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BOXER 700HDX, Operator'S Manual

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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 – Troubleshooting ........................................................................5–1

Section 6 – General Specifications

 ..............................................................6–1

Summary of Contents for 700HDX

Page 1: ...7 314 Manufactured by 700HDX Operator s Manual Phone Morbark LLC 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 co...

Page 2: ...on 39510 475 700HDX 2660 1206 7 25 18 64 3 5 16 W x 2 7 8 H MAT L 020 DURABLACK w 3M 305 SERIES 9485PC or EK ADHESIVE BACK w FULL COVERAGE SUBSTIUTE ADHESIVE MAY BE 1 OPTI SOLVE EXTREME or 2 tesa 4959...

Page 3: ...III...

Page 4: ...omponents Extended Coverage New Boxer Compact Utility Loaders One 1 year 1 000 hours whichever comes first Warranty from vendor applies minimum of one 1 year Can purchase prior to start up Used Equipm...

Page 5: ...returning this form may result in denial of warranty entitlements To restart the equipment in service date simply complete the form below and mail e mail or fax the completed form and bill of sale to...

Page 6: ...VI Morbark LLC 8507 South Winn Road P O Box 1000 Winn MI 48896 Affix Stamp Here...

Page 7: ...ions indicated whenever you see the Safety Alert symbol no matter which signal word appears next to the Safety Alert symbol INDICATES A HAZARDOUS SITUATION THAT IF NOT AVOIDED IS VERY LIKELY TO CAUSE...

Page 8: ...VIII REVISION LOG Rev Rev Date Pages Affected Description of Changes Jan 20 2017 All Initial Release...

Page 9: ...2 1 Right Rear View 2 2 Safety Decals 2 3 Operating Controls 2 5 Operating Controls Description 2 6 Section 3 Pre Start Inspection and Operation 3 1 Pre Start Inspection 3 1 Daily Service Checks 3 1...

Page 10: ...ance 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 T...

Page 11: ...site Resume work only when the operating area is clear Keep all non operating personnel away from the machine during operation Passengers must never be allowed to ride on the machine or any attachment...

Page 12: ...r the work area stop machine operation until the work area is clear Prior to unloading the unit and starting to work inspect the path you will travel and work site area for potential hazards Some of t...

Page 13: ...suming work Be alert to any unusual reaction to any of the controls If anything unusual is noticed shut the machine down and thoroughly inspect it to determine the cause of the problem Do not operate...

Page 14: ...or work site hazards Be sure the area has adequate light and is well ventilated NEVER operate the machine inside a closed area Clean up any oil grease mud water or snow which might cause the floor sur...

Page 15: ...able causing fire or an explosion If electrolyte is splashed into your eyes flush them immediately with clean water and seek medical attention If electrolyte is swallowed seek medical attention immedi...

Page 16: ...vere burns 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...

Page 17: ...machine before beginning the fueling process Keep the fuel nozzle in constant contact with the rim of the machines fuel tank When filling a portable fuel container always place it on the ground Never...

Page 18: ...Safety Precautions 1 8...

Page 19: ...ANEL REMOVED FOR CLARITY Left Front View Item No Description 1 Attachment mounting plate 2 Boom 3 Joysticks 4 Manual Holder 5 Fuel Fill Cap 6 Lift Cylinder 7 Fuel Tank 8 Right Track Assembly 9 Lift Cy...

Page 20: ...escription 1 Attachment mounting plate 2 Attachment hydraulic quick connects 3 Right track assembly 4 Operator s platform 5 Fuel tank 6 Fuel fill cap 7 Engine hour meter 8 Loader arm lift cylinder 9 L...

Page 21: ...Operating Controls 2 3 Safety Decals...

Page 22: ...12 WARNING BATTERY GROUND SYM 1 39510 007 13 NOTICE ULTRA LOW SULFUR DIESEL 2 39510 152 14 WARNING CA PROP 65 1 39510 014 15 BOXER LARGE 2 39510 443 16 700HDX DECAL 2 39510 444 17 BIG POWER DECAL 2 3...

