Morbark BOXER 532DX Operator'S Manual Download

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Routine Service and Maintenance

4.23

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

Pull the fuel line off the fuel filter assembly and place the line in a suitable sized

container.

NOTE:

a. Each of the fuel tanks holds approximately 6 gallons of fuel.
b. Make sure that the fuel hose is positioned 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.

Install a new spin on fuel filter (Item 4,

Figure 4–24

) as described earlier in this

section.

NOTE

•

The used fuel filter will be filled with diesel fuel. Make sure to drain the fuel from the

filter into an appropriate container.

•

Dispose of the used fuel filter in an appropriate manner and according to State and Local

regulations.

Install the fuel line onto the fuel filter assembly.

10.

Secure the fuel line onto the fuel filter assembly using the spring clamp removed

earlier.

Summary of Contents for BOXER 532DX

Page 1: ...347 295 Manufactured by 532DX Operator s Manual 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 B I G P O W E R I N A L L P L A C E S ...

Page 2: ...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 Record Numbers Here DA SERIAL NO 39510 154 XXXX 00 00 0000 39510 156 532 2680 1215 6 32 24 4 ...

Page 3: ...R 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 di...

Page 4: ...ing on 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 ...

Page 5: ...rt 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 Inc 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 warra...

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

Page 7: ...tions 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 coul...

Page 8: ...VIII ...

Page 9: ... 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 Cylinder Lock Installation 3 9 Cylinder Lock Removal 3 9 Operating Instructions 3 10 Machine Start up 3 10 Machine Shut down 3 11 Transportation 3 12 Lifting Procedures 3 13 Machine Travel Controls 3 14 Attachment I...

Page 10: ...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 Vibration Data 6 2 Noise Data 6 2 ...

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 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 12: ...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 13: ...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 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 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 repairs ...

Page 15: ...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 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 f...

Page 16: ...evere 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 treatment of penetrating fluid injuries Hydraulic system l...

Page 17: ...e 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 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 positioned...

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

Page 19: ...1 Attachment mounting plate 2 Tilt cylinder 3 Boom 4 Auxiliary hydraulic quick connects 5 Hand grip 6 Operating controls 7 Manual holder 8 Fuel filler cap 9 Lift cylinder 10 Fuel tank 11 Right track assembly 12 Lift cylinder safety lock 13 Hydraulic level check 7 1 2 3 4 5 6 8 9 10 11 13 12 ...

Page 20: ...tachment mounting plate 2 Attachment hydraulic quick connects 3 Right track assembly 4 Operator s platform 5 Air cleaner assembly 6 Fuel tank 7 Fuel filler cap 8 Engine hour meter 9 Loader arm lift cylinder 10 Loader arms 11 Tilt cylinder 1 11 2 10 2 9 8 7 6 5 4 3 ...

Page 21: ...iliary Valve 5 Danger Zone 6 Crush Hazard 7 Boxer Decal 8 Morbark Decal 9 ISO 46 Decal 10 Attachment Must Be Securely Fastened 11 Cable Eye Decal 12 Boxer Internet Address Decal 13 Morbark Decal NS Ultra Low Sulfur Diesel Fuel NS Danger Explosion Spark Arrestor NS Danger Explosion Ultra Low Sulfur Diesel 4 1 11 2 13 3 5 10 6 1 6 9 7 12 ...

Page 22: ... Read Operators Manual Warning Decal 5 Battery Connection Decal 6 CA PROP 65 Warning Decal 7 Diesel Fuel Decal 8 Safety Instructions Decal 9 Control Operation Instruction Decal 10 Lifting Point Decal 11 Auxiliary Power Control Warning 12 Made in USA Decal 13 Danger Auxiliary Valve 14 Burn Hazard 14 1 1 2 12 13 11 10 7 8 9 6 5 3 4 ...

Page 23: ...iary attachment activation control 7 Track widen control 8 Auxiliary hydraulic cylinder control 9 Right hand grip 10 Attachment tilt control 11 Right travel motor control 12 Left travel motor control 13 Loader arm lift control 14 Left hand grip 15 Travel crawl speed control 16 Engine throttle 17 Access panel Lock Levers 18 Lower service access panel 5 1 2 3 4 6 16 15 14 13 12 11 10 9 8 7 17 18 17 ...

Page 24: ...ting the switch fully to the right activates the engine starter 5 Ignition Key 6 Attachment Activation Lever Operator Presence Control With your right hand squeeze the AUXILIARY attachment control lever towards the hand hold to activate the attachment in the FORWARD motion NOTE The lever is spring loaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping...

