Rayco BOXER 385D CE Installation, Operator And Service Manual
  1. Manuals
  2. Brands
  3. Rayco Manuals
  4. Lawn and Garden Equipment
  5. BOXER 385D CE
  6. Installation, operator and service manual
Rayco BOXER 385D CE Installation, Operator And Service Manual

Rayco BOXER 385D CE Installation, Operator And Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
BOXEREQUIPMENT.COM
BOXER 385D CE
COMPACT TOOL CARRIER
·
OPERATOR
SERVICE
RAYCO MANUFACTURING LLC © 2021 ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSM385DCE-21
·
MAINTENANCE
·
MANUAL

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BOXER 385D CE and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Rayco BOXER 385D CE

Summary of Contents for Rayco BOXER 385D CE

  • Page 1 BOXEREQUIPMENT.COM BOXER 385D CE COMPACT TOOL CARRIER · · · OPERATOR SERVICE MAINTENANCE MANUAL RAYCO MANUFACTURING LLC © 2021 ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSM385DCE-21...
  • Page 2 Boxer 385D Operator Service Maintenance Manual Serial Number Location & Information Your machine’s Model, Weight, and The Engine information is located on Power Rating along with Serial Number a decal on your engine. Refer to your and Date of Manufacture of your Engine OEM Manual for decal location.
  • Page 3 Boxer 385D Operator Service Maintenance Manual Serial Number Location & Information Track Loader =Type of Rayco Equipment 001= The three digit number of produced Boxer 385DCE =Model of Rayco Equipment Production Date; 01=2 digit month; 20= 2 digit year TRACK LOADER...
  • Page 4 Boxer 385D Operator Service Maintenance Manual...

  • Page 5: Table Of Contents

    Boxer 385D Operator Service Maintenance Manual Table of Contents TABLE OF CONTENTS Safety 6-24 Decals and Location 26-29 Foreword 30-31 Operator Controls 32-34 Range of Motion Item Description 36-37 Pre-Operation 38-46 Operation 47-63 Fluid and Torque Specifications 64-68 Maintenance 69-85 Storage and Recommission 86-87 Troubleshoot...

