BIG POWER IN ALL PLACES Boxer Parts Manual Serial No.s 4 & Higher Part No. 45- Phone: Sales - 00--004, Parts and Service - 00-55-9 www.boxerequipment.com Morbark, Inc. 50 S. Winn Rd., P.O. Box 00, Winn, Michigan 49 www.morbark.com
PARTS MANUAL REVISION LOG Rev: Date Affected: Pages Changed: Description of Changes: - Feb 0, 04 All Initial Release A Oct, 04.0-. 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...94-00 Idler Wheel Repair Kit...94-0 Mid - Wheel Repair Kit...94-04 Air Filter Element...95- Air Filter Pre-cleaner...95- Air Filter Bonnet...95- Fuel Filter (In-Line)...95-0 Hydraulic Oil Filter...- Engine Oil Filter...95-4 Hydraulic Oil...Chevron Rykon Premium ISO 4 or equal Seal Kit for Tilt Cylinder...0-045 Seal Kit for Wheel Motor...5-0 Replacement Ignition Key...995-009
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) 55-9 www.morbark.com KG KW Record SERIAL NUMBER here.
Trencher Guard Assembly 5 5 4 4 0 9 9 5 4.
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 4 4.50 HARD FLAT WASHER 4 5.50 UNC DEFORMED LOCK NUT - GRADE 4 4 CRUMBER SHOE 5054. UNC X.5 HEX CAPSCREW 44. FLAT WASHER 4 54 9. LOCKWASHER 50 0. UNC HEX NUT RETAINING PLATE 0 CRUMBER BOOM 50.50 UNC X.00 HEX CAPSCREW - GRADE 9 4.50 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.
Trencher Assembly 9 5 4 0 9 5 5 4 9 4 4 4 5 9 0 5 5.4
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 9 4 9 HEX CAPSCREW - GRADE 00 HEX CAPSCREW - GRADE 0 HARD FLAT WASHER DEFORMED LOCK NUT 9 HEX CAPSCREW - GRADE 4 95 4 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 005 5 HEX CAPSCREW - GRADE 4 LOCK WASHER 50 HARD FLAT WASHER 0 BUSHING 595 9 PIN, RAM END 0 GREASE ZERK ADJUSTMENT BRACKET 5 PLATE HEX CAPSCREW - GRADE 4 95 4 HARD FLAT WASHER 4 50 5 ADJUSTMENT BOLT 5 JAM NUT 44 HEX NUT 0.5
Safety and Identification Decals Group 9,4 4 5 0 5 9.
Safety and Identification Decals Group Item No. Description Quantity Part Number DECAL, LIFT POINT/TIE DOWN 4 95-9 DECAL, BOXER 95-5 PLACARD, WEIGHT/POWER 95-4 PLACARD, SERIAL NUMBER 95-54 5 DECAL, OPERATION 95-0 DECAL, CALL BEFORE YOU DIG 95-49 DECAL, WWW.BOXEREQUIPMENT.COM 95- DECAL, LOGO, MORBARK WHITE LETTER 95-4 9 DECAL, GASOLINE/PETROL ONLY 95-00 DECAL, CAUTION, BURN HAZARD, SYS CONNECTOR 95-009 DECAL, CAUTION, CLOSE FUEL SHUT-OFF 95-00 DECAL, CAUTION, BURN HAZARD, DO NOT TOUCH 95-05 DECAL, WARNING, REFUELING WARNING 95-0 4 DECAL, WARNING, BATTERY GROUND (SYM) 95-00 5 DECAL, WARNING, STAY BACK, SYS DANGER 95-00 DECAL, WARNING, CALIFORNIA PROPOSITION 5 95-04 DECAL, WARNING, SPARK HAZARD 95-95 DECAL, WARNING, AUXILIARY VALVE 95-04 9 DECAL, WARNING, ABRUPT SPEED CHANGE 95-0 DECAL, WARNING, READ MANUAL/SYM WARNING 95-00 DECAL, WARNING, HIGH PRESSURE FLUID 95-5 DECAL, DANGER, CRUSH HAZARD, TRACK 95-44 NS DECAL, HYDRAULIC OIL, ISO PREMIUM 4 (LOCATED ON FILTER CAP) 95- NS DECAL, SERIAL NUMBER (SMALL) 95-05 NS DECAL, MANUFACTURING PLACARD 95- NS DECAL, LOW OIL 95- DECAL KIT 95-55.
