BIG POWER IN ALL PLACES Boxer D Parts Manual Serial No.s and Higher Part No. -80 Phone: Sales - 800-8-00, Parts and Service - 800--88 www.boxerequipment.com Manufactured by: Morbark, Inc. 80 S. Winn Rd., P.O. Box 000, Winn, Michigan 88 www.morbark.com
PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: Description of Changes: - Jan, 0 All Initial Release
Table of Contents Parts List and Illustrations Page Number Routine Maintenance Replacement Parts... Universal Mounting Plate and Loader Arm... Loader Arm Assembly... Decals Group... Travel Drive Group... 8 Idler Wheel and Spring Assembly... 0 Mid-Wheel Assembly... Main Control Valve Group... Auxiliary Valve Group... Rear Frame Assembly... Hydraulic Cooler Group... 8 Muffler Parts Group... 0 Hydraulic Pump Group... Battery Group... Diesel Fuel Group... Electrical Components Group... 8 Engine Cooling Group... 0 Motor Mounting Group... Schematics...
Routine Maintenance Replacement Parts The following parts should be considered as normal stock parts in your location. Keeping a supply of these will enable you to keep the Boxer in full service. Part Name Part Number Maintenance Kit...8-0 Idler Wheel Repair Kit...8-0 Mid - Wheel Repair Kit...8-0 Engine...-00 Air Filter Elements Outer...- Inner...- Fuel Filter...-00 Hydraulic Filter...88- Engine Oil Filter...-0 Hydraulic Filter Head...88- Hydraulic Oil... Chevron Rykon Premium ISO or equal Seal Kit for Tilt Cylinder...80-0 Seal Kit for Lilt Cylinder...80-0 Seal Kit for Wheel Motor...-08 Replacement Ignition Key...- Replacement Dash Panel Key...-
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Universal Mounting Plate 8 0 8 0 8 8 0
Universal Mounting Plate Item No. Description Quantity Part Number COUPLER LATCH PIN 000-80 SPRING -08 ROLL PIN -0 ATTACHMENT PLATE 0- PIN CLIP - RIGHT 000-80 ROUND PIN 00-80 GREASE ZERK - STRAIGHT 8-00 8 BOLT -0 LOCK WASHER -0 0 CONNEX BUSHING 8-00 PIN CLIP (CLOSED) 000-80 ROUND PIN 00-80 BOOM ARM 00-80 AUXILIARY HOSE -08 BULKHEAD FITTING 0-0 QUICK DISCONNECT, FEMALE 8- QUICK DISCONNECT, MALE 8-8 HOSE - HOSE - 0 CYLINDER - TILT 80-08 0A TILT CYLINDER SEAL KIT (Not Shown) 80-0 COUPLER LATCH STOP 00-80 0 DEGREE FITTING 0-0 PIN CLIP - TOP CYL 00-80 RELIEF BLOCK -8 BOLTS -08 FITTING 0- FITTING 0-0
