Rayco BOXER 385D CE User manual

RAYCO MANUFACTURING LLC © 2021 ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSM385DCE-21
BOXER 385D CE
COMPACT TOOL CARRIER
OPERATOR · SERVICE · MAINTENANCE · MANUAL
BOXEREQUIPMENT.COM

Boxer 385D Operator Service Maintenance Manual
2
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.
Serial Number Location
Serial Number Location & Information
m
b
b

Boxer 385D Operator Service Maintenance Manual
800.392.2686 3
BOXER 385DCE
385DCE0010121
43028
1920/947(kg)
2021
24.8HP (18.49kw)
TRACK LOADER
Track Loader =Type of Rayco Equipment 001= The three digit number of produced
Production Date; 01=2 digit month; 20= 2 digit year
Boxer 385DCE =Model of Rayco Equipment
Identification Numbers
Model Number Serial Number
Machine
Engine
Implement
Implement
Dealer Information
Name
Address
Dealer Contact Phone Number Hours
Sales
Parts
Service
Serial Number Location & Information
Always have a record of the model numbers and serial numbers for your machine to
specify when ordering parts. Record your machine model and serial numbers below
for your personal records.

Boxer 385D Operator Service Maintenance Manual
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Boxer 385D Operator Service Maintenance Manual
800.392.2686 5
Table of Contents
TABLE OF CONTENTS
Safety 6-24
Decals and Location 26-29
Foreword 30-31
Operator Controls 32-34
Range of Motion 35
Item Description 36-37
Pre-Operation 38-46
Operation 47-63
Fluid and Torque Specifications 64-68
Maintenance 69-85
Storage and Recommission 86-87
Troubleshoot 88-91
Machine Specifications 92-93
Schematics 94-99
Common Wear Parts 100
Index 102
Warranty 103-105

Boxer 385D Operator Service Maintenance Manual
6
Certified Engine Maintenance
Proper maintenance and repair is essential
to keep the engine and machine systems
operating correctly. As the heavy duty
off-road engine owner, you are responsible
for the required maintenance listed in the
Engine OwnerManual &Machine Operator,
Maintenance & Service Manual.
Attach a “Do Not Operate” warning tag
or a similar warning tag to the start switch
or to the controls before you service
the equipment or before you repair the
equipment.
Know the width of your equipment in order
to maintain proper clearance with you
operate the equipment near fences or near
boundary obstacles.
Be aware of high voltage power lines
and power cables that are buried. If the
machine comes in contact with these
hazards, serious injury or death may occur
from electrocution.
Wear a hard hat, protective glasses, and
other protective equipment, as required.
Do not wear loose clothing or jewelry that
can snag on controls or on other parts of
the equipment.
Make sure that all protective guards and
all covers are secured in place on the
equipment.
Keep the equipment free from foreign
material. Remove debris, oil, tools, and
other items from the deck, from walkways,
and from steps.
Secure all loose items such as lunch boxes,
tools, and other items that are not a part
of the equipment.
Know theappropriateworksitehandsignals
and the personnel that are authorized to
give the hand signals. Accept hand signals
from one person only.
Do not smoke when you service an
air conditioner. Also, do not smoke if
refrigerant gas may be present. Inhaling
the fumes that are released from a flame
that contact air conditioner refrigerant can
cause bodily harm or death. Inhaling gas
from air conditioner refrigerant through a
Safety
Breathing Diesel engine exhaust exposes you to chemicals known
to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65Warnings.ca.gov
43036
lighted cigarette can cause bodily harm
or death.
Never put maintenance fluids into glass
containers. Drain all liquids into a suitable
container.
Obey all local regulations for the disposal
of liquids.
Use all cleaning solutions with care. Report
all necessary repairs.
Do not allow unauthorized personnel on
the equipment.

Boxer 385D Operator Service Maintenance Manual
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Important Safety Information
Most accidents that involve product
operation, maintenance and repair are
caused by failure to observe basic safety
rules or precautions. An accident can
often be avoided by recognizing potentially
hazardous situations before an accident
occurs. A person must be alert to potential
hazards. This person should also have
the necessary training, skills and tools to
perform these functions properly.
Improper operation, lubrication,
maintenance or repair of this product can
be dangerous and could result in injury
or death.
Do not operate or perform any lubrication,
maintenance or repair on this product,
until you have read and understood the
operation, lubrication, maintenance and
repair information.
Safety precautions and warnings are
provided in this manual and on the product.
If these hazard warnings are not heeded,
bodily injury or death could occur to you
or to other persons.
The hazards are identified by the “Safety
Alert Symbol” and followed by a “Signal
Word”suchas “DANG E R”,“WARNING”
or “CAUTION”. The Safety Alert
“WARNING” label is shown below..
Safety Warnings
To highlightspecific safety information
the following designations are provided to
assist the reader.
i
Safety
SAFETY INSTRUCTIONS
Safety Instructions (or equivalent)
signs indicate specific safety-related
instructions or procedures.
Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
NOTICE
Is used to adress practices not related
to physical injury.

