BOXER 600HD, Operator'S Manual

Page 1: ...ufactured by 600HD 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 B I G P...

Page 2: ...ng 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...

Page 3: ...S EXCLUSIVE REMEDY The exclusive remedy of the purchaser in the event the product does not conform to this Warranty shall be repair or replacement of the product at the option of Morbark without charg...

Page 4: ...on the programs offered by the engine supplier Wear Items including but not limited to such items as lubricants anti freeze fluids filters belts bearings hoses and fittings etc Manufacturer s limited...

Page 5: ...rt date in service date and not returning this form may result in denial of warranty entitlements To restart the equipment in service date simply complete the form below and mail e mail or fax the com...

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

Page 7: ...ons 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 D...

Page 8: ...Controls 2 3 Machine Decals Front View 2 4 Machine Decals Rear View 2 5 Operating Controls Description 2 6 Section 3 Pre Start Inspection and Operation 3 1 Pre Start Inspection 3 1 Daily Service Chec...

Page 9: ...e Procedures 4 13 Weekly Maintenance Procedures 4 16 Monthly Maintenance Procedures 4 19 Fuel System Air Bleeding Procedures 4 22 Annual Maintenance Procedures 4 23 General Maintenance 4 27 Draining F...

Page 10: ...ob 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 attachm...

Page 11: ...er the work area stop machine operation until the work area is clear Prior to unloading the unit and starting to work inspect the path you will travel and work site area for potential hazards Some of...

Page 12: ...suming 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...

Page 13: ...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 su...

Page 14: ...able causing fire or an explosion If electrolyte is splashed into your eyes flush them immediately with clean water and seek medical attention If electrolyte is swallowed seek medical attention immedi...

Page 15: ...and remove the cap gradually WARNING Boxer Brush Sweeper Attachment Silica Dust Caution An OSHA ruling has established new permissible exposure limits PEL for occupa tional exposure to respriable crys...

Page 16: ...HE MACHINE BEFORE BEGINNING THE FUELING PROCESS KEEP THE FUEL NOZZLE IN CONSTANT CONTACT WITH THE RIM OF THE MACHINES FUEL TANK WHEN FILLING A PORTABLE GAS CONTAINER ALWAYS PLACE IT ON THE GROUND NEVE...

Page 17: ...iew Item No Description 1 Attachment mounting plate 2 Loader arms 3 Boom lift cylinder 4 Hydraulic cooler 5 Document holder 6 Engine radiator 7 Ignition switch and hour meter 8 Front tie down ring 9 R...

Page 18: ...Description 1 Attachment mounting plate 2 Operating controls 3 Left track assembly 4 Operator s Platform 5 Lift point 6 Radiator 7 Fuel Tank 8 Fuel filler cap fuel gauge 9 Loader arms 10 Attachment h...

Page 19: ...Controls Item No Description 1 High Low selector control 2 Attachment loader arm lift control joystick 3 Drive control joystick 4 Engine throttle 5 Engine temperature indicator light 6 Engine oil pres...

Page 20: ...escription 1 Crush hazard decal 2 Model number decal 3 Danger zone decal 4 Burn hazard decal 5 Battery explosion hazard decal 6 Boxer decal 7 Front tie down location decal 8 Rear tie down location dec...

Page 21: ...ing 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...

Page 22: ...cket Move the joystick right to lower the bucket 5 Drive Control Joystick Move the joystick to put the machine in motion Follow the decal to the left of the joystick to move the machine in the directi...

Page 23: ...Operating Controls 2 7...

Page 24: ...tart 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 C...

Page 25: ...iator 3 Air Filter 3 Fuel Filter Water Separator 3 Engine Idle Speed Check and Clean Battery Terminals and Battery Hydraulics Hydraulic Filter Hydraulic Fluid Level Hydraulic Hoses 3 3 and A 3 Grease...

Page 26: ...ck oil level The correct level is between those two lines Figure3 1 Engine Oil Level Check If the engine oil level is below the bottom line carefully add the proper amount of oil through the engine oi...

