Morbark BOXER 320 Operator's Manual

Serial No.s 3592 and Higher

Part No. 76347-292

Manufactured 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

BIG POWER IN ALL PLACES

Your machine’s Model, Weight, and Power Rating along with Serial Number and Date of Manufacture of your machine are located on the right side panel at the top.

The Engine information is located on a decal on your engine. Refer to your Engine OEM Manual for decal location.

Boxer Product Warranty

Morbark, LLC (Morbark) warrants to the original purchaser that this product will be free from defects in materials and workmanship under normal use and operating conditions subject to the conditions and exclusions stated below. No representative, agent or dealer of Morbark or any other person is authorized to modify, expand or extend this warranty in any manner or make any representation on Morbark’s behalf in connection with the sale of any product covered by this warranty. The warranty period starts with the start-up in-service date. See the Warranty Period Chart for information on the warranty period.

EXCLUSIONS

This warranty shall not apply to:

1. Product which has been subject to misuse, neglect, modication,

alteration, accident or lack of normal maintenance or service.

2. Fire damage.

3. Labor, unless provided by an authorized Morbark dealer.

REMANUFACTURED PARTS

Morbark reserves the right to use remanufactured parts, when available, for warranty replacement parts. The remanufactured component has the same warranty as if it was new.

PURCHASER’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 discretion to determine whether and to what extent the product is defective in material or workmanship. The acceptance by Morbark of any product returned is not an admission that the product is defective and if Morbark determines the product is not covered by this Warranty, the product may be returned to the purchaser at purchaser’s expense.

DISCLAIMER OF WARRANTY

This warranty is in lieu of all other warranties express or implied. Morbark makes no other warranties regarding the equipment and in particular, makes no implied warranty of

merchantability or tness for a particular purpose, which are expressly disclaimed.

LIMITATION OF DAMAGES

Morbark shall not be liable for any incidental or consequential damages, directly or by

subrogation, including, but not limited to, any claims for re damage, lost prots, downtime

or loss of use in the event the product is defective.

Morbark, LLC 8507 S. Winn Rd., P.O. Box 1000, Winn, Michigan 48896 Phone: Sales - 800-831-0042, Parts and Service - 800-255-8839 www.morbark.com

LIMITATION OF DAMAGES

Product Description

Morbark

Manufactured

Components

Vendor Purchased

Components

Extended Coverage

New Boxer Compact Utility Loaders

One (1) year/1,000 hours; whichever comes

rst

Warranty from vendor applies, minimum of one (1) year

Can purchase prior to start-up

Used Equipment As stated on equipment

order

N/A N/A

New Engines N/A See Engine Warranty

Statement

Can purchase prior to start-up or possibly up to two (2) years after startup depending on the programs offered by the engine supplier

Wear Items including but not limited to such items as, lubricants,

anti-freeze, uids, lters,

belts, bearings, hoses

and ttings, 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 irregular wear, lack of maintenance, damage due to accidents or vandalism are not covered.

N/A

iii

Boxer Warranty Registration

Dear Customer,

Morbark, LLC, manufacturer of the Boxer Compact Utility Loader, would like to thank you for your purchase. Morbark 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. Currently the warranty start date (in-service date) is listed as the date the Boxer Compact Utility Loader left Morbark, LLC, which may be several months before you received and placed your new Boxer product into service.

To ensure you get the full warranty coverage for your purchase, Morbark, LLC, will restart the warranty start date (in-service date) if you complete the information below and return this form to us with a copy of the equipment invoice (bill of sale) verifying the in-service date of your Boxer Compact Utility Loader. Without receipt of this form, we will continue to use the original equipment ship date as the warranty start 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 warranty form.

Fold

Company Name:___________________Contact Name:________________

Address:______________________________________________________

City:____________State/Province:_________Zip/Postal Code:__________

Phone:___________________E-mail address:________________________

Model No._________Serial No.___________Engine S/N_______________

Location Purchased:_______________Date Purchased_________________

I, (the purchaser) have read and fully understand the operator’s manual, safety instructions and warranty conditions provided with this equipment.

In-service date restart will only be accepted if this form and a copy of the bill of sale is completed and returned within 30 days of the in-service date.

Customers Signature:_____________________Date:__________________

Ax

Stamp

Here

Morbark, LLC 8507 S. Winn Rd. P.O. Box 1000 Winn, MI 48898

Safety Introduction

Be Prepared - Get to Know All Operating and Safety Instructions

This is the Safety Alert Symbol.

Wherever it appears, either in this manual or on safety signs on the machine, you should be alert to the potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.

Learn the Signal Words Used with the Safety Alert Symbol

The words “DANGER”, “WARNING”, and “CAUTION” are used throughout this manual and on labels on the machine to indicate hazards or unsafe practices. All three statements indicate that safety is involved. Observe the precautions 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 result in serious injury or death. It may also be used to alert against a highly unsafe practice.

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. It may also be used to alert against a generally unsafe practice.

This type of statement is used to draw attention to a procedure that needs to be followed to

prevent machine damage.

DANGER

WARNING

CAUTION

NOTICE

Table of Contents

Boxer Product Warranty ....................................................................................i

Safety Introduction ............................................................................................ v

Be Prepared - Get to Know All Operating and Safety Instructions ........ v

Learn the Signal Words Used with the Safety Alert Symbol .................. v

Section 1 – Safety Precautions ....................................................................1–1

GENERAL SAFETY .................................................................................. 1–1

OPERATING SAFETY .............................................................................. 1–2

SERVICE & MAINTENANCE SAFETY ....................................................1–4

ELECTRICAL SYSTEM HAZARDS ..........................................................1–4

Battery Hazards .................................................................................1–5

Jump Starting/Battery Charging Hazards ..........................................1–5

Hydraulic System Hazards ................................................................1–6

Fueling Hazards ................................................................................. 1–7

Section 2 – Operating Controls .................................................. 2–1

Component Locations ............................................................................... 2–1

Right Front View ................................................................................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

Attachment Installation and Removal ..............................................3–17

Attachment Lock Pins ......................................................................3–17

Installation of Non-Hydraulically Powered Attachments ..................3–19

Removal of Attachment ....................................................................3–21

Installation of Hydraulically Powered Attachments ..........................3–22

Operating Instructions for a Hydraulic Attachment ..........................3–27

Removal of Hydraulically Powered Attachments .............................3–29

vii

Section 4 – Routine Service and Maintenance ...........................................4–1

Daily Maintenance Procedures ................................................................. 4–2

Air Filter Replacement ..............................................................................4–4

Hydraulics Inspection and Service ..................................................... 4–5

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 Specications ........................................................... 6–1

Vibration Data ...........................................................................................6–2

Noise Data ................................................................................................ 6–2

1.1

Section 1 - Safety Precautions

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

GENERAL SAFETY

• Never operate the Boxer without first completely reading and understanding this Owner’s Manual.

• Only authorized, qualified, and trained personnel are allowed to operate this machine.

• Never operate the machine under the influence of alcohol, awareness altering drugs or medications that would affect your ability to operate safely.