Boxer 385D Operator Service Maintenance Manual
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A message, either written or pictorial,
follows to explain the hazard. Rayco cannot
anticipate every possible circumstance
that might involve a potential hazard. The
warnings in this publication and on the
product are therefore not all inclusive. If you
desire to make use of a tool, procedure,
work method, or operating technique not
specifically recommended by Rayco, you
must use it only if you have accurately
evaluated it and found that it threatens
no one’s safety. You should also ensure
that the product will not be damaged or
made unsafe by the operation, lubrication,
maintenance, or repair procedures that
you choose.
The procedures described in this “Safety”
section may not be fully explained here,
but a more complete explanation is given
in the “Operation”, or in the “Maintenance”
section.
The information, specifications, and
illustrations in this publication are on the
basis of information that was available at
the time that the publication was written.
The specifications, torques, pressures,
measurements, adjustments, illustrations,
and other items can change at any time.
These changes can affect the service that is
given to the product. Obtain the complete
and most current information before you
start any job. Rayco dealers have the most
current information available.
Rayco Manufacturing, Inc. is greatly
concerned with the safety of the operator,
as well as all in the vicinity of his work.
Rayco has provided shields, guards, safety
decals and other important safety features
to aid in using the machine properly. In
order to further ensure your safety we ask
that you properly operate and service your
machine.
This machine is capable of amputating
hands and feet and throwing objects.
Failure to observe safety instructions,
improper operation, lubrication,
maintenance, or repair of this product
could result in severe injury or death.
Do not operate or perform any lubrication,
maintenance, or repair on this product,
until you have read, you understand, and
you decide to do so in compliance with all
of the operation, lubrication, maintenance,
and troubleshooting information contained
in these Operator and Parts Manuals and
that contained in the Engine Operator
Manual, which are included with this
machine. Additional manuals are available
from Rayco or your Rayco dealer.
When replacement parts are required for
this product Rayco recommends using
Rayco replacement parts or parts with
equivalent specifications including but
not limited to, physical dimensions, type,
strength, and material.
FAILURE TO HEED THIS WARNING
WILL LEAD TO PREMATURE FAIL-
URES, PRODUCT DAMAGE, PERSON-
AL INJURY OR DEATH
Safety

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Safety
General Hazard Information
Read, understand and followall instructions
on the machine and in the manuals before
attempting to operate. Keep all manuals in
a safe place for future reference and for
ordering replacement parts.
Familiarize yourself with all controls in a
safe environment before operation. Know
how to stop the machine and disengage
the controls quickly.
Neverallow minorsto operatethis machine.
Never allow anyonewho has nothad proper
instruction to operate this machine.
Keep bystanders, children and pets away
from the machine and work area.
Never allow anyone to ride on this machine.
Never transport cargo, tools or wood on
this machine.
Keep the operator zone and adjacent area
clear for safe, secure footing.
Use the machine in daylight or under good
artificial lighting.
Use this machine for its intended purpose
only, deviation from the machines
capabilities could damage the equipment
and cause injury or death.
Engine exhaust contains products of
combustion which can be harmful to
your health. Always start and operate the
engine in a well ventilated area. If you are
in an enclosed area, vent the exhaust to
the outside.
Personal Protective Equipment
(PPE)
Head protection must conform to ANSI
Z89.1.
Eye protection mustconform toANSI Z87.1
and be the wrap around style. Always
wear the eye protection when operating
or working within the operational area of
the machine.
Hearing Protection - Plug type ear
protection or full ear coverage devices
(muff type) shall be worn at all times when
operating or within the operational area of
the machine.
Gloves - When operating or handling brush
within the operational area of the machine,
loose fitting gloves are the only gloves that
should be worn. DO NOT wear gauntlet
or strapped gloves.
Clothing Protection- Clothesmustbe close
fitting, but not restrictive of movement. DO
NOT wear loose fitting clothes, jewelry or
long dangling clothing; i.e. neckties, long
belts or chains.
Hooded sweat shirts may be worn only if
the hood is tightly drawn around the face
with drawstrings tucked into the outer
garment when not in use. If working near
traffic, wear reflective clothing.
Shoes - (Foot Protection)- Always over the
ankle work boots with skid resistant soles.
Breathing Protection - When breathing
protection is required the use of paper
masks that can tear away if caught or
entangled in material or machine must
be worn.
Flying Debris
Do not allow anyone to stand in front
or directly behind the machine. Flying
debris could be thrown past guards and

