Parts Manual MODEL BWF00
TABLE OF CONTENTS Control Panel CONTROLS- Pg. Control Panel-DECALS- Pg. Control Panel-HOSES- Pg. 9 Control Panel-TUBING- Pg. 8 Control Panel VALVES- Pg. Coupler Assembly Pg. 0 Engine/Pump Assembly Pg. Hydraulic-COOLER ASSEMBLY- Pg. Fuel Tank Assembly Pg. Hydraulic-LIFT CYLINDERS- Pg. 9 Hydraulic Plumping-PUMPS- Pg. Hydraulic-TILT CYLINDER- Pg. 8 General Overview Pg. Operator Platform Pg. Undercarriage Assembly Overview Pg. Undercarriage-CONT.- Pg. Undercarriage-HUB- Pg. Undercarriage-DRIVE MOTOR- Pg. Undercarriage-HUB/SPINDLE- Pg. 9 Valve Assembly-AUXILARY- Pg. Valve Assembly-BOOM/BUCKET- Pg. 0 Valve Assembly-LEFT TRACK- Pg. Valve Assembly-RIGHT TRACK- Pg. Valve/Manifold Assembly Pg. Wiring-BATTERY- Pg. Wiring-ENGINE COMPARTMENT- Pg. Wiring-FUSE PANEL- Pg. Wiring-SCHEMATIC- Pg.
General Overview Parts List. 0090 CONTROL PANEL ASSEMBLY. 000 ENGINE ASSEMBLY W/PUMPS. 00 OPERATOR PLATFORM ASSEMBLY. 0000 ASSEMBLY. UNDERCARRIAGE. 00 COUPLER ASSEMBLY. 000 TILT CYLINDER. 00 LIFT ARMS (BOOM) 8. 000 BATTERY INSTALL 9. 00 HYDRAULIC COOLER ASSEMBLY 0. 009 FUEL TANK ASSEMBLY. 000 LIFT CYLINDERS. 008 HYDRAULIC TANK ASSEMBLY
General Overview 0 8 9
CONTROL PANEL DECALS PARTS LIST. 98 DECAL, CNTRLS CRAWL VALVE OFF/ON. 90 DECAL, CNTRLS TRACK/BOOM/BUCKET. 990 DECAL, CRAWL SPEED. 99 DECAL, AUXILARY VALVE. 99 DECAL, THROTTLE SPEED. 99 DECAL, LIGHT PANEL. 000 DECAL, PARK BRAKE INSTRUCTIONS 8. 99 DECAL, WARN "READ OPERATORS MANUAL" 9. 000 DECAL, WARNING (REFUELING) 0. 98 DECAL, CAUTION "AUXILIARY POWER" Decals/Label Not Shown 98 DECAL, WARNING "CYLINDER LOCKS" 98 DECAL, CAUTION "AUXILIARY POWER" 98 DECAL, CAUTION "SECURE ATTACHMENT" 98 DECAL, DANGER "PINCH POINT" 98 DECAL, SAFETY INSTRUCTIONS 9 DECAL, MERTZ INSIGNIA 9 DECAL, MODEL "TL" 9 DECAL, BOXER -LARGE- W/RED 98 DECAL, "HYDRAULIC OIL ONLY" 98 DECAL, MADE IN USA SQUARE
CONTROL PANEL 9 8 0
CONTROL PANEL PARTS LIST. 9 LEVER, CONTROL. 90 GRIP, 900 TEXTURED. 008 HANDLE, TEE MOLDED. 0998 CABLE, THROTTLE. 99 SWITCH, IGNITION a. 99.00 MOLDED KEY SET ON RING. 00 NUT, M8-.. 000 BOLT, M8 X 0MM 8. 9.00.0 LEVER ASSY 9. 0.00 LEVER/KNOB ASSY 0. 00 TUBE, LEVER SPACER BOOM/BUCK (not visible). 00 STRIP, LEVER ADAPTER BOOM/BUCK. 00 STRIP, LEVER ADAPTER GRND DRIVE 008 ROUND, LEVER STEM GRND DRIVE. 00 ROUND, LEVER BOOM/BUCKET STEM (not visible). 00 ASSY, HARNESS LOW OIL PRESS LIGHT. 000 ASSY, LIGHT HIGH RANGE INDICATOR 00 ASSY, SWITCH HIGH RANGE 8. 008 HOLDER, MANUAL-PAK 9. 00 PAD, VINYL X 0. 00 SHEET, LIGHT PANEL. 9 PLUG, DASH. 00 PLUG, DASH. 9 LEVER/BRAKE CONTROL 0 METER, HOUR (not shown)
