Boxer 320 Parts Manual - Boxer Power and Equipment
Boxer 320 Parts Manual - Boxer Power and Equipment
Boxer 320 Parts Manual - Boxer Power and Equipment
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<strong>Boxer</strong> <strong>320</strong> <strong>Parts</strong> <strong>Manual</strong><br />
Part No. 999-843<br />
Serial No.s 1518 & Higher
COMPACT<br />
TM<br />
Table of Contents<br />
<strong>Parts</strong> List <strong>and</strong> Illustrations<br />
Page Number<br />
Routine Maintenance Replacement <strong>Parts</strong>...................................................................iv<br />
Universal Mounting Plate <strong>and</strong> Loader Arm ................................................................. 2<br />
Loader Arm Assembly................................................................................................. 4<br />
Decals Group ............................................................................................................. 6<br />
Travel Drive Group ..................................................................................................... 8<br />
Idler Wheel <strong>and</strong> Spring Assembly............................................................................. 10<br />
Mid-Wheel Assembly .................................................................................................11<br />
Main Control Valve Group ........................................................................................ 12<br />
Diverter Valve Group ................................................................................................ 14<br />
Rear Frame Assembly .............................................................................................. 16<br />
Hydraulic Filter <strong>and</strong> Engine Shroud Group............................................................... 18<br />
Muffler <strong>and</strong> Electrical Group...................................................................................... 20<br />
Pump Group.............................................................................................................. 21<br />
Battery Group............................................................................................................ 22<br />
Write your machines Serial Number in the space below for future reference. The serial<br />
number is located on the metal tag on the left side of the machine.<br />
MANUFACTURED BY:<br />
MERTZ MANUFACTURING LLC<br />
PONCA CITY, OKLAHOMA, USA<br />
DATE OF MANUFACTURE<br />
MODEL NO.<br />
ENGINE SERIAL NO.<br />
WEIGHT<br />
POWER<br />
LB<br />
HP<br />
S.N.<br />
COMPACT POWER EQUIPMENT<br />
800-476-9673<br />
cpiequipment.com<br />
KG<br />
KW<br />
Record SERIAL Number here<br />
iii
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Routine Maintenance Replacement <strong>Parts</strong><br />
The following parts should be considered as normal stock part items in your location. Keeping a<br />
supply of these will enable you to keep the <strong>Boxer</strong> in full service.<br />
Part Name<br />
Part Number<br />