Boxer 385D Operator Service Maintenance Manual
10
injure bystanders if they are in these
areas.
Pressurized Air and Water
Pressurized air and/or water can cause
debris and/or hot water to be blown out.
This could result in personal injury.
When pressurized air and/or pressurized
water is used for cleaning, wear
protective clothing, protective shoes, and
eyeprotection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning
purposes must be reduced to 205 kPa
(30 psi) when the nozzle is deadheaded
and the nozzle is used with an effective
chip deflector and personal protective
equipment. The maximum water pressure
for cleaning purposes must be below
275kPa (40 psi). Pressure can be trapped
in a hydraulic system. Releasing trapped
pressure can cause sudden machine
movement or attachment movement. Use
caution if you disconnect hydraulic lines of
fittings. High pressure oil that is released
can cause a hose to whip. High pressure
oil that is released can cause oil to spray.
Fluid penetration can cause serious injury
and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic
circuit long after the engine has been
stopped. The pressure can causehydraulic
fluid or items such as pipe plugs to escape
rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components
or parts until pressure has been relieved
or personal injury may occur. Do not
disassemble any hydraulic components
or parts until pressure has been relieved
or personal injury may occur. Refer to the
Service Manual for any procedures that are
required to relieve the hydraulic pressure
Always use a board or cardboard when you
check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid
penetration can cause serious injury and
possible death. A pin hole leak can cause
sever injury. If fluid is injected into your skin
you must get treatment immediately. Seek
treatment from a doctor that is familiar with
this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure the
fluids are contained during performance of
inspection, maintenance, testing, adjusting
and repair of the equipment. Prepare to
collect the fluid with suitable containers
before opening any compartment or
disassembling any component that
contains fluids.
Tools that are suitable for collecting fluids
and equipment thatis suitable for collecting
fluids
Tools that are suitable for containing
fluids and equipment that is suitable for
containing fluids
Obey all local regulations for the disposal
of liquids.
Safety

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Safety
Asbestos Information
Rayco recommends the use of only
genuine Rayco replacement parts. Use the
following guidelines when you handle any
replacement parts that contain asbestos or
when you handle asbestos debris.
Use caution. Avoid inhaling dust that
might be generated when you handle
components that contain asbestos fibers.
Inhaling this dust can be hazardous to
your health.
The componentsthat maycontain asbestos
fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets.
The asbestos that is used in these
components is usually bound in a resin or
sealed in some way. Normal handling is
not hazardous unless airborne dust that
contains asbestos is generated.
If dust thatmay contain asbestos is present,
there are several guidelines that should
be followed:
Never use compressed air for cleaning.
Avoid brushing materials that contain
asbestos.
Avoid grinding materials that contain
asbestos.
Use a wet method in order to clean up
asbestos material.
A vacuum cleaner that is equipped with a
high efficiency particulate air filter (HEPA)
can also be used.
Use exhaust ventilation on permanent
machining jobs.
Wear an approved respirator if there is no
other way to control the dust.
Complywithapplicablerulesandregulations
for the work place, In the United States,
refer to Occupational Safety and Health
Administration (OSHA) requirements.
Obey environmental regulations for the
disposal of asbestos.
Stay away from areas that might have
asbestos particles in the air
Dispose of Waste Properly
Improperly disposing of waste can threaten
the environment. Potentially harmful
fluids should be disposed of according
to local regulations.Always use leak proof
containers when you drain fluids. Do not
pour waste onto the ground, down a drain,
or into any source of water.
Crushing Prevention and Cutting
Prevention
Support the equipment properly before
you perform any work or maintenance
beneath that equipment. Do not depend
on the hydraulic cylinders to hold up the
equipment. Equipment can fall if a control
is moved, or if a hydraulic line breaks.
Do not perform any work until you have
read and followed the proper

