter Element...5- Inner Air Filter Element...5- Fuel Filter...-0 Fuel Filter Element...-0 Fuel Filter Head...- Hydraulic Oil Filter...- Engine Oil Filter...- Hydraulic Oil... Chevron Rykon Premium ISO or equal Seal Kit for Tilt Cylinder Seal Kit for Wheel Motor Replacement cartridge for Counterbalance valve...- Replacement Ignition Key...- iv

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6 Creep Valve Group, 5, 5 Back L eft F ront Right 5

7 Creep Valve Group Item No. Description Quantity Part Number TEST PORT DUST CAP 5- BOLT - FLAT WASHER -0 BOLT HANDLE END -55 HYDRAULIC MANIFOLD -50 TEST PORT FITTING DEGREE FITTING 5-05 TUBE TEE FITTING DEGREE FITTING () 5- TUBE SOLENOID VALVE COIL -50 CLAMP, SUPEREX RETURN HOSE 5-55 FITTING 5- RETURN HOSE TUBE MOUNTING BRACKET TUBE FITTING () DEGREE FITING () 5- ELECTRICAL HARNESS, SOLENOID VALVE CREEP VALVE CONTROL HANDLE SCREW -55 CREEP CONTROL VALVE -555 FLOW CONTROL CARTRIDGE -55 CHECK VALVE -55 POPPET VALVE CARTRIDGE O-RING, # 5- NYLOCK NUT -5 LOCK WASHER -0

8 Universal Mounting Plate and Loader Arm Group 5 5, 0 0 5

9 Universal Mounting Plate and Loader Arm Group Item No. Description Quantity Part Number MALE COUPLER ASSEMBLY 00-0 ROLL PIN 5-05 SPRING, 5/OD X.00-0 MALE COUPLER ROUND LATCH STOP MALE COUPLER ROUND LATCH PIN MALE COUPLER CASTING 5- ROUND PIN X / ( / ) 00-0 BOLT, HH /- X / - PIN CLIP, RIGHT GREASE ZERK - STRAIGHT -005 ROUND PIN X / CONNEX BUSHING -005 BOOM ARM WELDMENT (DIESEL) PIN RETAINER BUCKET TILT CYLINDER 0-0 BUCKET TILT CYLINDER SEAL KIT 0-0 LOCK WASHER / -0 PIN CLIP, LEFT FEMALE QUICK CONNECT MALE QUICK CONNECT 5- MALE QUICK CONNECT 5- FEMALE QUICK CONNECT 5- HOSE - HOSE, MALE 5-5 HOSE, FEMALE 5- HOSE NS PROTECTIVE SLEEVE (FOR #) 5-0 BULKHEAD FITTING, # 5-05 HOSE - 0 DEGREE FITTING RELIEF BLOCK - BOLT, RELIEF BLOCK 5-0 FITTING 5- FITTING

10 Loader Arm Group 5 5

11 Loader Arm Group Item No. Description Quantity Part Number BOOM ARM WELDMENT CONNEX BUSHING -005 ROUND PIN - / 00-0 BOOM CYLINDER SAFETY LOCK SAFETY LOCK RETAINER PIN AND RING -5 ARM LIFT CYLINDER 0-0 SEAL KIT 0-0 ROUND FLUTED KNOB - GREASE ZERK, STRAIGHT -005 ROUND PIN - / PIN RETAINER 00-0 PIN CLIP, CLOSED 00-0 BOLT - LOCK WASHER -0 0 DEGREE FITTING HOSE -5 HOSE - TEE FITTING 5-0 HOSE -5

12 Decals Group

13 Decals Group Item No. Description Quantity Part Number SAFETY DECAL KIT 5- BURN HAZARD 5-00 CABLE EYE HOOK AUX VALVE TO NEUTRAL DANGER 5-0 ATTACHMENT SECURE CAUTION 5-0 STAY BACK, DANGER SYMBOL 5-00 CRUSH HAZARD, DANGER SYMBOL 5-00 BURN HAZARD, CAUTION SYMBOL 5-05 HYD OIL RYKON PREMIUM ISO 5-05 INSTALL CYL LOCK, WARNING SYMBOL 5-0 READ MANUAL, WARNING SYMBOL 5-00 BATTERY GROUND 5-00 DIESEL FUEL SYMBOL WARNING CA PROP BOXER -LARGE 5-0 5DX DECAL 5-0 BIG POWER DECAL 5-0 OPERATOR CONTROLS -SAFETY OPERATOR CONTROLS 5-0 CONTROL PANEL DECAL 5-00 BOXER INTERNET ADDRESS DECAL 5-0 MORBARK LOGO DECAL 5-5 CALL BEFORE YOU DIG DECAL 5-5 TAG, MOD, WT, HP (NOT SHOWN) 5-5 TAG, SN, MAN DATE (NOT SHOWN) 5-5