  • Page 6: Safety

    Boxer 385D Operator Service Maintenance Manual Safety Certified Engine Maintenance Do not wear loose clothing or jewelry that can snag on controls or on other parts of Proper maintenance and repair is essential the equipment. to keep the engine and machine systems Make sure that all protective guards and operating correctly.
  • Page 7 Boxer 385D Operator Service Maintenance Manual Safety Important Safety Information Most accidents that involve product operation, maintenance and repair are Indicates a hazardous situation which, caused by failure to observe basic safety if not avoided, could result in death or rules or precautions.
  • Page 8 These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Rayco dealers have the most current information available. Rayco Manufacturing, Inc. is greatly concerned with the safety of the operator, as well as all in the vicinity of his work.
  • Page 9 Boxer 385D Operator Service Maintenance Manual Safety General Hazard Information Personal Protective Equipment (PPE) Head protection must conform to ANSI Z89.1. Eye protection must conform to ANSI Z87.1 and be the wrap around style. Always Read, understand and follow all instructions wear the eye protection when operating on the machine and in the manuals before or working within the operational area of...
  • Page 10 Boxer 385D Operator Service Maintenance Manual Safety injure bystanders if they are in these Do not remove any hydraulic components areas. or parts until pressure has been relieved or personal injury may occur. Do not Pressurized Air and Water disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur.
  • Page 11 Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according Rayco recommends the use of only to local regulations.Always use leak proof genuine Rayco replacement parts. Use the containers when you drain fluids. Do not...
  • Page 12 Boxer 385D Operator Service Maintenance Manual Safety “Lock-Out / Tag-Out” Do not use only the jack stand to support the tongue while in operation. procedures. Do not work beneath the cab of the machine Burn Prevention unless the cab is properly supported. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 13 Boxer 385D Operator Service Maintenance Manual Safety Any contact with hot coolant or with steam Fire Prevention and Explosion Prevention can cause severe burns. Allow cooling system components to cool before the All fuels, most lubricants, and some coolant cooling system is drained. mixtures are flammable.
  • Page 14 fire extinguisher Repair any lines that are loose or damaged. regularly. Obey the recommendations on Leaks can cause fires. Consult your Rayco the instruction plate. dealer for repair or for replacement parts. Fire Extinguisher Location Check lines, tubes and hoses carefully.
  • Page 15 Boxer 385D Operator Service Maintenance Manual Safety operation, this will help to prevent vibration, Always operate this machine with all safety rubbing against other parts, and excessive equipment in place and working. Make wear. sure all controls are properly adjusted for safe operation.
  • Page 16 Replacement parts which are authorized Before you start the machine, perform by Rayco are the only parts which should a walk-around inspection in order to be used for repair or replacement on this ensure that there are no hazards around machine.
  • Page 17 “Reference Material”. Consult your tipping the machine. The machine can tip Rayco dealer in order to obtain copies of when you work on hills, on banks and on the material. The information should be slopes. Also, the machine can tip when you...
  • Page 18 Boxer 385D Operator Service Maintenance Manual Safety Parking • feel for the machine, Park on a level surface. If you must park • identification of potential hazards, and on a grade, chock the machine. operating the machine safely by making appropriate decisions.
  • Page 19 Only use work tools that are approved by noisy environment. Hearing protection may Rayco for use on Rayco machines. Refer be needed when the machine is operated to the Operation and Maintenance Manual, with a cab that is not properly maintained or Rayco options”.
  • Page 20 Boxer 385D Operator Service Maintenance Manual Safety Operator training, behavior, • Move the attachments smoothly. mode, and stress • Adjust the machine speed and the Job site organization, preparation, route in order to minimize the vibration level. environment, weather and material •...
  • Page 21 Any alteration or any modification to the approved by Rayco or polycarbonate ROPS/FOPS Structure could weaken front guards that are approved by Rayco the structure. This places the operator are available for machines with a cab into an unprotected environment.
  • Page 22 6. It should be safely tested and verified replace the decal as well. Replacement that the lockout does prevent the release decals may be purchased from Rayco of energy. Mfg. or your Rayco dealer. Tag Out Procedure...
  • Page 23 Boxer 385D Operator Service Maintenance Manual Safety 1. Make all reasonable effort to contact while turning, parking, crossing intersec- the worker who placed the tag. tions, and in all driving situations. When arriving at the work site, do not set up 2.
  • Page 24 Boxer 385D Operator Service Maintenance Manual Safety Loading Your Combination NEVER load cargo inside the vehicle-in- tow or on the trailer. Cargo inside the vehicle -in-tow can cause sway or WHIPPING. NEVER overload your tow vehicle. Do not exceed the Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Ratings (GAWR), which are posted on a label inside the driver’s door opening.
  • Page 25 Boxer 385D Operator Service Maintenance Manual 800.392.2686...
  • Page 26 Boxer 385D Operator Service Maintenance Manual Decal Kit - 43578...
  • Page 27 Boxer 385D Operator Service Maintenance Manual Decal Kit - 43578 800.392.2686...
  • Page 28 Boxer 385D Operator Service Maintenance Manual Decal Location...
  • Page 29 Boxer 385D Operator Service Maintenance Manual Decal Location 800.392.2686...

  • Page 30: Foreword

    If this manual is lost, or local Engine Manufacturer Dealer for damaged or unreadable a new manual must obtaining engine parts and service. be replaced. Contact Rayco Mfg LLC for a replacement manual. Operation Some photographs or illustrations in the...
  • Page 31 Boxer 385D Operator Service Maintenance Manual Foreword Recommended service should always be performed at the interval that occurs first. Under extremely severe dusty or wet Never modify this machine! operating conditions, more frequent Modifications to this machine will not lubrication than is specified in the main- only void the warranty, but may cause tenance intervals chart might be neces- an unsafe condition that could result in...

  • Page 32: Operator Controls

    Boxer 385D Operator Service Maintenance Manual Operator Controls Figure 2-7 Operating Controls Description...
  • Page 33 Boxer 385D Operator Service Maintenance Manual Operator Controls the right side track for reverse travel. 6. Left Travel Motor Control - Push- ing the lever forward rotates the left side track for forward travel. Pulling the lever backwards rotates the left side track for reverse travel.
  • Page 34 Boxer 385D Operator Service Maintenance Manual Operator Controls NOTE:The lever is spring loaded and when released, will automatically move from the FORWARD motion position to the NEUTRAL position, stopping attach- DO NOT attach an auxiliary hydraulic ment motion. cylinder to the hydraulic circuit con- 13.

  • Page 35: Range Of Motion

    Boxer 385D Operator Service Maintenance Manual Range of Motion 72.899 " " " " 4" " 68" 800.392.2686...