CONTROL PANEL 0 9 8 0 8 9
CONTROL PANEL VALVE ASSEMBLYS 0 9. 00 ASSY, AUX VALVE. 00 ASSY, GRND DRIVE VALVE LEFT. 00 ASSY, GRND DRIVE VALVE RIGHT. 009 ASSY, MANIFOLD/-WAY. 009 ASSY, BOOM/BUCK/WDNG W/O (FXD). 00 ASSY, HARNESS LOW OIL PRESS LIGHT. 000 ASSY, LIGHT HIGH RANGE INDICATOR 8 99 SWITCH, IGNITION 9. 0998 CABLE, THROTTLE 9a. 0998.00 HANDLE, THROTTLE (not shown)
CONTROL PANEL TUBE ASSEMBLYS 8 9 0. 0 TUBE ASSY, PRESS EATON TO AUX. 0 TUBE ASSY, PRESS -WAY-LEFT TRK VLV. 08 TUBE ASSY, SIX-WAY TO EATON. 09 TUBE ASSY, PRESS -WAY TO RGHT VLV. 00 TUBE ASSY, PRESS EATON-RIGHT TRK VLV. 0 TUBE ASSY, LEFT TRK VLV TANK. 0 TUBE ASSY, PRESS EATON-LEFT TRK VLV 8. 0 TUBE ASSY, BOOM/BUCKET TO TANK 9. 0 TUBE ASSY, RIGHT TRK VLV TO TANK 0. 0 TUBE ASSY, AUX VLV TO TANK. 0 TUBE ASSY, BOOM/BKY TO PWR BEYOND 8
CONTROL PANEL HOSE LAYOUT 8 & 0 9. 00-0. HOSE ASSY, FC9-0 W/#8 ENDS (auxiliary hose). 00-0. HOSE ASSY, FC9-0 W/#8 ENDS (auxiliary hose). 000-0. HOSE ASSY, FC9-0-0 (boom cylinder). 000-08. HOSE ASSY, FC9-0-0 (boom cylinder). 000-0. HOSE ASSY, FC9-0-0 (tilt cylinder, hidden by #). 000-0. HOSE ASSY, FC9-0-0 (tilt cylinder). 00-0.8 HOSE ASSY, FC9-0-0 (from two small pumps) 8. 00-0.9 HOSE ASSY, FC9-08-0 (from pump) 9. 00-0.9 HOSE ASSY, FC9-08-0 (ground drive) 0. 00-0.9 HOSE ASSY, FC9-08-0 (ground drive) 9
Boom/Bucket Valve 009 8. 90 FITTING, 00-8-8. 98 FITTING, 0-8-8. 9 FITTING, 00--. 0 VALVE, WALVOIL SD/-P. 9 LEVER/HANDLE (not shown). 9.00 BOOT (not shown). 0.00 SPRING KIT, SECTION (FLOAT) 8. 9 PLUG, O-RING 90098- (plugs not shown in this picture) 0.00 SPRING ASSY "B" 0.00 SPRING ASSY "C" 0
MANIFOLD ASSEMBLY PARTS LIST 009. 90 FITTING, 0--8. 9 PLUG, O-RING 90098-. 90 FITTING, 00-8-8. 98 FITTING, 0-8-8. 9 FITTING, 00--. 90 FITTING, 00--. 9 FITTING, 0-8-8 8. 9 MANIFOLD, HYD CONTROLS 9. 0 VALVE, HYD -WAY CNTRL 9a. 0.00 HANDLE and KNOB 9b. 0.00 REPAIR KIT 0. FITTING, 8--F0G-S (not visible). 9 FITTING, F0HA0-S UNION (not visible). 9.00 SOLENOID VALVE. 9.00.0 CARTRIDGE ONLY. 9.00.0 COIL ONLY, DG. 9.00.0 SEAL KIT. 9.00 CARTRIDGE, PRESSURE COMPENSATING. 9.00.0 SEAL KIT. 9.00 CHECK VALVE. 9.00.0 SEAL KIT. 9.00 FLOW DIVIDER COMBINER..00.0 SEAL KIT. 9.00 ROTARY VALVE & HANDLE (not shown). 9.00.0 LEVER ASSY (not shown). 9.00.0 LEVER HANDLE ONLY (not shown). 9.00.0 SEAL KIT
MANIFOLD ASSEMBLY 009 9 8
LEFT TRACK VALVE 00. 0 VALVE, (GRND DRIVE). 98 FITTING, 0-8-8. 9 FITTING, 00--8. 909 FITTING, 000-8-8. 9 LEVER BOX. 9.00 BOOT (not shown)
RIGHT TRACK VALVE 00. 0 VALVE, (GRND DRIVE). 90 FITTING, 00-8-8. 9 FITTING, 00--8. 909 FITTING, 000-8-8. 9 LEVER BOX. 9.00 BOOT (not shown)
