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Boxer 525DX Parts ManualSN 4341 and HigherPart No. 76345-813Manufactured by:Phone:Sales - 800-831-0042,Parts and Service - 800-255-8839www.boxerequipment.comMorbark, Inc.8507 S. Winn Rd., P.O. Box 1000,Winn, Michigan 48896www.morbark.com

REVISION LOGRev:PagesAffected:Rev. Date:Descriptionof Changes:-Apr 9, 2015AllInitial ReleaseAApr 16, 201511, 23, 27, 35,36Numerous modificationsBJuly 7, 20158-9, 26-27moved boom lock holder to topof hyd tankCOct 15, 201525P/N change key switch & coverDJan. 30, 201913Updated Item#17EJan. 16, 202019Updated Items#25 & 26

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

Routine Maintenance Replacement PartsThe following parts should be considered as normal stock part items in your location. Keeping asupply of these will enable you to keep the Boxer in full service.Part NamePart NumberBoxer Replacement Kit.29834-702Idler Wheel Kit.29834-703Mid - Wheel Kit.29834-704Outer Air Filter Element.29135-771Inner Air Filter Element.29135-772Fuel Filter.29211-036Fuel Filter Element.29211-037Fuel Filter Head.29211-663Hydraulic Oil Filter .26838-326Engine Oil Filter.29211-627Hydraulic Oil . Chevron Rykon PremiumISO 46 or equalSeal Kit for Tilt Cylinder .26820-039Seal Kit for Wheel Motor .26713-028Replacement cartridge for Counterbalance valve.26663-356Replacement Ignition Key.29211-929Replacement Access Panel Key.29341-436

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Universal Mounting Plate and Loader Arm Group5268181073 2416251714817912112112 15, 161113101272710892419202023292261922313028

Universal Mounting Plate and Loader Arm GroupItem No.1DescriptionMALE COUPLER ASSEMBLYQuantityPart Number140011-8032ROLL PIN221154-0153SPRING224741-0874MALE COUPLER ROUND LATCH STOP230042-8035MALE COUPLER ROUND LATCH PIN230090-8036MALE COUPLER CASTING129510-4267ROUND PIN230024-8038BOLT421619-1039PIN CLIP, RIGHT130003-80310GREASE ZERK - STRAIGHT526891-00511ROUND PIN230025-80312CONNEX BUSHING623128-00513BOOM ARM WELDMENT140074-80514PIN RETAINER130014-80315BUCKET TILT CYLINDER126820-03116126820-039BUCKET TILT CYLINDER SEAL KIT17LOCK WASHER421171-14018PIN CLIP, LEFT230004-80319FEMALE QUICK CONNECT226538-21520MALE QUICK CONNECT226538-21621HOSE, BUCKET CYLINDER CYLINDER END126211-12222HOSE, SECOND AUXILIARY PORTS226593-24923HOSE, AUXILIARY HOSES226555-098NSPROTECTIVE SLEEVE (FOR #26)132257-901NSPROTECTIVE SLEEVE (FOR #26)132433-90124FITTING426510-30525HOSE, BUCKET CYLINDER ROD END126211-12326FITTING, 90 226510-10527GREASE ZERK, 90 126891-04228RELIEF BLOCK126614-68129BOLT, RELIEF 2057

Loader Arm Group12253698894651211131210155714162948118

Loader Arm GroupItem No.QuantityPart Number1BOOM ARM WELDMENT140074-8052CONNEX BUSHING823128-0053ROUND PIN230027-8034ROUND PIN430025-8035GREASE ZERK, STRAIGHT626891-0056PIN CLIP, CLOSED430016-8037PIN RETAINER230014-8038BOLT621619-1039LOCK WASHER621171-14010TEE FITTING226510-07611FITTING, 90 226510-105ARM LIFT CYLINDER226820-032SEAL KIT226820-03713HOSE, VALVE TO BOOM CYLINDER126211-15614HOSE, VALVE TO BOOM CYLINDER126211-12415HOSE, BOOM CYLINDER ROD TO ROD126211-11616HOSE, BOOM CYLINDER, CYLINDER TO CYLINDER126211-11512Description9

Decals Group327882216101529173121 252833219 26620165784 2324131815112829143130 1327101712