  • Page 36: Item Description

    Boxer 385D Operator Service Maintenance Manual Item Description Item No. Description Attachment mounting plate Loader arms Boom lift cylinder Hydraulic cooler Radiator filler pressure cap Engine radiator Left track assembly Front tie-down ring Right track assembly Battery Muffler Ignition switch and hour meter Fuel Tank Air Cleaner Manual Tube...
  • Page 37 Boxer 385D Operator Service Maintenance Manual Item Description Item No. Description Attachment mounting plate Loader arms Boom lift cylinder Hydraulic cooler Radiator filler pressure cap Engine radiator Left track assembly Front tie-down ring Right track assembly Battery Muffler Ignition switch and hour meter Fuel Tank Air Cleaner Manual Tube...

  • Page 38: Pre-Operation

    Boxer 385D Operator Service Maintenance Manual Pre-Operation IMPROPER USE OF THE COMPACT UTILITY LOADER COULD CAUSE SERIOUS INJURY OR DEATH. 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...
  • Page 39 Boxer 385D Operator Service Maintenance Manual Pre-Operation Daily Service Checks Table 3.1: Service Cycle Table Activity Daily (10 Hours) Safety Placards 3 and R Fuel 3 and A Engine Oil 3 and A Engine Oil Filter Engine Coolant 3 and A Engine Radiator 3*** Air Filter...
  • Page 40 Boxer 385D Operator Service Maintenance Manual Pre-Operation Figure 3-1 Engine Oil Level Check Figure 3-2 Engine Oil Filler Cap Pre-Start Service Checks NOTE: Extremely dusty or dirty working conditions may require 1. Check condition of all warning and more frequent checking, instructional decals.
  • Page 41 Boxer 385D Operator Service Maintenance Manual Pre-Operation Figure 3-4 Engine Coolant Level 4. Check engine coolant level. Figure 3-3 Fuel Tank The Boxer has one saddle fuel tank (Item Figure 3–3). The coolant is hot and under pressure . DO NOT check until the engine radiator 3.
  • Page 42 Boxer 385D Operator Service Maintenance Manual Pre-Operation NOTE: Some items in Figure 3–5 have been removed for clarity. • Allow engine to cool before removing the filter bowl. Spilled fuel can potentially ignite or explode. • Place a container underneath the filter assembly to catch any spilled fuel.
  • Page 43 Boxer 385D Operator Service Maintenance Manual Pre-Operation Figure 3-8 Hydraulic Hose Damage 1. End fittings damaged or leaking. 6. Release dirt from separator tube at 2. Outer covering chafed or cut, and the bottom of the air filter by squeez- wire reinforcing is exposed.
  • Page 44 Boxer 385D Operator Service Maintenance Manual Pre-Operation 9. Check for loose or missing fasten- ers. • Inspect for any loose or missing bolts. Before starting the engine: • Tighten or replace any missing bolts • Move all hydraulic control levers immediately.
  • Page 45 Boxer 385D Operator Service Maintenance Manual Pre-Operation Figure 3-9 Lubrication Points NOTE: Extremely dusty or dirty working conditions may require more frequent service/replacement 800.392.2686...
  • Page 46 Boxer 385D Operator Service Maintenance Manual Pre-Operation 4. Return the cylinder lock to the stor- age position (Item 1, Figure 3-10) on the loader arm. 5. Fully insert the safety lock pin (Item Make sure to install the cylinder lock before performing any service work Figure 3-10) and lock the knob...