Auxiliary Valve Assembly 00. 0 VALVE, (AUX). 98 FITTING, 0-8-8. 9 FITTING, 0-8-8. 9 FITTING, 000-8-8S. 9 LEVER/HANDLE. 0.00 SWITCH (replacement)
Hydraulic Plumbing, Pump 8 0 9 0. 00-0.9 HOSE ASSY, FC9-08-0 (pump pressure). 00-0.8 HOSE ASSY, FC9-0-0 (pump pressure). 00.00 HOSE, CUT -0 SUCTION ("). 00-0.9 HOSE ASSY, FC9-08-0 (pump suction). 9 FITTING, 0-0-8. 00 FITTING, 0--0 (HB x SAE). 90 FITTING, 0-0-8 8. 99 FITTING, 0-0-S 9. 09 PUMP, -SECTION (see engine assembly) 0. 90 FITTING, 00-- (top & bottom of right lift cylinder). 000-0. HOSE ASSY (lift cylinder jumper hoses, removed for clarity). 9 FITTING, 000-- (top & bottom of left lift cylinder)
Hydraulic Cooler Assembly 9 8 0,. 098 COOLER, OIL a. 098.00 MOTOR/FAN ASSY. 00 FILTER, HYD TANK a. 00.00 ELEMENT, HYD TANK FILTER (replacement). 99 FITTING, 00--. 909 FITTING, 0--. 90 FITTING, 00-- (top & bottom of right lift cylinder). 0 TUBE ASSY, EATON VALVE TO COOLER. 08 TUBE ASSY, COOLER TO FILTER 8. 000-0. HOSE ASSY (top & bottom cylinder jumper) 9. 9 FITTING, FITTING, 000-- (top & bottom of left lift cylinder) 0. 98 DIPSTICK, HYDRAULIC OIL LEVEL. 000 WELDMENT, HYDRAULIC ACCESS. 00 GASKET, HYD ACCESS 00 COOLER SHROUD (removed for clarity)
Hydraulic Tilt and Auxiliary 8 0 9. 000-0. HOSE ASSY, FC9-0-0. 000-0. HOSE ASSY, FC9-0-0. 00-0. HOSE ASSY, FC9-0 W/#8 ENDS. 00-0. HOSE ASSY, FC9-0 W/#8 ENDS. 0.9 AUXILIARY QUICK CONNECT SOCKET. 0.9 AUXILIARY QUICK CONNECT PIN. 9 FITTING, 0-- 8. FITTING, 8--F0G-S 9. 9 FITTING, ELBOW ADAPTER S-08 X J-0 0. 009 WELDMENT, BOXER PIVOT PIN-SHORT. 00 STRIP, BOOM STOP. 000 CYLINDER, TILT a. 000.00 REPAIR KIT
Hydraulic Lift Cylinders. 000 LIFT CYLINDER a. 000.00 REPAIR KIT. 000-0. HOSE ASSY (top & bottom cylinder jumper). FITTING, 00--S (top & bottom cylinder). 9 FITTING, 000-- (top & bottom cylinder). 08 TUBE ASSY, COOLER TO FILTER. 0 TUBE ASSY, EATON VALVE TO COOLER. 00 HARNESS, OIL COOLER 9
This page intentionally left blank. 0
Engine and Pump Assembly. 9090 ENGINE, HONDA GX0. 9C 0 BOLT, HH /8- X / NC G. 9C BOLT, HH /8- X NC G. 0 WASHER, FLAT / G. 90 FITTING, 0-0-8. 0 WASHER, LOCK /8 G. 989 ADAPTER, HYD PUMP MOUNT 8. 098 PUMP 9. 099 COUPLING, JAW ASSY (not visible) 9a. 90.00 SPIDER, RED COUPLER 0. 99 FITTING, 0-0-S. 00 FITTING, 0--0 (HB x SAE). 00 SQUARE, KEY ENGINE SHAFT (not visible). 008 OPTION, DRAIN HOSE (not visible). 0.0 8 NUT, HEX /8- NC SELF LOCKING. 00 PLATE, ENGINE MOUNT ADAPTER. 00 MUFFLER, COATED. 99 ARRESTOR, SPARK (not shown) 8. 9099 EXTENSION, MUFFLER (not shown) SERVICE ITEMS a. 9090.00 ELEMENT, AIR CLEANER b. 9090.00 FILTER, OUTER (Foam) c. 9090.00 COVER, FAN d. 9090.00 FILTER, FUEL e. 9090.00 HOSE, A OIL f. 9090.00 HOSE, B OIL g. 9090.008 GASKET, EXHAUST h. 9090.009 FILTER, OIL GX 0 TAF I. 9090.0 FAN, COOLING GX 0
