Morbark RAYCO 1800 AWL, Operator, Service, Maintenance Manual

Page 1: ...RAYCO MANUFACTURING 2019 ALL RIGHTS RESERVED PRINTED IN USA INDEX OSM1800AWL 19 ARTICULATED WHEEL LOADER OPERATOR SERVICE MAINTENANCE MANUAL ...

Page 2: ...uld be readily available for reference at all times Additional copies of this manual may be purchased from Rayco This Rayco machine was designed and manufactured by RaycoManufacturing Inc Wooster Ohio Duetocontinuous improvements Rayco reserves the right to make changes in engineering design and specifications or discontinue manufacture at any time without notice or obligation Always have a record...

Page 3: ...1800 AWL Operation Service Maintenance Manual 800 392 2686 3 Table of Contents TABLE OF CONTENTS Foreword 4 Safety 8 Operation 23 Maintenance 30 Specifications 46 Troubleshoot 48 Warranty 57 ...

Page 4: ... its capabilities Maintenance Intervals The maintenance section is a guide to equipment care The Maintenance Interval Schedule lists the items to be maintained at a specific service interval The Maintenance Interval Schedule lists the page number for the step by step instructions required to accomplish the scheduled maintenance procedure Use the service hour meter to determine servicing intervals ...

Page 5: ... machine anchorage points and use approved fall arrest harnesses and lanyards Machine Description The Boxer 1800 articulated loader is designed for your maximum benefit for every dol lar spent The machine is constructed for durability and easy maneuvering for tight work areas with a width of 50 5 inches and length of 132 7 inches including bucket The Boxer 1800 hosts a powerful three cylinder 24 H...

Page 6: ...ayco equipment you have 001 Three digit for the number of produced 01 Two digit month 01 Jan 02 Feb etc 20 Two digit year 20 2020 21 2021 etc It is attached to the machine at the location shown For ready reference record it in the boxes provided on the inside front cover of this manual For reference on communication regarding the engine record its model and serial numbers also in the boxes provide...

Page 7: ...Number Machine Engine Implement Implement Dealer Information Name Address Dealer Contact Phone Number Hours Sales Parts Service Serial number is located as shown Use the below table to record identification numbers and dealer information Serial Number Location BOXER 1800 1800 0010120 41005 3720 1687 kg 2020 25HP 18 64kw ARTICULATED LOADER ...

Page 8: ...nique 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 ex...

Page 9: ...tion must conform to ANSI Z89 1 and DO NOT wear under chin strapping while operating or within the operation area of the Horizontal Grinder Eyeprotection mustconformtoANSIZ87 1andbethewrap aroundstyle Alwaysweartheeyeprotectionwhenoperating 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 t...

Page 10: ...th 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 Caremustbetakeninordertoensurethefluidsarecontained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluidwithsuitablecontain...

Page 11: ...ved or if a hydraulic line breaks Do not perform any work until you have read and followed the proper Lock Out Tag Out procedures Do not work beneath the cab of the 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 startthe...

Page 12: ... Paper cloth and wooden materials could ignite if they come in contact with these parts 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 pro...

Page 13: ... Leaks can cause fires Usecautionwhenyouarerefuelingamachine Donotsmoke 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...

Page 14: ...at there are no hazards around the machine While the machine is in operation constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine 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 ...

Page 15: ...eels 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 CAUTION FLYING DEBRIS NEVERstandorallow anyone else to be directly in front of...

Page 16: ...ting 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 impac...

Page 17: ...ing or any adjustments to the machine stay clear of the follow ing 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 r...

Page 18: ...ds should be used Additional guards may be required for specific applications or work tools The Operation and Maintenance Manual for your machine or your work tool will provide specific requirements for the guards Consult your Rayco dealer for additional information Precautions for Welding on FRAME with ENGINE MACHINE Electronic Control Unit ECU Important ALWAYSdisconnectElectronicControlUnit ECU ...

Page 19: ...se of energy Tag Out Procedure This procedure is to be used only if it is not reasonable to use the lockout procedure Allaffectedpersonsaretobenotifiedthattheequipment will be shut off and tagged out Allenergysourcesfortheequipmentshouldbeidentified The equipment shall be shut off or otherwise de energized being careful to de energize all energy sources This includes all valves switches breakers o...