• KEEP CHILDREN CLEAR FROM THE WORK SITE AREA AT ALL TIMES!

• NEVER ALLOW A CHILD TO OPERATE OR RIDE ON THE MACHINE!

• Serious injury or death involving children can occur. Stay ALERT and be aware of your surroundings at all times. Stop operations if children wander onto the job 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 or shoes which will expose skin or feet to possible flying debris.

• Clothing should be relatively close fitting. Loose clothing, rings, and other jewelry should be avoided because of the danger of catching them on machine parts or controls or on any rotating parts, either on the machine or any attachment.

• Keep hands/fingers clear from all rotating parts.

• Never touch engine parts or machine components while they are hot.

• Always perform the “Standard Shut Down Procedure” shown in this manual, if the unit will be left unattended for any length of time.

• Use only original Morbark, LLC or approved replacement parts and attachments. Imitation parts may lead to unit damage and/or injury to personnel. The machines warranty may be voided if unauthorized parts and attachments are used.

Safety Precautions

1.2

OPERATING SAFETY

• Plan ahead and learn as much as possible about your job-site area before beginning any work.

• Know the exact location of overhead power lines or obstructions.

• Have all buried lines such as gas, electric, water, telephone, and cable TV, marked by the proper authorities.

• Prior to use, perform the “Pre-Start Inspection” and “Daily Maintenance” to make sure that the unit is in safe operating condition.

• Never operate a malfunctioning unit!

• Keep hands, gloves, shoes, control knobs, and operator platform clean. Slippery controls can cause you to lose control, which may result in an accident.

• Always keep a firm grip on the hand rails located at the operator’s platform during travel and operation to prevent falling off the unit.

• When working on an unfamiliar construction site, review, understand, and follow job site safety rules.

• Keep the work site clear of all non-operating personnel. Should a person enter 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-os

- Soft un-compacted soil

- Culverts

- Deep mud/Standing Water

- Large rocks

- Slippery surfaces

- Steep slopes

- Tall grass, trees or shrubs

If any of these conditions exist, correct the hazard or obstruction. If any of these conditions can not be corrected, avoid operating or traveling near them.

• Be extremely cautious traveling through or near trees, brush, shrubs or any obstacles which might obscure your vision. These might hide potential hazards, such as the edge of a steep slope, deep holes, large rocks, etc.

• Never operate near a ditch or embankment where loose or soft ground conditions could cause the surface to give way under the machine causing it to become unstable.

• Never exceed the rated capacity of the machine. When using attachments, know their capacity ratings and unit limitations. Unit specifications can be found in the Operator’s Manual.

Safety Precautions

1.3

• Never attempt to operate any attachment without first understanding proper installation and operating procedures. The center of gravity, stability, and operating characteristics of the entire machine will change with the use of different attachments.

• Operate all controls slowly and smoothly and never abruptly stop any function. This can cause the machine to become unstable.

• Always look in the direction of travel.

• Come to a complete stop prior to reversing travel directions.

• Reduce speed and proceed with caution when traveling in reverse or turning.

• Never travel with the loader boom or attachment raised. Lower the boom or attachment as soon as possible and travel with the boom at the lowest safe height.

• When traveling with a loaded bucket or forks, the load should be level and the bucket or forks tilted back to reduce spilling or losing the load.

• Approach corners slowly, turning too fast or sharp may cause the machine to tip over.

• Stay alert when operating near traffic or roadways.

• If the unit should begin to tip or become unstable, DO NOT try to stabilize the unit with your legs or arms.

• If the unit is involved in an accident or inadvertently damaged during operation, stop and perform a thorough inspection. Make sure the unit is in safe operating condition prior to resuming 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 steep slopes can be dangerous and there is a greater risk of the machine tipping over or becoming unstable. The list of rules below must be understood and followed for maximum safety:

- Avoid excessively steep slopes or unstable surfaces. If travel on a slope is necessary, keep the load low and proceed with extreme caution.

- DO NOT travel ACROSS excessively steep slopes under any circustances.

- Travel straight up and down slopes with the heavy end of the machine pointing up the incline. When the machine has no load, the operator’s platform end of the machine is considered the heavy end. When the machine is loaded or has an attachment on the front of the machine, the front is considered the heavy end.

- Turning on slopes is not a recommended practice, however if you must turn on slopes; reduce travel speed to as slow as possible, and exercise extreme caution. Avoid sharp turns or sudden movements.

- Wet or slick ground conditions should be avoided as reduced traction could cause the machine to slide down the slope.

- Do not attempt to install or remove attachments on a slope.

- Never park the unit on a slope.

Safety Precautions

1.4

SERVICE & MAINTENANCE SAFETY

Maintenance work can be hazardous if not done in a careful manner. All personnel should realize the hazards and strictly follow safe maintenance practices. Failure to comply with these safety precautions may result in serious personal injury and/or death.

• Use only Morbark, LLC supplied or approved replacement parts and attachments. Imitation parts may lead to unit damage and/or injury to personnel. Warranty may be voided if unauthorized parts and attachments are used.

• Wear the proper protective clothing and personal safety equipment necessary to perform the maintenance or service required.

• Keep the machine free of grass, leaves or other debris build-up.

• Clean up oil or fuel spillage.

Fuel, oil leaks or spills can create a re or explosion hazard.

• Prior to performing maintenance or service, park the unit in a level area away from obstructions and/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 require the boom to be raised, the “Hydraulic Cylinder Lock” must be installed.

• Know where all pinch points and rotating parts on the unit are. These areas must be avoided to prevent serious injury.

• Remove only those guards or covers on the component being serviced and replace them immediately upon completion of the work.

• Never attempt to adjust or service engine or machine components while they are hot.

ELECTRICAL SYSTEM HAZARDS

• Prior to working on the electrical system:

- Disconnect battery cables, removing the battery ground cable rst.

- When re-connecting the battery, connect the battery ground cable last.

- Never allow battery cables to contact hydraulic lines or rub against sharp edges.

WARNING

Safety Precautions

1.5

Battery Hazards

Before working with batteries, the following are important points about battery safety that you should be aware of:

• Batteries are always surrounded by extremely explosive gases. This is especially true when the battery is being charged. To avoid explosion:

- Do not smoke near batteries.

- Keep arcs, sparks, and open ames away from batteries.

- Perform battery service work only in a well ventilated area.

• Make sure to dispose of batteries according to local regulations.

• Electrolyte Hazards: NOTE: The batteries on the machine may be either be “wet cell” or “gel cell”. It is still

important to know and follow these warnings and cautions.

Battery electrolyte in standard “wet cell” batteries contains sulfuric acid which is poisonous and can cause severe chemical burns. To avoid personal injury:

- Wear a face shield to prevent sulfuric acid contact with your eyes.

- Wear chemical resistant gloves and clothing to keep acid o your skin and clothing.

- Since wet cell batteries give o explosive gases, use a ashlight to check the electrolyte

level, not an open ame such as a match.

- Never check the battery by placing a metal object across the battery posts. The resulting

spark could ignite anything ammable, causing re or an explosion.

- If electrolyte is splashed into your eyes, ush 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, ush and clean the area immediately with clean water and seek medical attention if necessary.

