Morbark BOXER 532DX User manual

Serial No.s 3612 and Higher
Part No. 76347-295
Manufactured by:
532DX Operator’s Manual
Phone: Morbark®, Inc.
Sales - 800-831-0042 8507 S. Winn. Rd., P.O. Box 1000,
Parts and Service - 800-255-8839 Winn, Michigan 48896
www.boxerequipment.com www.morbark.com
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.
Record Numbers Here
DA
SERIAL NO.
39510-154
XXXX
00-00-0000
®
39510-156
532
2680 1215.6
32 24.4

III
Boxer Product Warranty
Morbark, Inc. (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.

IV
Morbark, Inc.
8507 South Winn Road, 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 start-
up 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.
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

V
Boxer Warranty Registration
Dear Customer,
Morbark, Inc., 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, Inc., 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, Inc., 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, Inc.
P.O. Box 1000
8507 S. Winn Road.
Winn, MI 48896-1000
E-mail:[email protected]
Fax: [phone]
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:__________________

VI
Morbark, Inc.
8507 South Winn Road
P.O. Box 1000
Winn, MI 48896
Afx
Stamp
Here

VII
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

VIII

IX
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
Left Front View...................................................................................2–1
Right Rear View.................................................................................2–2
Safety Decals.....................................................................................2–3
Operating Controls.............................................................................2–5
Operating Controls Description..........................................................2–6
Section 3 – Pre-Start Inspection and Operation.........................................3–1
Pre-Start Inspection..................................................................................3–1
Daily Service Checks................................................................................3–1
Cylinder Lock Installation..........................................................................3–9
Cylinder Lock Removal......................................................................3–9
Operating Instructions.............................................................................3–10
Machine Start-up .............................................................................3–10
Machine Shut-down ......................................................................... 3–11
Transportation..................................................................................3–12
Lifting Procedures............................................................................3–13
Machine Travel Controls.........................................................................3–14
Attachment Installation and Removal .....................................................3–18
Attachment Lock Pins ......................................................................3–18
Installation of Non-Hydraulically Powered Attachments ..................3–19
Removal of Attachment....................................................................3–21
Installation of Hydraulically Powered Attachments ..........................3–21
Operating Instructions for a Hydraulic Attachment ..........................3–26
Travel Crawl Control ........................................................................3–27
Removal of Hydraulically Powered Attachments .............................3–29

X
Section 4 – Routine Service and Maintenance ...........................................4–1
Daily Maintenance Procedures.................................................................4–2
New Machine Brake-in Maintenance Procedures ..................................4–14
Weekly Maintenance Procedures...........................................................4–15
Monthly Maintenance Procedures ..........................................................4–16
Annual Maintenance Procedures ...........................................................4–20
General Maintenance .............................................................................4–22
Draining Fuel Tank (Diesel)..............................................................4–22
Fuse Panel.......................................................................................4–24
Track and Tension System Installation ............................................4–26
Section 5 – Troubleshooting ........................................................................5–1
Section 6 – General Specications..............................................................6–1
Vibration Data ................................................................................................6–2
Noise Data......................................................................................................6–2

1.1
Section 1 - Safety Precautions
Since Morbark Inc. 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. 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 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-offs
- 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 circumstances.
- 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 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 off your skin and clothing.
- Since “wet cell” batteries give off 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. NOTE: 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 off. 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 system, loosen the filler cap slowly to allow any pressure in the hydraulic tank
to be reduced. 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 tank, 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.
Diesel Engines:
• Shut the engine off 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 fuel 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

2.1
Section 2 - Operating Controls
Component Locations
Left Front View
Item No. Description
1 Attachment mounting plate
2 Tilt cylinder
3 Boom
4 Auxiliary hydraulic quick connects
5 Hand grip
6 Operating controls
7 Manual holder
8Fuel ller cap
9 Lift cylinder
10 Fuel tank
11 Right track assembly
12 Lift cylinder safety lock
13 Hydraulic level check
7
1
2
3
4
5
6
8
9
10
11 13
12

Operating Controls
2.2
Right Rear View
Item No. Description
1 Attachment mounting plate
2 Attachment hydraulic quick connects
3 Right track assembly
4 Operator’s platform
5 Air cleaner assembly
6 Fuel tank
7Fuel ller cap
8 Engine hour meter
9 Loader arm lift cylinder
10 Loader arms
11 Tilt cylinder
1
11
2
10
2
9
8
7
6
5
4
3