Morbark BOXER 532DX Operator's Manual
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Morbark BOXER 532DX Operator's Manual

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B I G P O W E R I N A L L P L A C E S
532DX Operator's Manual
Serial No.s 3612 and Higher
Part No. 76347-295
Manufactured by:
Phone:
Morbark
, Inc.
®
Sales - 800-831-0042
8507 S. Winn. Rd., P.O. Box 1000,
Parts and Service - 800-255-8839
Winn, Michigan 48896
®
www.boxerequipment.com
www.morbark.com

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  • Page 1 B I G P O W E R I N A L L P L A C E S 532DX Operator’s Manual Serial No.s 3612 and Higher Part No. 76347-295 Manufactured by: Phone: Morbark , Inc. ® Sales - 800-831-0042 8507 S. Winn. Rd., P.O. Box 1000, Parts and Service - 800-255-8839 Winn, Michigan 48896 ®...
  • Page 2 Your machine’s Model, Weight, and Power Rating along with Serial Number and Date of Manufacture of your machine are located on the right side panel at the top. The Engine information is located on a decal on your engine. Refer to your Engine OEM Manual for decal location.

  • Page 3: Boxer Product Warranty

    Boxer Product Warranty Morbark, Inc. (Morbark) warrants to the original purchaser that this product will be free from defects in materials and workmanship under normal use and operating conditions subject to the conditions and exclusions stated below. No representative, agent or dealer of Morbark or any other person is authorized to modify, expand or extend this warranty in any manner or make any representation on Morbark’s behalf in connection with the sale of any product...
  • Page 4 Morbark, Inc. 8507 South Winn Road, P.O. Box 1000, Winn, Michigan 48896 Phone: Sales - 800-831-0042, Parts and Service - 800-255-8839 www.morbark.com LIMITATION OF DAMAGES Morbark Vendor Purchased Product Description Manufactured Extended Coverage Components Components New Boxer Compact One (1) year/1,000...
  • Page 5 Currently the warranty start date (in-service date) is listed as the date the Boxer Compact Utility Loader left Morbark, Inc., which may be several months before you received and placed your new Boxer product into service.
  • Page 6 Affix Stamp Here Morbark, Inc. 8507 South Winn Road P.O. Box 1000 Winn, MI 48896...

  • Page 7: Safety Introduction

    Safety Introduction Be Prepared - Get to Know All Operating and Safety Instructions This is the Safety Alert Symbol. Wherever it appears, either in this manual or on safety signs on the machine, you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
  • Page 8 VIII...

  • Page 9: Table Of Contents

    Table of Contents Boxer Product Warranty ..................i Safety Introduction ....................v Be Prepared - Get to Know All Operating and Safety Instructions ..v Learn the Signal Words Used with the Safety Alert Symbol ....v Section 1 – Safety Precautions ..............1–1 General Safety ..................1–1 Operating Safety ..................1–2 Service &...
  • Page 10 Section 4 – Routine Service and Maintenance ...........4–1 Daily Maintenance Procedures ..............4–2 New Machine Brake-in Maintenance Procedures ........4–14 Weekly Maintenance Procedures ............4–15 Monthly Maintenance Procedures ............4–16 Annual Maintenance Procedures ............4–20 General Maintenance ................4–22 Draining Fuel Tank (Diesel) ..............4–22 Fuse Panel ..................4–24 Track and Tension System Installation ..........4–26 Section 5 –...

  • Page 11: Section 1 - Safety Precautions

    Section 1 - Safety Precautions Since Morbark Inc. has no direct control over machine application or operation, following the proper safety practices is the responsibility of the owner and/or operator. Remember that this unit is only as safe as those who operate it. Safety practices described throughout this Operator’s Manual must be followed at all times.

  • Page 12: Operating Safety

    Safety Precautions OPERATING SAFETY • Plan ahead and learn as much as possible about your job-site area before beginning any work. • Know the exact location of overhead power lines or obstructions. • Have all buried lines such as gas, electric, water, telephone, and cable TV marked by the proper authorities.
  • Page 13 Safety Precautions • Never attempt to operate any attachment without first understanding proper installation and operating procedures. The center of gravity, stability, and operating characteristics of the entire machine will change with the use of different attachments. • Operate all controls slowly and smoothly and never abruptly stop any function. This can cause the machine to become unstable.