14 Hydraulic Cooler Group 5 To tee on the botto mof the Auxiliary Valve Return lin e to Hydraulic Filter Assy. Item No. Description Quantity Part Number BOLT 5-05 FLAT WASHER - O-RING SEAL, # 5- HYDRAULIC COOLER KIT - 5 V COOLER FAN - FLAT WASHER, M -0 MOUNTING BOLT, M DEGEE ELBOW, # 5- CLAMP, MIKALOR - 5- RETURN HOSE RETURN HOSE 5-55

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16 Travel Drive Group

17 Travel Drive Group Item No. Description Quantity Part Number RUBBER TRACK 5-0 DRIVE SPROCKET 0-0 BOLT 5-55 ROUND, HUB -DRIVE RIGHT TRACK MODULE FITTING 5- MID-WHEEL SPOOL ASSEMBLY SEE PAGE 5 DRIVE MOTOR 5-00 CASTLE NUT 5-0 WOODRUFF KEY 5-0 BOLT -5 LEFT TRACK MODULE FRONT IDLER ASSEMBLY SEE PAGE LEFT GUIDE ROD HARDENED WASHER -0 BOLT - 5 BOLT - LOCK WASHER - COTTER PIN -0 RIGHT GUIDE ROD 00-0 TRACK WIDENING CYLINDER 0-0 SEAL KIT FITTING 5-5 PIVOT PIN FORK, PIVOT PIN 00-0 LOCK WASHER -0 BOLT - 5 BOLT 5-0 NUT -0 HOSE 0-00 TUBE, CONTROL VALVE TO LEFT SIDE OF LEFT CBV FITTING, 0 DEGREE, # 5-0 O-RING, # 5- COUNTERBALANCE VALVE -5 FITTING, # 5- TUBE, CONTROL VALVE TO RIGHT SIDE OF LEFT CBV TUBE, CONTROL VALVE TO LEFT SIDE OF RIGHT CBV TUBE, CONTROL VALVE TO RIGHT SIDE OF RIGHT CBV LOCK WASHER - BOLT -5 LOCK WASHER -0 HOSE HOSE - CARTRIDGE VALVE - BUSHING, VARIABLE WIDTH TRACK ADJUSTMENT -5

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

19 Mid Wheel Assembly 5 5 Item No. Description Quantity Part Number MID-WHEEL ASSEMBLY 00-0 NUT - FLAT WASHER - SEAL 5-5 SNAP RING 5- BEARING 5-0 MIDWHEEL 0-0 MIDWHEEL AXLE

20 Way Diverter Valve Group TO HYDRAULIC TANK

21 Way Diverter Valve Group Item No. Description Quantity Part Number KNOB - MAIN AUXILIARY LEVER 0-05 TEXTURED GRIP - AUXILIARY LEVER BOLT -0 SPACER WALVOIL -WAY VALVE -0 FITTING, # 5-0 TEE FITTING, # 5-5 FITTING, # 5- CLAMP 5- FITTING, # 5-0 PLUG, # 5-05 HOSE, ND AUXILARY 5-5 HOSE, TRACK EXTENSION - FITTING, # 5- TUBE, LOWER AUX BULKHEAD BULKHEAD FITTING, # 5-0 O-RING, # 5-0 TUBE, UPPER AUX BULKHEAD TUBE, MANIFOLD TO AUXILIARY FITTING, # 5- O-RING, # 5-0 NYLOCK NUT -5 5 NUT -0 NUT -

22 Main Control Valve Group TO CREEP VALVE 0 5 TO AUXILIARY VALVE 5

23 Main Control Valve Group Item No. Description Quantity Part Number CONTROL KNOB - ROUND LEVER SHAFT, DRIVE CONTROLS 00-0 ROUND LEVER SHAFT, BOOM/BUCKET CONTROLS 00-0 LOCK NUT -0 5 O-RING, # 5- FITTING 5- O-RING, # 5-0 FITTING 5-0 HOSE FITTING 5-0 TUBE, CONTROL VALVE TO RIGHT SIDE OF LEFT CBV TUBE, CONTROL VALVE TO CREEP VALVE TUBE, CONTROL VALVE TO LEFT SIDE OF RIGHT CBV TUBE, CONTROL VALVE TO RIGHT SIDE OF RIGHT CBV TUBE, CONTROL VALVE TO LEFT SIDE OF LEFT CBV HOSE CAP 5-55 TEE FITTING 5-5 STRAIGHT FITTING BOLT 5-5 WALVOIL CONTROL VALVE BLOCK -0 CAST HANDLE 00-0 NUT - M X.5 ZC - TRAVEL CONTROL HANDLE, CAST -

