Morbark BOXER 320 Operator'S Manual Download Page 83

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Troubleshooting

5.2

Engine will not start, starts

hard or fails to keep

running.

• Auxiliary hydraulics lever is

not in neutral position with

a hydraulically powered

attachment installed.

• Move lever to neutral position.

• Fuel tanks are empty.

• Fill fuel tanks with fuel.

• Air cleaner is dirty.

•

Clean air filter housing and

replace the filter elements.

• Spark plug dirty or fouled.

• Replace spark plug.

• Air in fuel system.

• Bleed air from fuel system.

See Perkins engine manual for

complete procedures and 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 storage container

and dispose of bad fuel

properly.

•

Refill fuel tanks with fresh,

clean fuel.

•

Replace fuel filter.

• 15 Amp fuse blown.

• Replace fuse.

Engine looses power.

• Engine load is excessive.

• Reduce ground speed.

• Reduce speed of attachment.

• Air cleaner is dirty.

•

Clean air filter housing and

replace the filter elements.

• Engine oil level in crankcase

is low.

• Add the appropriate engine

oil to crankcase. See engine

manual for oil specifications.

•

Cooling fins and air passages

under engine blower housing

are plugged.

• Remove obstruction from

cooling fins and air passages.

• Dirty or contaminated fuel

filter.

•

Replace fuel filter.

• Dirt, water or stale fuel is in

fuel system.

• Drain fuel in tanks into an

appropriate storage container

and dispose of bad fuel

properly.

•

Refill fuel tanks with fresh,

clean fuel.

•

Replace fuel filter.

Summary of Contents for BOXER 320

Page 1: ...anufactured by 320 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 com Revised 09 18 2018 B I G P O W E R I N A L L P L A C E S ...

Page 2: ...ower 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: ... S EXCLUSIVE REMEDY The exclusive remedy of the purchaser in the event the product does not conform to this Warranty shall be repair or replacement of the product at the option of Morbark without charge to the purchaser when the product is returned to Morbark s factory at 8507 South Winn Road Winn Michigan 48896 or at such other locations as may be designated by Morbark Morbark shall have sole dis...

Page 4: ...n the programs offered by the engine supplier Wear Items including but not limited to such items as lubricants anti freeze fluids filters belts bearings hoses and fittings etc Manufacturer s limited warranty extended to the original purchaser to cover conditions that are reasonably considered to have been within the manufacturer s control Conditions not within the manufacturer s control such as ir...

Page 5: ...art date in service date and not 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 Morbark LLC P O Box 1000 8507 S Winn Road Winn MI 48896 1000 E mail anonymous boxerequipment com Fax 989 866 2280 Please take the time to complete and return this warr...

Page 6: ...iv Affix Stamp Here Morbark LLC 8507 S Winn Rd P O Box 1000 Winn MI 48898 ...

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 DEATH OR EXTREMELY SERIOUS INJURY IT MAY ALSO BE USED TO ALERT AGAINST EQUIPMENT THAT MAY EXPLODE OR DETONATE IF HANDLED OR TREATED CARELESSLY Indicates a hazardous situation that if not avoided could...

Page 8: ... 2 1 Left Rear View 2 2 Operating Controls 2 3 Safety Decals 2 4 Operating Controls Description 2 6 Section 3 Pre Start Inspection and Operation 3 1 Pre Start Inspection 3 1 Daily Service Checks 3 1 Cylinder Lock Installation 3 7 Cylinder Lock Removal 3 7 Operating Instructions 3 8 Machine Start up 3 8 Machine Shut down 3 10 Transportation 3 11 Lifting Procedures 3 12 Machine Travel Controls 3 13 ...

Page 9: ...5 New Machine Brake in Maintenance Procedures 4 9 Weekly Maintenance Procedures 4 11 Monthly Maintenance Procedures 4 12 Annual Maintenance Procedures 4 17 General Maintenance 4 19 Draining Fuel Tank 4 19 Track and Tension System Installation 4 20 Section 5 Troubleshooting 5 1 Section 6 General Specifications 6 1 Vibration Data 6 2 Noise Data 6 2 ...