Air Filter Element................................................................................................................ 2393530.001<br />
Air Filter Pre-cleaner.......................................................................................................... 2393530.002<br />
Fuel Filter (In-Line)............................................................................................................. 2393525.004<br />
Hydraulic Oil Filter.............................................................................................................. 2420619.001<br />
Engine Oil Filter ................................................................................................................. 2393525.001<br />
Hydraulic Oil ...................................................................................................................... Chevron Rykon Premium<br />
ISO 46 or equal<br />
Seal Kit for Tilt Cylinder...................................................................................................... 3015042.001<br />
Seal Kit for Wheel Motor.................................................................................................... L112282.001<br />
Replacement Ignition Key.................................................................................................. 2414959.001<br />
This page intentionally left blank<br />
Special Tools<br />
Part Number<br />
Pressure/Flow Gauge Set.................................................................................................. 70661<br />
Test Port Pressure Gauge.................................................................................................. 999-990<br />
iv<br />
1
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Universal Mounting Plate <strong>and</strong> Loader Arm Group<br />
Universal Mounting Plate <strong>and</strong> Loader Arm Group<br />
Item No. Description Quantity Part Number<br />
1 COUPLER LATCH PIN 2 3010612<br />
2 SPRING 2 3010033<br />
3 ROLL PIN 2 2401687<br />
4 COUPLER- ATTACHMENT PLATE 2 3010925<br />
5 PIN CLIP - RIGHT 2 3014221<br />
6 ROUND PIN 2 3010895<br />
7 GREASE ZERK - STRAIGHT 7 2651851<br />
1<br />
8 BOLT 2 1913309C<br />
9 LOCK WASHER 2 2303412<br />
24<br />
20<br />
21<br />
22<br />
7<br />
23<br />
2<br />
12<br />
3<br />
4<br />
9<br />
5 6<br />
8<br />
7<br />
10 PIN CLIP (CLOSED) 4 3015284<br />
11 CYLINDER - TILT 1 3015042<br />
11A TILT CYLINDER SEAL KIT (Not Shown) 1 3015042.001<br />
12 CONNEX BUSHING 4 3010035<br />
13 BOOM ARM 1 3016210<br />
14 ROUND PIN 1 3010896<br />
15 BUSHING 10 3010035<br />
16 AUXILIARY HOSE 2 3016017<br />
17 BULKHEAD FITTING 2 2419674<br />
16<br />
10<br />
18 19<br />
17<br />
12<br />
16<br />
11<br />
10<br />
6<br />
7<br />
12<br />
18 QUICK DISCONNECT, FEMALE 1 2420686<br />
19 QUICK DISCONNECT, MALE 1 2420687<br />
20 HOSE ASSY, FC639-04-04 1 3600014-062.00<br />
21 90 DEGREE FITTING 2 2416665<br />
22 PIN CLIP - LEFT 2 3014222<br />
23 COUPLER LATCH STOP 2 3010378<br />
16<br />
7<br />
13<br />
24 HOSE 1 3600026-048.00<br />
14<br />
1168<br />
2<br />
3