Jump Starting/Battery Charging Hazards

Follow the instructions for jump starting or battery charging in the engine owner’s manual. You must be at the operator’s platform when attempting to start the unit with booster batteries and jumper cables so that you are at the controls when the engine starts.

Here are some general safety rules you must follow for jump starting the machine:

• Make sure to connect the positive jumper cable to the positive (RED) remote starter lug on the right side of the machine chassis.

• Connect the negative cable to the engine, machine chassis or the furthest ground point away from the battery. Never make the final connection at the starter or dead battery. Sparks may ignite the explosive gases surrounding the battery.

• When disconnecting cables after jump starting, remove the negative cable first and then the positive cable. IMPORTANT: DO NOT let the cable clamps touch when disconnecting them. Severe damage can occur to the booster battery or machine.

• Never charge a battery or attempt to jump start a frozen battery. The sudden surge in electrical power could cause the battery to explode.

Safety Precautions

1.6

Hydraulic System Hazards

The hydraulic system is under pressure whenever the engine is running and may hold

pressure even after the engine is shut o. Cycle all hydraulic controls after the loader boom

is resting on the ground. Some components will retain residual or trapped pressure. Use extreme caution when removing any hydraulic component.

During inspection of the hydraulic system:

• Cycle all hydraulic controls to release residual pressure.

• Wait for the hydraulic fluid to cool down before disconnecting 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 uids, immediately seek treatment by a doctor trained in the treatment of penetrating uid injuries.

• Hydraulic fluid can cause permanent eye injury. Wear safety glasses or a full face shield to provide appropriate eye protection.

• When venting or filling the hydraulic system, loosen the filler cap slowly to allow any pressure in the hydraulic tank to be released and remove the cap gradually.

WARNING

Safety Precautions

1.7

Fueling Hazards

Most fuels are highly ammable. Observe the following precautionary practices to reduce the possibility of a serious accident:

• Always refuel the unit in an open, well ventilated area away from sparks or open flames.

Gasoline Engines:

• Shut the engine o before attempting to fuel the machine. Never refuel a unit while it is running.

• Allow engine to cool before re-fueling.

• Always use a funnel or pour spout when lling the tanks.

• Under certain circumstances a static charge can develop and ignite the fuel.

Make sure that you are standing on the ground when lling the fuel tanks.

• If you are lling the fuel tanks from a service vehicle, make sure to connect the service vehicles ground cable to the machine before beginning the fueling process. Keep the fuel nozzle in constant contact with the rim of the machines fuel tank.

• When lling a portable gas container, always place it on the ground. Never ll 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 ll the container when it is positioned on the ground and keep the fuel container nozzle

in contact with the tank opening during lling.

• Make sure to move the unit from the transport truck or trailer and only refuel the unit on the ground, using an approved container.

• Keep sparks and ames away from fuel.

• Do not smoke while refueling or when handling the fuel container.

• Never cut or weld on or near fuel lines, tanks or containers.

• Never overll the tank.

• Clean up spilled fuel immediately.

• Store fuel in an approved container and keep out of the reach of children.

DANGER

Safety Precautions

1.8

Boxer Brush/Sweeper Attachment Silica Dust Caution

An OSHA ruling has established new permissible exposure limits (PEL) for occupational exposure to respriable crystalline silica. OSHA standard 29 CFR 1926.1153 covers the construction industry, and 29 CFR 1910.1053 covers the general and maritime industries. The rules also requires employee protections such as performing exposure assessments, using exposure control methods, using respiratory protections, offering medical surveillance, developing hazard communication information, and keeping silica-related records.

Under the new standard 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-ltered vacuuming or other methods that minimize

the likelihood of exposure are not feasible. The employer bears the burden of showing the alternative methods are not feasible.

-The use of non-grit, oil, or waxed based sweeping compounds are an acceptable dust suppression housekeeping method.

-The use of compressed air for cleaning is allowed where the compressed air is used in conjunction with a ventilation system that effectively captures the dust cloud created by the compressed air, or where no alternative method is feasible.

-The employer’s exposure control plan must include the description of the housekeeping measures.

2.1

Section 2 - Operating Controls

Component Locations

Right Front View

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 uid level check 8 Remote air cleaner assembly 9 Hydraulic cooler

10 Ignition switch and hour meter

Operating Controls

2.2

Left Rear View

Item No. Description

1 Attachment mounting plate 2 Operating controls

3 Hand grip 4 Service access panel 5 Operator’s platform 6 Fuel tank 7 Manual holder 8 Fuel ller cap/fuel gauge

9 Safety support 10 Loader arms 11 Attachment hydraulic quick connects 12 Tilt cylinder

Operating Controls

2.3

Operating Controls

Item No. Description

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

2345627

Operating Controls

2.4

Safety Decals

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

Operating Controls

2.5

Safety Decals (Continued)

Item No. Description

1 Crush hazard decal 2 Model number decal 3 Burn hazard decal 4 Cylinder lock 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

Operating Controls

2.6

Operating Controls Description

1. High/Low Selector Lever – Moving this lever either fully forwards or fully backwards selects the machine function speed. When the lever is in the Low position, all control and travel functions will be in the slower speed range. With the lever in the High position, all control and travel functions will be in the high speed range.

2. Ignition Switch and Key – Rotating the key switch one position to the right turns on the engine ignition and the low oil pressure warning. Rotating the key switch fully to the right activates the engine starter.

3. Engine Hour Meter Gauge

4. Hand Grip

5. Attachment Tilt – Pushing the lever forwards tilts the attachment plate forwards, lowering the attachment. Pulling the lever backwards tilts the attachment plate backwards, raising the attachment.

6. Right Travel Motor Control – Pushing the lever forward rotates the right side wheels 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 the control lever upwards increases the engine speed and moving the lever downwards slows the engine to idle speed.

11. Attachment Activation Lever/Operator Presence Control – With your left 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 the NEUTRAL position, stopping attachment motion.

If you want to reverse the operation of the attachment, move the auxiliary control lever to the REVERSE position. The control lever will remain in the REVERSE position detent until it is moved to the NEUTRAL position.

Operating Controls

2.7

DO NOT attach an 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

Operating Controls

2.8

3.1

Section 3 - Pre-Start Inspection and 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 INCLUDING WRITTEN, VISUAL, VIDEO OR VERBAL INSTRUCTIONS.

Pre-Start Inspection

It is very important to do a visual inspection of the machine before beginning operation. This inspection should include:

• Check all decals and warning signs for damage.

• Check engine oil.

• Check and rell fuel tanks.

• Check hydraulic lines and hoses for signs of damage or leaks.

• Inspect the machine for any signs of damage or loose fasteners.

• Check uid levels and any signs of leaking uids.

• 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 3-1: Service Cycle Table

Activity Daily (10 Hours)

Fuel 3 and R Engine Oil 3 and A Engine Oil Filter Air Filter Fuel Filter Engine Idle Speed Battery Hydraulics

- Hydraulic Filter

- Hydraulic Fluid

- Hydraulic Hoses

3 3

Grease 3*** Tracks 3 Visual Check for Loose/Missing Fasteners 3 Battery Check and Adjust Track Tension 3

Service Cycle - R = Replace 3 = Check A = Add ***Under very wet, muddy, dusty or dirty working conditions more frequent lubrication may

be required.