Page 10: ... 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 Wearing protective clothing and gear such as hard hats safety glasses safety shoes hearing protection breathing protection and long pants and shirts is highly recommended Do not operate in clothing ...

Page 11: ...er 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 the hazardous conditions you may encounter are Holes Deep ditches or excavations Drop offs Soft un compacted soil Culverts Deep mud Standing Water Large rocks Slippery surfaces Steep slopes Tall grass...

Page 12: ...esuming 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 the machine until all required repairs have been made If the unit must be left unattended shut the machine down and make sure that it can not be started by an unauthorized individual Operating on ste...

Page 13: ...nd 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 surface to become slippery If the machine requires maintenance take the machine out of service and attach a Do Not Operate tag at the control panel and remove the ignition key If maintenance or repair...

Page 14: ... 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 immediately If electrolyte is splashed onto exposed skin or clothing flush and clean the area immediately with clean water and seek medical attention if necessary Jump Starting Battery Charging Hazards Follow the instructions for...

Page 15: ...any hydraulic lines Hot hydraulic fluid can cause severe 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 DO NOT USE YOUR BARE HANDS If you are injected with hydraulic oil or any other fluids immediately seek treatment by a doctor trained in the treatme...

Page 16: ...the 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 gas container always place it on the ground Never fill a portable fuel container while it is inside a vehicle truck pick up bed or any surface To avoid static sparks when using a portable fuel container only fill the container when it is positione...

Page 17: ...andard the employer shall not allow dry sweeping or dry brushing where such activity could contribute to employee exposure to respirable crystalline silica unless wet sweeping HEPA filtered vacuuming or other methods that minimize the likelihood of exposure are not feasible The employer bears the burden of show ing the alternative methods are not feasible The use of non grit oil or waxed based swe...

Page 18: ...w Item No Description 1 Attachment mounting plate 2 Loader arms 3 Lift cylinder 4 Fuel tank 5 Left track assembly 6 Right track assembly 7 Hydraulic fluid level check 8 Remote air cleaner assembly 9 Hydraulic cooler 10 Ignition switch and hour meter 1 10 7 5 3 2 4 6 8 9 ...

Page 19: ...ent mounting plate 2 Operating controls 3 Hand grip 4 Service access panel 5 Operator s platform 6 Fuel tank 7 Manual holder 8 Fuel filler cap fuel gauge 9 Safety support 10 Loader arms 11 Attachment hydraulic quick connects 12 Tilt cylinder 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 20: ...scription 1 High Low selector control 2 Hand grip 3 Attachment tilt control 4 Right travel motor control 5 Left travel motor control 6 Loader arm lift control 7 Engine throttle 8 Auxiliary attachment activation control Operator presence 1 2 3 4 5 6 2 7 8 ...

Page 21: ...Item No Description 1 Crush hazard 2 Model number decal 3 Boxer decal 4 Burn hazard 5 Small Boxer decal 6 ISO 46 decal 7 Danger zone 8 Tie down decal 9 Lifting point decal 10 Morbark decal 11 Boxer internet decal 1 1 4 5 3 7 6 10 9 2 11 8 ...

Page 22: ...ock installation decal 5 Small operating warning decal 6 Gasoline only decal 7 Allow unit to cool warning decal 8 Read operator s manual warning decal 9 Small boxer decal 10 Danger zone decal 11 Safety instructions decal 12 Operating controls decal 13 Shutdown instruction decal 14 Attachment security decal 1 2 3 4 5 1 6 7 8 9 10 14 13 12 11 ...

Page 23: ...for forward travel Pulling the lever backwards rotates the right side wheels for reverse travel 7 Left Travel Motor Control Pushing the lever forward rotates the left side wheels for forward travel Pulling the lever backwards rotates the left side wheels for reverse travel 8 Boom Raise and Lower This lever controls the raising and lowering of the boom assembly 9 Hand Grip 10 Engine Throttle Moving...

Page 24: ...n auxiliary hydraulic cylinder to the hydraulic circuit controlled by the Attachment Activation Lever Operator Presence control Hydraulic pressure will not be held in the system when this control is returned to the NEUTRAL position CAUTION ...

Page 25: ...Operating Controls 2 8 ...