Decals GroupItem No.DescriptionQuantityPart Number1OBSOLETE/CALLOUT NO LONGER APPLICABLE--2CAUTION,BURN HAZARD/SYM CONNECT439510-0093LIFT POINT239510-0044“CALL BEFORE YOU DIG”139510-1495LOCKING PIN139510-0186WARNING,ATTACHMENT SECURE CAUTION239510-0137WARNING,STAY BACK/SYM DANGER239510-0068WARNING, CRUSH HAZARD/SYM DANGER439510-0019HYD OIL,ISO PREMIUM 46139510-01510WARNING,INSTALL CYL LOCK/SYM WARNING11WARNING,READ MANUAL/SYM WARNING139510-00812WARNING,BATTERY GROUND (SYM)139510-00713NOTICE,ULTRA LOW SULFUR DIESEL239510-15214WARNING CA PROP 65139510-01415BOXER -LARGE239510-07916“525DX” DECAL239510-28217BIG POWER DECAL239510-14018OPERATOR CONTROLS -SAFETY-139510-06819OPERATOR CONTROLS139510-06720CONTROL PANEL DECAL139510-07021BOXER INTERNET ADDRESS DECAL139510-02322MORBARK LOGO DECAL139510-14523TAG, MOD, WT, HP139510-15624TAG, SN, MAN DATE139510-15425ULTRA LOW SULPHUR DIESEL139511-95126CRAWL SPEED139510-19627TIE DOWN239510-00528WARNING, EXPLOSION HAZARD139511-95229WARNING, FIRE HAZARD139510-01130SHUT OFF FUEL139510-00331DANGER, CRUSH HAZARD239510-14432WARNING, AUXILIARY VALVE139510-02439510-01211

Travel Drive Group40 3128323330112026111213 14 1521254116351221756918 19 399101723 2238273229344241687437363

Travel Drive GroupItem No.QuantityPart Number1RUBBER TRACKDescription229510-4062DRIVE SPROCKET230109-8033BOLT1222425-2554ROUND, HUB -DRIVE230106-8035RIGHT TRACK MODULE140058-8056FITTING426510-1077MID-WHEEL SPOOL ASSEMBLY10SEE PAGE 158DRIVE MOTOR226713-006CASTLE NUT226732-321WOODRUFF KEY226713-0279BOLT821411-25710LEFT TRACK MODULE140057-80511FRONT IDLER ASSEMBLY2SEE PAGE 1412LEFT GUIDE ROD240027-80513HARDENED WASHER1221161-04414LOCK WASHER1221171-14315BOLT1221411-27616COTTER PIN221126-02217RIGHT GUIDE ROD240028-80518TRACK WIDENING CYLINDER126820-033SEAL KIT126820-03819FITTING226510-10520PIVOT PIN230025-80321FORK, PIVOT PIN230014-80322LOCK NUT221733-30726HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR226270-00127TUBE, CONTROL VALVE TO LEFT SIDE OF LEFT CBV140089-80528FITTING, 90 626510-10729O-RING, #10826511-91030COUNTERBALANCE VALVE226633-35631FITTING226510-21132TUBE, CONTROL VALVE TO RIGHT SIDE OF LEFT CBV140090-80533TUBE, CONTROL VALVE TO LEFT SIDE OF RIGHT CBV140091-80534TUBE, CONTROL VALVE TO RIGHT SIDE OF RIGHT CBV140088-80535LOCK WASHER1221171-14336BOLT221619-10537LOCK WASHER221161-01138HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR226270-00339HOSE, TRACK CYLINDER226211-13140COUNTERBALANCE VALVE226633-35641BUSHING, VARIABLE WIDTH TRACK ADJUSTMENT423121-16513

Idler Wheel and Spring Assembly12345151014Item No.Description111387109126QuantityPart Number1TENSION LOCK PLATE230010-8032JACKING BOLT WELDMENT240056-8053SPRING TENSIONER WELDMENT240007-8034SPRING229510-4385TRACK FORK WELDMENT240055-8016WHEEL ASSEMBLY, RIGHT SIDE140040-803WHEEL ASSEMBLY, LEFT SIDE140009-8037BEARING429510-4278IDLER SPACER TUBE430017-8039IDLER PIN240018-80310SEAL429510-43111SNAP RING224125-00812FRONT IDLER WHEEL229510-40413LOCK WASHER221171-14314BOLT221612-61115FLAT WASHER232217-901NOTE: Quantities Listed Are For Both Sides.1487

Mid Wheel Assembly1765432823 456Item No.1DescriptionMID-WHEEL ASSEMBLYQuantityPart Number1040010-80321733-4102NUT203FLAT WASHER2021161-1164SEAL2029510-4285SNAP -8038MIDWHEEL AXLE1030029-803NOTE: Quantities Listed Are For Both Sides.15

Hydraulic Cooler Group131 2 35467 89104To tee onthe botto m o fth e AuxiliaryValve10916Return lin eto HydraulicFilter Assy .1112Item No.10Description10QuantityPart Number1BOLT421625-7052LOCK WASHER421171-1893FLAT WASHER421161-1044O-RING SEAL226511-9125HYDRAULIC COOLER KIT126844-13126844-132612 V COOLER FAN17FLAT WASHER, M6421171-0378MOUNTING BOLT, M6421625-7859ELBOW, 90 226531-14610CLAMP426516-41011HOSE, OIL COOLER OUTLET TO FILTER INLET IN TANK118510-55812HOSE, VALVE RETURN TO COOLER INLET118510-55013SCREEN140053-805