Engine and Pump Assembly 0 9, 8,
Undercarriage Assembly. 00 WELDMENT, UNDERCARRIAGE FRAME. 00 ASSY, DRIVE MOTOR W/BRAKE. 00 ASSY, DRIVE MOTOR W/O BRAKE. 00 ASSY, HUB/SPINDLE FRONT. 00 ASSY, HUB/SPINDLE REAR. 0009 SHEET, COVER PLATE. 98C BOLT, HH /-8 X 8. 0 WASHER, LOCK / 9. 9098 INSERT, /-8 0. 00-0.9 HOSE ASSY, FC9-08-0 (ground drive). 00-0.9 HOSE ASSY, FC9-08-0 (ground drive). 0.00 BOLT, FLANGE HEAD /- NC X. 0.0 NUT, HEX FLANGE LOCK /-. 9C BOLT, HH /-8 X / NC G. 90 NUT, /-8 NC NYLOCK. 98 NUT, JAM / - NF. 0 CABLE, PUSH-PULL 8. 00 WELDMENT, BRAKE PIN HOUSING 9. 009 ROUND, BRAKE PIN (not visible, inside of item 8) 0. 9C 8 BOLT, HH /- X / NC G8. 00 8 NUT, /- NYLOCK
Undercarriage Assembly Overview 0000 8 9 0 8 9 0
Undercarriage Assembly-continued- 9 8 0. 00 WHEEL/TIRE ASSEMBLY a. 98 WHEEL b. 00 TIRE c. 09 VALVE STEM. 09 0 BOLT, WHEEL. 00 HUB AND SPINDLE ASSEMBLY REAR. 9C BOLT, HH /- X / G. 9C BOLT, HH /-8 X /. 009 SHEET, ADJUSTING BOLT RETAINER. 9C BOLT, HH /- X / 8. 0 WASHER, LOCK / G 9. 0009 SHEET, COVER PLATE 0. 00.0 CHAIN. 00.08 CHAIN. 9 LINK, CHAIN CONNECTING (not visible). 00 DIVE MOTOR ASSY (00 on opposite side)
Undercarriage Assembly, Hub. 00 HUB AND SPINDLE ASSEMBLY REAR (00 front). 00.0 CHAIN REAR (00.08 front). 009 WELDMENT, CHAIN TIGHTENER. 9098 8 INSERT, /-8
DRIVE MOTOR ASSEMBLIES 00 and 00 Serial # &. 9 MOTOR, HYD a. 9.00 rev A SEAL KIT, MOTOR. 0 VALVE, COUNTERBALANCE ASSY a. SEAL KIT, COUNTERBALANCE VALVE. 90 FITTING, 00-8-8 (not shown) Serial #,, 8, 9.. 9 rev A MOTOR, HYD W/VALVE a. 9.00 rev A SEAL KIT, MOTOR b. VALVE, COUNTERBALANCE ASSY c. SEAL KIT, COUNTERBALANCE VALVE. 90 FITTING, 00-8-8 (not shown) Serial #0. 9 rev B MOTOR, HYD a. SEAL KIT, MOTOR. 0 rev A VALVE, COUNTERBALANCE ASSY. SEAL KIT, COUNTERBALANCE VALVE. FITTING, (not shown). FITTING, (not shown) Serial #. 9 rev C MOTOR, HYD a.. 0 rev B VALVE, COUNTERBALANCE ASSY. 00 NUT, LOCK /- NYLON INSERT. 9C BOLT, HH /- X / NC G8. KEY 8. 0 COTTER PIN, /8 X (not shown) 9. 9 NUT, HEX -0 UNEF-8 SLOTTED 0. 00 ROUND, SPROCKET HUB BOLTED. 00 MACHINING, PARK BRAKE DISC (used on left side only). 00 PLATE, BRAKE SPACER (not shown, used on right side only). 00 TUBE, SPROCKET SPACER INNER. 00 TUBE, SPROCKET SPACER OUTER. 9C BOLT, SOC /-8 X / NC. 000 MACHINING, SPROCKET DRIVER NOTE: Item # is only difference between left and right Drive Motor Assemblies.