Access Cover Group 9 4 5 Item No. Description Quantity Part Number COVER, OIL COOLER 0-0 MOUNT, OIL COOLER 4005-0 PANEL, TOP COVER 0-0 4 PANEL, BOTTOM COVER 0-0 5 HOLDER, MANUAL 94- BOLT 9-00 FLAT WASHER -9 BOLT 9-055 9 LOCK WASHER -9 FLAT WASHER -5.
Battery Group 5 4 9 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 400-0 4 RED BATTERY TERMINAL INSULATOR 95-09 5 RED BATTERY TERMINAL INSULATOR - STARTER END 95-04 NEGATIVE CABLE, COMPLETE 400-0 BLACK BATTERY TERMINAL INSULATOR 95-04 BOLT 5-005 9 FLAT WASHER 4-0 NUT -04.9
Travel Drive Group 0 9 4 5 5,, 4 9 4.
Travel Drive Group Item No. Description Quantity Part Number BOLT 9-5 FRONT IDLER ASSEMBLY See Page FITTING 4 5-4 WHEEL MOTOR 5-00 5 WOODRUFF KEY 5-0 OUTPUT SHAFT 5-0 WHEEL MOTOR SEAL KIT (NOT SHOWN) 5-0 TRACK 95-40 9 DRIVE HUB 0-0 COTTER PIN -0 SPROCKET 09-0 FLAT WASHER -4 BOLT 45-55 4 CASTLE NUT 5-0 5 MID-WHEEL SPOOL ASSEMBLY See Page BOLT 9- WASHER -55 WASHER, LOCK -40 9 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-.
Idler Wheel and Spring Assembly 4 5 5 9 4 Item No. Description Quantity Part Number IDLER ASSY, FRONT, RH 40040-0 IDLER ASSY, FRONT, LH 40009-0 TENSION LOCK PLATE 00-0 JACKING BOLT WELDMENT 4005-0 SPRING TENSIONER WELDMENT 4000-0 4 SPRING 44-90 5 TRACK FORK WELDMENT 40055-0 WHEEL ASSEMBLY 4000-0 BEARING 95-4 IDLER SPACER TUBE 00-0 9 IDLER PIN 400-0 SEAL 95-4 SNAP RING 45-00 FRONT IDLER WHEEL 95-404 LOCK WASHER -4 4 BOLT - 5 FLAT WASHER -90.
Mid Wheel Assembly Item No. Description Quantity Part Number NUT -4 WASHER - SEAL 95-4 4 SNAP RING 95-49 5 BEARING 95-40 MIDWHEEL 0-0 MIDWHEEL AXLE 009-0 MID WHEEL, COMPLETE 95-50.
Hydraulic Control Group 5 4 0 9 5 4 0 4 5 0 9.4
Hydraulic Control Group Item No. Description Quantity Part Number VALVE, SD5/ - SPACER PLATE 00-0 BOLT, 5/- X / 4-05 4 NUT, 5/- -45 5 TRENCHER CONTROL LEVER 0-0 WASHER, 5/ -5 NUT - M X.5-0 FITTING, UNION ADAPTER 5-0 9 FITTING, TEE HB X HB X SAE 0 5-55 CLAMP 4 5-4 FITTING, HB X SAE ORING 90 5- HOSE, TO COUNTER BALANCE VALVE 5-549 HOSE, TO ENGINE COOLER 5-5 4 FITTING 5-4 5 HOSE, TO BULKHEAD 5- HOSE, TO BULKHEAD 5- SOLENOID -40 BOLT 4-00 9 WASHER -0 0 FITTING 5- HOSE 5- FITTING 5- HOSE, TO ENGINE PUMP 5-5 4 FITTING, ORS TEE 0 X 0SAE X 0ORS 5-5 5 FITTING, NIPPLE 5-45 TEST PORT DUST CAP 5-4.5
Hydraulic Control Group 4 9 9 5 4 5 0 5 4 9.