  • Page 14: Service & Maintenance Safety

    Failure to comply with these safety precautions may result in serious personal injury and/or death. • Use only Morbark supplied or approved replacement parts and attachments. Imitation parts may lead to unit damage and/or injury to personnel. Warranty may be voided if unauthorized parts and attachments are used.

  • Page 15: Battery Hazards

    Safety Precautions Battery Hazards Before working with batteries, the following are important points about battery safety that you should be aware of: • Batteries are always surrounded by extremely explosive gases. This is especially true when the battery is being charged. To avoid explosion: - Do not smoke near batteries.

  • Page 16: Hydraulic System Hazards

    Safety Precautions Hydraulic System Hazards The hydraulic system is under pressure whenever the engine is running and may hold pressure even after the engine is shut off. Cycle all hydraulic controls after the loader boom is resting on the ground. Some components will retain residual or trapped pressure. Use extreme caution when removing any hydraulic component.

  • Page 17: Fueling Hazards

    Safety Precautions Fueling Hazards Most fuels are highly flammable. Observe the following precautionary practices to reduce the possibility of a serious accident: • Always refuel the unit in an open, well ventilated area away from sparks or open flames. DANGER Diesel Engines: •...
  • Page 18 Safety Precautions...

  • Page 19: Section 2 - Operating Controls

    Section 2 - Operating Controls Component Locations Left Front View Item No. Description Attachment mounting plate Tilt cylinder Boom Auxiliary hydraulic quick connects Hand grip Operating controls Manual holder Fuel filler cap Lift cylinder Fuel tank Right track assembly Lift cylinder safety lock Hydraulic level check...

  • Page 20: Right Rear View

    Operating Controls Right Rear View Item No. Description Attachment mounting plate Attachment hydraulic quick connects Right track assembly Operator’s platform Air cleaner assembly Fuel tank Fuel filler cap Engine hour meter Loader arm lift cylinder Loader arms Tilt cylinder...

  • Page 21: Safety Decals

    Cylinder Lock Installation Warning Lifting Point Danger - Auxiliary Valve Danger Zone Crush Hazard Boxer Decal Morbark Decal ISO 46 Decal Attachment Must Be Securely Fastened Cable Eye Decal Boxer Internet Address Decal Morbark Decal Ultra Low Sulfur Diesel Fuel...
  • Page 22 Operating Controls Safety Decals (Continued) 12 13 Item No. Description Crush Hazard Auxiliary Valve Control Decal Boxer Decal “Read Operators Manual” Warning Decal Battery Connection Decal CA PROP 65 Warning Decal Diesel Fuel Decal Safety Instructions Decal Control Operation Instruction Decal Lifting Point Decal Auxiliary Power Control Warning Made in USA Decal...

  • Page 23: Operating Controls

    Operating Controls Operating Controls 14 13 12 11 10 Item No. Description High/Low speed control switch Engine coolant temperature gauge Engine oil pressure gauge Ignition switch Ignition key Auxiliary attachment activation control Track widen control Auxiliary hydraulic cylinder control Right hand grip Attachment tilt control Right travel motor control Left travel motor control...

  • Page 24: Operating Controls Description

    Operating Controls Operating Controls Description 14 13 12 11 10 – Selects the travel speed range. High/Low Speed Range Selector Switch – Gauge indicates the temperature of the Engine Coolant Temperature Gauge engine coolant. – Gauge indicates the engine oil pressure when the Engine Oil Pressure Gauge engine is running.
  • Page 25 Operating Controls Operating Controls Description (Continued) CAUTION DO NOT attach an auxiliary hydraulic cylinder to the Operator Presence control. Hydraulic pressure will not be held in the system when the Operator Presence control is returned to the NEUTRAL position. – Pushing the lever forward widens the track. Pulling the Track Widen Control lever backwards retracts the track to the normal track width.
  • Page 26 Operating Controls...