DRIVE MOTOR ASSEMBLIES 00 and 00, 8 9 0 8
Hub and Spindle Assembly 00 and 00 8 9 0. 0 COTTER PIN, /8 X. 9 NUT, HEX -0 UNEF-8 SLOTTED. 980 WASHER, " EXTRA THICK. 00 MACHINING, SPROCKET DRIVER FRONT. 00 MACHINING, SPROCKET DRIVER REAR. 99 SEAL. 08 BEARING, CONE. 088 BEARING, CUP 8. 00 MACHINING, SPINDLE HOUSING 9. 908 KEY, WOODRUFF 0. 00 MACHINING, SPINDLE 9
Coupler Assembly 009 8 8 9 0. 08 PIN, ROLL / x. 80 ZERK, /8 STR NPT. 000 SPRING. 000 BUSHING. 008 ROUND, MALE COUPLER LATCH STOP. 0090 MACHINING, CASTING MALE COUPLER. 0008 TUBE, SPACER PIVOT PIN 8. 00 ROUND, MALE COUPLER LATCH PIN 9. 00 WELDMENT, PIN " (CAST COUPLER) 0. 8-A ZERK, / 90 DEGREE. 99C BOLT, HH /8- X. 0 WASHER, LOCK /8. 8 ZERK, GREASE /-8. 009 WELDMENT, BOXER PIVOT PIN-LONG 0
Operator Platform 00 8 0,,,,, 9. 00 NUT, LOCK /- NYLON INSERT. 9C BOLT, HH /- X (not visible, for item #8 & #9). 9C BOLT, HH /8- X /. 98C BOLT, HH /- X / (not visible, pivot bolts for item #9). 0 WASHER, FLAT /. 0 WASHER, FLAT /. 0 WASHER, LOCK / 8. 00 PLATE, OPERATOR PLATFORM 9. 00 PLATE, OPERATOR PLATFORM SUPPORT 0. 00 PLATE, OP COUNTER WEIGHT. 0089 SPRING, LEAF SINGLE / X /. 0.0 BOLT, CARRIAGE /- X /. 0.0 NUT - HEX - /8- NC SELF LOCKING
Fuel Tank Assembly 8a 8,. 98C BOLT, HH /-8 X. 0 WASHER, LOCK /. 989.0 HOSE, FUEL /" CUT " LONG (not visible). 989.0 HOSE, FUEL /" CUT " LONG (not visible). 989.0 HOSE, FUEL /" CUT " LONG (not visible). 98.00 WRAP, CERAMIC (not visible, under tank). 08 VALVE, FUEL SHUTOFF (not visible) 8. 00 TANK, FUEL 8a. 00.00 FUEL CAP 9. 09 CLAMP, FUEL HOSE (not visible) 0. 8 FITTING, TEE (not visible). 00 STRIP, FUEL TANK CLAMP
8. 099 FUSE PANEL. FUSE, AMP (operator presence). FUSE, AMP (high/low speed indicator). 00 FUSE, AMP (fan/fuel solenoid). FUSE, AMP (oil indicator). FUSE, AMP (hour meter). 000 HARNESS, GROUND FUSE PANEL 8. 0 FUSE, AMP (charging wire)
BATTERY ASSEMBLY 000. 0090 BATTERY. 000 CABLE, NEGATIVE. 9099 ISOLATOR, BLACK. 000 CABLE, POSITIVE. 9099 ISOLATOR, RED. 0 HOLD DOWN KIT
Wiring, Engine Compartment 8. 90 SWITCH, OPERATOR PRESENCE. 08 RELAY. 9 MODULE, TIME DELAY. 0 FUSE, AMP ATO. 00 HARNESS, OPERATOR PRESENCE SWITCH. 000 HARNESS, HONDA ENGINE. 000 HARNESS, OPERATOR PRESENCE GRND 8. 00 SHEET, OPS GUARD
Electrical Schematic
PO BOX 0 (0) / 0 N WAVERLY / PONCA CITY, OK 0 PHONE: (80) - / FAX: (80) -8 / NT FAX: (80) -9 www.boxerok.com