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Loader Arm Assembly<br />
1<br />
20<br />
19<br />
16<br />
17<br />
2<br />
18<br />
12<br />
This page intentionally left blank<br />
16<br />
12 15<br />
14<br />
13<br />
3<br />
4<br />
5<br />
6<br />
7<br />
12<br />
11<br />
10<br />
9<br />
8<br />
1167<br />
Item No. Description Quantity Part Number<br />
1 BOOM ARM 1 3016210<br />
2 FLUTED KNOB 1 2394135<br />
3 ROUND PIN 2 3010838<br />
4 BOOM LOCK PIN 1 2397603<br />
5 BOOM LOCK 1 3016221<br />
6 LIFT CYLINDER HOSE ASSY 2 3600014-033.00<br />
7 BOLT 4 1913309C<br />
8 LOCK WASHER 4 2303412<br />
9 RETAINER PIN 1 3010725<br />
10 FITTING, SAE MALE STR 2 2416659<br />
11 BUSHING 7 3010035<br />
12 ROUND PIN 1 3010896<br />
13 90 DEGREE ZERK 1 2651851-A<br />
14 LIFT CYLINDER 1 3015040<br />
15 PIN CLIP 1 3015284<br />
16 GREASE ZERK 3 2651851<br />
17 ROUND PIN 1 3015052<br />
18 ENGINE SHROUD 1 3016141<br />
19 BOLT 4 1913318C<br />
20 LOCK WASHER 4 2303411<br />
4<br />
5
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Decal Group<br />
Decal Group<br />
Item No. Description Quantity Part Number<br />
1 CRUSH HAZARD DECAL 4 3012105<br />
1<br />
2 <strong>320</strong> DECAL 2 2400492<br />
3 BOXER DECAL 1 2400490<br />
4 BURN HAZARD DECAL 1 3012104<br />
2<br />
5 BOXER DECAL 1 2400491<br />
6 RYKON PREMIUM ISO 46 DECAL 1 2400467<br />
7 STAY BACK DECAL 2 3012107<br />
1<br />
8 MERTZ INSIGNIA 1 2396472<br />
9 ATTACHMENT SECURE DECAL 1 3012101<br />
3<br />
10 LIFTING EYE DECAL 1 0K18608.009<br />
11 QUICK CONNECT BURN HAZARD DECAL 1 3012103<br />
12 INSTALL CYL LOCK DECAL 1 3012108<br />
13 GASOLINE ONLY DECAL 1 3012114<br />
4<br />
10<br />
14 REFUELING WARNING DECAL 1 3012100<br />
15 READ MANUAL DECAL 1 3012106<br />
16 BOXER DECAL 1 2400489<br />
5<br />
17 OPERATOR SAFETY DECAL 1 3014124<br />
18 OPERATOR CONTROLS DECAL 1 3016199<br />
6<br />
19 AUX VALVE TO NEUTRALDECAL 1 3012102<br />
20 BATTERY GROUND DECAL (NOT SHOWN) 1 3012112<br />
21 TIE DOWN DECAL 3 0K18608.008<br />
1<br />
2<br />
11<br />
12<br />
9<br />
19<br />
17<br />
7<br />
8 21<br />
17<br />
15<br />
1<br />
13<br />
14<br />
18<br />
17<br />
16<br />
7<br />
21<br />
1166<br />
6<br />
7
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Travel Group<br />
Travel Group<br />
Item No. Description Quantity Part Number<br />
1 BOLT 8 1913367C<br />
2 FRONT IDLER ASSEMBLY 2 3010904<br />
3 FITTING 4 2416656<br />
4 WHEEL MOTOR 2 L112282<br />
5 WOODRUFF KEY 2 L112282.002<br />
6 OUTPUT SHAFT 2 L112282.003<br />
7 WHEEL MOTOR SEAL KIT (NOT SHOWN) 2 L112282.001<br />
8 FLANGE NUT 20 70.70492<br />
9 TRACK 2 2412017<br />
10 DRIVE HUB 2 3014195<br />
11 COTTER PIN 2 1630444<br />
12 SPROCKET 2 3014196<br />
13 FLAT WASHER 12 2398376<br />
14 BOLT 12 1913337F<br />
2<br />
17<br />
18<br />
8<br />
16<br />
8<br />
24<br />
1<br />
20<br />
15 CASTLE NUT 2 1471227<br />
16 MID-WHEEL “SPOOL” ASSEMBLY 6 3010906<br />
17 TRACK TENSION SPRING 2 2421900<br />
18 WELDMENT, TENSION BOLT PLATE 2 3010777<br />
19 PLATE, TENSION BOLT LOCK 2 3010778<br />
20 WELDMENT, TENSIONING BOLT 2 3016061<br />