Loader Arm Assembly 0 8 0 Item No. Description Quantity Part Number FLUTED KNOB - BUSHING 8-00 ROUND PIN 00-80 GREASE ZERK 8-00 BOOM SAFETY LOCK PIN - BOOM SAFETY LOCK 00-80 FITTING, SAE MALE STR 0-0 8 LIFT CYLINDER HOSE ASSY - 0 DEGREE ZERK 8-0 0 BOLT -0 LOCK WASHER -0 RETAINER CLIP 00-80 ROUND PIN 00-80 LIFT CYLINDER 80-00 PIN CLIP 00-80 ROUND PIN 008-80
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Decal Group 8 0 0 8
Decal Group Item No. Description Quantity Part Number CRUSH HAZARD DECAL 0-00 MODEL NUMBER DECAL 0-00 DANGER ZONE DECAL 0-00 BURN HAZARD DECAL 0-0 BATTERY EXPLOSION HAZARD DECAL 0-00 BOXER DECAL 0-0 TIE DOWN DECAL 0-00 8 CYLINDER LOCK INSTALLATION DECAL 0-0 AUXILIARY VALVE WARNING DECAL 0-0 0 DIESEL FUEL ONLY DECAL 0-00 READ OPERATOR S MANUAL WARNING DECAL 0-008 SAFETY INSTRUCTION DECAL 0-0 OPERATING CONTROLS DECAL 0-0 ATTACHMENT SECURITY DECAL 0-0 ISO HYDRAULIC FLUID DECAL 0-0 SHUT OFF FUEL DECAL (inside frame under filter) 0-00 CALIFORNIA PROP WARNING DECAL 0-0 8 CALL BEFORE YOU DIG DECAL 0- LIFTING EYE DECAL 0-00 0 MORBARK DECAL 0- BOXER INTERNET DECAL 0-0 TAG, MOD, WT, HP (NOT SHOWN) 0- TAG, SN, MAN DATE (NOT SHOWN) 0-
Travel Drive Group 0,, 8 8 0 8
Travel Drive Group Item No. Description Quantity Part Number BOLT 8-8 FRONT IDLER ASSEMBLY SEE PAGE 0 TUBE ASSY, RIGHT WHEEL MOTOR, REAR PORT 0-80 FITTING, 0-0 WHEEL MOTOR -0 WOODRUFF KEY -088 OUTPUT SHAFT -08 NS WHEEL MOTOR SEAL KIT (NOT SHOWN) -08 8 TRACK 0-0 DRIVE HUB 00-80 0 COTTER PIN -0 SPROCKET 00-80 FLAT WASHER - BOLT - CASTLE NUT - MID-WHEEL SPOOL ASSEMBLY SEE PAGE BOLT -0 WASHER -008 8 WASHER, LOCK -0 WASHER, LOCK 8-0 TUBE ASSY, LEFT WHEEL MOTOR, FRONT PORT 00-80 TUBE ASSY, LEFT WHEEL MOTOR, REAR PORT 8-80 TUBE ASSY, RIGHT WHEEL MOTOR, FRONT PORT 0-80 TUBE ASSY, RIGHT WHEEL MOTOR, REAR PORT 0-80
Idler Wheel and Spring Assembly 8 0 0 8 Item No. Description Quantity Part Number TENSION LOCK PLATE 000-80 JACKING BOLT WELDMENT 00-80 SPRING TENSIONER WELDMENT 000-80 SPRING -0 TRACK FORK WELDMENT 00-80 WHEEL ASSEMBLY 000-80 BEARING 0-8 IDLER SPACER TUBE 00-80 IDLER PIN 008-80 0 SEAL 0- SNAP RING -008 FRONT IDLER WHEEL 0-0 LOCK WASHER - BOLT - FLAT WASHER -0 0
Mid Wheel Assembly 8 Item No. Description Quantity Part Number MID-WHEEL ASSEMBLY (INCLUDES # S - 8) 000-80 NUT -0 WASHER - SEAL 0-8 SNAP RING 0- BEARING 0-0 MIDWHEEL 00-80 8 MIDWHEEL AXLE 00-80
Main Control Valve 8 0 8 8 0 8 0