Page 27: ...again Make sure to securely reinstall the dipstick into the dipstick tube before starting the engine Check engine fuel and fill as needed be sure engine is OFF 3 The Boxer has one saddle fuel tank Ite...

Page 28: ...pressure DO NOT check until the engine radiator is cool to the touch When the radiator is cool to the touch remove the radiator cap Item 1 Figure 3 4 and check the radiator fluid level The proper coo...

Page 29: ...ion fan which draws air from inside the machine Check the engine side of the radiator Item 1 Figure 3 5 to make sure that debris has not been sucked against the radiator blocking air flow DO NOT check...

Page 30: ...and Local regulations If water needs to be removed If the fuel bowl does not fill with fuel it may be necessary to air bleed the fuel system See Section 4 Fuel System Air Bleed instructions 1 2 CAUTI...

Page 31: ...tector DO NOT USE YOUR BARE HANDS If you are injected with hydraulic oil or any other fluids immediately seek treatment by a doctor trained in the treatment of penetrating fluid injuries Visually insp...

Page 32: ...rming any service work underneath the raised loader arm assembly 12 Grease pivot shafts with proper type of grease There are 13 grease points on this machine see Figure 3 9 Before starting the engine...

Page 33: ...Pre Start Inspection and Operation 3 10 Figure 3 9Lubrication Points NOTE Extremely dusty or dirty working conditions may require more frequent service replacement...

Page 34: ...nto the cylinder rod 6 Fully reinsert the safety lock pin Item 4 Figure 3 10 securing the cylinder lock in the support position Make sure that the safety lock pin goes behind the loader arm cylinder r...

Page 35: ...t and idle engine speeds 3 Rotate the ignition key counterclockwise to the PREHEAT position Item 3 Figure 3 12 to allow the glo plugs to warm the engine cylinders for approximately 10 seconds The Low...

Page 36: ...ine off 5 Leave the throttle setting at about the halfway position and allow the engine to idle This will begin warming the engine coolant and hydraulic oil When warming the hydraulic oil the operator...

Page 37: ...osition on Trailer 3 When the machine is positioned on the trailer properly lower the attachment to the trailer deck 4 Shut the engine off and remove the key 5 Secure the unit to the transport vehicle...

Page 38: ...4 Figure 3 14 Figure 3 14Travel 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 lift...

Page 39: ...using 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 The cogging condition...

Page 40: ...3 17 Figure 3 17 Reverse Travel Right Turn During Forward Travel Left Turn During Forward Travel To turn to the right move the left joystick forward and slightly to the right The farther forward and s...

Page 41: ...the left joystick backwards and slightly to the left The farther backwards and slightly to the left the left joystick is moved the faster the left turn will be made See Figure 3 21 Figure 3 21 Left H...

Page 42: ...r the machine Keep attachments as low as possible when traveling on slopes or rough terrain Figure 3 23 Slide Slope Travel Keep the heavy end of the machine towards the uphill direction when traveling...

Page 43: ...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...

Page 44: ...hment 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 NOTE Make sure tha...

Page 45: ...ure 3 28 Attachment Installed 5 Shut the engine off 6 Rotate the attachment lock pins Item 1 Figure 3 28 and Item 1 Figure 3 29 into the locked position securing the attachment to the machine Figure 3...

Page 46: ...Rotate the attachment lock pins to the UNLOCKED position Item 1 Figure 3 30 Figure 3 30 Attachment Locks in Unlocked Position 4 Start the engine and rotate the mounting plate downwards 5 Back away fr...

Page 47: ...arm and tilt the mounting plate forwards NOTE Make sure that both of the attachment lock pins Item 1 Figure 3 31 are in the unlocked position Figure 3 31 Attachment Locks in Unlocked Position 3 Slowl...

Page 48: ...e attachment lock pins Item 1 Figure 3 33 Item 1 Figure 3 34 into the locked position securing the attachment to the machine Figure 3 34 Attachment Locks in Locked Position 8 Start the engine and rais...