DANGER

Pre Start Inspection and Operation

3.2

Do the following pre-start service checks:

1. Check condition of all warning and instructional decals. Replace any damaged decals with genuine Morbark replacement decals.

2. Check engine oil:

• Make sure that the engine is OFF.

• Pull out the dipstick and look for both the 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 the engine manual.

NOTE: Make sure to reinstall and secure the oil ller cap.

Figure 3-2 Filler Cap

Pre Start Inspection and Operation

3.3

NOTE: Extremely dusty or dirty working conditions may require more frequent checking,

lling and/or changing of engine oil.

• After filling the oil, wait a few minutes and check the oil level again.

Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine.

Check engine fuel and ll as needed - be sure engine is OFF.

3. The Boxer has one saddle fuel tank (Item 1, Figure 3–3). Remote lter 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 lled 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 tank.

• Allow engine to cool before lling fuel tank.

• Do not overll because fuel could spill onto hot engine parts and ignite or

explode.

NOTICE

CAUTION

Pre Start Inspection and Operation

3.4

4. Check all hydraulic hoses, lines, and ttings.

injected with hydraulic oil or any other uids, immediately seek treatment by a doctor trained in the treatment of penetrating uid injuries.

• Visually inspect all of the hydraulic hoses, lines, and fittings for signs of damage, wear or leaking.

• If any signs of damage are visible, do not operate the machine until repairs have been made.

• 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, cracked welds, etc.

7. Check the track assemblies to make sure that:

• The tracks are in good condition and are not showing any signs of wear.

• Track tension is properly set.

• Track drive motors are not leaking oil or hydraulic uid.

1. End ttings 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.

WARNING

Pre Start Inspection and Operation

3.5

8. Grease pivot shafts with proper type of grease. There are 9 grease points on this machine, see Figure 3–5.

Before starting the engine:

• Move all hydraulic control levers forward and release the lever. Make sure that each lever automatically returns to the Neutral position.

• Move all hydraulic control levers rearward and release the lever. Make sure that each lever automatically returns to the Neutral position.

• 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 position, DO NOT use the machine until repairs have been completed.

CAUTION

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

Pre Start Inspection and Operation

3.7

Cylinder Lock Removal

1. Start the engine and raise the loader arm to its full height.

2. Shut o the engine.

3. Pull the safety lock pin (Item 4, Figure 3–6) fully outwards.

4. Return the cylinder lock to the storage position (Item 1, Figure 3–6) on the loader arm.

5. Fully insert the safety lock pin (Item 2, Figure 3–6) and the lock knob (Item 3, Figure 3–6) to secure the cylinder lock in the storage position.

Cylinder Lock Installation

Make sure to install the cylinder lock before performing any service work underneath the raised loader arm assembly.

1. Start the engine. (See Machine Start-up in this section for engine starting instructions).

2. Fully raise the loader arm.

3. Shut o 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, Figure 3–6) onto the cylinder rod.

6. Fully reinsert the safety lock pin (Item 4, Figure 3–6), securing the cylinder lock in the support position.

NOTE: Make sure that the safety lock pin goes behind the loader arm cylinder rod.

7. Lower the loader arm assembly until it is supported by the cylinder lock.

Figure 3-6 Operator’s Platform

WARNING

Pre Start Inspection and Operation

3.8

Operating Instructions

Machine 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

Pre Start Inspection and Operation

3.9

3. Pull the chock knob (Item 3, Figure 3–9) outwards to set the engine choke.

4. Rotate and hold the start switch (Item 1, Figure 3–9) in the START position until the engine starts.

Figure 3-9 Engine Keyswitch

5. As soon as the engine starts, release the starter key. The key will automatically return to the RUN position.

6. Slowly push the choke knob inwards. If the engine begins to sputter, pull the choke knob outwards slightly until the engine smoothes out. As soon as the engine warms up and begins to run rough, push the 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 systems to stick creating a run-away situation.

8. In cold weather (32º F [0º 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. Allow the engine to idle for another 5 minutes before beginning any machine operations.

WARNING

Pre Start Inspection and Operation

3.10

Machine Shut-down

To safely shut the machine down, the operator must:

1. 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 o the engine.

5. Clean o any accumulated mud and/or dirt from the machines operating surfaces, i.e. operator’s platform, both track assemblies, etc.

Pre Start Inspection and Operation

3.11

Transportation

1. Move the throttle control lever to the mid-range engine speed and set the transport speed to the LOW range. Raise the attachment so that it will clear the ramp of the transport trailer.

NOTE: The longer the attachment, like the trencher, the more the attachment needs to either be

tilted or raised. It is recommended to back the machine onto the transport trailer and position the machine so that the heaviest weight (center of balance) is towards the front (hitch end) of the trailer. See Figure 3–10.

The Boxer is designed for maximum working balance. When traveling on an incline,

always have the heaviest portion of the machine pointing uphill.

2. Follow general load carrying safety. Always carry the heaviest load pointing uphill.

NOTE: When operating without an attachment, the operator becomes the load.

Figure 3-10 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 o 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 the machine and trailer.

NOTE:

• Never tow or pull the machine. Damage to the hydraulic motors could result.

• If the machine is totally in-operable, using lifting straps or cables and a machine that can safely lift 4,000 lbs (1820 Kg), lift the machine and place on a trailer. See “Lifting Procedures” on page 3-12.

When transporting the machine, make sure to use DOT approved chains and binders (Item 1, Figure 3–12) to secure the machine to the “D” rings (Item 2, Figure 3–12) on the trailer. NOTE: It is recommended to secure the machine through the ring on the front of the machine (Item 2, Figure 3–12) and through the two rings on the Operator’s Platform (Item 4, Figure 3–11).

CAUTION

WARNING

Pre Start Inspection and Operation

3.12

Figure 3-11 Travel Chains and Binders

Lifting Procedures

When it becomes necessary to lift the machine

1. Use a lifting device that can safely lift 4,000 lbs (1820 Kg).

2. Use appropriate lifting chains (Item 1, Figure 3–12) 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 back.

CAUTION

Pre Start Inspection and Operation

3.13

Figure 3-12 Machine Lifting

Machine Travel Controls

• Levers and controls should return to the neutral position when they are released.

• Make sure that all of the controls are in the neutral (middle) position before starting the engine.

• Operate the controls gradually and smoothly. Excessive speed and quick control movements without regard for working conditions could cause an unsafe situation.

• Make sure to maintain your grip on both of the hand grips any time the machine is in motion.

Due to the spring tension system built into the track drive system as a safety mechanism, the machine can be put into an extreme situation during which the drive sprocket will bypass the rubber track guide holes causing a popping 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 rst 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 will cause the track drive sprocket to seat into the rubber track incorrectly, and cause damage to the track. If cogging occurs, stop travel function and check for and remove any debris or foreign matter in the drive system, check track for proper tension as shown in Section 4 of this manual and resume operation.