Page 23: ...ription 1 Engine coolant temperature gauge 2 Engine oil pressure gauge 3 Ignition switch 4 Ignition key 5 Track widen control 6 Right joystick 7 Left joystick 8 Engine throttle 9 Access panel Lock Lev...

Page 24: ...ontrol Pushing the lever forward retracts the track Pulling the lever backwards widens expands the track to the normal track width 6 Right Joystick Push joystick forward to lower the boom arm Pull joy...

Page 25: ...n reverse Push the joystick directly right to spin machine right Push the joystick directly left to spin machine left 8 Engine Throttle Moving the control lever forward increases the engine speed and...

Page 26: ...Operating Controls 2 8...

Page 27: ...s Check fluid levels and any signs of leaking fluids Do all Daily Service Checks Check machine controls to make sure that they automatically return to the neutral position The following information pr...

Page 28: ...il Level Check 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 It is important to add the c...

Page 29: ...into the tank until fuel level is at bottom of fill spout Allow engine to cool before filling fuel tanks Do not overfill fuel could spill onto hot engine parts and ignite or explode 4 Check engine coo...

Page 30: ...dd the proper coolant as shown in the Engine Manual 5 Inspect the radiator to make sure that the air flow is not blocked The fan located between the radiator and engine is a suction fan which draws ai...

Page 31: ...etrate 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 If you are injected...

Page 32: ...is not loose Check the widening bolt lock nut Item 2 Figure 3 8 to make sure that it is tight against the mounting block Item 3 Figure 3 8 NOTE The lock nut when it is fully tightened secures the tra...

Page 33: ...Pre Start Inspection and Operation 3 7 Figure 3 7 Lubrication Points CAUTION...

Page 34: ...re Start Inspection and Operation 3 8 Figure 3 8 Track Widening Stop Bolts NOTE Extremely dusty or dirty working conditions may require more frequent service replacement track widening stop bolts 1 2...

Page 35: ...afety lock pin goes behind the loader arm cylinder 7 Lower the loader arm assembly until it is supported by the cylinder lock Figure 3 9 Safety Lock Installation Cylinder Lock Installation Make sure t...

Page 36: ...re 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 3 Move the throttle lever Item 1 Figure 3 12 to about half way bet...

Page 37: ...lic motors Allow the engine to idle for another 5 minutes before beginning any machine operations When warming the hydraulic oil the operator must cycle all functions every 5 minutes This will assist...

Page 38: ...he operator becomes the load Figure 3 13 Transport Position on Trailer 3 When the machine is positioned on the trailer properly lower the attachment to the trailer deck 4 Shut the engine off and remov...

Page 39: ...e lifting eyes Item 2 Figure 3 15 located at the top of the boom arms 4 Make sure that the length of chain on each side of the lifting point is the same Item 3 A Figure 3 15 is the same as Item 3 B Fi...

Page 40: ...is functioning properly The cogging condition is most likely to occur while operating in a reverse direction pulling a heavy load and during the first 50 hours of track usage It is caused by the tensi...

Page 41: ...ghtly left the joystick is moved the faster the left turn will be made See Figure 3 19 Right Turn During Reverse Travel Left Turn During Reverse Travel Move the left joystick backwards and slightly to...

Page 42: ...nd holds while doing a spin turn to maintain your balance Move the left joystick directly to the right to spin the machine on it axis to the right Move the left joystick directly to the left to spin t...

Page 43: ...or the machine Keep attachments as low as possible when traveling on slopes or rough terrain Figure 3 23 Slide Slope Travel Keep the heavy end of the machine towards the uphill direction when travelin...

Page 44: ...ds securing the attachment to the machine If the lock pin does not drop into the locked position start the engine and tilt the attachment slightly forwards or backwards until the lock pins snap into p...

Page 45: ...tachment mounting plate Item 2 Figure 3 27 to remove any debris that might interfere with the attachment installation 2 Start the machines engine lower the loader arm and tilt the mounting plate forwa...

Page 46: ...g plate Figure 3 28 Attachment Installed 5 Shut the engine off 6 Rotate the attachment lock pins Item 1 Figure 3 29 into the locked position securing the attachment to the machine Figure 3 29 Attachme...

Page 47: ...ked Position 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 Figure 3...