Page 49: ...his will release the hydraulic pressure locked in the auxiliary hydraulic lines Figure 3 35 Auxiliary Control Lever b Remove the protective covers Items 3 Figure 3 36 from the attachment quick connect...

Page 50: ...at the quick connects are seated properly 12 Make sure that the hydraulic hoses are routed so that they will not be in the way or damaged during machine operation Figure 3 37 shows how the hoses might...

Page 51: ...d of the attachment as well as machine travel speed Figure 3 38 Auxiliary Attachment Controls Make sure that you are standing on the operator s platform and holding the Attachment Control Joystick in...

Page 52: ...the machine to move Stop all machine travel before releasing the joystick 5 When using a trencher tiller or other attachment that requires the machine to move while the attachment is in operation mov...

Page 53: ...Item 1 Figure 3 39 to align the notch on the collar with the lock button Item 2 Figure 3 39 4 Slide the collar backwards on the female quick connect Item 4 Figure 3 39 until it stops against the lock...

Page 54: ...nd A C Engine Radiator 3 Air Filter 3 R R Fuel Filter Water Separator 3 3 R Engine Idle Speed 3 Check and Clean Battery Terminals and Battery 3 3 Hydraulics Hydraulic Filter R Hydraulic Fluid Level 3...

Page 55: ...cause fuel could spill onto hot engine parts and ignite or explode Make sure engine is turned off 2 Check engine fuel and fill as needed a The Boxer has one saddle tank Item 1 Figure 4 1 on the left s...

Page 56: ...vel Check c If the engine oil level is below the add line carefully add the proper amount of oil through the engine oil filler Item 1 Figure 4 3 The oil fill port is remotely located adjacent to the b...

Page 57: ...that is only for any high heat overflow Do not add coolant to this container It will not be drawn into the engine If coolant is required make sure to add the proper coolant as shown in the Engine Man...

Page 58: ...Maintenance 4 5 Figure 4 5 Radiator Air Flow Inspection 6 Check the fuel filter water separator to make sure that there is no water in the filter bowl Item 1 Figure 4 6 Figure 4 6 Engine Fuel Filter W...

Page 59: ...he filter assembly to catch any spilled fuel 3 Rotate the filter bowl Item 1 Figure 4 6 and remove it from the filter assembly 4 Dispose of the fuel and water in the bowl according to State and Local...

Page 60: ...ng temperature fill as needed with the proper hydraulic oil be sure engine is OFF a Unscrew the dipstick assembly and remove from the machine Item 1 Figure 4 8 b Make sure that the hydraulic fluid is...

Page 61: ...lve to their end Items 1 2 4 5 and 6 Figure 4 9 Inspect the connections and look for signs of leaking hydraulic fluid wear or damage g Carefully inspect both sets of quick couples Item 2 Figure 4 9 to...

Page 62: ...Routine Service and Maintenance 4 9 Figure 4 9 Inspect Hydraulic Lines and Fittings 1 1 2 3 4 6 5...

Page 63: ...ce capable of safely supporting4 000 lbs See Figure 4 11 or suggested location of the support devices b Tilt the bucket downwards until the cutting edge is touching the ground See Figure 4 11 c Lower...

Page 64: ...1 Track Def lection Measurement and Adjustment e Remove track tension lock plate bolt Item 1 Figure 4 12 using a 9 16 wrench f Remove the adjustment bolt lock plate Item 2 Figure 4 12 Figure 4 12 Trac...

Page 65: ...ure 4 13 securing the track adjusting wrench to the service access cover and then remove the wrench Figure 4 13 Track Adjustment Bolt Lock Plate h With the tracks still off the ground start the engine...

Page 66: ...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 Make sure to dispose of...

Page 67: ...mount of hydraulic oil lubricate the rubber gasket on top of the new filter canister and install the filter onto the filter mount Figure 4 15 Hydraulic Oil Filter Do not over fill the hydraulic system...