24 Electrical Panel Parts Group

25 Electrical Panel Parts Group Item No. Description Quantity Part Number REGULATOR, RECTIFIER 5- BOLT IGNITION SWITCH W/KEY -5 IGNITION SWITCH COVER IGNITION KEY - NUT WITH NYLON INSERT 5-00 FUSE PANEL -5 MACH PAN HEAD MACHINE SCREW - BLADE TYPE FUSE ATO- -0 BLADE TYPE FUSE ATO- -05 BLADE TYPE FUSE ATC-5 - OIL PRESSURE GAUGE -5 WATER TEMPERATURE GAUGE -55 PLUG PLUG -00 PLUG -0 HIGH RANGE GROUND HARNESS TOGGLE SWITCH BOOT 5-0 TOGGLE SWITCH HIGH RANGE WIRING HARNESS PLUG -0 HOUR METER - HOUR METER TO TERMINAL STRIP HARNESS HOUR METER TO GROUND HARNESS GAUGE PANEL WELDMENT NUT -5 MAIN WIRING HARNESS FUSE PANEL GROUND HARNESS 00-05

26 Rear Frame Group To Engine Intake

27 Rear Frame Group Item No. Description Quantity Part Number BOLT -05 CONTROL PANEL LOCKING ACCESS PANEL FUEL TANK MOUNTING LOCK - RH FLAT WASHER -00 NUT -5 SPRING - STOP PLATE FLANGED NUT - BOLT - FLAT WASHER - OPERATOR PLATFORM RUBBER MATT -0 FUEL TANK - 5 FUEL TANK CAP -0 FUEL TANK MOUNTING LOCK - LH FLAT WASHER -00 BOLT -055 BOLT 5-0 LOCK WASHER -0 PUMP GUARD LOCKING LATCH -5 NS KEY, ACCESS PANEL LOCK -0 HAND GRIP - FLAT WASHER WING NUT - WRENCH RUBBER GROMMET - AIR CLEANER BODY ASSEMBLY 5- AIR FILTER ELEMENT - OUTER 5-0 AIR FILTER ELEMENT - INNER 5- AIR CLEANER MOUNTING BRACKET NYLOCK NUT -5 CARRIAGE BOLT -0 BOLT THROTTLE CABLE ASSEMBLY -00 THROTTLE LEVER KNOB -0 NS SPACER, CONTROL PANEL -0 NS MANUAL CONTAINER -

28 Hydraulic Filter and Engine Shroud Group LOCATED ON THE BOTTOM OF THE HYDRAULIC TANK IN FRONT OF THE SUCTIONPORT..

29 Hydraulic Filter and Engine Shroud Group Item No. Description Quantity Part Number HYDRAULIC FILTER ASSEMBLY 5-5 HEX HEAD BOLT - HYDRAULIC FILTER TOP COVER PLATE - O-RING SEAL KIT - 5 HYDRAULIC FILTER PRESSURE SPRING - HYDRAULIC FILTER ELEMENT - HYDRAULIC HOSE 5-55 CLAMP 5-0 DEGREE MALE FITTING 5- VENTED CAP WITH DIPSTICK - FILTER HOLDER BASKET - BOLT -055 LOCK WASHER - O-RING, # 5-5 PLUG, # 5-0 HYDRAULIC TANK CLEAN-OUT COVER -0 HYDRAULIC TANK CLEAN-OUT COVER GASKET -0 CERAMIC MAGNET - FLAT WASHER BOLT -05 ENGINE SHROUD DEGREE MALE FITTING 5- HOSE, PRESSURE RELIEF LINE

30 Muffler and Exhaust Group TO ENGINE EXHAUST MANIFOLD 5 5

31 Muffler and Exhaust Group Item No. Description Quantity Part Number BOLT 5- EXHAUST MANIFOLD GASKET - EXHAUST PIPE ASSEMBLY EXHAUST PIPE MUFFLER CLAMP -5 MUFFLER 5- EXHAUST TIP 5- BOLT -05 LOCK WASHER - FLAT WASHER -00 BOLT -055 MUFFLER GUARD 00-05