21 BOLT 2 1913309C<br />
22 WASHER 2 2303143<br />
23 WASHER, LOCK 2 2303412<br />
24 WASHER, LOCK 20 2303415<br />
5<br />
3<br />
19<br />
21, 22, 23<br />
15<br />
10<br />
9<br />
13<br />
12<br />
11<br />
6<br />
4<br />
14<br />
1164<br />
8<br />
9
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Idler Wheel <strong>and</strong> Spring Assembly<br />
Mid Wheel Assembly<br />
1116<br />
1117<br />
Item No. Description Quantity Part Number<br />
1 TENSION LOCK PLATE 1 3010778<br />
2 JACKING BOLT WELDMENT 1 3010786<br />
3 SPRING TENSIONER WELDMENT 1 3010777<br />
4 SPRING 1 2421900<br />
5 TRACK FORK WELDMENT, RIGHT SIDE 1 3010770P<br />
TRACK FORK WELDMENT, LEFT SIDE 1 3010770P<br />
6 BEARING 2 2410266<br />
7 IDLER SPACER TUBE 2 3010476<br />
8 IDLER PIN 1 3010474<br />
9 SEAL 2 2414963<br />
10 SNAP RING 1 2401861<br />
11 FRONT IDLER WHEEL 1 3010487<br />
12 FLAT WASHER 1 3010519<br />
13 BOLT 1 1913321C<br />
Item No. Description Quantity Part Number<br />
1 NUT 2 70.70492<br />
2 WASHER 2 2398376<br />
3 SEAL 2 2414982<br />
4 SNAP RING 2 2401860<br />
5 BEARING 2 2410265<br />
6 MIDWHEEL 1 3010763<br />
7 MIDWHEEL AXLE 1 3010781<br />
10<br />
11
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Main Control Valve Group<br />
Main Control Valve Group<br />
Item No. Description Quantity Part Number<br />
1 CONTROL KNOB 4 L117270<br />
2 BOOM/BUCKET CONTROL LEVER 3 3015134<br />
3 FITTING 4 2419618<br />
4 FITTING 5 2419630<br />
29<br />
28<br />
27<br />
32<br />
2<br />
26<br />
25<br />
24<br />
23<br />
31<br />
33<br />
1<br />
3<br />
2<br />
4 5<br />
6<br />
7<br />
30 8<br />
22<br />
19<br />
34<br />
20<br />
18<br />
17<br />
16<br />
11<br />
15<br />
9<br />
10<br />
11 4<br />
12<br />
13<br />
14<br />
5 TUBE ASSEMBLY 1 3016175<br />
6 FITTING 1 2420694<br />
7 TUBE ASSEMBLY 1 3016170<br />
8 TUBE ASSEMBLY 1 3016172<br />
9 FITTING 1 2419630<br />
10 COUNTERBALANCE VALVE 1 2405230<br />
11 LIFT CYLINDER HOSE ASSEMBLY 4 3600014-033.00<br />
12 TUBE ASSEMBLY 1 3016171<br />
13 TUBE ASSEMBLY 1 3016173<br />
14 TUBE 1 3016176<br />
15 90 DEGREE FITTING 1 2416668<br />
16 TUBE 3016181<br />
17 TEST PORT 1 2420662<br />
18 TEST PORT DUST CAP 1 2413363<br />
19 FITTING 1 2416661<br />
20 TEE FITTING 1 2420674<br />
21 CARTRIDGE 1 2402256<br />
22 NYLOCK NUT 2 2297460<br />
23 WASHER 6 2303140<br />
24 FITTING 2 2416660<br />
25 TUBE ASSEMBLY 1 3016174<br />
26 DIVERTER VALVE 1 2405228<br />
27 90 DEGREE FITTING 1 2416667<br />
28 FITTING 1 2416693<br />
29 BOLT 2 1913384C<br />
30 UNION FITTING 1 2420636<br />
31 CONTROL VALVE ASSEMBLY 1 2405216<br />
32 KNOB 1 L117280-1.001<br />
33 CONTROL LEVER 2 3015133<br />
34 TUBE 1 3016182<br />
21<br />
1169<br />
12<br />
13
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Diverter Valve Group<br />
1<br />
2<br />
3<br />
4<br />
15<br />
This page intentionally left blank<br />
13<br />
14<br />
6<br />
5<br />
13<br />
12<br />
11<br />
10<br />
9<br />
8<br />
7<br />
1165<br />
Item No. Description Quantity Part Number<br />
1 TEXTURED GRIP 1 2396752<br />
2 LEVER 1 3016068<br />
3 BOLT 3 1913384C<br />