  • Page 27: Section 3 - Pre-Start Inspection And Operation

    Section 3 - Pre-Start Inspection and Operation DANGER IMPROPER USE OF THE COMPACT UTILITY LOADER COULD CAUSE DEATH OR SERIOUS INJURY. BEFORE OPERATING THE MACHINE OR PERFORMING MAINTENANCE, THE OPERATOR MUST READ AND UNDERSTAND THE ENTIRE OPERATOR’S MANUAL, REVIEW MACHINE CONTROLS, LOCATE AND REVIEW ALL WARNINGS AND SAFETY PLACARDS, AND RELEVANT OPERATOR SAFETY MATERIALS INCLUDING WRITTEN, VISUAL, VIDEO OR VERBAL INSTRUCTIONS.
  • Page 28 Pre Start Inspection and Operation Do the following pre-start service checks: 1. Check condition of all warning and instructional decals. Replace any damaged decals with genuine Morbark replacement decals. 2. Check engine oil: • Make sure that the engine is OFF.
  • Page 29 Pre Start Inspection and Operation NOTICE Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine. 3. The Boxer has two saddle fuel tanks (Item 1, Figure 3–3). Each of the tanks has a fuel gauge located in the filler cap (Item 2, Figure 3–3).
  • Page 30 Pre Start Inspection and Operation NOTICE • The overflow bottle is a non-pressurized container that is only for any high heat overflow. Do not add coolant to this container. It will not be drawn into the engine. • If coolant is required, make sure to add the proper coolant as shown in the Engine Manual.
  • Page 31 Pre Start Inspection and Operation NOTE:Some items in Figure 3–5 have been removed for clarity. Figure 3-5 Radiator Air Flow Inspection 6. Check all hydraulic hoses, lines, and fittings. WARNING Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death.
  • Page 32 Pre Start Inspection and Operation • Visually inspect all of the hydraulic hoses, lines, and fittings for signs of damage, wear or leaking. • If any signs of damage are visible, do not operate the machine until repairs have been made.
  • Page 33 Pre Start Inspection and Operation CAUTION Before starting the engine: • Move all hydraulic control levers forward and release the lever. Make sure that each lever automatically returns to the Neutral position. • Move all hydraulic control levers rearward and release the lever. Make sure that each lever automatically returns to the Neutral position.
  • Page 34 Pre Start Inspection and Operation Figure 3-8 Track Widening Stop Bolts NOTE: Extremely dusty or dirty working conditions may require more frequent service/replacement track widening stop bolts.

  • Page 35: Cylinder Lock Installation

    Pre Start Inspection and Operation Cylinder Lock Installation WARNING Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly. 1. Start the engine. (See Machine Start-up in this section for engine starting instructions.) 2.

  • Page 36: Operating Instructions

    Pre Start Inspection and Operation Operating Instructions Machine Start-up To start the machine, the operator must: 1. Stand on the operator’s platform (Item 1, Figure 3–10). Figure 3-10 Operator’s Platform 2. Rotate the ignition key switch to the HEAT position (Item 1, Figure 3–11) for about 10 seconds.

  • Page 37: Machine Shut-Down

    Pre Start Inspection and Operation Figure 3-12 Throttle Settings 5. As soon as the engine starts, release the starter key. The key will automatically return to the RUN position (Item 3, Figure 3–11). 6. Leave the throttle setting at about the halfway position and allow the engine to idle.

  • Page 38: Transportation

    Pre Start Inspection and Operation Transportation 1. Move the throttle control lever to the mid-range engine speed and set the transport speed to the LOW range. Raise the attachment so that it will clear the ramp of the transport trailer. NOTE: The longer the attachment, like the trencher, the more the attachment needs to either be tilted or raised.

  • Page 39: Lifting Procedures

    Pre Start Inspection and Operation Figure 3-14 Travel Chains and Binders Lifting Procedures When it becomes necessary to lift the machine 1. Use a lifting device that can safely lift 4,000 lbs (1820 Kg). 2. Use appropriate lifting chains (Item 1, Figure 3–15) that can safely lift 4,000 lbs (1820 Kg).