WARNING

NOTICE

Pre Start Inspection and Operation

3.14

Forward Travel Reverse Travel

Push both control levers forward to travel straight forward. The farther these are moved, the faster the machine will travel. See Figure

3–13.

Figure 3-13

Forward Travel

Pull both control levers backward to travel straight backwards. The farther these are moved, the faster the machine will travel. See Figure

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 forward than the left control lever. The farther forward the right control is moved, the faster the left turn will be made. See

Figure 3–16.

Figure 3-16

Left Hand Turn

in Forward

Pre Start Inspection and Operation

3.15

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 3–17.

Figure 3-17

Right Hand Turn

in Reverse

Move the right hand control lever farther backward than the left control 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 pulling the left control lever backwards; to spin turn to the right, push the left control lever forward and while pulling the right control lever backward. See Figure 3–19.

Figure 3-19

Spin Turn

Pre Start Inspection and Operation

3.16

• Do not travel up or across a slope steeper than 15°. See Figure 3–20.

• Make sure that the tracks are extended to their widest position, providing the broadest stance for 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



15°

>15°



15°

>15°

Pre Start Inspection and Operation

3.17

Attachment Installation and Removal

Attachment Lock Pins

The mounting plate located at the front of the machine provides for the easy installation and safe use of the wide variety of available attachments. This system is very easy to use, but requires the proper use of the attachment lock pins. There are two positions for the attachment lock pins, the unlocked position and the locked position.

Once the machine has picked up an attachment, shut o the engine and rotate the attachment

locks into the “locked” position (Item 1, Figure 3–22). As you rotate the lock pin, it will drop downwards, 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 attachment until it is fully secured to the machine.

To release an attachment, rotate the attachment locks to the “unlocked” position (Item 1, Figure 3–23). The lock pins will automatically rise, releasing the attachment from the machine. If the pins do not release the attachment or are very hard to rotate, start the engine and tilt the attachment slightly forwards or backwards until the pins can be rotated.

CAUTION

Pins Locked

Pre Start Inspection and Operation

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

Pins Unlocked

Pre Start Inspection and Operation

3.19

Installation of Non-Hydraulically Powered Attachments

There are many available attachments that are very easy to install. To install any of the nonhydraulically powered attachments:

1. Position the attachment on a level surface.

Clean the inside lower edge of the female attachment mounting plate 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.

Make sure that both of the 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 rmly 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 attachment mounting plate.

Figure 3-24 Non-powered Attachment Installation

4. When the machines mounting plates top edge is seated in the attachment mounting plate, curl the machines mounting plate backwards slightly to allow the lower edge of the machines mounting plate to slide into position. See Figure 3–25.

NOTICE

Pre Start Inspection and Operation

3.20

Figure 3-25 Attachment Installed

5. Shut the engine o.

6. Rotate the attachment lock pins (Item 1, Figure 3–25 and Item 1, Figure 3–26) into the locked position, 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 o 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

Pins Locked

Pre Start Inspection and Operation

3.21

Removal of Attachment

1. Lower the attachment onto a rm, level surface.

2. Shut o the machine engine.

3. 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

Pins Unlocked

Pre Start Inspection and Operation

3.22

Installation of Hydraulically Powered Attachments

There are many hydraulically powered attachments available that are very easy to install. To install any of these attachments:

1. Position the attachment on a level surface.

Clean the lower edge of the female attachment mounting plate to remove any debris that

might interfere with the attachment installation.

2. Start the machine engine, lower the loader arm and tilt the 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 the attachments hydraulic hoses (Item 4, Figure 3–29) so that they are

not damaged during the installation process. Tuck the upper edge of the male mounting plate

into the upper lip of the female attachment mounting plate.

NOTICE

Pins Unlocked

Pre Start Inspection and Operation

3.23

Figure 3-29 Hydraulically Powered Attachment Installation

Figure 3-30 Hydraulically Powered Attachment Installed

5. Shut the engine o.

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.

CAUTION

Pre Start Inspection and Operation

3.24

Figure 3-31 Attachment Locks in Locked Position

8. Shut the engine o.

Make sure that the engine has been shut o 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 pressure locked in the auxiliary hydraulic lines. Leave the control lever in the detent position.

Figure 3-32 Auxiliary Control Lever

WARNING

Pins Locked

Pre Start Inspection and Operation

3.25

b. Remove the protective covers (Items 3, Figure 3–33) from the attachment quick

connectors.

c. Wipe o the end of each of the connectors (Items 1, 2, 4, 5, Figure 3–33) to remove any

dirt or debris.

Figure 3-33 Auxiliary Hydraulic Quick Connects

d. Insert the attachments 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 tugging on the attachment hoses to

make sure that the quick connects are seated properly.

Pre Start Inspection and Operation

3.26

11. Make sure that the hydraulic hoses are routed so that they will not be in the way or damaged during machine operation. Figure 3–34 shows how the hoses might be routed 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.

CAUTION

Pre Start Inspection and Operation

3.27

Operating Instructions for a Hydraulic Attachment

1. Move the engine throttle to the full speed setting. Raise the attachment o the ground and position it for use.

2. Move the HI/LOW selector lever (Item 2, Figure 3–35) to either the high speed or low speed setting depending on the attachment to be used. This setting will control both the functional speed of the attachment as well as machine travel speed.

Figure 3-35 Auxiliary Attachment Controls

3. With your left hand, squeeze the OPERATOR PRESENCE control lever (Item 1, Figure

3–35) towards the hand grip to activate the FORWARD motion of the attachment.

NOTE: The OPERATOR 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 you want to reverse the operation of the attachment, move the OPERATOR PRESENCE lever (Item 1, Figure 3-32) to the REVERSE position. The control lever will remain in the REVERSE position detent until it is moved to the NEUTRAL position.

• Make sure not to travel to fast for operating conditions when using a trencher, tiller or other attachment that requires the machine to move.

• Stop all machine travel before releasing the OPERATOR PRESENCE lever.

NOTICE

CAUTION

Pre Start Inspection and Operation

3.28

5. When using a trencher, tiller or other attachment that requires the machine to move while the attachment 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.

Pre Start Inspection and Operation

3.29

Removal of Hydraulically Powered Attachments

After use, the quick couples and hydraulic uid will be very hot. Wear gloves when disconnecting the auxiliary hydraulic lines.

To remove a hydraulically powered attachment;

1. Lower the attachment to the ground and shut o the engine.

2. Move the hydraulic control lever forward or backward to release any stored hydraulic pressure.

3. Some of the female couplings will have a lock button preventing accidental disconnection. To release this type of quick connect, rotate the collar on the female quick 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 tting.

5. If the female connector does not have the lock pin type collar, just slide the collar backwards until the male connector is released.