Page 48: ...ot damaged during the installation process 4 Tuck the upper edge of the male mounting plate into the upper lip of the female attachment mounting plate Figure 3 32 Hydraulically Powered Attachment Inst...

Page 49: ...hment lock pins are securely holding the attachment in position 9 Shut off the engine 10 Relieve hydraulic pressure stored in the hoses NOTE To relieve pressure in high flow side depress push buttons...

Page 50: ...male coupling Item 3 Figure 3 36 into the female bulkhead quick coupling Item 2 Figure 3 36 on the machine and push until the connector locks into position d Repeat the above process to connect the a...

Page 51: ...ring operation and prevent them from being damaged Figure 3 37 Attachment Hydraulic Hose Routing shown without hose covers 13 The attachment is now ready to use Before starting the engine make sure th...

Page 52: ...Pre Start Inspection and Operation 3 26...

Page 53: ...t rotate the collar on the female quick connect Item 1 Figure 3 41 to align the notch on the collar with the lock button Item 2 Figure 3 41 4 Slide the collar backwards on the female quick connect Ite...

Page 54: ...r I Air Filter C R R Fuel Filter I R Engine Idle Speed C Check and Clean Battery Ter minals and Battery I Hydraulics Hydraulic Filter I R R Hydraulic Fluid Level I R Hydraulic Hoses I Grease I Track T...

Page 55: ...ting the machine Allow engine to cool before filling fuel tanks Do not overfill because fuel could spill onto hot engine parts and ignite or explode Make sure engine is turned off 2 Check engine fuel...

Page 56: ...re during operation The engine is filled at the factory with Chevron Delo 400 Multigrade SAE 15W 40 The recommended ambient temperature range for this oil is 14 F 10 C minimum to 122 F 50 C maximum Re...

Page 57: ...e 4 4 and check the radiator fluid level The proper coolant level will be to the bottom of filler neck The overflow bottle is a non pressurized container that is only for any high heat overflow Do not...

Page 58: ...he engine side of the radiator Figure 4 5 to make sure that debris has not been sucked against the radiator blocking air flow NOTE Some items in Figure 4 5 have been removed for clarity 6 Release dirt...

Page 59: ...l dipstick can be reached through the opening in the front cover b Unscrew the dipstick assembly and remove from the machine Item 1 Figure 4 7 c Make sure that the hydraulic fluid is between the marke...

Page 60: ...e safety support b Follow all of the hoses line and tubes from the control valve to their end Items 2 3 4 and 5 Figure 4 8 Inspect the connections and look for signs of leaking hydraulic fluid wear or...

Page 61: ...Routine Service and Maintenance 4 8 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 1 1 2 2 3 4 4 5 5...

Page 62: ...grease There are 14 lubrication points on this machine see Figure 4 10 Figure 4 10 Lubrication Points NOTE Extremely dusty or dirty working conditions may require more frequent service replacement 1 E...

Page 63: ...sprocket is off the ground Shut off the engine Keeps hands and fingers from under the track and track guide rollers d Measure the gap between the bottom of the center bogey guide roller Item 1 Figure...

Page 64: ...e of the mounting block and inner edge of the stop bolt head must be 6 3 4 17 cm If this measurement is not maintained damage to the machine may occur b Make sure that the stop bolt lock nuts Item 2 F...

Page 65: ...Routine Service and Maintenance 4 12 Figure 4 12 Track Extension Widening Stop Bolt 1 2 3...

Page 66: ...p bolt is required a Loosen the lock nut Item 3 Figure 4 13 b Rotate the stop bolt Item 2 Figure 4 13 to set the correct measurement of 6 3 4 17 cm from the outside edge of the stop block to the botto...

Page 67: ...15 a Remove the three bolts Item 1 Figure 4 15 holding the filter cover Item 2 Figure 4 15 in place NOTE Press downwards on filter cover to relieve the upwards pressure from the spring b Remove the fi...

Page 68: ...s 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...

Page 69: ...ing c After the main element is removed check the condition of the inner element It should be replaced whenever it appears dirty typically every other time the main element is replaced Clean the area...

Page 70: ...g in the frame along the left side of the machine b Unscrew the filter canister NOTE The fuel filter will be filled with diesel fuel Make sure to drain the fuel from the filter into an appropriate con...