  • Page 47: Operation

    Boxer 385D Operator Service Maintenance Manual Operation Machine Start Up To start the machine the operator must: 1. Stand on the operator’s platform (Item 1, Figure 3-11) 2. Move the throttle lever (Item 1, Fig- 3-12) to about half way between fast and idle engine speeds.
  • Page 48 Boxer 385D Operator Service Maintenance Manual Operation º º 6. In cold weather (32 F [0 C]) after about 5 minutes of engine idling, operate all of the main hydraulic controls to cycle warmed hydraulic oil through the hydraulic lines into the cylinders and hydraulic motors.
  • Page 49 Boxer 385D Operator Service Maintenance Manual Operation Lift the machine approximately 12” to make sure that the machine is bal- anced before completing the lift. If lifting the machine with an attach- ment installed, the overall machine may not be balanced from front to back. Figure 3-14 Travel Chains and Binders When transporting the machine, make sure to use DOT approved chains and...
  • Page 50 Boxer 385D Operator Service Maintenance Manual Operation Machine Travel Controls If a cogging condition occurs, immedi- atley stop machine travel and auxillary functions and reverse travel direction slightly to de-compress track tension. Continued cogging will cause the track • Levers and controls should return drive sprocket to seat into the rubber to the neutral position when they track incorrectly, and cause damage to...
  • Page 51 Boxer 385D Operator Service Maintenance Manual Operation Forward Travel Reverse Travel Push both control Pull both control levers forward to trav- levers backward to el straight forward. travel straight back- The farther these are wards. The farther moved, the faster the these are moved, the machine will travel.
  • Page 52 Boxer 385D Operator Service Maintenance Manual Operation Right Turn During Reverse Travel Left Turn During Reverse Travel Move the left hand Move the right hand control lever farther control lever farther backward than the backwards than the right control lever. The left control lever.
  • Page 53 Boxer 385D Operator Service Maintenance Manual Operation 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. Figure 3-23 •...
  • Page 54 Boxer 385D Operator Service Maintenance Manual Operation Attachment Installation and Removal Pins Locked Attachment Lock Pins The mounting plate located at the front of the machine provides for the easy installation and safe use of the wide vari- ety of available attachments. This system is very easy to use, but requires the Figure 3-25 proper use of the attachment lock pins.
  • Page 55 Boxer 385D Operator Service Maintenance Manual Operation Installation of Non-Hydraulically Powered Attachments 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. There are many available attachments that are very easy to install.
  • Page 56 Boxer 385D Operator Service Maintenance Manual Operation 5. Shut the engine off. 6. Rotate the attachment lock pins (Item 1, Figure 3-28 and Item 1, Figure 3-29) into the locked posi- DO NOT go underneath the attachment tion, securing the attachment to the when it is raised.
  • Page 57 Boxer 385D Operator Service Maintenance Manual Operation Installation of Hydraulically Powered Attachments There are many hydraulically powered attachments available that are very easy to install. To install any of these attach- ments. 1. Position the attachment on a level surface. •...
  • Page 58 Boxer 385D Operator Service Maintenance Manual Operation 5. When the machine mounting plate’s Pins Locked top edge is seated in the attachment mounting plate, tilt the machine’s mounting plate backward slightly to allow the lower edge of the ma- chine’s mounting plate to slide into position.
  • Page 59 Boxer 385D Operator Service Maintenance Manual Operation E. Repeat the process to connect the attachment’s female quick con- nect on the other hose to the male bulkhead connector (Item 4, Figure Make sure that the engine has been shut off before beginning this 3-36) on the machine.
  • Page 60 Boxer 385D Operator Service Maintenance Manual Operation Operating Instructions for a ments motion. The engine will continue to run. Hydraulic Attachment When using an attachment that Before starting the engine, make sure will require the machine to move, that the Auxiliary Hydraulic control such as with a trencher or tiller, it lever is in the NEUTRAL position.
  • Page 61 Boxer 385D Operator Service Maintenance Manual Operation have a lock button preventing ac- cidental disconnection. To release this type of quick connect, rotate the collar on the female quick connect • Make sure not to travel to fast for operating conditions when using a (Item 1, Figure 3–39) to align the...
  • Page 62 Boxer 385D Operator Service Maintenance Manual Operation Battery Master-Disconnect To maximize battery voltage drop when the machine is off the Boxer is eqipped with a master-disconnect switch. To access the switch: 1. Unclip the two latches (Item 1, Fig- ure 3-40) on the panel in front of the operator’s platform.
  • Page 63 Boxer 385D Operator Service Maintenance Manual Operation 800.392.2686...