  • Page 40: Machine Travel Controls

    Pre Start Inspection and Operation Machine Travel Controls • Levers and controls should return to the neutral position when they are released. • Make sure that all of the controls are in the neutral (middle) position before starting the engine. •...
  • Page 41 Pre Start Inspection and Operation Right Turn During Forward Travel Left Turn During Forward Travel To turn to the To turn to the left, right, move the move the right left hand control hand control lever lever farther farther forward forward than than the left the right control...
  • Page 42 Pre Start Inspection and Operation Spin Turn CAUTION Make sure to use the machine hand holds while doing a spin turn to maintain your balance. Move the travel control levers in opposite directions to spin the machine on it axis. To spin left, move the right control lever forward while pulling the left control lever backward;...
  • Page 43 Pre Start Inspection and Operation WARNING • Do not travel up or across a slope steeper than 15°. See Figure 3–23. • Make sure that the tracks are extended to their widest position, providing the broadest stance for the machine. •...

  • Page 44: Attachment Installation And Removal

    Pre Start Inspection and Operation Attachment Installation and Removal Attachment Lock Pins The mounting plate located at the front of the machine provides for the easy installation and safe use of the wide variety of available attachments. This system is very easy to use, but requires the proper use of the attachment lock pins.

  • Page 45: Installation Of Non-Hydraulically Powered Attachments

    Pre Start Inspection and Operation Installation of Non-Hydraulically Powered Attachments CAUTION Make sure to keep your hands and feet away from the attachment during the unlocking process. As the attachment becomes free from the machine, it may move. Pins Unlocked Figure 3-26 Attachment Locks in Unlocked Position There are many available attachments that are very easy to install.
  • Page 46 Pre Start Inspection and Operation 4. When the top of the attachment mounting plate (Item 1, Figure 3–28) is firmly seated in the attachment mounting bracket (Item 2, Figure 3–28), tilt the attachment mounting plate backward slightly to allow the lower edge of the attachment mounting bracket to slide into place on the attachment mounting plate.

  • Page 47: Removal Of Attachment

    Pre Start Inspection and Operation Removal of Attachment 1. Lower the attachment onto a firm, level surface. 2. Shut off the machine engine. 3. Rotate the attachment lock pins to the UNLOCKED position (Item 1, Figure 3–30). Pins Unlocked Figure 3-30 Attachment Locks in Unlocked Position 4.
  • Page 48 Pre Start Inspection and Operation 3. Slowly drive towards the attachment and align the top edge of the male mounting plate (Item 1, Figure 3–32) and the upper lip of the female attachment mounting plate (Item 2, Figure 3–32). NOTICE Make sure to position the attachments hydraulic hoses (Item 4, Figure 3–32) so that they are...
  • Page 49 Pre Start Inspection and Operation 6. Shut the engine off. CAUTION DO NOT go underneath the attachment when it is raised. 7. Rotate the attachment lock pins (Item 1, Figure 3–34) into the locked position securing the attachment to the machine. Pins Locked Figure 3-34 Attachment Locks in Locked Position 8.
  • Page 50 Pre Start Inspection and Operation 3-35 Auxiliary Control Lever b. Remove the protective covers (Items 4, Figure 3–36) from the attachment quick connectors. c. Wipe off the end of each of the connectors (Items 1, 2, 3, 5 Figure 3–36) to remove any dirt or debris.
  • Page 51 Pre Start Inspection and Operation 12. Make sure that the hydraulic hoses are routed so that they will not be in the way or damaged during machine operation. Figure 3–37 shows how the hoses might be routed to keep them out of the way during operation and prevent them from being damaged.

  • Page 52: Operating Instructions For A Hydraulic Attachment

    Pre Start Inspection and Operation Operating Instructions for a Hydraulic Attachment 1. Move the engine throttle to the full speed setting. 2. Raise the attachment off the ground and position it for use. CAUTION Make sure that you are standing on the operator’s platform and holding the Operator Presence control in the operating position.

  • Page 53: Travel Crawl Control

    Pre Start Inspection and Operation Travel Crawl Control The travel system on the machine can be adjusted to make the attachment more effective in tough digging situations. The travel “crawl” control allows the travel speed to be adjusted from full speed forward or reverse to no movement at all. To adjust the travel speed using the crawl control, move the engine throttle lever to the maximum engine speed and: NOTE: Make sure that the High/Low travel speed switch (Item 3, Figure...
  • Page 54 Pre Start Inspection and Operation d. While holding both of the control levers in the reverse position and the attachment operating, rotate the CRAWL control lever counter-clockwise until you set the proper travel speed for the attachment being used. NOTE: Rotating the crawl control lever counter-clockwise increases the travel speed from very slow to full operating speed.