Boxer 385D Operator Service Maintenance Manual
12
“Lock-Out / Tag-Out”
procedures.
Do not workbeneath thecab ofthe machine
unless the cab is properly supported.
Unless you are instructed otherwise, never
attempt adjustments while the machine
is moving or while the engine is running.
Never jump across the starter solenoid
terminals in order to start the engine.
Unexpected machine movement could
result.
Whenever there are equipment control
linkages, the clearance in the linkage
area will change with the movement of
the equipment or the machine. Stay clear
of areas that may have a sudden change
in clearance with machine movement or
equipment movement.
Avoid contact with the rotating feed wheel,
cutter wheel and rotor.
Always shut-off the engine and wait for all
moving parts, belts, fans, rotors, drums,
cutting wheels (etc) to come to a complete
stop before opening access covers and/or
guards. Stay clear of all rotating and moving
parts. A moving belt, pulley, sprocket and
chain can suddenly pull a limb into them
causing loss or severe injury.
If it is necessary to remove guards in order
to perform maintenance, always install the
guards after the maintenance is performed.
Keep objects away from moving fan blades.
The fan blade will throw or cut objects.
Do not use a kinked wire cable or a frayed
wire cable. Wear gloves when you handle
wire cable.
When you strike a retainer pin with force,
the retainer pin can fly out. The loose
retainer pin can injure personnel. Make
sure that the area is clear of people when
you strike a retainer pin. To avoid injury to
your eyes, wear protective glasses when
you strike a retainer pin.
If equipment is unhitched from the tow
vehicle for operation, always block the
wheels and support the tongue weight with
blocking to prevent unintended movement.
Do not use only the jack stand to support
the tongue while in operation.
Burn Prevention
Do not touch any part of an operating
engine. Allow the engine, radiator, exhaust
and hydraulic reservoir to cool before
any maintenance is performed. Relieve
all pressure in the air system, oil system,
lubrication system, fuel system, and/or in
the cooling system before any lines, fittings
or related items are disconnected.
In addition, avoid contact with other related
hot engine partssuch as exhaustmanifolds,
turbochargers and mufflers.
External exhaust parts become very hot
during operation. Paper, cloth, and wooden
materials couldignite iftheycome incontact
with these parts
Coolant
Whentheengineisatoperatingtemperature,
the engine coolant is hot. The coolant is
also under pressure. The radiator and all
lines to the heaters or to the engine contain
hot coolant.
Safety

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Safety
Any contact with hot coolant or with steam
can cause severe burns. Allow cooling
system components to cool before the
cooling system is drained.
Check thecoolant levelonly afterthe engine
has been stopped.
Ensure that the filler cap is cool before
removing the filler cap. The filler cap must
be cool enough to touch with a bare hand.
Remove the filler cap slowly in order to
relieve pressure.
Cooling system conditioner contains alkali.
Alkali can cause personal injury. Do not
allow alkali to contact the skin, the eyes
or the mouth.
Oils
Hot oil and hot components can cause
personal injury. Do not allow hot oil to
contact the skin. Also, do not allow hot
components to contact the skin.
Remove the hydraulic tank filler cap only
after the engine has been stopped. The
filler cap must be cool enough to touch
with a bare hand. Follow the standard
procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte
to contact the skin or the eyes. Always
wear protective glasses for servicing
batteries. Wash hands after touching the
batteries and connectors. Use of gloves
is recommended.
Fire Prevention and Explosion
Prevention
All fuels, most lubricants, and some coolant
mixtures are flammable.
Flammable fluids that are leaking or
spilled onto hot surfaces or onto electrical
components can cause a fire. Fire may
causepersonal injuryandproperty damage.
Remove all flammable materials such as
fuel, oil, and debris from the machine.
Do not allow any flammable materials
to accumulate on the machine. Serious
personal injury can occur when fuel or oil
is spilled on yourself or your clothes, which
can ignite.
Store fuels and lubricants in properly
marked containers away from unauthorized
persons. Store oily rags and any flammable
materials in protective containers. Do not
smoke in areas that are used for storing
flammable materials.
Do not operate the machine near any flame.
Extinguish all cigarettes, cigars, pipes and
other sources of ignition.
Exhaust shields (if equipped) protect hot
exhaust components from oil spray or
fuel spray in case of a break in a line, in a
hose, or in a seal. Exhaust shields must
be installed correctly.
Do not weldon linesor on tanks that contain
flammable fluids. Do not flame cut lines or
tanks that contain flammable fluid. Clean
any such lines or tanks thoroughly with a
nonflammable solvent prior to welding or
flame cutting. Check all electrical wires
daily. Repair any wires that are loose or
frayed before you operate the machine.
Clean all electrical connections and tighten
all electrical connections.
Dust that is generated from repairing
nonmetallic hoods or non metallic fenders
can be flammable and/or explosive. Repair
such components in a well ventilated area
away from open flames or sparks.
Inspect all lines and hoses for wear or
for deterioration. The hoses must be
properly routed. The lines and the hoses
must have adequate support and secure