Page 71: ...If any signs of damage are visible remove and replace the battery Wear the proper protective clothing when handling the battery Leaking battery fluid contains acid that can cause burns Fumes from the...

Page 72: ...old down clamp Items 4 and 6 Figure 4 20 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...

Page 73: ...ct the O ring Item 2 Figure 4 21 on the drain plug Replace the O ring if any signs of damage are noted Figure 4 21 Hydraulic Tank Drain Plug c When all of the hydraulic fluid has drained out of the ta...

Page 74: ...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 Figure 4 22 Hydra...

Page 75: ...N THE ENGINE IS COLD 4 FUEL TANKS SHOULD ONLY BE DRAINED IN AN AREA THAT IS WELL VENTILATED 5 WIPE UPANY DIESEL FUEL THAT SPILLS 1 Park the machine on a level surface to ensure that the fuel tank is c...

Page 76: ...ioned lower than the fuel valves to make sure that all fuel is drained from the tanks 7 Open the fuel valves on the bottom of each tank and allow the fuel to drain into the drain pan 8 Install a new s...

Page 77: ...Item 1 Figure 4 24 until only diesel fuel without any air bubbles comes out of the air bleed 15 Fully tighten the air bleed bolt Make sure to clean up any spilled fuel from in and around the engine co...

Page 78: ...in illustration Figure 4 25 Fuse Circuit Amp Rating 1 Voltage Regulator 3 2 Crawl Speed Solenoid 3 3 Hydraulic Oil Cooler Fan 15 4 Fuel Solenoid 15 5 Hour Meter 1 6 Indicator Gauges 1 7 In line Start...

Page 79: ...ion assembly when the track came off of the machine proceed to Step 2 If not skip to Step 7 2 Fully extend the track assemblies 3 Shut off the engine 4 Install tension bolt and thrust washer Item 1 Fi...

Page 80: ...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 Loosen track tension by rotating the tension bolt Item 3 Figure 4 28...

Page 81: ...ure 4 29 securing the drive sprocket Item 3 Figure 4 29 to the drive motor Figure 4 29 Remove Drive Sprocket 12 Slide the track Item 2 Figure 4 30 on the front idler wheel Item 1 Figure 4 30 making su...

Page 82: ...e track sprocket holes Figure 4 31 Insert Drive Sprocket into Track 14 Position the drive sprocket and the track onto the drive motor 15 Rotate the drive sprocket Item 1 Figure 4 32 and track to align...

Page 83: ...t Track Tension 18 Set Track Tension Start the engine and slowly rotate the track forward and backward to make sure that the track is properly seated on the drive sprocket 19 Fully rotate the track fo...

Page 84: ...battery terminals and fully clean battery terminals and cable clamps If the cable clamps can not be properly cleaned replace connectors Relay or starter switch is defective Contact Authorized Service...

Page 85: ...see Section 4 Replacing Fuel Filter for air bleed instructions Dirty or contaminated fuel filter Replace fuel filter Dirt water or stale fuel is in fuel system Drain fuel in tanks into an appropriate...

Page 86: ...adiator Abnormal engine vibration Engine mounting bolts are loose Tighten engine mounting bolts With the machines engine turned off the boom creeps downward more than 3 per hour less than 3 per hour i...

Page 87: ...Troubleshooting 5 4...

Page 88: ...ols Boom Loader Arms Four position spring centered lever control Up neutral down and float Bucket Attachment Tilt Three position spring centered lever control Extend neutral and curl Auxiliary Attachm...

Page 89: ...0 in 1524 mm Ground Speed Max 3 0 mph 4 83 kph Dump Angle 37 deg 37 deg Reach 34 in 864 mm Tip Capacity 2100 lb 952 5 kg Operating Capacity 35 of tip load 735 lb 333 5 kg Operating Capacity 50 of tip...

Page 90: ...the slope of the hill 16 THIS IS A 15 DEGR EE SLOP E DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES To avoid serious injury operate your unit up and down the face of slopes Travel...

Page 91: ...General Specifications 6 4...

Page 92: ...Manufactured by Phone Morbark LLC 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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