4 FLAT WASHER 3 2303143<br />
5 FITTING, SAE MALE 90 1 2420651<br />
6 CLAMP 1 2413378<br />
7 HOSE 1 2400873-039.00<br />
8 VALVE 1 2405229<br />
9 RELIEF VALVE CARTRIDGE 1 2402256<br />
10 NYLOCK NUT 3 2297460<br />
11 FITTING, SAE 1 2419630<br />
12 TUBE ASSY 1 3016176<br />
13 HOSE 2 3016017<br />
14 FITTING, SAE MALE 90 1 2416667<br />
15 FITTING, SAE MALE STR 2 2416660<br />
14<br />
15
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Rear Frame Group<br />
Rear Frame Group<br />
Item No. Description Quantity Part Number<br />
1 MANUAL HOLDER 1 2400822<br />
2 FUEL TANK CAP/FUEL GAUGE 1 2412003.001<br />
3 FUEL TANK 1 2412003<br />
4 FLAT WASHER 2 2303140<br />
5 BOLT 2 1913308C<br />
31<br />
2<br />
3 4<br />
31<br />
7<br />
5<br />
1<br />
6 8<br />
9<br />
11 8<br />
10<br />
31<br />
31<br />
8<br />
8<br />
12<br />
13<br />
25<br />
21<br />
22 23<br />
24<br />
26<br />
27<br />
28<br />
29<br />
30<br />
6 FITTING 1 2296593<br />
7 HOSE CLAMP 1 2293369<br />
8 FUEL HOSE 2 2400876.008<br />
9 CLAMP 1 2410371<br />
10 GROMMET 1 2290736<br />
11 FUEL SHUTOFF VAVLE 1 2402268<br />
12 ENGINE OIL FILTER 1 12-050-01-S<br />
13 FUEL FILTER 1 2393525.004<br />
14 OPERATOR PLATFORM 1 3016150<br />
15 COMPRESSION SPRING 2 2417921<br />
16 BOLT 2 1913389C<br />
17 WASHER 4 247111<br />
18 ROUND BUSHING 2 3015268<br />
19 RUBBER MATT 1 2391393<br />
20 SELF LOCKING NUT 2 70.70307<br />
21 HAND GRIP 2 2396730<br />
22 FLAT WASHER 4 2303148<br />
23 BOLT 4 1913318C<br />
24 ACCESS PANEL LOCK 2 2397211<br />
25 UPPER CONTROL PANEL 1 3016090<br />
26 LOWER SERVICE ACCESS PANEL 1 3016194<br />
27 AIR CLEANER WING NUT 1 12-100-01-S<br />
28 AIR FILTER COVER, INNER 1 24-096-01-S<br />
29 AIR FILTER PRECLEANER 1 2393530.002<br />
30 AIR FILTER ELEMENT 1 2393503.001<br />
31 CLAMP 5 2409375<br />
19<br />
15<br />
20<br />
16<br />
17<br />
18<br />
14<br />
1170<br />
16<br />
17
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Hydraulic Filter Group<br />
Hydraulic Filter Group<br />
Item No. Description Quantity Part Number<br />
1 HYDRAULIC FILTER ASSEMBLY 1 2420619<br />
2 HEX HEAD BOLT 3 2420619.007<br />
3 HYDRAULIC FILTER TOP COVER PLATE 1 2420619.005<br />
4 O-RING SEAL KIT 1 2420619.002<br />
5 HYDRAULIC FILTER PRESSURE SPRING 1 2420619.006<br />
6 HYDRAULIC FILTER ELEMENT 1 2420619.001<br />
7 FILTER HOLDER BASKET 1 2420619.003<br />
8 BOLT 2 1913344C<br />
9 WASHER 2 2303143<br />
13<br />
14<br />
12<br />
15<br />
16<br />
17<br />
18<br />
19<br />
10 FILTER HEAD 1 2420619.004<br />
11 DIPSTICK - PLUG ASSEMBLY 1 3016158<br />
12 90 DEGREE MALE FITTING 1 2416668<br />
13 VENT HOSE 1 2400830.03<br />
14 HYDRAULIC TANK VENT CAP 1 2416209<br />
15 ENGINE SHROUD 1 3016141<br />
16 BOLT 4 2416217<br />
17 LOCK WASHER 4 2303411<br />
18 HYDRAULIC TANK CLEAN-OUT COVER 1 2413360<br />
19 TANK CLEAN-OUT COVER GASKET 1 2413360.001<br />
2<br />
3<br />
4<br />
5<br />
6<br />
1<br />
11<br />
7<br />
4<br />
8<br />
9<br />
10<br />
4<br />
1173<br />
18<br />
19
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Muffler <strong>and</strong> Electrical Group<br />