Boxer 385D Operator Service Maintenance Manual
14
clamps. Tighten all connections to the
recommended torque. Leaks can cause
fires.
Use caution when you are refueling a
machine. Do not smoke while you are
refueling a machine. Do not refuel a
machine near open flames or sparks.
Always stop the engine before refueling.
Fill the fuel tank outdoors.
Gases from a battery can explode. Keep
any open flames or sparks away from the
top of a battery. Do not smoke in battery
charging areas.
Never check the battery charge by placing
a metal object across the terminal posts.
Use a voltmeter or a hydrometer.
Improper jumper cable connections can
cause an explosion that can result in injury.
Refer to the Operation Section of this
manual for specific instructions.
Do not charge a frozen battery. This may
cause an explosion.
Fire Extinguisher
Make sure that a fire extinguisher is
available. Be familiar with the operation
of the fire extinguisher. Inspect the fire
extinguisher andservicethefire extinguisher
regularly. Obey the recommendations on
the instruction plate.
Fire Extinguisher Location
Make sure that a fire extinguisher is on
the machine. Make sure that you are
familiar with the operation of the fire
extinguisher. Inspect the fire extinguisher
and service the fire extinguisher. Obey the
recommendations on the instruction plate.
Mount the fire extinguisher in an easily
accessible place on the machine, for
crawlers mount on the left side of the cab
behind the seat. Consult your Rayco dealer
for the proper procedure of mounting the
fire extinguisher.
Ether Starting Fluid
Ether is flammable and poisonous.
Use ether in well ventilated areas. Do not
smoke while you are replacing an ether
cylinder or while you are using an ether
spray.
Do not store ether cylinders in living
areas or in the operator compartment of a
machine. Do not store ether cylinders in
direct sunlight or in temperatures above 49
°C (120 °F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly.
Do not puncture an ether cylinder. Keep
ether cylinders away from unauthorized
personnel.
Do not spray ether into an engine if the
machine is equipped with a thermal starting
aid for cold weather starting.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not
strike high pressure lines. Do not install
any lines that are bent or damaged.
Repair any lines that are loose or damaged.
Leaks can cause fires. Consult your Rayco
dealer for repair or for replacement parts.
Check lines, tubes and hoses carefully.
Do not use your bare hand to check for
leaks. Use a board or cardboard to check
for leaks. Tighten all connections to the
recommended torque.
Replace the parts if any of the following
conditions are present:
End fittings are damaged or leaking
Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced. Make sure
that all clamps, guards, and heat shields
are installed correctly. During machine
Safety

Boxer 385D Operator Service Maintenance Manual
800.392.2686 15
Safety
operation, this will help to prevent vibration,
rubbing against other parts, and excessive
wear.
Electrical Storm Injury
Prevention
When lightning is striking in the vicinity of
the machine, the operator should never
attempt the following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator’s CAB during
an electrical storm, stay in the operator’s
CAB. If you are on the ground during an
electrical storm, stay away from the vicinity
of the machine!
While Operating the Machine
All personnel using this Machine must
be trained in the operation, safety and
maintenance repair procedures. Careless
use of thisEquipment couldresult inserious
injury or even death.
ALL PROCEDURES IN THE SAFETY
AND OPERATION SECTIONS OF
THIS MANUAL MUST BE READ
AND UNDERSTOOD BEFORE
STARTING THIS MACHINE.
All operators must be wearing the proper
Personal Protective Equipment before
attempting to start and operate this
machine.
Do not allow children or other spectators
to standby and watch the machine in
operation.
Familiarize yourself with all of the controls
in a safe environment before starting to
work with this machine.
Always have more than one person at the
job site. If an accident occurs, someone is
there to assist or obtain help.
Never operate or allow someone to operate
the machine while under the influence of
alcohol, drugs, or any medication that
could affect the operator’s performance
and concentration. Maintain a drug-free
work place.
Always operate this machine with all safety
equipment in place and working. Make
sure all controls are properly adjusted for
safe operation.
Do notchange theengine governorsettings
or over speed the engine. The governor
controls themaximum safe operating speed
of the engine
Never leave this machine unattended with
the engine running.
Use only your hand to operate the controls.
Never use a foot, knee, rope or any
extension device.
Never hand-feed this machine for any
reason.
Contact with moving parts, belts or rotating
cutter wheels can kill, injure or dismember.
Turn off engine and wait for all movement
to stop before working on this machine.
Lock-out/Tag Out all controls.
If equipped, the Emergency Stop buttons
must be operating properly. These should
each be checked and verified to shut
down the engine by the operator prior to
performing any work.
Stay away from the discharge chute
while the rotor is turning. Material being
discharged can cause severe injury,
blindness or death.
Always operate this machine from the
operator area. Never stand directly in front
or in back of machine as flying objects could
be thrown during operation.
Never move this machine, or make
adjustments or repairs, while the engine
is running.
While Servicing and Performing
Maintenance on the Machine
ALWAYS Block the wheels to prevent
unintended movement.
Adhere to your LOCK-OUT/TAG-OUT
procedure when performing maintenance
or repairs to this machine. Locking and
tagging out equipment safeguards those
working on equipment from being injured
by its unexpected energized or releasing
stored energy.