Page 25: ...heels for forward travel Pulling the lever backwards rotates the right side wheels for reverse travel 11 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 12 Left Hand Grip 13 Boom Raise and Lower This lever controls the raising and lowering of the boom assembly 14 Attachme...

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

Page 27: ...oose 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 Service Cycle Table DANGER Activity Daily 10 Hours Fuel Check and fill Engine Oil Check and fill if low E...

Page 28: ...een 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 the engine manual NOTE Make sure to reinstall and secure the oil filler cap Figure 3 2 Filler Cap NOTE E...

Page 29: ...sure that each 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 the fuel gauges 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 coolant level The coolant is hot and under pressure DO NOT check until the engine radiator is co...

Page 30: ...d 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 on top of the unit is a suction fan which draws air from inside the machine Check the engine side of the radiator Figure 3 5 to make sure that debris has not been sucked against the radiator blocking air flow DO NOT check until the engine radiator is cool to the t...

Page 31: ...netrate 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 treatment of penetrating fluid injuries Figure 3 5 Radiator Air Flow Inspection WARNING ...

Page 32: ...ts on this machine see Figure 3 7 on page 3 7 11 Inspect the Track Widening Stop Bolts one for each track assembly Item 1 Figure 3 8 for Signs of wear or damage and make sure that the bolt 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 track widening ...

Page 33: ...ol levers rearward and release the lever Make sure that each lever automatically returns to the Neutral position The Auxiliary Control Lever will remain in last position used until it is manually moved to the Neutral position If any of the levers other than the Auxiliary Control Lever do not automatically return to the Neutral position DO NOT use the machine until repairs have been made Figure 3 7...

Page 34: ...Pre 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 3 ...

Page 35: ...safety 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 to install the cylinder lock before performing any service work underneath the raised loader arm assembly Cylinder Lock Removal 1 Start the engine and raise the loader arm to its full height 2 Shut of...

Page 36: ...0 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 between fast and idle engine speeds 4 Rotate and hold the starter switch in the START Item 4 Figure 3 11 position until the engine starts Figure 3 11 Ignition Switch 1 1 2 3 4 5 6 7 ...

Page 37: ...ulic 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 in warming the hydraulic oil in all systems evenly and more rapidly Failure to do this can cause the control systems to stick creating a run away situation Machine Shut down To safely shut the machin...

Page 38: ...the 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 remove the key 5 Secure the unit to the transport vehicle with DOT Department of Transportation approved chains binders in accordance to DOT guidelines Make sure to use the appropriate tie down locations ...

Page 39: ...he 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 Figure 3 15 so that the machine is lifted straight upwards Lift the machine approximately 12 to make sure that the machine is balanced before completing the lift If lifting the machine with an attachme...

Page 40: ...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 spring being fully compressed due to high track load If a cogging condition occurs immediately stop machine travel and auxiliary functions and reverse travel direction slightly to de compress track tension Continued cogging w...

Page 41: ...r The farther forward the right control 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 hand control lever farther backward than the right control lever The farther forward the left control is moved the faster the right turn will be made See Figure 3 20 Figure 3 20 Right Hand Turn in Reverse Move the righ...

Page 42: ...ce 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 to spin turn to the right push the left control lever forward while pulling the right control lever backward See Figure 3 22 Figure 3 22 Spin Turn CAUTION ...

Page 43: ...for 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 traveling up or down a slope NOTE When the machine has no attachment or load the heavy end is the operator s platform end of the machine See Figure 3 24 Figure 3 24 Uphill Downhill Travel WARNING 16 15 15 15...

Page 44: ...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 25 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 45: ...ttachment 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 forwards NOTE Make sure that both of the attachment lock pins Item 1 Figure 3 26 are in the unlocked position Refer to Attachment Lock Pins on page 3 18 3 Slowly drive towards the attachment and align the...

Page 46: ...ng 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 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 mounti...

Page 47: ...cked 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 30 Attachment Locks in Unlocked Position 4 Start the engine and rotate the mounting plate downwards 5 Back away from the attachment NOTE It may be necessary to lower the loader arm assembly slightly...

Page 48: ...not 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 Installation 5 When the machines mounting plates top edge is seated in the attachment mounting plate tilt the machines mounting plate backwards slightly to allow the lower edge of the machines mounting p...

Page 49: ...y of the main hydraulic controls forward and backward to release any stored hydraulic pressure 11 Attach the hydraulic hoses to the quick connects See Figure 3 34 There are two hydraulic hoses that need to be connected The quick connect system prevents you from incorrectly connecting the hydraulic hoses but both hoses need to be connected for the attachment to operate Make sure that the engine has...