Page 68: ...c oil level dip stick Item 1 Figure 4 16 check the hydraulic oil level Add the appropriate hydraulic fluid as needed through the filler port Item 2 Figure 4 16 on top of the hydraulic oil tank Make su...

Page 69: ...ions Items 5 and 6 Figure 4 17 for signs of leaking corrosion or damage Make sure that the battery clamp Item 3 Figure 4 17 is securely holding the battery in position If needed tighten the lock nut I...

Page 70: ...re 4 18 Figure 4 18 Remove Protective Screen b Using compressed air or a garden hose Item 1 Figure 4 19 spray air water through the engine radiator from the outside to remove any built up dirt or debr...

Page 71: ...Routine Service and Maintenance 4 18 Figure 4 19 Clean Engine Radiator c Reinstall and secure the protective screen 1...

Page 72: ...ever 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...

Page 73: ...AS 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 PERF...

Page 74: ...ny spilled fuel c Rotate the filter bowl Item 3 Figure 4 21 and remove it from the filter assembly d Dispose of the fuel and water in the bowl according to State and Local regulations e Remove the pap...

Page 75: ...is a NEGATIVE ground system Figure 4 22 Battery and Tie Downs 5 4 1 2 3 6 Fuel System Air Bleeding Procedure 1 Loosen the air bleed bolt Item 1 Figure 4 23 DO NOT remove this bolt 2 Crank the engine u...

Page 76: ...g if any signs of damage are noted Extremely dusty or dirty working conditions may require more frequent service replacement Figure 4 24 Hydraulic Tank Drain Plug c When all of the hydraulic fluid has...

Page 77: ...ure 4 25 and fill the hydraulic tank with the proper hydraulic fluid Chevron Rykon Premium ISO 46 or equivalent until the fluid level is just below the upper marker hole in the dipstick Figure 4 25 Hy...

Page 78: ...touch a Remove the protective screen Item 1 Figure 4 26 from over the engine radiator and hydraulic radiator b Position a container of suitable size under the front of the machine c Remove the radiato...

Page 79: ...50 mix of radiator coolant and water according to the specifications in the Engine Manual Make sure to fill the radiator only to the bottom of filler neck Item 1 Figure 4 27 Figure 4 27 Radiator Fill...

Page 80: ...fuel line 6 Loosen spring clamp Item 3 Figure 4 28 on the incoming fuel line Item 4 Figure 4 28 and slide the clamp along the fuel line away from the filter assembly 7 Place a suitable sized container...

Page 81: ...intenance 4 28 Figure 4 28 Fuel Line to Fuel Filter Water Separator 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...

Page 82: ...stalled 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 connection...

Page 83: ...system Drain fuel in tank into an appropriate storage container and dispose of bad fuel properly Refill fuel tank with fresh clean fuel Empty fuel water separator bowl Replace fuel filter 15 Amp fuse...

Page 84: ...r cap Contact Service Dealer Abnormal engine vibration Engine mounting bolts are loose Tighten engine mounting bolts With the engine turned off the boom creeps down ward more then 3 per hour less than...

Page 85: ...lace rubber track Track guide fingers worn damaged or missing Replace rubber track Starter does not turn the engine over Auxiliary hydraulics Operator presence lever is either in Forward or Reverse po...

Page 86: ...ader Arms Three position spring centered lever control Up neutral down Bucket Attachment Tilt Three position spring centered lever control Ex tend neutral and curl Auxiliary Attachment Control Two pos...

Page 87: ...Engine rpm was set 3 000 rpm The hand arm and whole body vibration measurements were made with the operator present Vibration Test hand arm Declared value is 5 1 m s2 Vibration Test whole body Declar...

Page 88: ...the slope of the hill 16 THIS IS A 15 DEGRE E SLOPE DO NOT TRAVEL ACROSS OR UP AND DOWN A SLOPE GREATER THAN 15 DEGREES To avoid serious injury operate your unit up and down the face of slopes Travel...

Page 89: ...Manufactured by BIG POWER IN ALL PLACES 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...