Main Control Valve Item No. Description Quantity Part Number CONTROL KNOB - BOOM/BUCKET CONTROL LEVER 00-80 STRAIGHT FITTING 0-08 STRAIGHT FITTING 0-0 TUBE, COUNTERBALANCE TO CONTROL VALVE 00-80 0 DEGREE FITTING 0-0 TUBE ASSEMBLY, LEFT HAND DRIVE MOTOR, FRONT PORT 00-80 8 TUBE ASSEMBLY, LEFT HAND DRIVE MOTOR, REAR PORT 8-80 CARTRIDGE VALVE - 0 COUNTERBALANCE VALVE - LIFT CYLINDER HOSE ASSEMBLY -0 TUBE ASSEMBLY, RIGHT HAND DRIVE MOTOR, FRONT PORT 0-80 TUBE ASSEMBLY, RIGHT HAND DRIVE MOTOR, REAR PORT 0-80 TUBE, COUNTERBALANCE TO AUX VALVE 000-80 0 DEGREE FITTING 0-08 TUBE 00-80 TEST PORT 8-8 TEST PORT DUST CAP 8- STRAIGHT FITTING 0-0 0 TEE FITTING 0- CARTRIDGE -8 NYLOCK NUT - STRAIGHT FITTING 0-0 TUBE, DIVERTER TO AUX VALVE 008-80 DIVERTER VALVE - 0 DEGREE FITTING 0-0 STRAIGHT FITTING 0-0 8 BOLT -0 UNION FITTING -0 0 CONTROL VALVE ASSEMBLY -0 KNOB - CONTROL LEVER 008-80 NUT - M8 X. -08 NUT - M0 X. ZC -0 ROUND LEVER SHAFT 008-80 TRAVEL CONTROL HANDLE, CAST -8 STRAIGHT FITTING 8-0 8 TUBE 8-80
Auxiliary Valve Group 0 8 Item No. Description Quantity Part Number TEXTURED GRIP - LEVER 00-80 BOLT -0 FLAT WASHER -008 FITTING, SAE MALE 0 - CLAMP -0 HOSE, TO HYDRAULIC COOLER 80-8 VALVE - RELIEF VALVE CARTRIDGE -0 0 NYLOCK NUT - FITTING, SAE 0-0 TUBE ASSY, AUX TO COUNTERBALANCE 000-80 HOSE -0 FITTING, SAE MALE 0 0-0 FITTING, SAE MALE STR 0-0
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Rear Frame Group 8 8 0 0 8
Rear Frame Group Item No. Description Quantity Part Number WING NUT - TRACK TENSION WRENCH 00-80 RUBBER GROMMET - HAND GRIP - BOLT -0 LOWER SERVICE ACCESS PANEL 00-80 UPPER CONTROL PANEL 00-80 8 ACCESS PANEL LOCK - NS KEY, ACCESS PANEL LOCK - RUBBER MATT -0 0 COMPRESSION SPRING -88 SELF LOCKING NUT - ROUND BUSHING 00-80 OPERATOR PLATFORM 00-80 WASHER - BOLT -8 ENGINE OIL FILTER -0 BOLT -0 8 WASHER - BELT GUARD 00-80 0 SELF LOCKING NUT -0 ENGINE BELT -0 AIR FILTER HOUSING - OUTER AIR FILTER ELEMENT - INNER AIR FILTER ELEMENT - BONNET -0 CLAMP - MANUAL HOLDER -0 8 THROTTLE ASSEMBLY -00 NS AIR FILTER CONNECTION HOSE -0
Hydraulic Cooler Group 8 0 8 8
Hydraulic Cooler Group Item No. Description Quantity Part Number HYDRAULIC COOLER ASSEMBLY 8- BOLT - FLAT WASHER -0 FAN 8- O-RING - # - FITTING - CLAMP -0 8 HOSE - AUX VALVE TO COOLER INLET 80- HOSE - COOLER OUTLET TO FILTER INLET 80-0 HYDRAULIC TANK CLEAN OUT COVER 8-0 COVER GASKET 8-0 CERAMIC MAGNET (in hydraulic tank) 8- HYDRAULIC OIL DIPSTICK 0088-80 BOLT -0 FLAT WASHER -0 FILTER ASSEMBLY MOUNTING BRACKET 0-80 REPLACEMENT SPIN ON FILTER ELEMENT 88-8 HOSE - FILTER OUTLET TO TANK INLET 80- HYDRAULIC FILTER HEAD 88-
Muffler Parts Group 0 8 0 8 0 8 0