Pump Group<br />
1<br />
10<br />
9 2<br />
12<br />
2<br />
1<br />
3<br />
11<br />
8<br />
7<br />
4<br />
10<br />
3 4<br />
6<br />
5<br />
1171<br />
Item No. Description Quantity Part Number<br />
1 IGNITION SWITCH 1 2414959<br />
2 MOLDED KEY SET ON RING 1 2414959.001<br />
3 MUFFLER 1 24 068 06-S<br />
4 SHEET METAL SCREW 1 2411995<br />
5 SPARK ARRESTOR 1 2393530.003<br />
6 REMOTE MOUNT POSITIVE JUMPER TERMINAL 1 2702350<br />
7 MUFFLER GASKET 2 2390590.008<br />
8 ENGINE, KOHLER CH20 (20 HP) 1 2393530<br />
9 LOCK NUT 4 2702013<br />
10 ENGINE HOUR METER 1 2391384<br />
11 LOW OIL PRESSURE ALARM (not shown) 1 2396139<br />
12 LOW OIL ALARM HARNESS (not shown) 1 3012074<br />
13 IGNITION HARNESS (not shown) 1 3012070<br />
14 ENGINE THROTTLE (not shown) 1 2396134<br />
15 GUARD, MUFFLER (not shown) 1 24 314 02-S<br />
5<br />
9<br />
8<br />
7<br />
6<br />
1172<br />
Item No. Description Quantity Part Number<br />
1 HIGH-SIDE TUBE ASSY 1 3016182<br />
2 LOW-SIDE TUBE ASSY 1 3016181<br />
3 LOCK WASHER 2 2303412<br />
4 BOLT 2 1913327C<br />
5 PUMP 1 2417601<br />
6 HYDRAULIC INLET TUBE 1 3015087<br />
7 CLAMP 1 2413378<br />
8 90 DEGREE O-RING FITTING, #12 1 2420650<br />
9 O-RING, #12 1 2394886<br />
10 O-RING, #10 2 2394885<br />
11 MALE FITTING, #10 2 2420638<br />
12 90 DEGREE FITTING 2 2416668<br />
20<br />
21
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Battery Group<br />
This page intentionally left blank<br />
2<br />
3<br />
4<br />
1<br />
6<br />
5<br />
1174<br />
Item No. Description Quantity Part Number<br />
1 BATTERY 1 2505090<br />
2 ADJUSTABLE BATTERY HOLDDOWN 1 2410242<br />
3 RED BATTERY TERMINAL INSULATOR 1 2290993<br />
4 BLACK BATTERY TERMINAL INSULATOR 1 2290994<br />
5 BATTERY CABLE 2 3012005<br />
6 BATTERY HOLDOWN, ADJSTBLE 10” BOLTS 2 2413219<br />
22<br />
23
COMPACT<br />
TM<br />
COMPACT<br />
TM<br />
Hydraulic Schematic<br />
Electrical Schematic<br />
Aux.<br />
Attachment<br />
Motor<br />
BLUE 16 GA<br />
RED 14 GA<br />
RED/WHITE 16 GA<br />
BLACK 16 GA<br />
Tilt<br />
Cylinder<br />
IGNITION<br />
SWITCH<br />
Lift<br />
Cylinder<br />
Right Track<br />
Motor<br />
BLACK 8 GA BATTERY CABLE<br />
GREEN 18 GA<br />
Left Track<br />
Motor<br />
RED 10 GA<br />
8GPM<br />
Pump<br />
3GPM<br />
Pump<br />
Tank &<br />
Filter<br />
RED 12 GA<br />
BLUE 16 GA<br />
HOUR METER<br />
BLACK 16GA<br />
RED/WHITE 14 GA<br />
WHITE 16 GA<br />
BLACK 14 GA<br />
RED 18 GA<br />
GREEN 18 GA<br />
OIL<br />
PRESSURE<br />
WARNING<br />
HORN<br />
STARTER<br />
SOLENOID RED 8GABATTERY CABLE<br />
POSITIVE<br />
JUMPER<br />
POST<br />
RED 14 GA<br />
BLUE 16 GA<br />
RED/WHITE14 GA<br />
WHITE 16 GA<br />
SEE KOHLER COMMAND<br />
CH18-745 ENGINE SCHEMATICS FOR MORE<br />
DETAILS<br />
GROUND<br />
2305<br />
30A FUSE<br />
2306<br />
24<br />
25
COMPACT<br />
TM<br />
Compact <strong>Power</strong> Inc.<br />
P.O. Box 40 • Fort Mill, SC 29716<br />
Phone: 800-476-9673 • Fax: 803-548-2762<br />
Web Site: http://www.cpiequipment.com/<br />
Part No. 999-843 (Serial No.s 1518 & Higher)
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