Boxer 385D Operator Service Maintenance Manual
16
To prevent fires, clean debris and chaff from
the engine and muffler areas.
Periodically check that all nuts and bolts,
hoseclamps, andhydraulic fittings aretight.
When removing the fuel cap, unscrew
it slowly, and hold it firmly. The cap may
otherwisebethrownduetopressurebuildup
caused by an increase in temperature.
For your safety, repair or replace all
damaged or worn parts immediately.
Replacement parts which are authorized
by Rayco are the only parts which should
be used for repair or replacement on this
machine.
Altering this equipment, or using this
equipment in such a way as to circumvent
its design capabilitiesand capacities, could
result in serious injury or fatality and WILL
VOID THE WARRANTY.
Do not alter this machine in any manner.
Alterations such as attaching a rope to the
control bar may result in personal injury
or death.
NEVER remove the cap from the hydraulic
tank or reservoir while the machine is
running. Hot oil under pressure will cause
injury.
Relieve hydraulic system pressure before
repairing or adjustingfittings, hoses,tubing,
or other system components
Before Starting Engine
Start the engine only from the operator
compartment. Never short across the
starter terminate or across the batteries.
Shorting could damage the electrical
system by bypassing the engine neutral
start system.
Inspect the condition of the seat belt (if
equipped) and of the mounting hardware.
Replace any parts that are worn or
damaged. Regardless of appearance,
replace the seat belt after three years of
use. Do not use a seat belt extension on
a retractable seat belt.
Adjust the seat so that full pedal travel
can be achieved with the operator’s back
against the back of the seat.
Make sure that the machine is equipped
with a lighting system that is adequate
for the job conditions. Make sure that all
machine lights are working properly.
Before you start the engine and before
you move the machine, make sure that no
one is underneath the machine, around the
machine, or on the machine. Make sure
that the area is free of personnel.
Visibility Information
Before you start the machine, perform
a walk-around inspection in order to
ensure that there are no hazards around
the machine.
Whilethemachineisinoperation,constantly
survey the area around the machine in order
to identify potential hazards as hazards
become visible around the machine.
Your machine may be equipped with visual
aids. Some examples of visual aids are
Closed Circuit Television and mirrors.
Before operating the machine, ensure
that the visual aids are in proper working
condition and that the visual aids are clean.
Adjust the visual aids using the procedures
that are located in this Operation and
Maintenance manual.
It may not be possible to provide direct
visibility on large machines to all areas
around the machine. Appropriate job site
organization is required in order to minimize
hazards that are caused by restricted
visibility. Job site organization isa collection
of rules and procedures that coordinates
machines and people that work together
in the same area. Examples of job site
organization include the following:
Safety instructions
Controlled patterns of machine movement
and vehicle movement
Workers that direct traffic to move when
it is safe
• Restricted areas
• Operator training
• Warning symbols or warning signs on
machines or on vehicles
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Safety
• A system of commincation
• Communication between workers
and operators prior to approaching
the machine
• Modifications of the machine
configuration by the user that result
in a restriction of visibility shall be
evaluated.
Engine Starting
If a warning tag is attached to the start
switch or to the controls, do not start the
engine. Also, do not move any controls.
Move allhydraulic controlsto theNEUTRAL
position before you start the engine.
Diesel engine exhaust contains products
of combustion which can be harmful to
your health. Always start the engine in a
well ventilated area. Always operate the
engine in a well ventilated area. If you are
in an enclosed area, vent the exhaust to
the outside.
Before Operation
Video tapes and safety information are
available in English for this machine. A
list of some of the material is available in
the Operation and Maintenance Manual,
“Reference Material”. Consult your
Rayco dealer in order to obtain copies of
the material. The information should be
reviewed by every person that operates
the machine.
Clear all personnel from the machine and
from the area.
Clear all obstacles from the path of the
machine. Beware of hazards such as wires,
ditches, etc.
Make sure that all windows are clean.
Secure all doors in the closed position.
Secure the windows in the open position
or in the shut position.
Make sure that the machine horn, the
backup alarm and all other warning devices
are working properly.
Fasten the seat belt securely (if equipped).
Lower the armrest.
Operation
Only operate the machine controls when
the engine is running. Do not leave the
operators station while machine is running.
Before you move the machine, you must
be certain that no one will be endangered.
While you operate the machine and the
work tool slowly in an open area, check
for proper operation of all controls and all
protective devices.
Do not allow riders on the machine.
Note any needed repairs during machine
operation. Report any needed repairs.
Use only Rayco Approved Work Tools on
this machine. Obey all the lift restrictions.
Refer to Operation and Maintenance
Manual, “Rayco Approved Work Tools”
for the approved work tools and the lift
restriction information.
If equipped, carry work tools low. Lower
the lift arms fully. Tilt back the work tool
in order to keep the work tool off of the
ground. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward
on a grade, immediately remove the load
and turn the machine downhill.
Avoid any conditions that can lead to
tipping the machine. The machine can tip
when you work on hills, on banks and on
slopes. Also, the machine can tip when you
cross ditches, ridges or other unexpected
obstacles.
Avoid operating the machine across the
slope. When possible, operate themachine
up the slopes and down the slopes.
Maintain control of the machine. Do not
overload the machine beyond the machine
capacity. Never straddle awirecable. Never
allow personnel to straddle a wire cable.
Know the maximum dimensions of your
machine.
If equipped with a Rollover Protection
Structure (ROPS), always keep the ROPS
installed during machine operation.
Observe all applicable local government
regulations when you use this machine.