Page 26: ...ulic lines and hoses for signs of damage or leaks Inspect the machine for any signs of damage or loose fasteners 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 presents details on these inspection points and service checks Daily Service Checks Table 3...

Page 27: ... full and add oil lines Item 1 Figure 3 1 indicated by the letters F and A The correct oil level is between those two lines Figure 3 1 Engine Oil 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 Item 1 Figure 3 2 It is important to add the correct type of engine oil as stated in ...

Page 28: ...s needed be sure engine is OFF 3 The Boxer has one saddle fuel tank Item 1 Figure 3 3 Remote filter cap Item 2 Figure 3 3 and insert a clean tank level gauge into tank and remove This will show you the level of gas remaining in the tank Make sure that the tank has been filled on a daily basis Figure 3 3 Fuel Level Check Carefully pour the fuel into the tank not exceeding the max fill on your gas t...

Page 29: ...he machine until repairs have been made Some examples of common hydraulic hose damage are shown in Figure 3 4 Figure 3 4 Hydraulic Hose Damage 5 Check for loose or missing fasteners Inspect for any loose or missing bolts Tighten or replace any missing bolts immediately 6 While you are performing the daily maintenance inspect the machine for any signs of damage such as missing or damaged components...

Page 30: ...tically 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 The Auxiliary Control Lever will remain in the Reverse position until it is manually moved to the Neutral position If any of the levers other than the Auxiliary Control Lever does not automatically return to the Neutral pos...

Page 31: ...Pre Start Inspection and Operation 3 6 Figure 3 5 Lubrication Points Extremely dusty or dirty working conditions may require more frequent service replacement NOTICE ...

Page 32: ...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 Fully raise the loader arm 3 Shut off the engine 4 Release the cylinder lock from its storage position Item 1 Figure 3 6 by removing the lock knob Item 3 Figure 3 6 and pulling the safety lock pin Item 2 Figure 3 6 5 Place the cylinder lock Item 5 Fi...

Page 33: ...hine Start up To start the machine the operator must 1 Stand on the operator s platform Item 1 Figure 3 7 Figure 3 7 Operator s Platform 2 Move the throttle lever Item 1 Figure 3 8 to about half way between fast and idle engine speeds Figure 3 8 Throttle Settings 1 1 ...

Page 34: ... choke knob inwards to the normal operating position 7 Leave the throttle setting at about the halfway position and allow the engine to idle This will begin warming the hydraulic oil When warming the hydraulic oil the operator must cycle all functions every 5 minutes This will assist in warming the hydraulic oil in all systems evenly and more rapidly Failure to do this can cause the control system...

Page 35: ...Park the machine on a solid level area 2 Lower the loader arm and attachment to the ground 3 Idle the engine for 5 10 minutes to allow the machine to cool down 4 Shut off the engine 5 Clean off any accumulated mud and or dirt from the machines operating surfaces i e operator s platform both track assemblies etc ...

Page 36: ...ansport 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 remove the key 5 Secure the unit to the transport vehicle with DOT Department of Transportation approved chains binders Items 1 and 2 Figure 3 11 and DOT guidelines Make sure to use the appropriate tie down locations Items 3 and 4 Figure 3 11 on th...

Page 37: ...te lifting chains Item 1 Figure 3 12 that can safely lift 4 000 lbs 1820 Kg 3 Route the chains through the lifting eye Item 2 Figure 3 12 located directly in front of the operating controls Lift the machine approximately 12 to make sure that the machine is balanced before completing the lift If lifting the machine with an attachment installed the overall machine may not be balanced from front to b...

Page 38: ... noise called cogging This situation is part of the track drive systems safety design and indicates that this portion of the safety system is functioning properly Drive system damage can be caused by excessive cogging 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 tension spr...

Page 39: ... 3 14 Figure 3 14 Reverse Travel Right Turn During Forward Travel Left Turn During Forward Travel To turn to the right move the left hand control lever farther forward than the right control lever The farther forward the left control is moved the faster the right turn will be made See Figure 3 15 Figure 3 15 Right Hand Turn in Forward To turn to the left move the right hand control lever farther f...