  • Page 55: Removal Of Hydraulically Powered Attachments

    Pre Start Inspection and Operation Removal of Hydraulically Powered Attachments CAUTION After use, the quick couples and hydraulic fluid will be very hot. Wear gloves when dis- connecting the auxiliary hydraulic lines. To remove a hydraulically powered attachment; 1. Lower the attachment to the ground and shut off the engine. 2.

  • Page 56: Section 4 - Routine Service And Maintenance

    Routine Service and Maintenance Section 4 - Routine Service and Maintenance The following information presents the routine service and maintenance required to make sure that the machine functions safely and properly. More detailed service information is contained in the Service Manual. Table 4-1 Service Cycle Table Daily Machine...

  • Page 57: Daily Maintenance Procedures

    Routine Service and Maintenance Daily Maintenance Procedures Do the following procedures daily or every 10 operating hours: 1. Check condition of all warning and instructional decals. Before operating the machine, replace any missing or damaged decals. NOTE: Make sure to read and understand all WARNING and SAFETY decals before operating the machine.
  • Page 58 Routine Service and Maintenance 3. Check engine oil - a. Make sure that the engine is OFF. b. Pull out the dipstick (Item 1, Figure 4–2) and look for the “FULL” line. Figure 4-2 Oil Level Check c. If the engine oil level is below the add line, indicated by the letter “A” on the dipstick, carefully add the proper amount of oil through the engine oil filler (Item 1, Figure 4–3).
  • Page 59 Routine Service and Maintenance 4. Check engine coolant level. CAUTION • The coolant is hot and under pressure. DO NOT check until the engine radiator is cool to the touch. • Remove radiator cap (Item 1, Figure 4–4) and check the radiator fluid level. The proper coolant level will be to the bottom of filler neck.
  • Page 60 Routine Service and Maintenance 5. Inspect the radiator to make sure that the air flow is not blocked. The fan located on engine side of radiator unit is a suction fan, which draws air from inside the machine. Check the engine side of the radiator (Figure 4–5) to make sure that debris has not been sucked against the radiator blocking air flow.
  • Page 61 Routine Service and Maintenance CAUTION If you are checking the fluid level after a period of use, the hydraulic system and hydraulic fluid will be very hot. Wear gloves when inspecting the hydraulic fluid level. 7. Check hydraulic oil level, fill as needed with the proper hydraulic oil - be sure engine is off.
  • Page 62 Routine Service and Maintenance 8. Check hydraulic hoses. WARNING Hydraulic oil under pressure can penetrate body tissue causing serious injury and possible death. When troubleshooting a hydraulic system for leaks, always use cardboard or wood as a detector. DO NOT USE YOUR BARE HANDS.
  • Page 63 Routine Service and Maintenance Figure 4-8 Inspect Hydraulic Lines and Fittings d. If any signs of damage are visible, do not operate the machine until repairs have been made.
  • Page 64 Routine Service and Maintenance e. Some examples of common hydraulic hose damage are shown in Figure 4–9: Figure 4-9 Hydraulic Hose Damage 1. End fittings damaged or leaking. 2. Outer covering chafed or cut, and wire reinforcing is exposed. 3. Hose shows signs of kinking or crushing. 4.
  • Page 65 Routine Service and Maintenance 10. Check both track assemblies for: a. The proper tension. Too little or too much tension can cause premature track wear and travel motor damage. b. Make sure that the tracks are not worn or damaged. c.
  • Page 66 Routine Service and Maintenance c. Make sure that the stop bolt lock nuts (Item 2, Figure 4–12) are tight against the mounting block (Item 3, Figure 4–12). d. Make sure to check both track assembly stop bolts. 1/4” - 3/8” Figure 4-11 Track Deflection Measurement and Adjustment 4.11...
  • Page 67 Routine Service and Maintenance Figure 4-12 Track Widening Stop Bolts 4.12...
  • Page 68 Routine Service and Maintenance 13. If the stop bolt lock nut (Item 4, Figure 4–13) is loose, check the distance between the mounting block (Item 5, Figure 4–13) and bottom side of the bolt head (Item Figure 4–13). The correct measurement is 7” from the outside edge of the stop block to the bottom edge of the head of the stop bolt (Item 1, Figure 4–13).