  • Page 64: Fluid And Torque Specifications

    Boxer 385D Operator Service Maintenance Manual Fluid and Torque Specifications & F AYCO UBRICATION LUID PECIFICATIONS Engine Oil During the initial break-in period, the engine will consume more oil than usual. Check the engine oil level daily. ONLY USE CH-4 (or better) CLASSIFICATION OILS WITH A 10 TBA OR HIGHER. See the Engine Operator Manual for engine lubricating oil specifications.
  • Page 65 Boxer 385D Operator Service Maintenance Manual Fluid and Torque Specifications Lubricating Grease All machines are completely serviced at the factory before shipping. The operator should check all grease fittings to familiarize with the location and correct service schedule plan. Use the normal shutdown procedure (See “Operating Instructions”), before lubricating the machine. Apply grease using a standard low pressure/low volume grease gun.
  • Page 66 Boxer 385D Operator Service Maintenance Manual Fluid and Torque Specifications RAYCO COOLANT SPECIFICATIONS Coolant / Antifreeze Recommendations Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. These antifreezes are intended for aluminum automotive engines and are unacceptable for diesel engines. Use antifreeze that is formulated with a low silicate level and the proper coolant additives for heavy duty diesel engines.
  • Page 67 Boxer 385D Operator Service Maintenance Manual Fluid and Torque Specifications Torque Specifications General Torque Information Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Maintenance Section, if necessary.
  • Page 68 Boxer 385D Operator Service Maintenance Manual Fluid and Torque Specifications...

  • Page 69: Maintenance

    • Please contact Rayco Mfg. for a course of the life of the machine. When listing of approved maintenance consulting this manual regarding the longer...
  • Page 70 Boxer 385D Operator Service Maintenance Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes...
  • Page 71 Boxer 385D Operator Service Maintenance Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 72 Boxer 385D Operator Service Maintenance Manual 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 Activity...
  • Page 73 Boxer 385D Operator Service Maintenance Manual Maintenance Daily Maintenance Procedures filler (Item 1, Figure 4-3). To reach the oil filler cap, remove the lower locking service panel. It is impor- Do the following procedures daily or tant to add the correct type of every 10 operating hours.
  • Page 74 Boxer 385D Operator Service Maintenance Manual Maintenance Figure 4-4 Engine Coolant Level Check NOTICE Figure 4-3 • The overflow bottle is a non- Engine Oil Filler Cap pressurized container that is only • NOTE: Extremely dusty or dirty for any high heat overflow. Do not working conditions may require add coolant to this container.
  • Page 75 Boxer 385D Operator Service Maintenance Manual Maintenance DO NOT check until the engine radiator is cool to the touch. 5. Inspect the radiator to make sure that the air flow is not blocked. The fan located on top of the unit is a suction fan, which draws air from inside of the machine.
  • Page 76 Boxer 385D Operator Service Maintenance Manual Maintenance Release dirt from separator tube at the bottom of the air filter by squeez- ing the rubber dust ejector valve Hydraulic Oil under pressure can (Item 1, Figure 4-7) underneath the penetrate body tissue causing seri- air filter.
  • Page 77 Boxer 385D Operator Service Maintenance Manual Maintenance look for signs of leakage or dam- age to the drive motors and to their hydraulic connections. G. Carefully inspect both sets of quick couplers (Item 2, Figure 4-9) to make sure that they are not damaged or leaking.