Figure 3-36 Quick Connect Locking Collar

6. Repeat this procedure on the other hydraulic line.

7. Cover the hose connections with the dust caps (Item 5, Figure 3–36) and store the hydraulic hoses to prevent damage.

8. Follow the instructions in “Removal of Attachment” earlier in this section to complete the attachment removal.

CAUTION

Pre Start Inspection and Operation

3.30

4.1

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

Activity

Daily

(10 Hours)

New

Machine

(20 Hours)

Weekly

(50 Hours)

Monthly

(200 Hours) Annual

Safety Placards 3 and R Fuel 3 and A Engine Oil 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

Check and Adjust Track Tension

Service Cycle - R = Replace 3 = Check A = Add * First 20 operational hours, then follow normal service cycle. ** Extremely dusty or dirty working conditions may require more frequent service/replacement. *** Under very wet and muddy conditions, more frequent lubrication may be required.

*** Check when cold, ll to 1/4” below ll mark.

Routine Service and Maintenance

4.2

Daily Maintenance Procedures

Do the following procedures daily or every 10 operating hours:

1. Check condition of all warning and instructional decals. Before operating the machine, replace any missing or damaged decals.

Make sure to read and understand all WARNING and SAFETY decals before

operating the machine.

• Allow engine to cool before lling fuel tanks.

• Do not overll because fuel could spill onto hot engine parts and ignite or

explode.

• Make sure engine is turned o.

2. Check engine fuel and ll 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 ller cap (Item 2, Figure, 4-1). Remove cap

and visually inspect fuel level to make sure that the indicator is showing the proper fuel

level. Make sure that the tank has been lled on a daily basis. Carefully pour gas into the tank, not exceeding the max ll indication shown by the

gauge in the fuel cap.

NOTICE

CAUTION

Routine Service and Maintenance

4.3

3. Check engine oil -

a. Make sure that the engine is OFF.

b. Pull out the dipstick (Item 1, Figure 4–2) and look for the “FULL” line.

Figure 4-2 Oil Level Check

c. If the engine oil level is below the add line, indicated by the lower line on the dipstick,

carefully add the proper amount of oil through the engine oil ller (Item 1, Figure 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 lled 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 ller cap.

Figure 4-3 Engine Oil Fill

Routine Service and Maintenance

4.4

Air Filter Replacement

1. Check air lter and replace paper elements if they are extremely dirty or plugged.

2. Replace the outer paper element* (Item 3, Figure 4–4) and check inner element* (Item 2,

Figure 4–4).

a. Unhook the two retaining clips and remove the end cap (Item 1, Figure 4–4) from the air

cleaner housing.

b. Pull the outer air cleaner element (Item 3, Figure 4–4) out of the housing.

c. After the main element is removed, check the condition of the inner element (Item 2,

Figure 4–4). 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 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 in the air cleaner housing.

i. Reinstall the end cap (Item 1, Figure 4–4) so the dust ejector valve is down and secure

the end cap with the two retaining clips.

*In extremely dusty or dirty operating conditions, this service cycle may need to be shortened.

Figure 4-4 Air Filter Assembly

NOTE: Extremely dusty or dirty working conditions may require more frequent checking,

lling and/or changing of engine oil.

d. After lling the oil, wait a few minutes and check the oil level again.

Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine.

NOTICE

Routine Service and Maintenance

4.5

Hydraulics Inspection and Service

If you are checking the uid level after a period of use, the hydraulic system and hydraulic uid will be very hot. Wear gloves when inspecting the hydraulic uid level.

1. Check hydraulic oil level, ll as needed with the proper hydraulic oil - be sure engine is OFF

a. The hydraulic dipstick is located under the large nut (Item 1, Figure 4–5) on the

hydraulic tank ller 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 uid is 1/4” below the marker hole in the dip stick.

Figure 4-5 Hydraulic Fluid Level Dip Stick

d. Add the proper hydraulic uid (Chevron Rykon Premium ISO 46 hydraulic uid or

equivalent).

Do not over ll the hydraulic system. Damage to the hydraulic system might result.

CAUTION

NOTICE

Routine Service and Maintenance

4.6

2. Check hydraulic hoses.

injected with hydraulic oil or any other uids, immediately seek treatment by a doctor trained in the treatment of penetrating uid injuries.

a. Fully raise the loader arm, install and secure the 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 uid,

wear or damage.

c. Carefully inspect both sets of quick couples (Item 2, Figure 4–6) to make sure that they

are not damaged or leaking.

d. Make sure to check for signs of leakage or damage to the drive motors (Item 4,

Figure 4–6) and to their hydraulic connections.

Figure 4-6 Inspect Hydraulic Lines and Fittings

WARNING

Routine Service and Maintenance

4.7

e. If any signs of damage are visible, do not operate the machine until repairs have

been made.

f. Some examples of common hydraulic hose damage are 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. End ttings 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

Routine Service and Maintenance

4.8

NOTE: Extremely dusty or dirty working conditions may require more frequent service/ replacement.

4. Check both track assemblies for:

a. The proper tension. Too little or too much tension can cause premature track wear and

travel motor damage.

b. Make sure that the tracks are not worn or damaged.

5. Check for loose or missing fasteners.

a. Inspect for any loose or missing bolts or fasteners.

b. Tighten or replace any missing bolts or fasteners before operating the machine.

6. Check for proper track tension.

a. Raise the machine o the ground and support it using a device capable of safely

supporting 4000 lbs. See Figure 4–9 for suggested location of the support devices, as an example, place a concrete or solid wooden block under the operators platform and solid supports under the bucket.

b. Tilt the bucket downwards until the cutting edge is touching 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 o the ground. Shut o the engine.

Keeps hands and ngers 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 a 1/4” - 3/8” deection.

e. If an adjustment is needed, remove the adjustment nut lock plate and rotate the tension

adjustment nut (Item 2, Figure 4–9) until the proper track deection measurement is achieved. Reinstall and secure the adjustment nut lockplate.

f. With the tracks still o the ground, start the engine and rotate just the track being

adjusted three or four times in both forward and reverse. Shut o the engine after

rotating the track.

g. Re - measure the deection dimension.

h. Check the other track for the correct tension measurement. If needed, repeat Steps 6e -

6g.

i. Lower the machine onto the ground.

Figure 4-9 Track Deection Measurement and Adjustment

CAUTION

1/4”-3 /8”

Routine Service and Maintenance

4.9

New Machine Brake-in Maintenance Procedures

Do the following after the rst 20 operating hours for a new machine only.

1. Change engine oil - Refer to the engine manual for the proper engine oil changing instructions.

2. Change engine oil lter, which is located on the left side of the engine. Refer to the engine

manual for the proper engine oil lter changing instructions. The oil lter is located at the

front of the engine (Item 1, Figure 4–10).

Figure 4-10 Engine Oil Filter

3. Change the hydraulic lter. See Service Manual and Figure 4–11.

a. Remove the front cover (Item 3, Figure 4–11) to enable access to the lter assembly

(Item 11, Figure 4–11).

b. Remove the three bolts (Item 6, Figure 4–11) holding the lter cover (Item 7, Figure

4–11) in place.

Press downwards on lter cover to relieve the upwards pressure from the spring.

c. Remove the lter cover and spring (Item 8, Figure 4–11).

d. Remove the lter element (Item 9, Figure 4–11) and replace with a new lter element.

e. Inspect the lter cover O-ring (Item 10, Figure 4–11) for any signs of wear or damage.