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Main Control Valve 61925261926282324222125292718

Main Control Valve GroupItem No.QuantityPart Number1VALVE BLOCKDescription126661-2202BOLT321624-0533ROUND LEVER SHAFT230154-8054LOCK NUT421731-7085CONTROL KNOB229341-4626ROUND LEVER SHAFT230153-8057LOCK NUT421731-7108TRAVEL CONTROL HANDLE, CAST229341-4989FITTING426510-20810HOSE, BUCKET CYLINDER, ROD END126211-12311HOSE, BUCKET CYLINDER, CYLINDER END126211-12212HOSE, VALVE TO BOOM NCE VALVE226633-35615TUBE, COUNTERBALANCE VALVE140090-80516FITTING226510-21117TUBE, COUNTERBALANCE VALVE140091-80518TUBE, COUNTERBALANCE VALVE140088-80519FITTING, 90 626510-10720TUBE, COUNTERBALANCE VALVE140089-80521BOLT421625-01122LOCK WASHER421171-13723FLAT WASHER421161-00724NUT, INSERT421737-40625HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR226270-00326HOSE, COUNTER BALANCE VALVE TO TRACK MOTOR226270-00127HOSE CLAMP427112-26228BOLT221619-10329NYLOC NUT221733-30330FITTING, 45 126510-13231HOSE, “C” ON BLOCK TO PRESSURE ON MAIN VALVE140097-80532FITTING, 90 126510-13033TUBE140092-80534FITTING126512-50519

Diverter Valve Group106107439911151312148211619515211722 2318202024252420

Diverter Valve GroupItem No.QuantityPart Number1VALVE BANKDescription126661-2082SPACER130151-8053MOUNT, VALVE BANK130152-8054BOLT321624-0655NYLOC NUT321733-4576MAIN AUXILIARY LEVER130101-8057TEXTURED GRIP129341-4638NUT121731-7109AUXILIARY TTING126510-21113HOSE, “D”ON BLOCK TO PRESSURE ON AUXILIARY VALVE126265-19314FITTING226512-21215HOSE, SECOND AUXILIARY - FROM VALVE TO 20718TUBE126265-20719FITTING226510-20720HOSE, TRACK CYLINDER226211-13121FITTING126512-61722PLUG, 41025HOSE, VALVE RETURN TO AUXILIARY VALVE118510-55121

Crawl Valve Group1195342106861371122019142081115161710182221

Crawl Valve GroupItem No.QuantityPart Number1CRAWL CONTROL VALVEDescription126682-5012MOUNTING BRACKET130079-8053BOLT121619-1034LOCK WASHER121171-1405BOLT121619-0556FLAT WASHER221161-0087NYLOCK NUT121733-4578TEE FITTING226510-0809HOSE, “E” ON BLOCK TO BACK PUMP126265-19110TEST PORT FITTING226538-42511TEST PORT DUST 90 DEGREE FITTING126510-10715HOSE, “C” ON BLOCK TO PRESSURE ON MAIN VALVE126265-19216HOSE, “F” ON BLOCK TO FRONT PUMP126265-19017FITTING, 90 126510-10718HOSE, “D” ON BLOCK TO PRESSURE ON AUXILIARY VALVE126265-19319HOSE, VALVE RETURN TO AUXILIARY VALVE118510-55120CLAMP, HOSE226516-41021HOSE, VALVE RETURN TO OIL COOLER INLET118510-550NSFITTING, STRAIGHT HOSE BARBED126517-16623

Electrical Panel Parts 1117289245

Electrical Panel Parts GroupItem No.QuantityPart Number1BOLTDescription421619-0052LOCK WASHER421171-1393FLAT WASHER421161-0084IGNITION SWITCH W/KEY129211-9355IGNITION KEY SWITCH COVER129295-0086IGNITION KEY129211-9297NUT WITH NYLON INSERT422522-0068FUSE PANEL127311-9159MACH PAN HEAD MACHINE SCREW422341-41010BLADE TYPE FUSE ATO-1227311-91011BLADE TYPE FUSE ATO-3227311-90512BLADE TYPE FUSE ATC-15227311-90313OIL PRESSURE GAUGE129317-15214WATER TEMPERATURE LUG124722-01918HIGH RANGE GROUND HARNESS147005-80519TOGGLE SWITCH BOOT129295-02720TOGGLE SWITCH129295-02621HIGH RANGE WIRING HARNESS147004-80522PLUG124722-01023HOUR METER129316-96224HOUR METER TO TERMINAL STRIP HARNESS147001-80525HOUR METER TO GROUND HARNESS147002-80526GAUGE PANEL WELDMENT140024-80527MAIN WIRING HARNESS147007-80528FUSE PANEL GROUND HARNESS147003-80525

Rear Frame Group272612425223223719 202140341361861715 16425414ToEngineIntake13291298739261031 342838113028353332