  • Page 78 Boxer 385D Operator Service Maintenance Manual Maintenance 10. Check for proper track tension. Keep hands and fingers from under the track and guide rollers A. Raise the machine off the ground and support it using a device Figure 4-11 capable of safely supporting 4,000 Track Deflection Measurement and Adjustment lbs (1820 Kg).
  • Page 79 Boxer 385D Operator Service Maintenance Manual Maintenance G. Adjust the track tension by rotat- New Machine Brake-in ing the tension bolt (Item 3, Fig- Procedures ure 4–12) COUNTERCLOCKWISE Do the following after the first 20 operat- to tighten the track and CLOCK- ing hours for a new machine only: WISE to loosen the track.
  • Page 80 Boxer 385D Operator Service Maintenance Manual Maintenance D. Using a small amount of hydraulic oil, lubricate the rubber gasket on top of the new filter canister and install the filter onto the filter mount. Do not over fill the hydraulic system.
  • Page 81 Boxer 385D Operator Service Maintenance Manual Maintenance Weekly Maintenance Procedures A. Remove the protective cover screen (Item 1, Figure 4-18). Do the following procedures weekly or B. Using compressed air or a garden every 50 operating hours. hose (Item 1, Figure 4-19) spray 1.
  • Page 82 Boxer 385D Operator Service Maintenance Manual Maintenance Monthly Maintenance or damaged with new genuine Procedures Boxer repair parts as required. Do the following procedures monthly E. Handle new elements carefully; or every 200 operating hours. do not use if the sealing sur- 1.
  • Page 83 Boxer 385D Operator Service Maintenance Manual Maintenance 5. Replace the fuel filter D. Dispose of the fuel and water in the bowl according to State and Local regulations. E. Remove the paper filter (Item 4, Figure 4-21) and dispose of ac- cording to State and Local regula- •...
  • Page 84 Boxer 385D Operator Service Maintenance Manual Maintenance 6. Check battery for signs of leak- Fuel System AIr Bleeding age or for corrosion on the battery Procedure cables. 1. Loosen the air bleed bolt (Item 1, A. Check the battery (Item 4, Figure Figure 4-23).
  • Page 85 Boxer 385D Operator Service Maintenance Manual Maintenance Annual Maintenance Procedures C. When all of the hydraulic fluid has drained out of the tank, reinstall Do the following procedures annually. and secure the drain plug. 1. Do all the Daily, Weekly, and Monthly maintenance procedures.
  • Page 86 Boxer 385D Operator Service Maintenance Manual Maintenance 4-26) at the bottom of the radiator and allow all of the coolant to drain from the radiator. Figure 4-25 Figure 4-26 Hydraulic Fluid Level Dip Stick Radiator Drain E. Close the petcock and refill the Start the machine and run the en- radiator with a 50-50 mix of radia- gine at low idle for several minutes.
  • Page 87 Boxer 385D Operator Service Maintenance Manual Maintenance NOTICE General Maintenance Draining Fuel Tank The fuel tank holds 4.5 gallons(17 liters) of diesel fuel. • Diesel fuel is extremely 8. Remove the fuel line from the filter flammable and highly explosive. assembly and immediately place it in •...
  • Page 88 Boxer 385D Operator Service Maintenance Manual Machine Storage and Re-comissioning Short Term Storage Long Term Storage Follow these guidelines when storing the Follow these guidelines when storing the machine for one year or less. machine for more than a year. 1.
  • Page 89 Boxer 385D Operator Service Maintenance Manual Machine Storage and Re-commissioning Re-commissioning Machine After Storage Follow these guidelines when re-com- missioning the machine after storage. 1. Install the battery 2. Check fluid levels. • Fill as necessary 3. Perform “Pre-Start Inspection” prior to starting the machine.