Muffler Parts Group Item No. Description Quantity Part Number NUT -0 LOCK WASHER -0 BOLT - FLAT WASHER - EXHAUST MANIFOLD GASKET - NUT (FLEX EXHAUST TO MANIFOLD) -00 EXHAUST FLEX JOINT -0 8 MUFFLER MOUNTING BRACKET 00-80 FLAT WASHER -008 0 BOLT -0 NUT -0 MUFFLER ASSEMBLY -0 BOLT -00 LOCK WASHER -8 UPPER HEAT SHIELD -0 BOLT -0 LOWER HEAT SHIELD -0 8 NUT -0 MUFFLER -0 0 LOCK WASHER -8 BOLT -0 MUFFLER HEAT SHIELD -0 LOCK WASHER -08 NUT -0 EXHAUST TIP -08 EXHAUST PIPE CLAMP -0 FLAT WASHER -0 8 BOLT 0-0
Hydraulic Pump Group ENGINE FLY WHEEL 8 0 TO TANK (To Bottom of Invertor Valve) 8 (To Top of Invertor Valve)
Hydraulic Pump Group Item No. Description Quantity Part Number PUMP DRIVE MOUNTING KIT -0 MOUNTING FLANGE -0 CAP SCREWS (PUMP MOUNT FASTENER KIT) 0-0 PUMP DRIVE HOUSING -0 FLAT WASHER -0 BOLT (PUMP MOUNT FASTENER KIT) -0 PUMP DRIVE HUB - 8 HYDRAULIC PUMP -0 LOCK WASHER -0 0 BOLT -0 TUBING - PUMP TO HIGH-LOW SPEED CONTROL 8-80 TUBING - PUMP TO HIGH-LOW SPEED CONTROL 8-80 O-RING, #0-0 O-RING, # - 0 FITTING - CLAMP -0 SUCTION HOSE 80-8 FITTING 0- FITTING 0-
Battery Parts Group 8 Item No. Description Quantity Part Number HOLDOWN CLAMP -0 FLAT WASHER -00 NUT, WING - BATTERY - POSITIVE BATTERY CABLE 00-80 CORRUGATED FABRIC LOOM -0 TERMINAL INSULATOR, RED -0 8 BATTERY TERMINAL INSULATOR, RED -0 NEGATIVE BATTERY CABLE 00-80 NS POWER CABLE 00-80
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Diesel Fuel Group 8 0 0 8
Diesel Fuel Group Item No. Description Quantity Part Number FUEL TANK CAP/FUEL GAUGE 8- FLAT WASHER -008 LOCK WASHER - BOLT -0 BUSHED ELBOW 8- FUEL RETURN LINE -0 FUEL RETURN LINE GROMMET - 8 FUEL TANK -0 0 FITTING - 0 RUBBER GROMMET -8 FUEL LINE -0 CLAMP -0 FUEL LINE -0 CLAMP - BOLT -0 WASHER -00 NUT - 8 FUEL FILTER/WATER SEPARATOR ASSEMBLY -0 FUEL FILTER/WATER SEPARATOR BODY -0 0 FUEL FILTER -00 FUEL FILTER BOWL -00
Electrical Components Group 8 0 8
Electrical Components Group Item No. Description Quantity Part Number WARNING LIGHT ASSEMBLY -08 IGNITION SWITCH W/KEYS - SCREW -0 IGNITION KEY - HOUR METER - IGNITION SWITCH/HOUR METER MOUNTING PLATE 00-80 WARNING SOUNDER -0 8 0A RELAY -0 0 AMP FUSE - 0 AMP FUSE -0 AMP FUSE -0 AMP FUSE -0 ENGINE WIRING HARNESS -0
Engine Cooling Group 8 0 0 8 TO POF RADIA TO R TO POF ENGINE TO WA TER PUMP TO BOTT OM OF RADIA TO R 0