32 Engine and Radiator Group

33 Engine and Radiator Group Item No. Description Quantity Part Number AIR CLEANER ASSEMBLY Reference only HOSE CLAMP 5-0 TUBE, AIR INTAKE 5-05 HOSE CLAMP INTAKE HOSE ELBOW -0 PUMP GUARD WATER TEMP SENDER -5 OIL PRESSURE SENDER - ELBOW FITTING 5- TERMINAL INSULATOR 5-0 POWER CABLE 00-0 LOCK WASHER - LOCK NUT -50 BOLT FLAT WASHER -0 FLAT WASHER - BOLT 5-05 ISOLATOR MOUNT, LOWER 5-05 NUT -0 0 ISOLATOR MOUNT, UPPER 5-0 WASHER AND ISOLATORS FURNISHED WITH ENGINE See engine manual BOLT 5- OIL FILTER - HOSE CLAMP 5-5 SUCTION HOSE 5-5 BOLT -00 LOCK WASHER - INSERT -0 PROTECTIVE SCREEN -0 0 RADIATOR SHROUD INSERT -0 RADIATOR OVERFLOW BOTTLE - BOLT -00 LOCK WASHER - 5 BOLT -00 RADIATOR SHROUD TOP FLAT WASHER -00 LOCK WASHER - BOLT RADIATOR MOUNT NUT -50 FLAT WASHER -00 RUBBER MOUNT -0 RADIATOR - 5 RADIATOR CAP - AIR INTAKE HOSE -0 RADIATOR COVER FLAT WASHER -00 BOLT CLAMP, AIR BREATHER 5-5 NUT -05

34 Diesel Fuel Supply and Filter Group RETURN LINE FROM ENGINE FUEL GALLERY (RIGHT SIDE) TO FUEL FEED/ INJECTION PUMP ON ENGINE (RIGHT SIDE)

35 Diesel Fuel Supply and Filter Group Item No. Description Quantity Part Number FUEL HOSE -0 BREATHER - FITTING 5- BREATHER TUBE -0 5 FUEL HOSE -0 SPRING CLAMP TEE FITTING 5-5 ELBOW FITTING 5- BUSHING 5-00 FUEL SHUT OFF VALVE 5-0 HOSE CLAMP 5- FUEL HOSE -0 TEE FITTING 5- FUEL HOSE FUEL HOSE 0-0 FUEL FILTER ASSEMBLY -0 FUEL FILTER ELEMENT -0 FUEL FILTER HEAD - PLUG - 0 NUT -5 FLAT WASHER -00 BOLT ELBOW FITTING 5-5 BREATHER TUBE -0

36 Battery Group 5 Item No. Description Quantity Part Number BATTERY TERMINAL INSULATOR, RED 5-0 NEGATIVE BATTERY CABLE 00-0 BATTERY HOLDOWN, WITH BOLTS, WING NUTS, FLAT WASHERS 5-0 V BATTERY POSITIVE BATERY CABLE CORRUGATED FABRIC LOOM -0 TERMINAL INSULATOR, RED 5-0 NS POWER CABLE 00-0

37 Pump Drive Mounting Kit Group ENGINE FLY WHEEL 5 Item No. Description Quantity Part Number PUMP DRIVE MOUNTING KIT 5-0 MOUNTING FLANGE 5- CAP SCREWS (PUMP MOUNT FASTENER KIT) 5- PUMP DRIVE HOUSING FLAT WASHER -0 BOLT (PUMP MOUNT FASTENER KIT) -0 PUMP DRIVE HUB 5-0 HYDRAULIC PUMP -00 BOLT -5

38 Pump and Radiator Group

39 Pump and Radiator Group Item No. Description Quantity Part Number HOSE CLAMP -0 LOWER RADIATOR HOSE - UPPER RADIATOR HOSE 5-0 SPEED NUT WASHER -00 LOCK WASHER - BOLT -00 BOLT 5-0 LOCK WASHER -0 NUT 5-5 THROTTLE BRACKET NUT -5 THROTTLE LEVER -0 SCREW -0 5 THROTTLE CABLE CLAMP 5-05 WASHER -00 BOLT -05 BOLT 5- BOLT -5 0 LOCK WASHER -0 RIGHT HAND ENGINE MOUNTING PLATE CLAMP - O-RING, # 5- FITTING O-RING, # 5- FITTING 5- FITTING 5- LEFT HAND ENGINE MOUNTING PLATE TUBE, HYDRAULIC TUBE, HYDRAULIC 00-0 ENGINE -0 FAN BELT 5-00 SPACER 5-0 FAN - 5 FAN SAFETY SCREEN 5-0 HYDRAULIC TANK HOSE 5-5 5

40 Hydraulic Schematic AUX. VALVE SECT. CONTROL VALVE VALVE C'BALANCE RIGHT VALVE C'BALANCE LEFT F C MANIFOLD TILT CYL IN COOLER OUT FILTER, IN TANK LIFT CYL. LEFT LIFT CYL. RIGHT ROD END ROD END A D PUMP SUCTION FROM TANK E B MOTOR RIGHT MOTOR LEFT AUX. HOSES LEFT ROD END TRACK WIDENING CYL RETURN TO TANK BOTTOM BOTTOM AUX HOSES RIGHT HYDRAULIC MOTORS ONLY BULKHEAD 5-5

41 Electrical Schematic

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