Hydraulic Control Group Item No. Description Quantity Part Number VALVE, SD5/ -4 BOLT, 5/- X / 5-0 NUT, NYLOC, 5/ - -45 4 CAST HANDLE 94-4 5 TRAVEL CONTROL LEVER 009-0 NUT, M-.5-0 MOLDED HANDLE 94-49 TRAVEL CONTROL LEVER 009-0 9 NUT - M X.5 ZC 4 - ADAPTOR, UNION 5-505 FITTING -54 FITTING 4 5-0 ASSEMBLY, HOSE 4 5-4 FITTING, ORS 0 X 0 SAE MALE STR 5-0 5 ASSEMBLY, HOSE, PISTON TO BANK - FITTING 5-0 FITTING, ORS TEE 0 X 0SAE X 0ORS 5- ASSEMBLY, HOSE, PUMP TO BANK 555-9 FITTING 5-0 0 ASSEMBLY, HOSE, PISTON TO BANK -9 VALVE, SOLENOID - FITTING, ORS TEE 0 X 04 5- ASSEMBLY, HOSE, COUNTERBALANCE VALVE TO VB PSI 555-5 4 FITTING 5-5 5 TEST PORT DUST CAP 5-4 TEST PORT FITTING 5-44 FITTING 5- FITTING 5-59 NS SPACER PLATE 00-0.
Rear Frame Parts 4 4 5 9.
Rear Frame Parts Item No. Description Quantity Part Number CONTROL PANEL 400-0 TEXTURED GRIP 94-44 SUB PANEL 00-0 4 BOLT 9-055 5 BOLT 9-05 BOLT, CARRIAGE 4-0 LOCK WASHER 4-9 FLAT WASHER 4-00 9 NUT 4-45 CONTROL THROTTLE 4-00 HOUR METER 9-9 IGNITION W/KEY 995-00 NS KEY 995-009 KEY CHAIN 9595-5 4 TERMINAL, REMOTE MOUNT JUMPER 4-40 NS RUBBER MATT 9-90.9
Hydraulic Filter and Tank Group 5 4 9 4 9 5.0
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 5-4 4 HOSE 5-50 5 DIPSTICK 4004-0 HOSE 5-5 HYDRAULIC TANK CLEAN-OUT COVER 49-40 HYDRAULIC TANK CLEAN-OUT COVER GASKET, COMES W/# 49-440 9 FITTING 5-4 HOSE 4-90 FITTING 5- MOUNT, BREATHER 400-0 FITTING, BREATHER 555-004 4 BREATHER 49-5 5 BOLT 5-00 WASHER, FLAT 4-9 COOLER, HYDRAULIC 44- CLAMP, HOSE -5 9 BOLT, CLAMP, HOSE -4.
Muffler Parts Group 4 5 9 4 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 5-405 HOSE, DRAIN, ENGINE 95- PLUG, HOSE 54-4 BOLT, ENGINE 4 4-9 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) 995-09 4 SHEET METAL SCREW -00.
Hydraulic Pump Group 9 5 4 Item No. Description Quantity Part Number PUMP, HYDRAULIC -055 BOLT 5- FLAT WASHER -40 4 FITTING 5-0 5 FITTING 5- HOSE 555-5 HOSE 5-5 CLAMP, HOSE 5-4 9 HOSE 5-50 FITTING 5-45.
Fuel System Parts 9 5 4 4 5.4
Fuel System Parts Item No. Description Quantity Part Number FUEL TANK 9-40 FUEL TANK CAP 49- BOLT 9-05 4 LOCK WASHER -9 5 FLAT WASHER - BUSHING, STEEL 5-00 VALVE, SHUT OFF 995-0 HOSE CLAMP 5-0 9 FUEL HOSE 9-90 FUEL FILTER 95-0 FUEL HOSE 0-90 FITTING, BARBED 5-0 FUEL, SHUT OFF, ELECTRIC 4055-90 4 BOLT 459-044 5 NUT -45 GROMMET 4-9 FUEL LINE 50-90.5
Air Filter Assembly 4 5 9 Item No. Description Quantity Part Number AIR CLEANER ASSEMBLY 995- HOSE CLAMP 4 5-0 FILTER MOUNTING BAND 995-4 BOLT 9-055 5 FLAT WASHER -5 NYLOC NUT -45 AIR FILTER ELEMENT - INNER 95- AIR FILTER ELEMENT - OUTER 95-9 RUBBER ELBOW, 90 995-00 STEEL TUBE, 90 94-0 RUBBER HOSE -90.
Hydraulic Schematic 400-0 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.
Electric Schematic HOUR METER 4000-0 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.
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 # 4005-0.9
BIG POWER IN ALL PLACES Phone: Sales - 00--004, Parts and Service - 00-55-9 www.boxerequipment.com Morbark, Inc. 50 S. Winn Rd., P.O. Box 00, Winn, Michigan 49 www.morbark.com.0