Engine Cooling Group Item No. Description Quantity Part Number BOLT -0 FLAT WASHER -008 FRONT SHROUD 00-80 FLAT WASHER -0 BOLT -0 RADIATOR CAP - OVERFLOW TANK HOSE 0-0 8 OVERFLOW TANK -8 HOSE CLAMP -00 0 PROTECTIVE COVER 8-0 UPPER RADIATOR HOSE -0 RADIATOR HOSE - WATER PUMP TO TUBE 0-0 RADIATOR TUBE -80 LOWER RADIATOR HOSE -0 RADIATOR -0 LOCK WASHER - FLAT WASHER -008 8 BOLT -0 ELECTRIC FAN -0 0 FLAT WASHER -00 BOLT -
Motor Mounting Group 0 8
Motor Mounting Group Item No. Description Quantity Part Number BOLT - FLAT WASHER -0 LEFT HAND MOUNTING PLATE 0-80 BOLT -0 FLAT WASHER -0 HYDRAULIC PUMP -0 BELL HOUSING ADAPTER ASSEMBLY -0 8 RIGHT HAND MOUNTING PLATE 0-80 ENGINE OIL FILTER -0 0 ENGINE HEAT SENSOR.00 BELT GUARD 00-80
Hydraulic Schematic DIVERTER VALVE HYD. PUMP TILT CYL. SUCTION FROM TANK ROD END COUNTERBALANCE VALVE CONTROL VALVE RIGHT WHEEL MOTOR LEFT WHEEL MOTOR FRONT OF VEHICLE AUX. VALVE IN VENT HOSE HYD. COOLER OUT LIFT CYL. HYD. FILTER RETURN TO TANK AUX. HOSES ROD END
I H S R 8 O N H /8 LOOM x IN -F- AWG VIO -E- AWG RED/WHT -G- AWG BLK -A- AWG RED/WHT -B- AWG GRN/WHT AWG GRN/WHT D C F F F 0 F 0 Electrical Schematic / LOOM x IN /8 LOOM x 0 IN /8 LOOM x IN F 8 /8 LOOM x 8 IN /8 LOOM x 8 IN / LOOM x IN 8 0 8 8 / LOOM x 0 IN WATER TEMP 8 SWITCH 8 IN /8 LOOM x IN 8 0 8 8 0 8 8 8 AWG BRN 0 AWG BLK AWG YEL AWG RED/WHT AWG RED/YELLOW AWG BLK F 0 / LOOM x IN 0 / LOOM x IN /8 LOOM x IN /8 LOOM x IN / LOOM x IN IN IN /8 LOOM x IN 8 0 80 8 / LOOM x IN P F F BLK F F E F G -H- AWG RED/WHT -C- AWG BLK -D- AWG RED A B REAR VIEW J K AWG RED AWG BLK AWG GRN AWG BLK/WHT AWG VIO -M- AWG VIO -L- AWG VIO AWG YEL AWG RED -H- AWG BLK -I- AWG RED/BLU -K- AWG BLK -J- AWG RED AWG BLK AWG RED/BLU AWG YEL L M AWG ORG -N- AWG BLK -O- AWG BLK AWG BLK AWG BLK AWG BLK AWG BLK AWG RED/WHT AWG RED/WHT AWG GRN AWG RED/YEL AWG BRN AWG BRN AWG BLU AWG ORG AWG RED/BLU 0 AWG BLK AWG ORG -R- AWG ORG -S- AWG BLK -P- AWG BLK/WHT -Q- AWG ORG WARNING LIGHT PANEL P Q WARNING BUZZER FUSE 0 AMP AWG GRN AWG BLK/WHT AWG BLK FUSE BLOCK B WATER GA RED/WHT GA RED ENG. COOLER COOLER RELAY COOLER 0A POWER IN GA RED/BLU FAN HYD OIL COOLER 0A GA BRN GA YEL POWER IN SPARE A GA BLU GA RED/WHT POWER IN ENGINE KILL A FUSE BLOCKS A & B COOLER FAN ARRAY SPARE GROUNDS OIL COOLER GLOW PLUGS DETAIL B DIODE SPLICE OIL PRESSURE SWITCH IN STARTER 0 AC IGNITION SWITCH 0 ACC. HOUR METER 0 0 AWG ORG AWG VIO L M TO BATTERY, SEE 00-80 FOR BATTERY INSTALL AWG BLK/WHT AWG BLK/WHT AWG BLK DEUTSCH AWG BLK AWG BLK AWG ORG -M- AWG ORG -L- AWG ORG IN ITEM QTY PART # DESCRIPTION LENGTH (IN) ITEM QTY PART # DESCRIPTION LENGTH (IN) ITEM QTY PART # DESCRIPTION LENGTH (IN) 8-0 LOOM, BLACK SPLIT /8 0 8-8 WIRE, GA GREEN 8 REF CONNECTOR, 8-0 LOOM, BLACK SPLIT /8 8-8 WIRE, GA GREEN 8 80 REF PANEL, WARNING LIGHT 8-0 LOOM, BLACK SPLIT / 8- WIRE, GA PURPLE REF CONNECTOR, LIGHT PANEL 8-0 LOOM, BLACK SPLIT /8 8-0 WIRE, GA YELLOW 8 - PLUG, ALTENATOR (KUBOTA 8-80) 8-0 LOOM, BLACK SPLIT /8 0 8- WIRE, GA BLACK - 8-0 LOOM, BLACK SPLIT / 8- WIRE, GA BLACK 0 8-0 LOOM, BLACK SPLIT /8 8-0 LOOM, BLACK SPLIT /8 8 8- WIRE, GA BLACK - PLUG, KILL SOLENOID (KUBOTA -0) 0 - STRAIN RELIEF, METRI-PAK 80 8- WIRE, GA RED/BLU 8-0 WIRE, GA VIO - TUBING, SHRINK / BLACK 8- WIRE, GA ORANGE 8. 8-0 WIRE, GA VIO 8-0 TERMINAL, RING - GA #8 8- WIRE, GA ORANGE - PLUG, KILL TIMER (KUBOTA -80) - TERMINAL, RING -0 GA #8 8- WIRE, GA ORANGE 8 - TERMINAL,AMP(800) - - TERMINAL, RING -0 GA #0 8- WIRE, GA RED/WHITE 0 REF STRIP, JUMPER SOCKET (FUSE BLOCK) - TERMINAL, RING -0 GA / 8-8 WIRE, GA RED/WHITE REF STRIP, JUMPER SOCKET (FUSE BLOCK) - TERMINAL, RING -0 GA /8 8- WIRE, GA RED/YELLOW 8 0 REF TERMINAL, SOCKET - (FUSE BLOCK) -00 TERMINAL, FEM SPADE BLUE 0 8- WIRE, GA BLACK/WHITE -088 BLOCK, FUSE BLADE TYPE- FUSE -0 CONNECTOR, BUTT -0 GA 8- WIRE, GA BLACK/WHITE 8-0 WIRE, GA BROWN 0-0 CONNECTOR, BUTT - GA 8 8- WIRE, GA GREEN/WHITE 8-0 WIRE, GA BROWN 0-0 CONNECTOR, RECEPTACLE 8- WIRE, GA ORG 8-0 WIRE, GA BROWN 8-0 WEDGE LOCK, RECEPTACLE, CONTACT 8- WIRE, GA ORG 8-0 WIRE, 0 GA BLACK 8 - CONTACT, SOCKET -8 8-00 LOOM, BLACK SPLIT / 8-0 WIRE, 0 GA RED - TERMINAL, FEMALE METRI-PACK 80 8-00 LOOM, BLACK SPLIT / 8-0 WIRE, GA BLACK - CONNECTOR, FEM -WAY METRI-PACK 80 8-00 LOOM, BLACK SPLIT / 0 8- WIRE, GA RED - SEAL, METRI-PAK 80 GREEN 8-0 LOOM, BLACK SPLIT /8 8 8- WIRE, GA RED - CONNECTOR, PIN SOCKET RELAY 8-00 LOOM, BLACK SPLIT / 0 8 8- WIRE, GA YELLOW - FUSE, BLADE TYPE AT0-0 0-0 0 AMP BLADE FUSE - 8- WIRE, GA BLACK - HOLDER, FUSE ATO SEALED 8-0 LOOM, BLACK SPLIT / 8- WIRE, GA RED 8 - DIODE, A HVCA FLASHER 8 8-0 LOOM, BLACK SPLIT /8 8 8- WIRE, GA RED IN IN IN IN IN IN IN IN IN x 0-80 GA BROWN POWER IN FROM ACC. FUSE BLOCK A GA GRE HOUR METER A GA VIO POWER TO FAN RELAY A GA ORG WARNING SYSTEM A GA RED/YEL ALT/KILL TIMER A
BIG POWER IN ALL PLACES Phone: Sales - 800-8-00, Parts and Service - 800--88 www.boxerequipment.com Manufactured by: Morbark, Inc. 80 S. Winn Rd., P.O. Box 000, Winn, Michigan 88 www.morbark.com