big power in all places - boxer® equipment · boxer replacement kit ... 9 elbow, 90° 2 26531-146...

Boxer 525DX Parts ManualSN 4341 and Higher

Part No. 76345-813

Manufactured by:

Phone: Sales - 800-831-0042,Parts and Service - 800-255-8839 www.boxerequipment.com

Morbark, Inc.8507 S. Winn Rd., P.O. Box 1000,

Winn, Michigan 48896www.morbark.com

B I G P O W E R I N A L L P L A C E S

®

REVISION LOG

Rev: Rev. Date: PagesAffected:

Description of Changes:

- Apr 9, 2015 All Initial ReleaseA Apr 16, 2015 11, 23, 27, 35,

36Numerous modifications

B July 7, 2015 8-9, 26-27 moved boom lock holder to top of hyd tank

C Oct 15, 2015 25 P/N change key switch & cover

TABLE OF CONTENTSParts List and Illustrations Page Number

Routine Maintenance Replacement Parts .................................................................................2Universal Mounting Plate and Loader Arm Group .....................................................................6Loader Arm Group .....................................................................................................................8Decals Group...........................................................................................................................10Travel Drive Group ..................................................................................................................12Idler Wheel and Spring Assembly............................................................................................14Mid-Wheel Assembly ...............................................................................................................15Hydraulic Cooler Group ...........................................................................................................16Main Control Valve Group .......................................................................................................18Diverter Valve Group ...............................................................................................................20Crawl Valve Group ...................................................................................................................22Electrical Panel Parts Group ...................................................................................................24Rear Frame Group ..................................................................................................................26Hydraulic Filter and Engine Shroud Group ..............................................................................28Muffler and Exhaust Group......................................................................................................30Engine and Radiator Group .....................................................................................................32Pump and Radiator Group.......................................................................................................34Diesel Fuel Supply and Filter Group........................................................................................36Battery Group ..........................................................................................................................38Pump Drive Mounting Kit Group ..............................................................................................39Hydraulic Schematic ................................................................................................................40Electrical Schematic ................................................................................................................41

Routine Maintenance Replacement PartsThe following parts should be considered as normal stock part items in your location. Keeping a supply of these will enable you to keep the Boxer in full service.

Part Name Part Number

Boxer Replacement Kit ....................................................................................................29834-702 Idler Wheel Kit .................................................................................................................29834-703 Mid - Wheel Kit ................................................................................................................29834-704 Outer Air Filter Element ...................................................................................................29135-771Inner Air Filter Element ....................................................................................................29135-772Fuel Filter.........................................................................................................................29211-036 Fuel Filter Element ..........................................................................................................29211-037 Fuel Filter Head ...............................................................................................................29211-663Hydraulic Oil Filter ..........................................................................................................26838-326Engine Oil Filter ...............................................................................................................29211-627Hydraulic Oil ................................................................................................................... Chevron Rykon Premium

ISO 46 or equalSeal Kit for Tilt Cylinder ..................................................................................................26820-039Seal Kit for Wheel Motor .................................................................................................26713-028Replacement cartridge for Counterbalance valve ...........................................................26663-356Replacement Ignition Key................................................................................................29211-929 Replacement Access Panel Key......................................................................................29341-436

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Universal Mounting Plate and Loader Arm Group

7

Universal Mounting Plate and Loader Arm Group

Item No. Description Quantity Part Number

1 MALE COUPLER ASSEMBLY 1 40011-803

2 ROLL PIN 2 21154-015

3 SPRING 2 24741-087

4 MALE COUPLER ROUND LATCH STOP 2 30042-803

5 MALE COUPLER ROUND LATCH PIN 2 30090-803

6 MALE COUPLER CASTING 1 29510-426

7 ROUND PIN 2 30024-803

8 BOLT 4 21619-103

9 PIN CLIP, RIGHT 1 30003-803

10 GREASE ZERK - STRAIGHT 5 26891-005

11 ROUND PIN 2 30025-803

12 CONNEX BUSHING 6 23128-005

13 BOOM ARM WELDMENT 1 40074-805

14 PIN RETAINER 1 30014-803

15 BUCKET TILT CYLINDER 1 26820-031

16 BUCKET TILT CYLINDER SEAL KIT 1 26820-039

17 LOCK WASHER 4 21171-140

18 PIN CLIP, LEFT 2 30004-803

19 FEMALE QUICK CONNECT 2 26538-215

20 MALE QUICK CONNECT 2 26538-216

21 HOSE, BUCKET CYLINDER CYLINDER END 1 26211-122

22 HOSE, SECOND AUXILIARY PORTS 2 26593-249

23 HOSE, AUXILIARY HOSES 2 26555-098

NS PROTECTIVE SLEEVE (FOR #26) 1 32257-901

NS PROTECTIVE SLEEVE (FOR #26) 1 32433-901

24 FITTING 4 26510-305

25 HOSE, BUCKET CYLINDER ROD END 1 26211-123

26 FITTING, 90° 2 26510-105

27 GREASE ZERK, 90 ° 1 26891-042

28 RELIEF BLOCK 1 26614-681

29 BOLT, RELIEF BLOCK 2 21454-028

30 FITTING 2 26510-213

31 FITTING 1 26510-205

8

Loader Arm Group

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9

Loader Arm Group


1 BOOM ARM WELDMENT 1 40074-805

2 CONNEX BUSHING 8 23128-005

3 ROUND PIN 2 30027-803

4 ROUND PIN 4 30025-803

5 GREASE ZERK, STRAIGHT 6 26891-005

6 PIN CLIP, CLOSED 4 30016-803

7 PIN RETAINER 2 30014-803

8 BOLT 6 21619-103

9 LOCK WASHER 6 21171-140

10 TEE FITTING 2 26510-076

11 FITTING, 90° 2 26510-105

12ARM LIFT CYLINDER 2 26820-032

SEAL KIT 2 26820-037

13 HOSE, VALVE TO BOOM CYLINDER 1 26211-156

14 HOSE, VALVE TO BOOM CYLINDER 1 26211-124

15 HOSE, BOOM CYLINDER ROD TO ROD 1 26211-116

16 HOSE, BOOM CYLINDER, CYLINDER TO CYLINDER 1 26211-115

10

Decals Group

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Decals Group


1 OBSOLETE/CALLOUT NO LONGER APPLICABLE - -

2 CAUTION,BURN HAZARD/SYM CONNECT 4 39510-009

3 LIFT POINT 2 39510-004

4 “CALL BEFORE YOU DIG” 1 39510-149

5 LOCKING PIN 1 39510-018

6 WARNING,ATTACHMENT SECURE CAUTION 2 39510-013

7 WARNING,STAY BACK/SYM DANGER 2 39510-006

8 WARNING, CRUSH HAZARD/SYM DANGER 4 39510-001

9 HYD OIL,ISO PREMIUM 46 1 39510-015

10 WARNING,INSTALL CYL LOCK/SYM WARNING 39510-012

11 WARNING,READ MANUAL/SYM WARNING 1 39510-008

12 WARNING,BATTERY GROUND (SYM) 1 39510-007

13 NOTICE,ULTRA LOW SULFUR DIESEL 2 39510-152

14 WARNING CA PROP 65 1 39510-014

15 BOXER -LARGE 2 39510-079

16 “525DX” DECAL 2 39510-282

17 BIG POWER DECAL 2 39510-140

18 OPERATOR CONTROLS -SAFETY- 1 39510-068

19 OPERATOR CONTROLS 1 39510-067

20 CONTROL PANEL DECAL 1 39510-070

21 BOXER INTERNET ADDRESS DECAL 1 39510-023

22 MORBARK LOGO DECAL 1 39510-145

23 TAG, MOD, WT, HP 1 39510-156

24 TAG, SN, MAN DATE 1 39510-154

25 ULTRA LOW SULPHUR DIESEL 1 39511-951

26 CRAWL SPEED 1 39510-196

27 TIE DOWN 2 39510-005

28 WARNING, EXPLOSION HAZARD 1 39511-952

29 WARNING, FIRE HAZARD 1 39510-011

30 SHUT OFF FUEL 1 39510-003

31 DANGER, CRUSH HAZARD 2 39510-144

32 WARNING, AUXILIARY VALVE 1 39510-024

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11

Travel Drive Group

13


1 RUBBER TRACK 2 29510-4062 DRIVE SPROCKET 2 30109-8033 BOLT 12 22425-2554 ROUND, HUB -DRIVE 2 30106-8035 RIGHT TRACK MODULE 1 40058-8056 FITTING 4 26510-1077 MID-WHEEL SPOOL ASSEMBLY 10 SEE PAGE 158 DRIVE MOTOR 2 26713-006

CASTLE NUT 2 26732-321WOODRUFF KEY 2 26713-027

9 BOLT 8 21411-25710 LEFT TRACK MODULE 1 40057-80511 FRONT IDLER ASSEMBLY 2 SEE PAGE 1412 LEFT GUIDE ROD 2 40027-80513 HARDENED WASHER 12 21161-04414 LOCK WASHER 12 21171-14315 BOLT 12 21411-27616 COTTER PIN 2 21126-02217 RIGHT GUIDE ROD 2 40028-80318 TRACK WIDENING CYLINDER 1 26820-033

SEAL KIT 1 26820-03819 FITTING 2 26510-10520 PIVOT PIN 2 30025-80321 FORK, PIVOT PIN 2 30014-80322 LOCK WASHER 2 21171-14023 BOLT 2 21619-10324 BOLT 2 21612-27025 NUT 2 21733-30726 HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR 2 26270-001 27 TUBE, CONTROL VALVE TO LEFT SIDE OF LEFT CBV 1 40089-80528 FITTING, 90 ° 6 26510-10729 O-RING, #10 8 26511-91030 COUNTERBALANCE VALVE 2 26633-35631 FITTING 2 26510-21132 TUBE, CONTROL VALVE TO RIGHT SIDE OF LEFT CBV 1 40090-80533 TUBE, CONTROL VALVE TO LEFT SIDE OF RIGHT CBV 1 40091-80534 TUBE, CONTROL VALVE TO RIGHT SIDE OF RIGHT CBV 1 40088-80535 LOCK WASHER 12 21171-14336 BOLT 2 21619-10537 LOCK WASHER 2 21161-01138 HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR 2 26270-00339 HOSE, TRACK CYLINDER 2 26211-131 40 COUNTERBALANCE VALVE 2 26633-35641 BUSHING, VARIABLE WIDTH TRACK ADJUSTMENT 4 23121-165

Travel Drive Group

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Idler Wheel and Spring Assembly


1 TENSION LOCK PLATE 2 30010-8032 JACKING BOLT WELDMENT 2 40056-8053 SPRING TENSIONER WELDMENT 2 40007-8034 SPRING 2 29510-4385 TRACK FORK WELDMENT 2 40055-8016 WHEEL ASSEMBLY, RIGHT SIDE 1 40040-803

WHEEL ASSEMBLY, LEFT SIDE 1 40009-8037 BEARING 4 29510-4278 IDLER SPACER TUBE 4 30017-8039 IDLER PIN 2 40018-803

10 SEAL 4 29510-43111 SNAP RING 2 24125-00812 FRONT IDLER WHEEL 2 29510-40413 LOCK WASHER 2 21171-14314 BOLT 2 21612-61115 FLAT WASHER 2 32217-901

NOTE: Quantities Listed Are For Both Sides.

15

Mid Wheel Assembly

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8

65432

1


1 MID-WHEEL ASSEMBLY 10 40010-803

2 NUT 20 21733-4103 FLAT WASHER 20 21161-1164 SEAL 20 29510-4285 SNAP RING 20 29510-4296 BEARING 20 29510-4307 MIDWHEEL 10 30102-8038 MIDWHEEL AXLE 10 30029-803

NOTE: Quantities Listed Are For Both Sides.

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Return lin eto HydraulicFilter Assy .

To tee onthe botto m ofthe Auxiliary

Valve


1 BOLT 4 21625-7052 LOCK WASHER 4 21171-1893 FLAT WASHER 4 21161-1044 O-RING SEAL 2 26511-9125 HYDRAULIC COOLER KIT 1 26844-131

6 12 V COOLER FAN 1 26844-1327 FLAT WASHER, M6 4 21171-0378 MOUNTING BOLT, M6 4 21625-785

9 ELBOW, 90° 2 26531-14610 CLAMP 4 26516-41011 HOSE, OIL COOLER OUTLET TO FILTER INLET IN TANK 1 18510-55812 HOSE, VALVE RETURN TO COOLER INLET 1 18510-55013 SCREEN 1 40053-805

Hydraulic Cooler Group

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Main Control Valve Group

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Main Control Valve Group


1 VALVE BLOCK 1 26661-2202 BOLT 3 21624-0533 ROUND LEVER SHAFT 2 30154-8054 LOCK NUT 4 21731-7085 CONTROL KNOB 2 29341-4626 ROUND LEVER SHAFT 2 30153-8057 LOCK NUT 4 21731-7108 TRAVEL CONTROL HANDLE, CAST 2 29341-4989 FITTING 4 26510-20810 HOSE, BUCKET CYLINDER, ROD END 1 26211-12311 HOSE, BUCKET CYLINDER, CYLINDER END 1 26211-12212 HOSE, VALVE TO BOOM CYLINDER 1 26211-15613 FITTING 4 26510-21414 COUNTERBALANCE VALVE 2 26633-35615 TUBE, COUNTERBALANCE VALVE 1 40090-80516 FITTING 2 26510-21117 TUBE, COUNTERBALANCE VALVE 1 40091-80518 TUBE, COUNTERBALANCE VALVE 1 40088-80519 FITTING, 90° 6 26510-10720 TUBE, COUNTERBALANCE VALVE 1 40089-80521 BOLT 4 21625-01122 LOCK WASHER 4 21171-13723 FLAT WASHER 4 21161-00724 NUT, INSERT 4 21737-406

25 HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR 2 26730-00326 HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR 2 26730-00127 HOSE CLAMP 4 27112-26228 BOLT 2 21619-10329 NYLOC NUT 2 21733-30330 FITTING, 45° 1 26510-13231 HOSE, “C” ON BLOCK TO PRESSURE ON MAIN VALVE 1 40097-80532 FITTING, 90° 1 26510-13033 TUBE 1 40092-80534 FITTING 1 26512-505

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Diverter Valve Group

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Diverter Valve Group


1 VALVE BANK 1 26661-2082 SPACER 1 30151-8053 MOUNT, VALVE BANK 1 30152-8054 BOLT 3 21624-0655 NYLOC NUT 3 21733-4576 MAIN AUXILIARY LEVER 1 30101-8057 TEXTURED GRIP 1 29341-4638 NUT 1 21731-7109 AUXILIARY LEVER 2 30100-80510 KNOB 2 29341-49711 NUT 2 21731-70812 FITTING 1 26510-21113 HOSE, “D”ON BLOCK TO PRESSURE ON AUXILIARY VALVE 1 26265-19314 FITTING 2 26512-21215 HOSE, SECOND AUXILIARY - FROM VALVE TO COUPLING 2 26555-09816 FITTING 2 26510-20917 TUBE 1 26265-20718 TUBE 1 26265-20719 FITTING 2 26510-20720 HOSE, TRACK CYLINDER 2 26211-13121 FITTING 1 26512-61722 PLUG, FITTING 1 26511-08523 FITTING 1 26531-14424 CLAMP 2 26516-41025 HOSE, VALVE RETURN TO AUXILIARY VALVE 1 18510-551

22

Crawl Valve Group

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Crawl Valve Group


1 CRAWL CONTROL VALVE 1 26682-5012 MOUNTING BRACKET 1 30079-8053 BOLT 1 21619-1034 LOCK WASHER 1 21171-1405 BOLT 1 21619-0556 FLAT WASHER 2 21161-0087 NYLOCK NUT 1 21733-4578 TEE FITTING 2 26510-0809 HOSE, “E” ON BLOCK TO BACK PUMP 1 26265-19110 TEST PORT FITTING 2 26538-42511 TEST PORT DUST CAP 2 26538-41612 FITTING 1 26510-10813 TUBE 1 40092-80514 90 DEGREE FITTING 1 26510-10715 HOSE, “C” ON BLOCK TO PRESSURE ON MAIN VALVE 1 26265-19216 HOSE, “F” ON BLOCK TO FRONT PUMP 1 26265-19017 FITTING, 90° 1 26510-10718 HOSE, “D” ON BLOCK TO PRESSURE ON AUXILIARY VALVE 1 26265-19319 HOSE, VALVE RETURN TO AUXILIARY VALVE 1 18510-55120 CLAMP, HOSE 2 26516-41021 HOSE, VALVE RETURN TO OIL COOLER INLET 1 18510-550NS FITTING, STRAIGHT HOSE BARBED 1 26517-166

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Electrical Panel Parts Group

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1 BOLT 4 21619-0052 LOCK WASHER 4 21171-1393 FLAT WASHER 4 21161-0084 IGNITION SWITCH W/KEY 1 29211-9355 IGNITION KEY SWITCH COVER 1 29295-0086 IGNITION KEY 1 29211-9297 NUT WITH NYLON INSERT 4 22522-0068 FUSE PANEL 1 27311-9159 MACH PAN HEAD MACHINE SCREW 4 22341-41010 BLADE TYPE FUSE ATO-1 2 27311-91011 BLADE TYPE FUSE ATO-3 2 27311-90512 BLADE TYPE FUSE ATC-15 2 27311-90313 OIL PRESSURE GAUGE 1 29317-15214 WATER TEMPERATURE GAUGE 1 29316-85515 PLUG 1 24722-01516 PLUG 1 24722-00817 PLUG 1 24722-01918 HIGH RANGE GROUND HARNESS 1 47005-80519 TOGGLE SWITCH BOOT 1 29295-02720 TOGGLE SWITCH 1 29295-02621 HIGH RANGE WIRING HARNESS 1 47004-80522 PLUG 1 24722-01023 HOUR METER 1 29316-96224 HOUR METER TO TERMINAL STRIP HARNESS 1 47001-80525 HOUR METER TO GROUND HARNESS 1 47002-80526 GAUGE PANEL WELDMENT 1 40024-80527 MAIN WIRING HARNESS 1 47007-80528 FUSE PANEL GROUND HARNESS 1 47003-805

Electrical Panel Parts Group

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Rear Frame Group

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ToEngineIntake

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Rear Frame Group


1 BOLT 2 21619-2052 CONTROL PANEL 1 40095-8053 LOCKING ACCESS PANEL 1 40007-8054 FUEL TANK MOUNTING LOCK - RH 1 30054-8055 FLAT WASHER 2 21161-0086 NUT 2 21733-4577 SPRING 4 24741-1888 STOP PLATE 2 30045-8059 FLANGED NUT 2 21733-41110 BOLT 2 21619-41311 FLAT WASHER 2 21161-11612 OPERATOR PLATFORM 1 40026-80513 RUBBER MAT 1 32233-90114 FUEL TANK 2 39236-43115 CAP, FUEL TANK 2 26849-17016 FUEL TANK MOUNTING LOCK - LH 1 30055-80517 FLAT WASHER 2 21161-00818 BOLT 2 21619-05519 BOLT 2 21625-10620 LOCK WASHER 2 21171-14021 PUMP GUARD 1 40044-80522 ACCESS PANEL 2 29341-495NS KEY, ACCESS PANEL 1 29341-43623 HAND GRIP 2 29341-46424 FLAT WASHER 2 21161-00825 WING NUT 2 21713-21226 WRENCH 1 30051-80327 RUBBER GROMMET 2 24721-37928 AIR CLEANER BODY ASSEMBLY * 1 29295-136

29 AIR FILTER ELEMENT - OUTER 1 29135-77130 AIR FILTER ELEMENT - INNER 1 29135-77231 AIR CLEANER MOUNTING BRACKET 1 30157-80532 CARRIAGE BOLT 2 21661-02333 BOLT 2 21619-05334 FLAT WASHER 6 21161-06235 NYLOC NUT 4 21733-00536 THROTTLE CABLE ASSEMBLY 1 24731-00237 THROTTLE LEVER KNOB 1 24731-01838 BOLT 4 21625-25439 LOCK WASHER 4 21171-143NS SPACER, CONTROL PANEL 2 33107-703NS MANUAL CONTAINER 1 39234-21040 BOOM CYLINDER SAFETY LOCK 1 30027-80541 SAFETY LOCK RETAINER PIN AND RING 1 21129-43542 ROUND FLUTED KNOB 1 29341-496

* Assembly included with P/N’s: 29135-771 & 29135-772

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Hydraulic Filter and Engine Shroud Group

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Hydraulic Filter and Engine Shroud Group


1 COOLER SHROUD 1 32058-804

2 HEX HEAD BOLT 4 21619-053

3 HEX HEAD BOLT 2 21619-055

4 LOCK WASHER 6 21171-139

5 FLAT WASHER 10 21161-110

6 NYLOC NUT 2 21733-457

7 SUPPORT, COOLER SHROUD 1 32059-804

8 ASSEMBLY, CLEAN OUT COVER (INCLUDES NUMBER 9) 2 26849-402

9 GASKET, CLEAN OUT COVER 2 26849-440

10 VENTED CAP WITH DIPSTICK 1 26849-167

11 HOSE, OIL COOLER OUTLET TO FILTER INLET IN TANK 1 18510-558

12 CLAMP 2 26516-410

13 FITTING 1 26531-146

14 FITTING 1 26531-147

HYDRAULIC FILTER ASSEMBLY 1 26838-31515 HYDRAULIC FILTER TOP 1 26838-31516 HEX HEAD BOLT 2 21619-05517 LOCK WASHER 2 21171-13918 O-RING SEAL KIT 1 26838-32719 FILTER HOLDER BASKET 1 26838-33120 HYDRAULIC FILTER ELEMENT 1 26838-32621 HYDRAULIC FILTER PRESSURE SPRING 1 26838-32822 HYDRAULIC FILTER TOP PLATE 1 26838-31623 HEX HEAD BOLT 3 26838-329

24 90 DEGREE MALE FITTING 1 26510-11025 HOSE, PRESSURE RELIEF LINE 1 26900-06126 PLUG 1 26511-087NS O-RING 1 26511-912NS CERAMIC MAGNET 1 26849-172

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TO ENGINEEXHAUST

MANIFOLD

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Muffler and Exhaust Group

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Muffler and Exhaust Group


1 BOLT 4 21625-7162 EXHAUST MANIFOLD GASKET 1 29211-6793 EXHAUST PIPE ASSEMBLY 1 40054-805

4 EXHAUST PIPE 1 40055-8055 MUFFLER CLAMP 2 29323-4546 MUFFLER 1 29295-1047 EXHAUST TIP 1 29135-834

8 BOLT 4 21619-0539 LOCK WASHER 4 21171-13910 FLAT WASHER 4 21161-11011 MUFFLER GUARD 1 30026-805

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Engine and Radiator Group

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Engine and Radiator Group


1 AIR CLEANER ASSEMBLY 1 Reference only2 HOSE CLAMP 5 26516-0233 INTAKE HOSE ELBOW 2 29295-1464 HOSE CLAMP 1 27112-2675 INTAKE HOSE ELBOW 1 29295-0806 NUT 4 21733-4097 WATER TEMP SENDER 1 29317-1258 OIL PRESSURE SENDER 1 29317-1189 ELBOW FITTING 1 25434-32110 TERMINAL INSULATOR 1 29315-03111 POWER CABLE 1 47004-80312 LOCK WASHER 1 21171-18913 LOCK NUT 1 21733-50714 BOLT 4 21624-25515 FLAT WASHER 4 21161-04416 FLAT WASHER 8 21161-61317 BOLT 8 21625-70518 ISOLATOR MOUNT, LOWER 2 29295-09519 NUT 2 21733-30320 ISOLATOR MOUNT, UPPER 2 29295-09421 WASHER AND ISOLATORS FURNISHED WITH ENGINE 2 See engine manual22 BOLT 2 21625-11223 OIL FILTER 1 29211-62724 HOSE CLAMP 2 26516-01625 HOSE, SUCTION TANK TO PUMP 1 18510-57526 BOLT 6 21619-00327 LOCK WASHER 6 21171-13728 INSERT 6 21737-40629 PROTECTIVE SCREEN 1 29211-03430 RADIATOR SHROUD 1 30074-80531 INSERT 2 21737-41032 RADIATOR OVERFLOW BOTTLE 1 29326-92633 BOLT 6 21619-00334 LOCK WASHER 6 21171-13735 BOLT 2 21619-05136 RADIATOR SHROUD TOP 1 30075-80537 INSERT 4 21737-40638 LOCK WASHER 4 21171-13739 BOLT 4 21619-00340 RADIATOR MOUNT 2 30063-80541 NUT 2 21733-52042 FLAT WASHER 2 21161-00743 RUBBER MOUNT 2 24721-01944 RADIATOR 1 29211-42945 RADIATOR CAP 1 29326-93146 RADIATOR COVER 1 30076-80547 FLAT WASHER 8 21161-11048 LOCK WASHER 8 21171-13949 BOLT 4 21619-05350 CLAMP, AIR BREATHER 1 29295-11151 TUBE AIR INTAKE 1 33969-703

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Pump and Radiator Group

35

Pump and Radiator Group


1 HOSE CLAMP 2 26516-0162 LOWER RADIATOR HOSE 1 29295-0203 UPPER RADIATOR HOSE 1 29295-0934 SPEED NUT 4 21732-5555 WASHER 4 21161-0076 LOCK WASHER 4 21171-1377 BOLT 4 21619-0038 BOLT 4 29295-0689 LOCK WASHER 1 21171-19210 NUT 1 22533-25211 THROTTLE BRACKET 1 30125-80512 NUT 1 21733-45713 THROTTLE LEVER 1 32231-90114 SCREW 1 21266-01215 THROTTLE CABLE CLAMP 1 29295-02516 WASHER 1 21161-00817 BOLT 1 21619-05618 BOLT 1 21625-73319 BOLT 16 21612-75320 LOCK WASHER 16 21171-14021 RIGHT HAND ENGINE MOUNTING PLATE 1 30068-80522 CLAMP 1 27112-26123 O-RING 1 26511-91624 FITTING 1 26517-51825 O-RING 2 26511-91026 FITTING 1 26510-11127 FITTING 1 26510-11128 LEFT HAND ENGINE MOUNTING PLATE 1 30069-80529 HOSE, “E” ON BLOCK TO BACK PUMP (RUBBER) 1 26265-19130 HOSE, “F” ON BLOCK TO FRONT PUMP (RUBBER) 1 26265-19031 ENGINE 1 29211-40832 FAN BELT 1 29295-02033 SPACER 1 29295-06734 FAN 1 29326-81735 FAN SAFETY SCREEN 1 29295-07136 HOSE, SUCTION TANK TO PUMP 1 18510-575

36

TO FUEL FEED/INJECTION PUMPON ENGINE(RIGHT SIDE)

RETURN LINEFROM ENGINEFUEL GALLER Y(RIGHT SIDE)

1 2

3

46

7

23

2221

24

18

15

6

9

106

121113

116

9

19

26

65

8

25

11

14

16

17

20

Diesel Fuel Supply and Filter Group

37

Diesel Fuel Supply and Filter Group


1 FUEL HOSE 1 32249-901

2 BREATHER 1 26849-1433 FITTING 1 25978-1364 BREATHER TUBE 1 32267-9015 FUEL HOSE 1 32271-9016 SPRING CLAMP AR 26516-2307 TEE FITTING 1 25978-1658 ELBOW FITTING 1 25978-1349 BUSHING 2 25312-00110 FUEL SHUT OFF VALVE 2 29295-01311 HOSE CLAMP AR 26516-11012 FUEL HOSE 1 32269-901

13 TEE FITTING 1 25978-16814 FUEL HOSE 1 32258-90115 FUEL HOSE 1 32270-90116 FUEL FILTER ASSEMBLY 1 29211-036

17 FUEL FILTER ELEMENT 1 29211-03718 FUEL FILTER HEAD 1 29211-663

19 PLUG 1 39236-44220 NUT 2 21733-45621 FLAT WASHER 2 21161-00722 BOLT 2 21625-00523 ELBOW FITTING 1 25978-13524 BREATHER TUBE 1 32268-90125 FUEL TANKS 2 39236-43126 CAP, FUEL TANKS 2 26849-170

38

56

1 2

3

4

3

7

Battery Group


1 BATTERY TERMINAL INSULATOR, RED 1 29315-0472 NEGATIVE BATTERY CABLE 1 47007-8033 BATTERY HOLD DOWN, WITH BOLTS, WING NUTS, FLAT WASHERS 1 29315-3024 12V BATTERY 1 29315-2655 POSITIVE BATTERY CABLE 1 47008-8056 CORRUGATED FABRIC LOOM 1 18763-0237 TERMINAL INSULATOR, RED 1 29315-046

NS POWER CABLE 1 47004-803

39

23

4ENGINE FLY

WHEEL 6

78

9

5

1

Pump Drive Mounting Kit Group


1 PUMP DRIVE MOUNTING KIT 1 29295-098

2 MOUNTING FLANGE 1 29295-1163 CAP SCREWS (PUMP MOUNT FASTENER KIT) 10 21451-6314 PUMP DRIVE HOUSING 1 29295-0995 FLAT WASHER 2 21161-0116 BOLT (PUMP MOUNT FASTENER KIT) 2 21612-0287 PUMP DRIVE HUB 1 29295-011

8 HYDRAULIC PUMP 1 26711-0019 BOLT 2 21619-105

40

Hydraulic Schematic

48003-805

NS

RE

F48

002-

805

KIT

,HY

DR

AU

LIC

,HO

SE

11

RE

F26

633-

356

CO

UN

TER

BA

LAN

CE

VA

LVE

10R

EF

2671

3-00

6M

OTO

R, T

RA

CK

9R

EF

2682

0-03

3C

YLI

ND

ER

, TR

AC

K8

RE

F26

820-

032

CY

LIN

DE

R, L

IFT

7R

EF

2666

1-20

8VA

LVE

BA

NK

6R

EF

2682

0-03

1C

YLI

ND

ER

, TIL

T5

RE

F26

661-

220

VALV

E B

AN

K4

RE

F26

682-

501

MA

NIF

OLD

, HY

DR

AU

LIC

3R

EF

2684

4-13

1C

OO

LER

, HY

DR

AU

LIC

2

RE

F26

838-

390

FILT

ER

, TA

NK

1R

EF

2671

1-00

1P

UM

P, H

YD

RA

ULI

CS

YM

QTY

PAR

T N

UM

BE

RD

ES

CR

IPTI

ON

LIFT

CY

LIN

DE

R

QU

ICK

DIS

CO

NN

EC

TTO

AU

X A

TTA

CH

ME

NT

LEFT

TR

AC

KR

IGH

T TR

AC

K

TILT

CY

LIN

DE

R

TRA

CK

CY

LIN

DE

R

CO

OLE

R

CO

UN

TER

BA

LAN

CE

VALV

E B

AN

K

VALV

E B

AN

K

HY

DR

AU

LIC

MA

NIF

OLD

PU

MP

FE

CDG

BA

5

3

2

1

4

9

7

88

6

1010

1111

41

14 GA LT-BLU

18 GA YEL

12 GA RED -A-

14 GA YEL

14 GA BLK

18 GA GRN

14 GA BLU -E-

-F-

TIE AFTER

ASSY

WATCH FOR

REVERSAL

WATCH FOR

REVERSAL

WATCH FOR

REVERSAL

WATCH FOR

REVERSAL

TIE AFTER

ASSY

NOTES:

1. HEAT SHRINK 27136-123 ALL

BARE CONNECTIONS

2. SHRINK W/S ALL SPLICES

3. HRNS MUST BE 100% CONTINUITY

CHECKED

4. LABEL HARNESS PER MORBARK

SPECIFICATIONS, 48001-000

DETAIL

A

ITE

MQ

TYPA

RT

NU

MB

ER

DE

SC

RIP

TIO

NLE

NG

TH (I

N)

ITE

MQ

TYPA

RT

NU

MB

ER

DE

SC

RIP

TIO

NLE

NG

TH (I

N)

291

1876

3-02

0LO

OM

, SP

LIT

BLA

CK

1/4

849

118

141-

128

WIR

E, 1

2 G

A B

RO

WN

18.5

281

1876

3-02

0LO

OM

, SP

LIT

BLA

CK

1/4

948

118

141-

265

WIR

E, 1

4 G

A LI

GH

T B

LUE

87

271

1876

3-02

0LO

OM

, SP

LIT

BLA

CK

1/4

947

118

141-

309

WIR

E, 1

2 G

A B

LAC

K56

261

1876

3-02

0LO

OM

, SP

LIT

BLA

CK

1/4

746

118

141-

309

WIR

E, 1

2 G

A B

LAC

K2

251

1876

3-02

2LO

OM

, SP

LIT

BLA

CK

3/8

15

451

1814

1-31

1W

IRE

, 12

GA

RE

D73

241

1876

3-02

2LO

OM

, SP

LIT

BLA

CK

3/8

6

441

1814

1-31

1W

IRE

, 12

GA

RE

D7.

5

231

1876

3-02

2LO

OM

, SP

LIT

BLA

CK

3/8

7.

543

118

141-

314

WIR

E, 1

4 G

A Y

ELL

OW

75.5

221

1876

3-02

2LO

OM

, SP

LIT

BLA

CK

3/8

6

421

1814

1-31

5W

IRE

, 14

GA

BLA

CK

16.5

211

1876

3-02

2LO

OM

, SP

LIT

BLA

CK

3/8

16

411

1814

1-32

1W

IRE

, 16

GA

BLA

CK

22

201

1876

3-02

3LO

OM

, SP

LIT

BLA

CK

1/2

6640

118

141-

323

WIR

E, 1

6 G

A R

ED

22

191

1876

3-02

7LO

OM

, SP

LIT

BLA

CK

7/1

68

391

1814

1-32

4W

IRE

, 18

GA

GR

EE

N

81

181

1876

3-02

7LO

OM

, SP

LIT

BLA

CK

7/1

68

381

1814

1-32

6W

IRE

, 18

GA

YE

LLO

W80

.5

171

2713

6-12

3TU

BIN

G, S

HR

INK

, 1/4

BLA

CK

371

1814

1-33

5W

IRE

, 16

GA

BR

OW

N50

.5

161

2721

4-23

4TE

RM

INA

L, 5

/16

RIN

G 1

2-10

AW

G36

118

141-

374

WIR

E, 1

6 G

A R

ED

/WH

ITE

7

151

2721

4-21

1TE

RM

INA

L, 3

/8 R

ING

16-

14 A

WG

351

1814

1-39

5W

IRE

, 16

GA

BLA

CK

/WH

ITE

7

146

2721

5-10

9TE

RM

INA

L, S

NA

P FO

RK

16-

14AW

G #

634

118

141-

622

WIR

E, 1

4 G

A B

LUE

42

134

2721

5-13

8TE

RM

INA

L, S

NA

P FO

RK

12-

10AW

G #

1033

118

141-

622

WIR

E, 1

4 G

A B

LUE

42

123

2721

5-13

5TE

RM

INA

L, S

NA

P FO

RK

12-

10AW

G #

832

118

141-

646

WIR

E, 1

6 G

A B

RO

WN

/BLA

CK

111

6547

112

2721

5-11

0TE

RM

INA

L, S

NA

P FO

RK

16-

14AW

G #

831

127

257-

134

ALT

ER

NAT

OR

PLU

G

102

2721

5-20

3TE

RM

INA

L, S

NA

P FO

RK

22-

18AW

G #

1030

127

257-

175

CO

NN

EC

TOR

,SU

MIT

OM

O

92

2721

5-20

4TE

RM

INA

L, S

NA

P FO

RK

22-

18AW

G #

6

86

2721

6-06

0TE

RM

INA

L, F

EM

SPA

DE

BLU

E

73

2724

5-10

6C

ON

NE

CTO

R, B

UTT

12-

10 G

A

62

2724

5-20

6C

ON

NE

CTO

R, B

UTT

16-

14 G

A

52

2725

6-71

6TE

RM

INA

L, F

EM

ALE

ME

TRI 2

8013

41

2725

6-71

7C

ON

NE

CTO

R, F

EM

2-W

AY M

ETR

I 280

31

2731

1-91

3FU

SE

, BLA

DE

TY

PE

AT0

-30

21

2731

1-91

6H

OLD

ER

, FU

SE

ATO

SE

ALE

D

11

2931

5-71

9D

IOD

E, 3

A B

OX

ER

BE

AC

ON

30

A B

30A BLADE

FUSE

C D

E F

5/16

SEE

DETAIL

A

2FBLK

2F

2F

2F

12 GA BLK

12 GA RED

16 GA RED

16 GA B

LK

16 GA BLK/WHT16

GA RED/W

HT

-C- 16 G

A BRN/BL

K

16 GA BLK/WHT

16 GA RED/WHT

16 GA BRN

14 GA LT-BLU

14 GA BLU

12 GA BRN

18 GA YEL

18 GA GRN

16 GA RED

16 GA BLK

12 GA BLK

14 GA LT-BLU

18 GA YEL

F

12 GA RED

-B- 12 GA RED

14 GA YEL

14 GA BLK

14 GA BLK -F-

18 GA GRN

F

F

F

F

F

-D- 16 G

A BRN

12 GA BRN

810

10

10

-A- 12 GA RED

10

14 GA BLU -E-

6

6

6

66

6

6

6

12 GA BLK

10

3/8

16 GA BRN/BLK 14 GA YEL

88

8

10

14 GA BLU

14 GA BLU

10(A)

(A)

(B)

(B)

(B)

3 IN x 8

3 1/2 IN x 6

3 IN

2 IN

1 IN

1 1/2 IN

1 1/2 IN

1 1/2 IN

1 IN

28 IN

32 1/2 IN

5 1/2 IN

9 IN

1 IN

1 IN

1 IN

1 IN

2 IN x 8

1/2 LOOM x 66 IN

7/16 LOOM x 8 IN

7/16

LOOM x 8 IN

3/8 LOOM

x 6 IN

3/8 LOOM x 15 IN

3/8 LOOM x 16 IN

1/4 LOOM x 7 IN

3/8 LOOM X 7 1/2 IN

1/4 LOOM x 8 IN

1/4 LOOM x 9 IN

1/4 LOOM x 9 IN

3/8 LOOM x 6 IN

1

2 3

4 5

8

8

9

10

10

11

1112

12

13

13

13

13

14

15

16

18

19

20

22

25

21

23

24

29

28

27

26

30

31

48

49

34

37

42

40

36

40

38 41

35

39

46

47

49

32

37

33

42

44

45

45

32

43

47

48

38

43

42 39

Electrical Schematic

47006-805

42

NOTES:

43

NOTES:

Phone: Sales - 800-831-0042,Parts and Service - 800-255-8839 www.boxerequipment.com ®

Morbark, Inc.8507 S. Winn Rd., P.O. Box 1000,

Winn, Michigan 48896www.morbark.com

Manufactured by:

B I G P O W E R I N A L L P L A C E S

big power in all places - boxer® equipment · boxer replacement kit ... 9 elbow, 90° 2 26531-146...

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