Replace as needed.

f. Reinstall spring and lter cover.

Make sure that the O-ring is properly seated in the lter cover.

g. Start and run the engine for about 30 seconds.

NOTICE

Routine Service and Maintenance

4.10

Using the hydraulic oil level dip stick (Item 1, Figure 4–11), check the hydraulic oil level.

Add the hydraulic uid to within a 1/4” below indicator mark.

Figure 4-11 Hydraulic Oil Filter Assembly

Routine Service and Maintenance

4.11

Weekly Maintenance Procedures

Do the following procedures weekly or every 50 operating hours:

1. Do all Daily maintenance procedures.

2. Check the battery (Item 6, Figure 4–12) and 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

Routine Service and Maintenance

4.12

Monthly Maintenance Procedures

Do the following procedures monthly or every 200 operating hours:

1. Do all Daily and Weekly maintenance procedures.

2. Replace engine oil and engine oil lter - see engine manual.

3. Check air lter and replace outer paper element (Item 3, Figure 4–13).

4. Replace the outer paper element* (Item 3, Figure 4–13) and check inner element* (Item 2,

Figure 4–13).

a. Unhook the two retaining clips and remove the end cap (Item 1, Figure 4–13) from the

air cleaner housing.

b. Pull the outer air cleaner element (Item 3, Figure 4–13) out of the housing.

c. After the main element is removed, check the condition of the inner element (Item 2,

Figure 4–13). 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 will

damage the elements. Replace dirty, bent or damaged elements with new genuine Morbark repair parts as required.

e. Handle new elements carefully, do not use if the sealing surfaces are bent or damaged.

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 in the air cleaner housing.

i. Reinstall the end cap (Item 1, Figure 4–13) so the dust ejector valve is down and secure

the end cap with the two retaining clips.

*In extremely dusty or dirty operating conditions, this service cycle may need to be shortened.

Figure 4-13 Air Filter Assembly

Routine Service and Maintenance

4.13

5. Replace fuel lter (Item 2, Figure 4–14).

• GASOLINE IS VERY FLAMMABLE. HANDLE WITH EXTREME CAUTION.

• MAKE SURE THAT THE ENGINE HAS BEEN ALLOWED TO COOL BEFORE PERFORMING THIS OPERATION.

• MAKE SURE THAT THERE ARE NO OPEN FLAMES IN THE WORK AREA.

• ONLY PERFORM THIS PROCEDURE IN AN AREA WITH PROPER VENTILATION.

• DO NOT SMOKE WHILE PERFORMING THIS OPERATION.

• CLEAN UP ANY SPILLED FUEL BEFORE STARTING THE ENGINE.

a. Locate fuel lter assembly (Item 2, Figure 4–14) along the left side of the engine.

b. Shut o fuel using the fuel shut o 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 lter

sliding the clamps along the fuel line away from the lter. and remove the fuel lines.

d. Replace the fuel lter with a new lter (Item 2, Figure 4–14).

NOTE:

• The old fuel lter will be lled with gasoline. Make sure to drain the fuel from the lter into an appropriate container.

• Dispose of the used fuel lter in an appropriate manner and according to State and Local regulations.

e. Install and secure the fuel lines and reopen the fuel valve.

DANGER

Routine Service 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.

NOTICE

Routine Service and Maintenance

4.15

Wear the proper protective clothing when handling the battery. Leaking battery uid contains acid that can cause burns. Fumes from the leaking uid can cause respiratory

problems.

6. Check battery for signs of leakage or corrosion on the battery cables.

• On a monthly basis, check the battery (Item 8, Figure 4–15) for signs of leaking electrolyte. If any signs of damage are visible, remove and replace the battery.

• 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 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 battery brush. Reinstall and secure the cable clamps.

• Check the battery hold down clamp (Items 2 and 5, Figure 4–15) to make sure that the battery is being held securely to the machine.

If the battery needs to be replaced, make sure to dispose of the old battery according to State

and Local regulations.

CAUTION

NOTICE

Routine Service and Maintenance

4.16

Figure 4-15 Battery and Connections

Routine Service and Maintenance

4.17

Annual Maintenance Procedures

Do the following procedures annually:

1. Do all Daily, Weekly, and Monthly maintenance procedures.

2. Replace air lter** See page 4-12, Step 3.

3. Check engine idle speed (refer to engine manual).

4. Replace hydraulic uid**

a. Place a suitable sized container at the right rear corner of the Boxer.

b. Remove the hydraulic tank drain plug (Item 1, Figure 4–16) and drain all hydraulic uid

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 uid has drained out of the tank, reinstall, and secure the drain

plug.

Make sure to dispose of the used hydraulic uid in an appropriate manner and according to

State and Local regulations.

• The hydraulic filter will be filled with hydraulic fluid. Make sure to dispose of the used hydraulic filter in an appropriate manner and according to State and Local regulations.

d. Replace hydraulic lter** See page 4-9, Step 3.

NOTICE

Routine Service and Maintenance

4.18

The hydraulic dipstick is located underneath the hydraulic ller plug, located along the

outside of the machine. See Figure 4–17.

Do not over ll the hydraulic system. Damage to the hydraulic system 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 uid until the uid 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 o the engine.

h. Recheck the hydraulic uid level as described above.

NOTICE

Routine Service and Maintenance

4.19

Draining Fuel Tank

• GASOLINE IS EXTREMELY FLAMMABLE AND HIGHLY EXPLOSIVE.

• A FIRE OR EXPLOSION FROM GASOLINE CAN BURN YOU OR OTHERS AND CAUSE PROPERTY DAMAGE.

• DRAIN FUEL FROM TANKS WHEN THE ENGINE IS COLD.

• FUEL TANKS SHOULD ONLY BE DRAINED IN AN AREA THAT IS WELL VENTILATED.

• WIPE UP ANY GASOLINE THAT SPILLS.

1. 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 o fuel using the fuel shut o 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 the fuel lter (Item 2,

Figure 4–18). Slide the clamp along the fuel line (Item 3, Figure 4–18) away from the lter.

DANGER

General Maintenance

Routine Service and Maintenance

4.20

6. Pull the fuel line o of the fuel lter and position the line in a suitable sized container.

NOTE: The fuel tank holds approximately 4.5 gallons of fuel.

7. Open the fuel valve on the bottom of the tank and allow the fuel to drain into the drain pan.

8. Remove the upper hose clamp (Item 3, Figure 4–18) and install a new fuel lter (Item 2,

Figure 4–18) as described earlier in this section.

NOTE:

• The old fuel lter will be lled with gasoline. Make sure to drain the fuel from the lter

into an appropriate container.

• Dispose of the used fuel lter in an appropriate manner and according to State and Local

regulations.

9. When the fuel has fully drained, install the lower fuel line onto the new fuel lter.

10. Slide the hose clamp close to the fuel lter 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.

• Spilled fuel may be ignited by a hot engine.

CAUTION

Track and Tension System Installation

1. Securely elevate the machine. See Figure 4–19 and Track Tensioning instructions.

• Make sure that the machine has been securely elevated and that there is no danger of it tipping before beginning this procedure.