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18
Parking
Park on a level surface. If you must park
on a grade, chock the machine.
Move the joystick control slowly to the
NEUTRAL position in order to stop the
machine.
Move the throttle control lever to the LOW
IDLE position.
Lower all implements (if equipped) so that
the work tool implement rests firmly on
the ground.
Move the hydraulic controls to the
NEUTRAL position.
Turn the engine start switch key to OFF
position and remove the key.
Disconnect the operator restraint devices
(if equipped) and exit the machine.
Block the wheels (if equipped), and set
manual brake (if equipped) to prevent
movement.
Slope Operation
The crawler should not be operated on
slopes that are steeper than 30°. While
this may not cause a loss of oil pressure,
loss of traction could occur thus creating
a rollover condition.
NOTE: A 30° slope is equivalent to a
58% grade. A constant grade of 58%
represents a 58’ change in elevation
across a horizontal distance of 100’.
Machines that are operating safely
in various applications depend on
these criteria: the machine model,
configuration, machine maintenance,
operating speed of the machine,
conditions of the terrain, fluid levels,
and tire inflation pressures. The most
important criteria are the skill and
judgment of the operation.
A well trained operator that follows
the instructions in the Operation and
Maintenance Manual has the greatest
impact on stability. Operator training
provides a person with the following
abilities:
• observation of working and
environmental conditions
• feel for the machine,
• identification of potential hazards, and
operating themachine safely by making
appropriate decisions.
• When you work on side hills and when
you work on slopes, consider the
following important points:
• Speed of travel – At higher speeds,
forces of inertia tend to make the
machine less stable.
• Roughness of terrain or surface –
The machine may be less stable with
uneven terrain.
• Direction of travel – Avoid operation
the machine across the slope. When
possible, operate the machine up the
slopes and operate the machine down
the slopes.
• Place the heaviest end of the machine
uphill when you are working on an
incline.
• Mounted equipment – Balance of
the machine may be impeded by the
following components: equipment
that is mounted on the machine,
machine configuration, weights, and
counterweights.
• Nature of surface – Ground that
has been newly filled with earth
may collapse from the weight of the
machine.
• Surface material – Rocks and moisture
of the surface material may drastically
affect the machine’s traction and
machine’s stability. Rocky surfaces
may promote side slipping of the
machine.
• Slippage due to excessive loads – This
may cause downhill tracks or downhill
tires to dig into the ground, which will
increase the angle of the machine.
• Width of tracks or tires – Narrower
tracks or narrowertires furtherincrease
the digging into the ground which
causes the machine to be less stable.
• Implements attached to the machine
hitch or drawbar – This may decrease
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Safety
the weight on the uphill tracks. This
may also decrease the weight on the
uphill tires. The decreased weight will
cause the machine to be less stable.
• Height of the working load of the
machine When the working loads are
in higher positions, the stability of the
machine is reduced.
• Operated equipment – Be aware of
performance features ofthe equipment
in operation andthe effectson machine
stability.
• Operating techniques – Keep all
attachments or pulled loads low to the
ground for optimum stability.
• Machine systems have limitations on
slopes – Slopes can affect the proper
function and operation of the various
machine systems. These machine
systems are needed for machine
control on slopes.
• Note: Safe operation on steep
slopes may require special machine
maintenance. Excellent skill of the
operator and proper equipment
for specific applications are also
required.Consult the Operation and
Maintenance Manual sections for the
proper fluid level requirements and
intended machine use.
Work Tool options - Attachments
Only use work tools that are approved by
Rayco for use on Rayco machines. Refer
to the Operation and Maintenance Manual,
Rayco options”.
If you are in doubt about the compatibility
of a particular work tool with your machine,
consult your Rayco dealer.
Make sure that all necessary guarding is
in place on the host machine and on the
work tool.
If equipped, keep all windows and doors
closed on the machine.
Always wear protective glasses. Always
wear the protective equipment that is
recommended in the work tool’s operation
manual. Wear any other protective
equipment that is required for the operating
environment.
To prevent personnel from being struck by
flying objects, ensure that all personnel are
out of the work area.
While you are performing any maintenance,
any testing, or any adjustments to the
machine, stay clear of the following areas:
cutting edges, pinching surfaces, and
crushing surfaces.
Equipment Lowering with Engine
Stopped
Before lowering any equipment with the
engine stopped, clear the area around the
equipment of all personnel. The procedure
to use will vary with the type of equipment
to be lowered. Keep in mind this system
use a high pressure fluid to raise or lower
equipment. The procedure will cause high
pressure hydraulicoil tobe releasedinorder
to lower the equipment. Wear appropriate
personal protective equipment and follow
the established procedure in the Operation
and Maintenance Manual.
Sound Level Information
The operator Equivalent Sound Pressure
Level is used to measure a work cycle
sound exposure level
Hearing protection may be needed when
the machine is operated with an open
operator station for extended periods in a
noisy environment. Hearing protection may
be needed when the machine is operated
with a cab that is not properly maintained or
when the doors and windows are open for
extended periods or in a noisy environment.
Vibration Data Information
concerning hand/arm vibration
level
When the machine is operated accordingto
the intended use, the hand/arm vibration of
this machine is rated by meter per second
squared.
Note: Vibration levels are influenced by
many different parameters listed below.