  • Page 90: Troubleshoot

    Boxer 385D Operator Service Maintenance Manual Trouble Shoot The following procedures will assist you in determining the potential cause of a machine operating problem. Make sure to follow all safety precau- tions stated in this manual when doing any work on the machine. Problem Possible Causes Corrective Action...
  • Page 91 Boxer 385D Operator Service Maintenance Manual Trouble Shoot Problem Possible Causes Corrective Action Engine will not start, starts • Auxiliary hydraulics/ Operator • Move lever to neutral position. hard, or fails to keep run- presence lever is either in ning. Forward or Reverse position with no hydraulically powered attachment installed.
  • Page 92 Boxer 385D Operator Service Maintenance Manual Trouble Shoot Problem Possible Causes Corrective Action Engine overheats. • Engine load is excessive. • Reduce ground speed. • Reduce speed of attachment. • Engine oil level in crankcase is low. • Add the appropriate engine oil to crankcase.
  • Page 93 Boxer 385D Operator Service Maintenance Manual Trouble Shoot Problem Possible Causes Corrective Action The machine does not • Engine is not running at full • Advance throttle to full engine travel in either forward or speed. speed. reverse directions. • •...

  • Page 94: Machine Specifications

    Boxer 385D Operator Service Maintenance Manual Machine Specifications Engine System Kubota D902-E4B-EPI-2, EPA/CARB, 4-cycle, Type TIER 4 Liquid Cooled Cooling System 4.5 Quarts (4.25 Liiters) Radiator Capacity 24.8 HP (18.5 kW) HP / KW 4.5 Gallons (17 Liters) Fuel Tank Dual Element, Dry Type Air Cleaner Hydraulic System...
  • Page 95 Boxer 385D Operator Service Maintenance Manual Machine Specifications Units English Metric Dump Angle deg. deg. Reach Tip Capacity 1100 Operating Capacity, 35% of tip load. Weight (without Bucket)(*w/Bucket) 1900 Ground Pressure 22.6 Vibration Data Engine rpm was set @ 3,000 rpm. The hand-arm and whole body vibration measurements were made with the operator present.
  • Page 96 Boxer 385D Operator Service Maintenance Manual Hydraulic Schematic - M48010-803 PRESSURE 500 PSI REDUCING 803869 BUCKET CYLINDER M26820-301 SAFETY VALVE BRAKE 2.5 X 10.25 SOLENOID VALVE M26676-203 805793 SAFETY VALVE SOLENOID M26676-203 2800 DIVERTER VALVE M26629-153 PUMP M26711-055 0.69 CI/0.2 CI...
  • Page 97 Boxer 385D Operator Service Maintenance Manual Hydraulic Schematic - M48010-803 TRACK MOTOR TRACK MOTOR WITH BRAKE WITH BRAKE (28.7 CU. IN. TYP.) M26713-009 M26713-009 BOOM CYLINDER M26820-302 3 X 12 AUX VALVE M26629-155 C/B VALVE 3000 M26633-221 OIL COOLER M26844-131 FILTER ASSEMBLY M26838-315 VALVE BANK...
  • Page 98 Boxer 385D Operator Service Maintenance Manual Wiring Schematic - 43028 FUSE BLOCK BREAKER 761432 RELAY IGN SW HR METER COOLER HORN SWITCH FLOW BRAKE DIVERT BRAKE SWITCH SAFETY INTERLOCK...
  • Page 99 Boxer 385D Operator Service Maintenance Manual Wiring Schematic - 43028 ALTERNATOR ALARM GLOW PLUG WTR TEMP OIL PRES BATTERY HORN NUETRAL SAFETY FLOW SAFETY DIVERT VALVE 800.392.2686...
  • Page 100 Boxer 385D Operator Service Maintenance Manual Wiring Schematic - 43028 FROM WIRE DESCRIPTION COLOR GAUGE PLUG# PIN # PLUG# PIN# (FUNCTION IMPRINT) FUEL SOL HOLD FUSE PWR ALT EXCITE FUSE PWR SFTY INTERLOCK PWR FUSE PWR KEY POWER FAN RELAY PWR WARNING LMP PWR FUSE PWR DIODE ANODE...
  • Page 101 Boxer 385D Operator Service Maintenance Manual Wiring Schematic - 43028 BRAKE SIG SP11 BRAKE GND DIODE CATHODE SP11 DIODE ANODE DIODE CATHODE SP11 DIODE ANODE DIODE CATHODE SP11 DIODE ANODE FLOW DIVERTER SP11 FLOW DIV GND KEY POWER SPLICE CIRCUITS WIRE CONNECTED TO SPLICE...

  • Page 102: Common Wear Parts

    Boxer 385D Operator Service Maintenance Manual Common Wear Parts REPLACEMENT PARTS FILTERS & FILTER KITS DESCRIPTION PART# DESCRIPTION PART# Ignition Switch w/Key M29211-935 Engine Oil Filter M29295-045 Ignition Key M29211-929 Fuel Filter Element M29211-107 Male Quick Connect 806796 Outer Air Filter 780270 Female Quick Connect 806795...
  • Page 103 Boxer 385D Operator Service Maintenance Manual 800.392.2686...

  • Page 104: Index

    Boxer 385D Operator Service Maintenance Manual Index Operator Training, 20 PPE (Personal Protective Attachments Equipment), 9 Installing and Removing, 54-59 Pre-Transportation, 23 ROPS (Rollover Protection Structure), 21 Fuse Panel, 99 Signal Words, 7 Towing, 23-24 Joysticks Joystick Operation, 51-52 Track Track Adjustment, 76-77 Machine Intended Use, 31...
  • Page 105 Boxer 385D Operator Service Maintenance Manual Boxer® Warranty Registration Dear Customer, , manufacturer of the Boxer® Compact Utility Loader, would like to thank you for your purchase. is committed to providing unsurpassed products and product support to our customers. To accomplish this, we need to update our database with information regarding your purchase.

  • Page 106: Warranty

    (2) years from said date of delivery. Rayco receives warranty from their This warranty does not cover and Rayco supplier. makes no warranties with respect to (i) any 5. Pockets and Teeth...
  • Page 107 If you have a situation where you are not sure if a component is covered under warranty, To obtain performance of this warranty, please do not hesitate to contact us. Rayco the original retail purchaser must request wants you and your customer to be 100% warranty service from a Rayco dealer satisfied with our products and service.
  • Page 108 We care about your safety. When operating your RAYCO® machinery always wear an approved helmet complete with ear muffs, face shield and the proper eye wear. Never operate under the influence of alcohol or drugs. Know your RAYCO, read and understand your owner’s manual cover to cover.

Table of Contents