• To fully stabilize the machine, it may be necessary to insert an additional support at the front of the machine, under the hydraulic tank. When this support has been installed, raise the boom.

CAUTION

Routine Service and Maintenance

4.21

Figure 4-19 Machine Elevation

2. Shut o the engine.

If any of the track tensioning components have come out of the track tension assembly when

the track came o of the machine, proceed to Step 3. If not, skip to Step 6.

3. Install tension bolt and thrust washer (Item 1, Figure 4–20) into the track frame.

Make 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 lower edge of the idler rollers.

• Make sure to slide the tension system components as far back into the track frame as possible.

NOTICE

Routine Service and Maintenance

4.22

Figure 4-20 Track 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.

Routine Service and Maintenance

4.23

NOTICE

On recent models, the track tension wrench 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

Routine Service and Maintenance

4.24

Figure 4-23 Install track onto front idler wheel

10. Slide the track (Item 2, Figure 4–23) onto 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

Routine Service and Maintenance

4.25

12. Position the drive sprocket and track onto the drive motor.

13. Rotate the drive sprocket (Item 1, Figure 4–25) and track to align the bolt holes.

Figure 4-25 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

NOTICE

Routine Service and Maintenance

4.26

16. Start the engine and slowly rotate the track forward and reverse to make sure that the track is properly seated on the drive sprocket.

17. Fully rotate the track forward and backward several times.

18. Shut o 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.

5.1

Section 5 - Troubleshooting

The following procedures will assist you in determining the potential cause of a machine operating problem.

Make sure to follow all safety precautions stated in this manual when

doing any work on the machine.

Problem Possible Causes Corrective Action

Starter does not turn the engine over.

• Auxiliary hydraulics lever is either in Forward or Reverse position 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 connectors.

• Relay or starter switch is defective.

• Contact Authorized Service Dealer.

• Engine is in hydraulic lock

due to a cylinder lled with

fuel.

• Contact Authorized Service Dealer.

NOTICE

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 lter housing and

replace the lter 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 lter

for air bleed instructions.

• Dirty or contaminated fuel

lter.

• Replace fuel lter.

• Dirt, water or stale fuel is in fuel system.

• Drain fuel in tanks into an appropriate storage container and dispose of bad fuel properly.

• Rell fuel tanks with fresh, clean fuel.

• Replace fuel lter.

• 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 lter housing and

replace the lter elements.

• Engine oil level in crankcase is low.

• Add the appropriate engine oil to crankcase. See engine

manual for oil specications.

• Cooling ns and air passages under engine blower housing are plugged.

• Remove obstruction from

cooling ns and air passages.

• Dirty or contaminated fuel

lter.

• Replace fuel lter.

• Dirt, water or stale fuel is in fuel system.

• Drain fuel in tanks into an appropriate storage container and dispose of bad fuel properly.

• Rell fuel tanks with fresh, clean fuel.

• Replace fuel lter.

Troubleshooting

5.3

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. See engine

manual for oil specications.

• Cooling ns and air passages under engine blower housing are plugged.

• Remove obstruction from

cooling ns and air passages.

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.

• 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 uid is cold. • Fully warm hydraulic uid.

• Hydraulic uid level is low. • Check and ll the hydraulic

uid tank with the appropriate hydraulic uid.

• Fuel tanks are empty and engine stops.

• Fill fuel tanks with fuel.

• If all above has been checked.

• Contact authorized service dealer.

**Tested with warm oil and no more than 530 lbs (240 Kg) in the bucket. Measure the downward drop at the attachment lock pins on the back of the mount plate.

6.1

Section 6 - General Specications

Engine System

Type

Kohler Command Pro

Cooling System

Air Cooled

HP / KW

20 / 14.9

Fuel Tank

4.5 Gallons

Hydraulic System

Pressure (Auxiliary/Boom & Tilt Cylinder Circuit)

3000 psi system relief

Pressure Ground Drive Circuit

3000 psi system relief

Flow Auxiliary

8 GPM (High) 3 GPM (Low) @ 3700 rpm

Flow Ground Drive

8 GPM (High) 3 GPM (Low) @ 3700 rpm

Reservoir Capacity

16 gallons

Filter

10 Micron

Electrical System

Battery

12 Volt

Control System

Starting

Keyed ignition switch

Throttle/Choke

Remote Mount Throttle - Choke engine mounted

Steering

Two spring centered control lever with zero turning type controls

Boom/Loader 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

Universal CUL Attachment Plate

Warranty

Engine Warranty

Two Year

Product Warranty

One Year

Ground Drive System-Dimensions

Units English Metric

Wheelbase 32 in. 813 mm Ground Clearance 5.0 in. 127 mm Overall Length (w/ Bucket) 87 in. 2210 mm Overall Length (without Bucket) 68 in. 1727 mm Overall Width (Fully Retracted) N/A in. N/A mm Overall Width (Fully Extended) 34.5 in. 876 mm Overall Height 49 in. 1235 mm Overall Operating Height (Fully Raised) 92 in. 2337 mm

General Specications

6.2

Units English Metric

Hinge Pin Height (Fully Raised) 70 in. 1765 mm Dump Height 54 in. 1372 mm Ground Speed (Max) 3.4 mph 5.5 kph Dump Angle 34 deg. 34 deg. Reach 28 in. 711 mm Tip Capacity 1250 lb. 567 kg Operating Capacity, 35% of tip load. 438 lb. 199 kg Operating Capacity, 50% of tip load. 875 lb. 397 kg Weight (without Bucket)(*w/Bucket) 1850 lb. 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 was set @ 3750 rpm. The noise measurements were made with the operator present.

The declared value for the operator is 86dB LPA.

The Guaranteed SWL value is 103dB LWA.

General Specications

6.3

SUGGESTED

GUIDE FOR SIGHTING SLOPES FOR SAFE OPERATION

A COMPACT UTILITY LOADER WITH AN ATTACHMENT.

NOT REMOVE THIS PAGE FROM THE MANUAL.

1 6

15 DEGREES MAX.

1. Fold this page along dotted line indicated above. DO NOT remove the page from the manual.

2. Hold page before you so that its left edge is vertically parallel toatree trunk or other upright structure.

3. Sight across the fold in the direction of the hill slope you want to measure.

4. Compare the angle of the fold with the slope of the hill.

1 6

THI

S ISA15

REESLOPE

DONOTTRAVELACROSSORUPANDDOWN ASLOPEGREATERTHAN15 DEGREES

To avoidserious injury, operate your unitup and down thefaceofslopes. Travel across slopes with great caution. Do not operate on slopesgreater than 15 degrees. Maketurns gradually to prevent tipping or loss of control. Exerciseextreme caution when changing directionon slopes. Controlofthe machine maybeaffected by installed attachments. Reduce travel speedon slopes. Read and understand allWarnings and Operating Instructions in the Operator’s Manual.

WARNING

FOLD ALONG DOTTED LINE

DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES.

THIS IS A 15 DEGREE SLOPE

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 PLA

CES

Morbark BOXER 320 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual