big power in all places - morbark, llc routine maintenance replacement parts the following parts...

Boxer 322D Parts ManualSerial No.s 2793 and Higher

Part No. 76345-809

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

®

PARTS MANUAL REVISION LOG

Rev: DateAffected:

PagesChanged:

Description of Changes:

- Jan 6, 2015 All Initial Release

1

Table of Contents

Parts List and Illustrations Page Number

Routine Maintenance Replacement Parts .................................................................. 2Universal Mounting Plate and Loader Arm ................................................................. 2Loader Arm Assembly................................................................................................. 4Decals Group.............................................................................................................. 6Travel Drive Group ..................................................................................................... 8Idler Wheel and Spring Assembly............................................................................. 10Mid-Wheel Assembly .................................................................................................11Main Control Valve Group ........................................................................................ 12Auxiliary Valve Group ............................................................................................... 14Rear Frame Assembly .............................................................................................. 16Hydraulic Cooler Group ............................................................................................ 18Muffler Parts Group .................................................................................................. 20Hydraulic Pump Group ............................................................................................. 22Battery Group ........................................................................................................... 24Diesel Fuel Group..................................................................................................... 26Electrical Components Group................................................................................... 28Engine Cooling Group .............................................................................................. 30Motor Mounting Group.............................................................................................. 32Schematics ............................................................................................................... 34

Rev: DateAffected:

PagesChanged:

Description of Changes:

- Jan 6, 2015 All Initial Release

2

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

Part Name Part Number

Maintenance Kit ...............................................................................................................29834-701 Idler Wheel Repair Kit......................................................................................................29834-703 Mid - Wheel Repair Kit.....................................................................................................29834-704 Engine .............................................................................................................................29211-004Air Filter Elements Outer ......................................................................................................................29135-771 Inner .......................................................................................................................29135-772Fuel Filter.........................................................................................................................29295-003Hydraulic Filter.................................................................................................................26838-114Engine Oil Filter ...............................................................................................................29295-045Hydraulic Filter Head .......................................................................................................26838-113 Hydraulic Oil .................................................................................................................... Chevron Rykon Premium

ISO 46 or equalSeal Kit for Tilt Cylinder ...................................................................................................26820-045Seal Kit for Lilt Cylinder ...................................................................................................26820-043Seal Kit for Wheel Motor..................................................................................................26735-087Replacement Ignition Key................................................................................................29211-929 Replacement Dash Panel Key.........................................................................................29341-436

1

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2

21

1

2 3

45

6 7

891110

71222

1167

89 7

9 812

7

23

1314

15

15

171615

14 18

19

20

1025

24

2627

Universal Mounting Plate

3

Universal Mounting Plate

Item No. Description Quantity Part Number

1 COUPLER LATCH PIN 2 30090-8032 SPRING 2 24741-0873 ROLL PIN 2 21154-0154 ATTACHMENT PLATE 1 29510-4265 PIN CLIP - RIGHT 1 30003-8036 ROUND PIN 2 30024-8037 GREASE ZERK - STRAIGHT 6 26891-0058 BOLT 4 21619-1039 LOCK WASHER 4 21171-14010 CONNEX BUSHING 6 23128-00511 PIN CLIP (CLOSED) 2 30004-80312 ROUND PIN 2 30025-80313 BOOM ARM 1 40055-80314 AUXILIARY HOSE 2 26265-07815 BULKHEAD FITTING 2 26510-30516 QUICK DISCONNECT, FEMALE 1 26538-21517 QUICK DISCONNECT, MALE 1 26538-21618 HOSE 1 26211-11919 HOSE 1 26211-11620 CYLINDER - TILT 1 26820-028

20A TILT CYLINDER SEAL KIT (Not Shown) 1 26820-04521 COUPLER LATCH STOP 2 30042-80322 90 DEGREE FITTING 2 26510-10523 PIN CLIP - TOP CYL 1 30016-80324 RELIEF BLOCK 1 26614-68125 BOLTS 2 21454-02826 FITTING 2 26510-21327 FITTING 1 26510-205

4

1

2 3

5

67

8

1011

1272

9

13

14

1011152

4

16

4

2

3

9

Loader Arm Assembly


1 FLUTED KNOB 1 29341-4962 BUSHING 7 23128-0053 ROUND PIN 2 30027-8034 GREASE ZERK 2 26891-0055 BOOM SAFETY LOCK PIN 1 21129-4356 BOOM SAFETY LOCK 1 30062-8037 FITTING, SAE MALE STR 2 26510-1058 LIFT CYLINDER HOSE ASSY 2 26211-1159 90 DEGREE ZERK 2 26891-04210 BOLT 3 21619-10311 LOCK WASHER 3 21171-14012 RETAINER CLIP 1 30014-80313 ROUND PIN 1 30025-80314 LIFT CYLINDER 1 26820-03015 PIN CLIP 2 30016-80316 ROUND PIN 1 30108-803

5


6

3

21

15

1

2

3

4

5

67

7

1

6 11

101

84 14

913

12

17

716

19

2120

18

Decal Group

7

Decal Group


1 CRUSH HAZARD DECAL 4 39510-0012 MODEL NUMBER DECAL 2 39510-1003 DANGER ZONE DECAL 2 39510-0064 BURN HAZARD DECAL 2 39510-0575 BATTERY EXPLOSION HAZARD DECAL 1 39510-0076 BOXER DECAL 2 39510-1407 TIE DOWN DECAL 3 39510-0058 CYLINDER LOCK INSTALLATION DECAL 1 39510-0129 AUXILIARY VALVE WARNING DECAL 1 39510-024

10 DIESEL FUEL ONLY DECAL 1 39510-01011 READ OPERATOR’S MANUAL WARNING DECAL 1 39510-00812 SAFETY INSTRUCTION DECAL 1 39510-02213 OPERATING CONTROLS DECAL 1 39510-02114 ATTACHMENT SECURITY DECAL 1 39510-01315 ISO 46 HYDRAULIC FLUID DECAL 1 39510-01516 SHUT OFF FUEL DECAL (inside frame under filter) 1 39510-00317 CALIFORNIA PROP 65 WARNING DECAL 1 39510-01418 CALL BEFORE YOU DIG DECAL 1 39510-14919 LIFTING EYE DECAL 1 39510-00420 MORBARK DECAL 1 39510-14521 BOXER INTERNET DECAL 1 39510-02322 TAG, MOD, WT, HP (NOT SHOWN) 1 39510-15523 TAG, SN, MAN DATE (NOT SHOWN) 1 39510-154

8

2

119

4

5

6

7

15

89

1011

14

12

13

16, 17, 18

4

20

21

22

3

5

Travel Drive Group

9


1 BOLT 8 21619-2582 FRONT IDLER ASSEMBLY 1 SEE PAGE 103 TUBE ASSY, RIGHT WHEEL MOTOR, REAR PORT 1 42033-8044 FITTING, 45° 4 26510-0525 WHEEL MOTOR 2 26735-102

6 WOODRUFF KEY 2 26735-0887 OUTPUT SHAFT 2 26737-086

NS WHEEL MOTOR SEAL KIT (NOT SHOWN) 2 26735-0878 TRACK 2 29510-4019 DRIVE HUB 2 30106-80310 COTTER PIN 2 21126-02211 SPROCKET 2 30109-80312 FLAT WASHER 12 21161-11613 BOLT 12 22425-25514 CASTLE NUT 2 22531-36115 MID-WHEEL “SPOOL” ASSEMBLY 6 SEE PAGE 1116 BOLT 2 21619-10317 WASHER 2 21161-00818 WASHER, LOCK 2 21171-14019 WASHER, LOCK 8 21171-14320 TUBE ASSY, LEFT WHEEL MOTOR, FRONT PORT 1 40071-80321 TUBE ASSY, LEFT WHEEL MOTOR, REAR PORT 1 26598-80322 TUBE ASSY, RIGHT WHEEL MOTOR, FRONT PORT 1 42034-80423 TUBE ASSY, RIGHT WHEEL MOTOR, REAR PORT 1 42033-804

Travel Drive Group

10

12

34

510

78

14 138

7 12

1110

9

15

6

Idler Wheel and Spring Assembly


1 TENSION LOCK PLATE 1 30010-8032 JACKING BOLT WELDMENT 1 40057-8013 SPRING TENSIONER WELDMENT 1 40007-8034 SPRING 1 24741-1905 TRACK FORK WELDMENT 1 40055-8016 WHEEL ASSEMBLY 1 40070-803

7 BEARING 2 29510-4278 IDLER SPACER TUBE 2 30017-8039 IDLER PIN 1 40018-803

10 SEAL 2 29510-43111 SNAP RING 1 24125-00812 FRONT IDLER WHEEL 1 29510-40413 LOCK WASHER 1 21171-14314 BOLT 1 21612-61115 FLAT WASHER 1 32217-901

11

23

45

67

8

65

432

1

Mid Wheel Assembly


1 MID-WHEEL ASSEMBLY (INCLUDES #’S 4 - 8) 1 40010-803

2 NUT 2 21733-4103 WASHER 2 21161-1164 SEAL 2 29510-4285 SNAP RING 1 29510-4296 BEARING 1 29510-4307 MIDWHEEL 1 30102-8038 MIDWHEEL AXLE 1 30029-803

12

456

737

3435

36

30

31

228

29 8

1

2

33

91011 4

1213

1415

16

11

1817

19

20

21

22

2325

24

2726

38

3

Main Control Valve

13

Main Control Valve


1 CONTROL KNOB 2 29341-4622 BOOM/BUCKET CONTROL LEVER 3 30097-8033 STRAIGHT FITTING 4 26510-2084 STRAIGHT FITTING 5 26510-2095 TUBE, COUNTERBALANCE TO CONTROL VALVE 1 40029-8036 90 DEGREE FITTING 1 26510-1097 TUBE ASSEMBLY, LEFT HAND DRIVE MOTOR, FRONT PORT 1 40071-8038 TUBE ASSEMBLY, LEFT HAND DRIVE MOTOR, REAR PORT 1 26598-8039 CARTRIDGE VALVE 1 26633-366

10 COUNTERBALANCE VALVE 1 26633-22111 LIFT CYLINDER HOSE ASSEMBLY 4 26596-20112 TUBE ASSEMBLY, RIGHT HAND DRIVE MOTOR, FRONT PORT 1 42034-80413 TUBE ASSEMBLY, RIGHT HAND DRIVE MOTOR, REAR PORT 1 42033-80414 TUBE, COUNTERBALANCE TO AUX VALVE 1 40030-80315 90 DEGREE FITTING 1 26510-10816 TUBE 40073-80317 TEST PORT 1 26538-42518 TEST PORT DUST CAP 1 26538-41619 STRAIGHT FITTING 1 26510-20720 TEE FITTING 1 26510-33521 CARTRIDGE 1 26661-25822 NYLOCK NUT 2 21733-45723 STRAIGHT FITTING 2 26510-20924 TUBE, DIVERTER TO AUX VALVE 1 40028-80325 DIVERTER VALVE 1 26629-15326 90 DEGREE FITTING 1 26510-10727 STRAIGHT FITTING 1 26510-20728 BOLT 2 21619-06229 UNION FITTING 1 26512-50530 CONTROL VALVE ASSEMBLY 1 26661-20631 KNOB 1 29341-49732 CONTROL LEVER 2 30098-80333 NUT - M8 X 1.25 4 21731-70834 NUT - M10 X 1.5 ZC 4 21731-71035 ROUND LEVER SHAFT 2 30098-80336 TRAVEL CONTROL HANDLE, CAST 2 29341-49837 STRAIGHT FITTING 1 25843-01638 TUBE 1 26598-802

14

1

23

4

5

6

15

14

13

1211

10

9 7

13

8

Auxiliary Valve Group


1 TEXTURED GRIP 1 29341-4632 LEVER 1 30101-8033 BOLT 3 21619-0624 FLAT WASHER 3 21161-0085 FITTING, SAE MALE 90 1 26531-1446 CLAMP 1 26516-4107 HOSE, TO HYDRAULIC COOLER 1 18510-5568 VALVE 1 26629-1559 RELIEF VALVE CARTRIDGE 1 26661-20910 NYLOCK NUT 3 21733-45711 FITTING, SAE 1 26510-20912 TUBE ASSY, AUX TO COUNTERBALANCE 1 40030-80313 HOSE 2 26265-07614 FITTING, SAE MALE 90 1 26510-10715 FITTING, SAE MALE STR 2 26510-206

15


16

1

23

4

7

5

6

910

1112

1514

1316

1718

192021

22

23

24

272622

25

828

Rear Frame Group

17

Rear Frame Group


1 WING NUT 2 21713-2122 TRACK TENSION WRENCH 1 30051-8033 RUBBER GROMMET 2 24721-3794 HAND GRIP 2 29341-4645 BOLT 4 21619-0566 LOWER SERVICE ACCESS PANEL 1 40032-8037 UPPER CONTROL PANEL 1 40021-8038 ACCESS PANEL LOCK 2 29341-495

NS KEY, ACCESS PANEL LOCK 2 29341-4369 RUBBER MATT 1 32234-901

10 COMPRESSION SPRING 2 24741-18811 SELF LOCKING NUT 2 21733-46112 ROUND BUSHING 2 30033-80313 OPERATOR PLATFORM 1 40022-80314 WASHER 4 21161-51615 BOLT 2 21619-35816 ENGINE OIL FILTER 1 29295-04517 BOLT 2 21619-05518 WASHER 2 21171-13719 BELT GUARD 1 40065-80320 SELF LOCKING NUT 2 21733-40721 ENGINE BELT 1 29295-07622 AIR FILTER HOUSING 1 29295-13623 OUTER AIR FILTER ELEMENT 1 29135-77124 INNER AIR FILTER ELEMENT 1 29135-77225 BONNET 1 29321-40626 CLAMP 1 29295-11127 MANUAL HOLDER 1 39234-21028 THROTTLE ASSEMBLY 1 24731-003NS AIR FILTER CONNECTION HOSE 1 32236-901

18

234

5

6

7

9

58

7

6

13

14151656

5

6

7

91718

7

19

10

11

12

1

Hydraulic Cooler Group

19

Hydraulic Cooler Group


1 HYDRAULIC COOLER ASSEMBLY 1 26844-1312 BOLT 4 21625-7313 FLAT WASHER 4 21171-0374 FAN 1 26844-132

5 O-RING - #12 4 26511-9126 FITTING 4 26531-146

7 CLAMP 4 26516-4108 HOSE - AUX VALVE TO COOLER INLET 1 18510-5569 HOSE - COOLER OUTLET TO FILTER INLET 1 18510-553

10 HYDRAULIC TANK CLEAN OUT COVER 1 26849-40211 COVER GASKET 1 26849-44012 CERAMIC MAGNET (in hydraulic tank) 1 26849-17213 HYDRAULIC OIL DIPSTICK 1 40088-80314 BOLT 2 21619-05315 FLAT WASHER 2 21161-06216 FILTER ASSEMBLY MOUNTING BRACKET 1 30141-80317 REPLACEMENT SPIN ON FILTER ELEMENT 1 26838-11418 HOSE - FILTER OUTLET TO TANK INLET 1 18510-55319 HYDRAULIC FILTER HEAD 1 26838-113

20

Muffler Parts Group

32456

7

58

9

16

19

10

22 25

26

11

14

17

21

12

13

182728

2324

2120

20

21

15

21

Muffler Parts Group


1 NUT 2 21733-3032 LOCK WASHER 5 21161-0113 BOLT 1 21625-7164 FLAT WASHER 1 21171-1395 EXHAUST MANIFOLD GASKET 2 29135-2216 NUT (FLEX EXHAUST TO MANIFOLD) 4 21733-0057 EXHAUST FLEX JOINT 1 29295-0298 MUFFLER MOUNTING BRACKET 1 40064-8039 FLAT WASHER 2 21161-008

10 BOLT 2 21619-10511 NUT 4 21733-30512 MUFFLER ASSEMBLY 1 29211-053

13 BOLT 2 21612-03014 LOCK WASHER 2 21171-18915 UPPER HEAT SHIELD 1 29211-04516 BOLT 4 21619-05517 LOWER HEAT SHIELD 1 29211-04618 NUT 2 21731-30919 MUFFLER 1 29211-04420 LOCK WASHER 4 21171-18921 BOLT 4 21612-02922 MUFFLER HEAT SHIELD 1 29211-04723 LOCK WASHER 1 21171-40824 NUT 1 21731-03525 EXHAUST TIP 1 29211-04826 EXHAUST PIPE CLAMP 1 29211-05227 FLAT WASHER 2 21161-11028 BOLT 1 21620-061

22

23

4ENGINE FLYWHEEL 6

78

9 10

5 15 16 17

1

14 16

TO TANK

1311

18 19(To Bottom of Invertor Valve)

12(To Top of Invertor Valve)

Hydraulic Pump Group

23

Hydraulic Pump Group


1 PUMP DRIVE MOUNTING KIT 1 29295-0322 MOUNTING FLANGE 1 29211-0533 CAP SCREWS (PUMP MOUNT FASTENER KIT) 10 29211-0544 PUMP DRIVE HOUSING 1 29211-0555 FLAT WASHER 2 21171-1406 BOLT (PUMP MOUNT FASTENER KIT) 2 21625-106

7 PUMP DRIVE HUB 1 29295-1128 HYDRAULIC PUMP 1 26711-0559 LOCK WASHER 4 21171-14010 BOLT 2 21625-10611 TUBING - PUMP TO HIGH-LOW SPEED CONTROL 1 26598-80212 TUBING - PUMP TO HIGH-LOW SPEED CONTROL 1 26598-80113 O-RING, #10 2 26511-910

14 O-RING, #12 1 26511-91215 90° FITTING 1 26531-14516 CLAMP 2 26516-41017 SUCTION HOSE 1 18510-57318 FITTING 1 26510-21319 FITTING 1 26510-211

24

56

8 9

4

23

1

1

7

Battery Parts Group


1 HOLDOWN CLAMP 2 29315-302

2 FLAT WASHER 2 21161-0073 NUT, WING 2 21713-1154 BATTERY 1 29315-2655 POSITIVE BATTERY CABLE 1 47006-8036 CORRUGATED FABRIC LOOM 1 32243-9017 TERMINAL INSULATOR, RED 1 29315-3098 BATTERY TERMINAL INSULATOR, RED 1 29315-0479 NEGATIVE BATTERY CABLE 1 47007-803

NS POWER CABLE 1 47004-803

25


26

Diesel Fuel Group

21

20

19

8

1

9

13

15

1011

12

12

13

12

23 4

5

67

14

16 17

18

27

Diesel Fuel Group


1 FUEL TANK CAP/FUEL GAUGE 1 26849-1732 FLAT WASHER 2 21161-0083 LOCK WASHER 2 21171-1394 BOLT 2 21619-0535 BUSHED ELBOW 1 25978-1796 FUEL RETURN LINE 1 32249-901

7 FUEL RETURN LINE GROMMET 1 39236-4418 FUEL TANK 1 32244-9019 90° FITTING 1 26531-132

10 RUBBER GROMMET 1 24721-38911 FUEL LINE 1 32251-90112 CLAMP 4 26516-23013 FUEL LINE 1 32251-901

14 CLAMP 1 26516-23515 BOLT 1 21619-06216 WASHER 1 21161-00717 NUT 1 21733-45718 FUEL FILTER/WATER SEPARATOR ASSEMBLY 1 29211-056

19 FUEL FILTER/WATER SEPARATOR BODY 1 29211-04920 FUEL FILTER 1 29295-00321 FUEL FILTER BOWL 1 29211-050

28

3

1

3

3

25

15

1

13

2 3

4

56

11

7

8

910

12

13

Electrical Components Group

29

Electrical Components Group


1 WARNING LIGHT ASSEMBLY 1 29295-0812 IGNITION SWITCH W/KEYS 1 29211-9353 SCREW 2 22341-4064 IGNITION KEY 1 29211-9295 HOUR METER 1 29316-9626 IGNITION SWITCH/HOUR METER MOUNTING PLATE 1 30110-8037 WARNING SOUNDER 1 29295-1058 50A RELAY 1 29295-0229 30 AMP FUSE 1 27311-91310 15 AMP FUSE 1 27311-91011 1 AMP FUSE 1 27311-90312 3 AMP FUSE 3 27311-90513 ENGINE WIRING HARNESS 1 29295-033

30

Engine Cooling Group

TO WATERPUMP

TO BOTT OMOF RADIA TO R

TO P O FENGINE

TO P O FRADIA TO R

1

2

3

45

6

7

9

8

10

11

9

9

12

9

13

14 99

16

1819

2021

15

17

31

Engine Cooling Group


1 BOLT 2 21619-1052 FLAT WASHER 2 21161-0083 FRONT SHROUD 1 40056-8034 FLAT WASHER 6 21161-0115 BOLT 6 21619-1056 RADIATOR CAP 1 29326-929

7 OVERFLOW TANK HOSE 1 32301-9018 OVERFLOW TANK 1 29326-9289 HOSE CLAMP 6 26516-003

10 PROTECTIVE COVER 1 18763-01411 UPPER RADIATOR HOSE 1 32242-90112 RADIATOR HOSE - WATER PUMP TO TUBE 1 32240-90113 RADIATOR TUBE 1 32126-804

14 LOWER RADIATOR HOSE 1 32241-90115 RADIATOR 1 29326-90116 LOCK WASHER 4 21171-13917 FLAT WASHER 4 21161-00818 BOLT 4 21619-05519 ELECTRIC FAN 1 29326-93020 FLAT WASHER 4 21161-00721 BOLT 4 21459-136

32

Motor Mounting Group

11

1

23

45

6

7

8

9

10

33

Motor Mounting Group


1 BOLT 12 21612-7532 FLAT WASHER 12 21171-1403 LEFT HAND MOUNTING PLATE 1 30137-8034 BOLT 2 21619-1055 FLAT WASHER 2 21171-1406 HYDRAULIC PUMP 1 26711-0557 BELL HOUSING ADAPTER ASSEMBLY 1 29295-0328 RIGHT HAND MOUNTING PLATE 1 30136-8039 ENGINE OIL FILTER 1 29295-04510 ENGINE HEAT SENSOR 1 2393531.00511 BELT GUARD 1 40065-803

34

Hydraulic SchematicC

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NTE

RB

ALA

NC

EVA

LVE

CO

NTR

OL

VALV

E

LEFT

WH

EEL

MO

TOR

RIG

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TILT

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35

Electrical Schematic

5/8

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3 IN

1/4

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5 IN

1/8

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x 4

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1/4

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25

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29

32

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35

75

70

69

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8081

5466

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14 AWG BRN14 AWG BRN

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16 AWG BLK/WHT -Q-

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47016-803

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 - morbark, llc routine maintenance replacement parts the following parts...

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