Boxer 385D Operator Service Maintenance Manual
20
Operator training, behavior,
mode, and stress
Job site organization, preparation,
environment, weather and material
Machine type, quality of the seat, quality of
the suspension system, attachments, and
condition of the equipment.
Guidelines for Reducing Vibration Levels
on Equipment
The following guidelines can help reduce
the whole body vibration level:
• Use the right typeand sizeof machine,
equipment, and attachments.
• Properly adjust machines.
• Operate machines smoothly.
• Maintain the conditions of the terrain.
a. Remove any large rocks or
obstacles
b. Fill any ditches and holes
c.Providemachines,and schedule
time in order to maintain the
conditions of the terrain.
• Maintain machines according to the
manufacturer’s recommendations.
a. Tire pressures
b. Brake and steering systems
c .Controls, hydraulic system
and linkages
• Keep the terrain in good condition.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines and schedule time
in order to maintain the conditions of
the terrain.
• Use a seat that meets “ISO 7096”.
Keep the seat maintained and
adjusted.
• Adjust the seatand suspension forthe
weight and the size of the operator.
• Inspect and maintain the seat
suspension and adjustment
mechanisms.
• Perform the following operations
smoothly.
a. Steer
b. Brake
c. Accelerate
d. Shift the gears
• Move the attachments smoothly.
• Adjust the machine speed and the
route in order to minimize the vibration
level.
• Drive around obstacles and rough
terrain.
• Slow down when it is necessary to
go over rough terrain.
• Minimize vibrations for a long work
cycle or a long travel distance.
• Haul the machines between
workplaces.
• Less operator comfort maybe caused
by other risk factors. The following
guidelines can be effective in order
to provide better operator comfort:
• Adjust the seatand adjustthe controls
in order to achieve good posture.
• Adjust the mirrors in order to minimize
twisted posture.
• Provide breaks in order to reduce
long periods of sitting.
• Avoid jumping from the cab.
• Minimize repeated handling of loads
and lifting of loads.
• Minimize any shocks and impacts
during sports and leisure activities.
Guards (Operator Protection)
There are different types of guards that are
used to protect the operator. The machine
and themachineapplication determinesthe
type of guard that should be used.
A daily inspection of the guards is required
in order to check for structures that are
bent, cracked or loose. Never operate a
machine with a damaged structure.
The operator becomes exposed to a
hazardous situation if the machine is used
improperly or if poor operating techniques
are used. This situation can occur even
though a machine is equipment with an
appropriate protective guard.
Followtheestablishedoperatingprocedures
that are recommended for your machine
Safety