Page 50: ...attachment s 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 e Repeat the above process to connect the attachments female quick connect Item 5 Figure 3 36 on the other hose to the male bulkhead connector Item 1 Figure 3 36 on the machine f Check the security of both connections by gently tug...

Page 51: ... to keep them out of the way during operation and prevent them from being damaged Figure 3 37 Attachment Hydraulic Hose Routing 13 The attachment is now ready to use Before starting the engine make sure that the Auxiliary Hydraulic 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 functi...

Page 52: ...oaded and when released will automatically move from the FORWARD motion position to NEUTRAL stopping the attachments motion The engine will continue to run Figure 3 38 Auxiliary Attachment Controls 4 Lower the attachment to begin work If you want to reverse the operation of the attachment move the auxiliary control lever Item 1 Figure 3 38 to the REVERSE position The control lever will remain in t...

Page 53: ...d switch Item 3 Figure 3 39 is in the HIGH position 1 With the attachment raised off the ground move the AUXILIARY control lever Items 1 2 Figure 3 39 to either the FORWARD or REVERSE position Figure 3 39 Auxiliary Control 2 Lower and position the attachment in the work position a Rotate the CRAWL control lever Item 1 Figure 3 40 to adjust the travel speed as needed Figure 3 40 Crawl Speed Adjust ...

Page 54: ...chine travels more hydraulic power will be directed to the hydraulic attachment e When the crawl travel speed has been set properly steering and direction control can be adjusted by using either or both of the travel control levers When using CRAWL VALVE control and the travel controls together with an attachment activated DO NOT release the Attachment Activation Lever until the travel controls ar...

Page 55: ...t 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 Item 4 Figure 3 41 until it stops against the lock button Item 3 Figure 3 41 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 ...

Page 56: ...or 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 Tension I Visual Check for Loose Missing Fasteners I Clean Oil Cooler Fins I Inspect and Adjust Track Tension I Inspect both Track Widening Stop Bolts I Service Cycle R Replace I Inspect A Add C Clean...

Page 57: ...because fuel could spill onto hot engine parts and ignite or explode Make sure engine is turned off 2 Check engine fuel and fill as needed a The Boxer has a saddle tank Item 1 Figure 4 1 on each side of the machine Figure 4 1 Fuel Level Check b Each of the tanks 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 indicator i...

Page 58: ...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 Refer to the engine Operation and Maintenance Manual for additional information on the proper selection of engine oil NOTE Make sure to reinstall and secure the oil filler cap Figure 4 3 Engine Oil Fill...

Page 59: ...re 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 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 CAUTION NOTICE Figure 4 4 Filler Cap 1 ...

Page 60: ...ws 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 NOTE Some items in Figure 4 5 have been removed for clarity 6 Release dirt from separator tube at the bottom of the air filter by squeezing the rubber dust ejector valve Item 1 Figure 4 6 underneath the air filter Figure 4 5 Radiator Ai...

Page 61: ...raulic oil 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 marker holes in the dip stick Figure 4 7 Hydraulic Fluid Level Dip Stick d Add the proper hydraulic fluid Chevron Rykon Premium ISO 46 hydraulic fluid or equivalent until the fluid level is 1 4 be...

Page 62: ...the 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 damage c Carefully inspect both sets of quick couples Item 1 Figure 4 8 to make sure that they are not damaged or leaking Make sure to check for signs of leakage or damage to the drive motors and t...

Page 63: ...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 64: ... 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 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 1 3 4 2 ...

Page 65: ...r bogey guide roller Item 1 Figure 4 11 and the track The proper tension will be about a 1 4 3 8 deflection e If an adjustment is needed rotate the track tension adjustment nut Item 2 Figure 4 11 until the proper track deflection measurement is achieved f With the tracks still off the ground start the engine and rotate just the track being adjusted three or four times in both forward and reverse S...

Page 66: ...1 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 Figure 4 11 Track Deflection Measurement and Adjustment 1 2 1 4 3 8 ...

Page 67: ...Routine Service and Maintenance 4 12 Figure 4 12 Track Widening Stop Bolts 1 2 3 ...

Page 68: ... 4 13 b Rotate the stop bolt Item 3 Figure 4 13 to set the correct measurement of 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 c After adjusting the stop bolt make sure to fully tighten the lock nut securing the stop bolt d Fully extend the track assemblies and make sure that either one or both of the flat washers Item 2 Figure 4 13 a...

Page 69: ...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 filter cover and spring Item 4 Figure 4 15 c Remove the filter element Item 5 Figure 4 15 and replace with a new filter element d Inspect the filter cover O ring Item 3 Figure 4 15 for any signs of wear...

Page 70: ...rs 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 Figure 4 16 Battery and Cable Connections 1 3 2 ...

Page 71: ...of the housing c After the main element is removed check the condition of the inner element Item 3 Figure 4 17 It should be replaced whenever it appears 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...

Page 72: ...hrough the opening in the frame along the left side of the machine b Unscrew the filter canister Item 2 Figure 4 18 NOTE The fuel filter will be filled with diesel fuel Make sure to drain the fuel from the filter into an appropriate container Dispose of the used fuel filter in an appropriate manner and according to State and Local regulations c Before installing the new canister filter lubricate t...

Page 73: ...y 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 leaking fluid can cause respiratory problems To prevent corrosion spray on a battery protectent and sealer onto both terminals and cable clamps after cables are installed The electrical system on this mach...

Page 74: ...own 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 Figure 4 20 Battery and Connections 1 2 3 4 5 6 ...

Page 75: ...ect 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 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 The hydraulic filter will be filled with ...

Page 76: ...gure 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 Figure 4 22 Hydraulic Fluid Level Dip Stick f Start the machine and run the engine at low idle for several minutes Shut off the engine g Recheck the hydraulic fluid level as described above NOTICE ...

Page 77: ...EN 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 completely drained 2 Lower the loader arms and stop the engine and remove the key 3 Allow the engine to cool completely 4 Shut off the fuel valve Item 1 Figure 4 23 located on the bottom of each of th...

Page 78: ...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 spin on fuel filter Item 4 Figure 4 24 as described earlier in this section NOTE The used fuel filter will be filled with diesel fuel Make sure to drain the fuel from the filter into an appropriate con...

Page 79: ... 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 compartment of the machine Spilled fuel may be ignited by a hot engine Fuse Panel The electrical circuits on the machine are protected by fuses The fuse panel is located below the gauge indicator panel...

Page 80: ...n 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 Starter Solenoid Fuse not shown in illustration located in the RED power line between the ignition switch and the starter motor 30 ...

Page 81: ...sion 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 Figure 4 27 into track frame NOTE Make sure that the thrust plate is rotated as far backwards as possible on the tension bolt releasing all track tension 5 Install tension spring Item 2 Figure 4 27 int...

Page 82: ...e 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 CLOCKWISE using a 1 5 8 wrench NOTE On recent models the track tension wrench is located under the removable service access cover 1 2 3 1 2 3 ...

Page 83: ...gure 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 sure that the track lugs are on each side of the idler wheel Figure 4 30 Install track onto front idler wheel 3 2 1 2 1 ...

Page 84: ...he 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 the bolt holes Figure 4 32 Install Track and Drive Sprocket 16 Install and secure the 6 drive sprocket lock washers Item 2 Figure 4 32 and mounting bolts Item 3 Figure 4 32 2 1 1 2 3 ...

Page 85: ...et 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 forward and backward several times 20 Shut off the engine 21 Double check track tension Adjust as needed 22 Install track tension bolt lock plate Item 2 Figure 4 33 and secure it with the lock bolt Ite...

Page 86: ... 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 Dealer Engine is in hydraulic lock due to a cylinder filled with fuel Allow engine to cool before attempting this procedure Remove fuel injectors and turn engine over to pump excess fuel from engine ...

Page 87: ...d 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 30 Amp fuse blown Replace fuse Engine looses power Engine load is excessive Reduce grou...

Page 88: ...radiator 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 is normal for this machine Valve spool leakage Contact Service Dealer Cylinder seals are leaking Replace cylinder seals With the machines engine turned off boom drops downward quickly and then stops C...

Page 89: ...Troubleshooting 5 4 ...

Page 90: ...pring centered lever control Up neutral down and float Bucket Attachment Tilt Three position spring centered lever control Extend neutral and curl Auxiliary Attachment Control Three position detent lever control Wheel Track Options 9 Wide Track 7 track available Track Widening Undercarriage from 34 5 43 5 Drive Train Planetary Gear Drive Creep Control Variable Operator Platform Fixed Stand On Plat...

Page 91: ...re 3 6 psi 0 2531 kg cm2 Vibration Data Engine rpm was set 2800 rpm The hand arm and whole body vibration measurements were made with the operator present Vibration Test hand arm Declared value is 4 4 m s2 Vibration Test whole body Declared value is 1 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 was set 2800 rom T...

Page 92: ... the slope of the hill 16 THIS IS A 15 DEGRE E SLOPE 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 slopes...

Page 93: ...General Specifications 6 4 ...

Page 94: ...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 Manufactured by BIG POWER IN ALL PLACES ...

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