Page 40: ...ontrol lever The farther forward the right control is moved the faster the left turn will be made See Figure 3 18 Figure 3 18 Left Hand Turn in Reverse Spin Turn Make sure to use the machine hand holds while doing a spin turn to maintain your balance CAUTION 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 ...

Page 41: ...or the machine Keep attachments as low as possible when traveling on slopes or rough terrain Figure 3 20 Slide Slope Travel Keep the heavy end of the machine towards the uphill direction when traveling up or down a slope NOTICE When the machine has no attachment or load the heavy end is the operator s platform end of the machine See Figure 3 21 Figure 3 21 Uphill Downhill Travel WARNING 16 15 15 1...

Page 42: ...rds 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 place Figure 3 22 Attachment Locks in Locked Position Until the attachment lock pins are fully in the locked position the attachment has not been safely secured to the machine Do not stand near the at...

Page 43: ...on 3 18 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 Figure3 23 Attachment Locks in Unlocked Position CAUTION 1 1 Pins Unlocked ...

Page 44: ...e attachment lock pins Item 1 Figure 3 23 are in the unlocked position See Attachment Lock Pins earlier in this section 3 When the top of the attachment mounting plate Item 1 Figure 3 24 is firmly seated in the attachment mounting bracket Item 2 Figure 3 24 tilt the attachment mounting plate backward slightly to allow the lower edge of the attachment mounting bracket to slide into place on the att...

Page 45: ...on securing the attachment to the machine Figure 3 26 Attachment Locks in Locked Position DO NOT go underneath the attachment when it is raised 7 Start the engine and raise the attachment off the ground Visually inspect the bottom edge of the attachments mounting plate to make sure that both of the attachment lock pins are securely holding the attachment in position CAUTION 1 1 1 Pins Locked ...

Page 46: ... Rotate the attachment lock pins to the UNLOCKED position Item 1 Figure 3 27 Figure 3 27 Attachment Locks in Unlocked Position 4 Start the engine and rotate the mounting plate downwards 5 Back away from the attachment It may be necessary to lower the loader arm assembly slightly to fully disengage from the attachment NOTICE 1 1 Pins Unlocked ...

Page 47: ...e mounting plate forwards Make sure that both of the attachment lock pins Item 1 Figure 3 28 and Item 3 Figure 3 29 are in the unlocked position Figure 3 28 Attachment Locks in Unlocked Position 3 Slowly drive towards the attachment and align the top edge of the male mounting plate Item 1 Figure 3 29 and the upper lip of the female attachment mounting plate Item 2 Figure 3 29 Make sure to position...

Page 48: ...nting plate backwards slightly to allow the lower edge of the machines mounting plate to slide into position See Figure 3 30 Figure 3 30 Hydraulically Powered Attachment Installed 5 Shut the engine off DO NOT go underneath the attachment when it is raised 6 Rotate the attachment lock pins Item 1 Figure 3 30 Item 1 Figure 3 31 into the locked position securing the attachment to the machine 1 3 4 2 ...

Page 49: ...the engine has been shut off before beginning this procedure 9 Move any of the main hydraulic controls forward and backward to release any stored hydraulic pressure 10 Attach the hydraulic hoses to the quick connects See Figure 3 33 a Move the AUXILIARY control lever Item 1 Figure 3 32 either towards the hand grip or backwards into the REVERSE detent position This will release the hydraulic pressu...

Page 50: ...ents male coupling Item 2 Figure 3 33 into the female bulkhead quick connect coupling Item 1 Figure 3 33 on the machine and push until the connector locks into position e Repeat the above process to connect the attachments female quick connect Item 4 Figure 3 33 on the other hose to the male bulkhead connector Item 5 Figure 3 33 on the machine f Check the security of both connections by gently tug...

Page 51: ...outed to keep them out of the way during operation and prevent them from being damaged Figure 3 34 Attachment Hydraulic Hose Routing 12 The attachment is now ready to use Before starting the engine make sure that the Auxiliary control lever is in the NEUTRAL position If this control is left in either the forward or reverse position and the engine is started the attachment will begin to function CA...

Page 52: ...PRESENCE lever is spring loaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping the attachments motion The engine will continue to run When using an attachment that will require the machine to move such as with a trencher or tiller it is recommended to set the HI LOW selector lever to the LOW speed position 4 Lower the attachment to begin work NOTE If...

Page 53: ...ttachment is in operation move the travel control levers slightly in either the forward or reverse position Using too fast a travel speed can create an unsafe operating condition or cause damage to the machine If the engine begins to labor or stalls release the travel controls completely until the engine returns to full operating power ...

Page 54: ...ck connect Item 1 Figure 3 36 to align the notch on the collar with the lock button Item 2 Figure 3 36 4 Slide the collar backwards on the female quick connect Item 4 Figure 3 36 until it stops against the lock button The male connector will be released Move the attachment hose away from the bulkhead fitting 5 If the female connector does not have the lock pin type collar just slide the collar bac...

Page 55: ...Pre Start Inspection and Operation 3 30 ...

Page 56: ...3 and A R R Engine Oil Filter R R Air Filter 3 R R Fuel Filter R Engine Idle Speed 3 Check and Clean Battery Ter minals and Battery 3 3 Hydraulics Hydraulic Filter R R Hydraulic Fluid Level 3 A and R Hydraulic Hoses 3 Grease 3 Tracks 3 Visual Check for Loose Missing Fasteners 3 Check and Adjust Track Tension 3 Service Cycle R Replace 3 Check A Add First 20 operational hours then follow normal serv...

Page 57: ...ld spill onto hot engine parts and ignite or explode Make sure engine is turned off 2 Check engine fuel and fill as needed be sure engine is OFF a The Boxer has one saddle tank Item 1 Figure 4 1 on the left side of the machine Figure 4 1 Fuel Level Check b The fuel tank has a fuel gauge located in the filler cap Item 2 Figure 4 1 Remove cap and visually inspect fuel level to make sure that the ind...

Page 58: ...e 4 3 The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature 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 Refer to the engine Operation and Maintenance M...

Page 59: ...ssurized air this will damage the elements Replace dirty bent or damaged elements with new genuine Morbark LLC repair parts as required e Handle new elements carefully do not use if the sealing surfaces are bent or damaged f Check all parts for wear cracks or damage g Replace any damaged components h If needed install the new inner element followed by the outer element Slide each fully into place ...

Page 60: ...ic dipstick is located under the large nut Item 1 Figure 4 5 on the hydraulic tank filler port Item 2 Figure 4 5 located on the right side of the machine b Unscrew the dipstick assembly and remove from the machine Item 1 Figure 4 5 c Make sure that the hydraulic fluid is 1 4 below the marker hole in the dip stick Figure 4 5 Hydraulic Fluid Level Dip Stick d Add the proper hydraulic fluid Chevron R...

Page 61: ...safety support b Follow all of the hoses line and tubes from the control valve to their end Items 1 8 and 9 Figure 4 6 It will be necessary to remove the service access cover Item 5 Figure 4 6 Remove the four bolts and washers Items 6 and 7 Figure 4 6 and then the service cover Inspect the connections and look for signs of leaking hydraulic fluid wear or damage c Carefully inspect both sets of qui...

Page 62: ...shown in Figure 4 7 Figure 4 7 Hydraulic Hose Damage 3 Outer covering ballooning Lubricate pivot shafts with grease There are 9 lubrication points on this machine see Figure 4 8 Figure 4 8 Lubrication Points 1 3 4 2 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 Outer covering ballooning ...

Page 63: ...the ground See Figure 4 9 c Lower the loader arm assembly pushing the front of the machine upwards Continue raising the machine until the rear drive 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 4 9 and the track The proper tension will be about ...

Page 64: ... filter See Service Manual and Figure 4 11 a Remove the front cover Item 3 Figure 4 11 to enable access to the filter assembly Item 11 Figure 4 11 b Remove the three bolts Item 6 Figure 4 11 holding the filter cover Item 7 Figure 4 11 in place Press downwards on filter cover to relieve the upwards pressure from the spring c Remove the filter cover and spring Item 8 Figure 4 11 d Remove the filter ...

Page 65: ...enance 4 10 Using the hydraulic oil level dip stick Item 1 Figure 4 11 check the hydraulic oil level Add the hydraulic fluid to within a 1 4 below indicator mark Figure 4 11 Hydraulic Oil Filter Assembly 3 4 5 6 7 8 9 10 11 1 2 ...

Page 66: ...d cable connections Items 4 and 5 Figure 4 12 for signs of leaking corrosion or damage To complete this check remove the service access panel Item 1 Figure 4 12 by removing the four bolts and washers Items 2 and 3 Figure 4 12 and then the access panel Make sure that the battery clamp Item 7 Figure 4 12 is securely holding the battery in position Figure 4 12 Battery and Cable Connections NOTICE 1 2...

Page 67: ...ppears dirty typically every other time the main element is replaced Clean the area around the base of the inner element before removing it so dirt does not get into the engine d 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...

Page 68: ...ng the left side of the engine b Shut off fuel using the fuel shut off valve Item 1 Figure 4 14 by rotating the valve handle horizontally across the fuel line c Remove the spring clamps Item 3 Figure 4 14 from above and below the fuel filter sliding the clamps along the fuel line away from the filter and remove the fuel lines d Replace the fuel filter with a new filter Item 2 Figure 4 14 NOTE The ...

Page 69: ...ce and Maintenance 4 14 Figure 4 14 Fuel Filter Replacement Make sure to clean up any spilled fuel from in and around the engine compartment of the machine Spilled fuel may be ignited by a hot engine 2 3 3 1 NOTICE ...

Page 70: ...nto both terminals and cable clamps after cables are installed The electrical system on this machine is a NEGATIVE ground system 7 Remove the service access panel Item 1 Figure 4 15 to access the battery and cables Check both of the battery cables Items 3 and 4 Figure 4 15 for signs of damage or corrosion Loosen the cable clamps and remove the cable from the battery Clean the terminals with a batt...

Page 71: ...Routine Service and Maintenance 4 16 Figure 4 15 Battery and Connections 6 2 3 4 5 1 ...

Page 72: ... fluid from the machine Make sure to inspect the O ring Item 2 Figure 4 16 on the drain plug Replace the O ring if any signs of damage are noted Figure 4 16 Hydraulic Tank Drain Plug c When all of the hydraulic fluid has drained out of the tank reinstall and secure the drain plug Make sure to dispose of the used hydraulic fluid in an appropriate manner and according to State and Local regulations ...

Page 73: ...em might result e Unscrew the dipstick assembly and remove from the machine Item 1 Figure 4 17 Fill the hydraulic tank with the proper hydraulic fluid until the fluid level is at but not above the upper marker hole in the dipstick Figure 4 17 Hydraulic Fluid Level Dip Stick f Start the machine and run the engine at low idle for several minutes g Shut off the engine h Recheck the hydraulic fluid le...

Page 74: ... Park the machine on a level surface Ensure that the fuel tank is completely drained 2 Lower the loader arms stop engine and remove the key 3 Allow the engine to cool completely 4 Shut off fuel using the fuel shut off valve Item 1 Figure 4 18 by rotating the valve handle horizontally across the fuel line Figure 4 18 Fuel Shut Off Valves 5 Loosen the lower intake hose clamp Item 3 Figure 4 18 at th...

Page 75: ...l the lower fuel line onto the new fuel filter 10 Slide the hose clamp close to the fuel filter to secure the fuel line 11 Fill the fuel tank with fresh fuel 12 Open the fuel valve 13 Start the engine and allow it to idle for several minutes to make sure that all air bubbles are out of the fuel system Make sure to clean up any spilled fuel from in and around the engine compartment of the machine S...

Page 76: ...e sure that the thrust plate is rotated as far backwards as possible on the tension bolt releasing all track tension 4 Install tension spring Item 2 Figure 4 20 into track frame 5 Install idler wheel assembly Item 3 Figure 4 20 into track frame NOTE Make sure that the idler wheel assembly is installed so that the axle bolt head is visible and that the lower edge of the idler wheel aligns with the ...

Page 77: ...k Drive Components 6 Remove track tension lock plate bolt Item 1 Figure 4 21 using a 9 16 wrench Figure 4 21 Remove Lock Plate 7 Remove lock plate Item 2 Figure 4 21 8 Loosen track tension by rotating the tension bolt Item 3 Figure 4 21 CLOCKWISE using a 1 5 8 wrench ...

Page 78: ...nch is located under the removable service access cover 9 Using a 3 4 wrench or tire cross Item 1 Figure 4 22 remove the 6 bolts Item 2 Figure 4 22 securing the drive sprocket to the drive motor and remove the drive sprocket Item 3 Figure 4 22 Figure 4 22 Remove Drive Sprocket 3 2 1 ...

Page 79: ...o the front idler wheel Item 1 Figure 4 23 making sure that the track lugs are on each side of the idler wheel 11 Insert the drive sprocket Item 1 Figure 4 24 into rear of track Item 2 Figure 4 24 between the track lugs and with the sprocket teeth in the track sprocket holes Figure 4 24 Insert Drive Sprocket into Track 1 2 1 2 ...

Page 80: ... Install Track and Drive Sprocket 14 Install and secure the 6 drive sprocket lock washers Item 2 Figure 4 25 and mounting bolts Item 3 Figure 4 25 Tighten the bolts evenly around the drive sprocket 15 Rotate the tension bolt Item 3 Figure 4 26 COUNTER CLOCKWISE until the correct track tension is set See Track Tensioning earlier in this manual Figure 4 26 Set Track Tension 1 2 3 3 2 1 NOTICE ...

Page 81: ...ck is properly seated on the drive sprocket 17 Fully rotate the track forward and backward several times 18 Shut off the engine 19 Double check track tension Adjust as needed 20 Install track tension bolt lock plate Item 2 Figure 4 26 and secure the lock plate with the lock bolt Item 1 Figure 4 26 21 Return the machine to service ...

Page 82: ...n with no hydraulically powered attachment installed Move lever to neutral position Battery is dead Charge the battery if battery does not hold a charge replace the battery Electrical connections are corroded or loose Check electrical connections for good contact Remove cables from battery terminals and fully clean terminals and cable clamps if the cable clamps can not be properly cleaned replace ...

Page 83: ... Drain fuel in tanks into an appropriate storage container and dispose of bad fuel properly Refill fuel tanks with fresh clean fuel Replace fuel filter 15 Amp fuse blown Replace fuse Engine looses power Engine load is excessive Reduce ground speed Reduce speed of attachment Air cleaner is dirty Clean air filter housing and replace the filter elements Engine oil level in crankcase is low Add the ap...

Page 84: ...eakage Contact Service Dealer Cylinder seals are leaking Replace cylinder seals With the machines engine turned off boom drops downward quickly and then stops Cylinder seals are leaking Replace cylinder seals The machine does not travel in either forward or reverse directions Engine is not running at full speed Advance throttle to full engine speed Hydraulic fluid is cold Fully warm hydraulic flui...

Page 85: ...r Arms Three position spring centered lever control Up neutral and down Bucket Attachment Tilt Three position spring centered lever control Extend neutral and curl Auxiliary Attachment Control Two position detented Third position spring return to neutral Wheel Track Options 7 Wide Track Drive Train Two Wheel Motors Creep Control N A Operator Platform Suspended Stand On Platform Mount Plate Univers...

Page 86: ... 839 kg Ground Pressure 3 2 psi 22 0 kpa Vibration Data Engine rpm was set 3700 rpm The hand arm and whole body vibration measurements were made with the operator present Vibration Test hand arm Declared value is 0 3 m s2 Vibration Test whole body Declared value is 4 3 m s2 Noise Data Tests were performed in accordance with EU Directive 2000 14 EC in addition to ISO 3744 and ISO 6395 Engine rpm wa...

Page 87: ... 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 across slopes with great caution Do not operate on slopes greater than 15 degrees Make turns gradually to prevent tipping or loss of control Exercise extreme caution when changing direction on slope...

Page 88: ...Phone Sales 800 831 0042 Morbark LLC Parts and Service 800 255 8839 8507 S Winn Rd www boxerequipment com P O Box 1000 www morbark com Winn Michigan 48896 Manufactured by BIG POWER IN ALL PLACES ...

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