  • Page 69: New Machine Brake-In Maintenance Procedures

    Routine Service and Maintenance New Machine Brake-in Maintenance Procedures Do the following after the first 20 operating hours for a new machine only. 1. Change engine oil. Refer to the engine manual for the proper engine oil changing instructions. 2. Change engine oil filter, which is located on the left side of the - engine. Refer to the engine manual for the proper engine oil filter changing instructions.

  • Page 70: Weekly Maintenance Procedures

    Routine Service and Maintenance Weekly Maintenance Procedures Do the following procedures weekly or every 50 operating hours: 1. Do all Daily maintenance procedures 2. Check the battery (Item 1, Figure 4–16) and cable connections (Items 2 and 3, Figure 4–16) for signs of leaking, corrosion or damage. (Some items have been removed for clarity.) NOTE: The electrical system on this machine is a NEGATIVE ground system.

  • Page 71: Monthly Maintenance Procedures

    Do not wash the paper element and inner element or use pressurized air, this will damage the elements. Replace dirty, bent or damaged elements with new genuine Morbark repair parts as required. e. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.
  • Page 72 Routine Service and Maintenance i. Reinstall the end cap (Item 1, Figure 4–17) so the dust ejector valve is down and secure the end cap with the two retaining clips. *In extremely dusty or dirty operating conditions, this service cycle may need to be shortened.
  • Page 73 Routine Service and Maintenance e. Loosen, but DO NOT remove, the air bleed bolt (Item 2, Figure 4–19). f. Raise and lower the primer pump handle (Item 1, Figure 4–19) until only diesel fuel without any air bubbles comes out of the air bleed. g.
  • Page 74 Routine Service and Maintenance • Check the battery hold down clamp (Items 4 and 6, Figure 4–19) to make sure that the battery is being held securely to the machine. NOTE: If the battery needs to be replaced, make sure to dispose of the old battery according to local regulations.

  • Page 75: Annual Maintenance Procedures

    Routine Service and Maintenance Annual Maintenance Procedures Do the following procedures annually: 1. Do all Daily, Weekly and Monthly maintenance procedures. 2. Replace air filter** See page 4-14, Step 3. 3. Check engine idle speed (Refer to engine manual). 4. Replace hydraulic fluid**. a.
  • Page 76 Routine Service and Maintenance NOTICE Do not over fill the hydraulic system. Damage to the hydraulic system might result. e. Unscrew the dipstick assembly and remove from the machine. (Item 1, Figure 4–22) and fill the hydraulic tank with the proper hydraulic fluid (Chevron Rykon Premium ISO 46 or equivalent) until the fluid level is at but not above the upper marker hole in the dipstick.

  • Page 77: General Maintenance

    Routine Service and Maintenance General Maintenance Draining Fuel Tank (Diesel) DANGER 1. DIESEL FUEL IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE. 2. A FIRE OR EXPLOSION FROM DIESEL FUEL CAN BURN YOU OR OTHERS AND CAUSE PROPERTY DAMAGE. 3. DRAIN FUEL FROM TANKS WHEN THE ENGINE IS COLD. 4.
  • Page 78 Routine Service and Maintenance 5. Loosen the intake hose clamp (Item 2, Figure 4–24) at the top of the fuel filter assembly (Item 1, Figure 4–24). Slide the clamp along the fuel line (Item 3, Figure 4–24) away from the fuel filter assembly. Figure 4-24 Fuel Filter 6.

  • Page 79: Fuse Panel

    Routine Service and Maintenance 11. Fill the fuel tanks with fresh diesel fuel. NOTE: Place a container underneath the fuel injection pump to catch any spilled diesel fuel. Dispose of the used fuel in an appropriate manner. 12. Loosen the air bleed screw on the top of the filter assembly slightly. DO NOT remove this bolt.
  • Page 80 Routine Service and Maintenance All fuses and their locations are shown in illustration Figure 4–25. Fuse Circuit Amp Rating Voltage Regulator Crawl Speed Solenoid Hydraulic Oil Cooler Fan Fuel Solenoid Hour Meter Indicator Gauges In-line Starter Solenoid Fuse (not shown in illustration - located in the RED power line between the ignition switch and the starter motor.) Figure 4-25 Fuse Panel 4.25...

  • Page 81: Track And Tension System Installation

    Routine Service and Maintenance Track and Tension System Installation 1. Securely elevate the machine. See Figure 4–26 and Track Tensioning instructions. CAUTION • Make sure that the machine has been securely elevated and that there is no danger of it tipping before beginning this procedure. •...
  • Page 82 Routine Service and Maintenance Figure 4-27 Track Drive Components Installed 7. Move rubber track away from the machine. Figure 4-28 Remove Lock Plate 8. Remove track tension lock plate bolt (Item 1, Figure 4–28) using a 9/16” wrench 9. Remove lock plate (Item 2, Figure 4-28) 10.
  • Page 83 Routine Service and Maintenance 11. Using a ¾” wrench (or tire cross) (Item 1, Figure 4–29), remove the 6 bolts (Item Figure 4-29) securing the drive sprocket (Item 3, Figure 4–29) to the drive motor. Figure 4-29 Remove Drive Sprocket 12.
  • Page 84 Routine Service and Maintenance 13. Insert the drive sprocket (Item 1, Figure 4–31) into rear of the track (Item 2, Figure 4–31), between the track lugs and with the sprocket teeth in the track sprocket holes. Figure 4-31 Insert Drive Sprocket into Track 14.
  • Page 85 Routine Service and Maintenance NOTE: Tighten the bolts evenly around the drive sprocket. 17. Rotate the tension bolt (Item 3, Figure 4–33) COUNTER CLOCKWISE until the correct track tension is set. See Track Tensioning earlier in this manual. Figure 4-33 Set Track Tension 18.

  • Page 86: Section 5 - Troubleshooting

    Section 5 - Troubleshooting The following procedures will assist you in determining the potential cause of a machine operating problem. NOTICE Make sure to follow all safety precautions stated in this manual when doing any work on the machine. Problem Possible Causes Corrective Action •...
  • Page 87 Troubleshooting Problem Possible Causes Corrective Action • Auxiliary hydraulics lever is • Move lever to neutral Engine will not start, starts hard, or fails to keep run- not in neutral position with position. ning. a hydraulically powered attachment installed. • Fuel tanks are empty. •...
  • Page 88 Troubleshooting Problem Possible Causes Corrective Action • Dirty or contaminated fuel filter. • Replace fuel filter. Engine looses power. • Dirt, water, or stale fuel is in • Drain fuel in tanks into fuel system. an appropriate storage container and dispose of bad fuel properly.
  • Page 89 Troubleshooting...

  • Page 90: Section 6 - General Specifications

    Section 6 - General Specifications Engine System Kubota D1105-T-E3B Type Liquid Cooled Cooling System 32.8 Turbocharged Engine System - Intake 8.6 Gallons Fuel Tank Heavy-Duty Air Cleaner Air Cleaner Hydraulic System Air to oil cooler with electric fan Oil Cooling System Pressure (Auxiliary/Boom &...

  • Page 91: Vibration Data

    General Specifications Units English Metric 60 in. 1524 mm Dump Height 3.0 mph 4.83 kph Ground Speed (Max) 37 deg. 37 deg. Dump Angle 34 in. 864 mm Reach 2100 lb. 952.5 kg Tip Capacity 735 lb. 333.5 kg Operating Capacity, 35% of tip load. 1,500 lb.
  • Page 92 General Specifications DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES. SUGGESTED GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION OF A COMPACT UTILITY LOADER WITH AN ATTACHMENT. DO NOT REMOVE THIS PAGE FROM THE MANUAL. 15 DEGREES MAX.
  • Page 93 General Specifications...
  • Page 94 BIG POWER IN ALL PLACES Manufactured by: Phone: Sales - 800-831-0042 Morbark, Inc. Parts and Service - 800-255-8839 8507 S. Winn. Rd., P.O. Box 1000, www.boxerequipment.com Winn, Michigan 48896 ® www.morbark.com...

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