Page 20: ...pply your brakes and NEVER speed up Let off the gas pedalandholdthesteeringwheelinastraight aheadposition A combinationdisturbance isimproperhandling whipping sway over steering or other deviation of the tow vehicle or trailer from their intended path due to one or more causes improper loading steering inputs excessive speed cross winds passing vehicles rough roads etc IF A COMBINATIONDISTURBANCEO...

Page 21: ...r onto the hitch ball and follow the instructions below to properly fasten the coupler to the hitch ball Do not allow your self to become distracted Ensure that the coupler is properly fastened to the hitch ball before moving to the next step COUPLER Push down on the latch and fully open the coupling Lower the coupler onto the hitch ball Checkthattheballclampispositionedbelowthecoupler The coupler...

Page 22: ...front wheels enter the trailer channels and continue driving the machine up the ramps until the rear drive wheels are on the trailer 4 Remove the machine tie down pin from the storage sleeve on the trailer and insert it through the matching holes in the machine and the trailer 5 Raisethetrailerrampsandlocktheminthetravelposition with the lock bars and associated retaining pins Secure the Load Secu...

Page 23: ...oader Boom 5 Engine Compartment 6 Hydraulic Quick Disconnect QD Fittings 7 Boxer Attachment Plate 8 Gauge Display Panel 9 Operator Switch Panel 10 Side Control Console and Joystick 11 Hydraulic Tank 12 Fuel Tank 13 Cooling Package 14 Air Filter 15 Horn Button Getting to know your machine 3 1 7 8 5 10 9 12 6 11 13 14 4 15 2 ...

Page 24: ...aneuver f Work Light Switch The work light switch activates the front and rear work lights g Park Brake Switch The parking brake switch engages and disengages the parking brake The parking brake is required to be on switch illuminated when starting the engine Note When dismounting the machine be sure to set the parking brake h Auxiliary Flow Switch The auxiliary flow switch changes the direction o...

Page 25: ...oystick forward towards the front of the machine To roll the attachment forward dump push the joystick outward to the right of the machine To roll the attachment back scoop pull the joystick towards the operator to the left of the machine When working with multiple personnel or operators it is good practice to use proper hand signals when operating the boom to minimize injury or property damage Fo...

Page 26: ...e temperature is extremely cold it may be necessary to usecoldweatherstart ingprocess Followtheman u fac tur er s recommended procedure Always change the hydraulic oil filter at the prop er times Wheel Maintenance The tires on the Boxer 1800 are designed to give ample traction and provide little ground disturbance The operator has the ability to set the tire pressure between 15 and 50 psi dependin...

Page 27: ...nto the attachment plate If the levers do not seat in inspect for damage or rust and service as needed After the attachment plate has be locked onto the machine and the hydraulic hoses need to be attached locate the two buttons 4 on top of the coupler block To make the hose attachment process easier press down on the buttons 4 on the coupler block to relieve pressure and then connect the attachmen...

Page 28: ...al such as dry grass or straw 3 When covering the engine for storage allow the engine and muffler to cool off completely 4 Operatetheengineaftercheckingandrepairingdamaged wirings or pipes and clearing flammable materials that may have accumulated while in storage such as debris brought in by mice Removal from Storage Remove all coverings Wipe excess oil from hy drau lic cylinder rods Lubricate ma...

Page 29: ...blacknegative jumper cable to the negative post of the stalled machine where thebatteryblacknegative cableisalreadyconnected 7 Start the engine on the boost machine and allow it to run at high idling speed for about ten minutes This will partially charge the stalled engine s battery 8 Start the stalled engine 9 Immediately after starting the stalled engine disconnect the jumper cables in reverse o...

Page 30: ...quipment Know the appropriate work site hand signals and the per sonnel 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 In haling gas from ...

Page 31: ...1800 AWL Operation Service Maintenance Manual 800 392 2686 31 Maintenance Maintenance Log Date of Service Machine Hours Description of Service Maintenance Notes ...

Page 32: ...DER BUSHINGS CHECK BOOM WEAR PARTS CHECK FUEL FILTER CHECK FAN BELT TENSION DAMAGE REPLACE FUEL FILTER CHECK TIRES RIMS CLEAN BATTERY TERMINALS REPLACE FAN BELT CHECK AIR INTAKE HOSES CLAMPS CHECK RADIATOR HOSES CLAMPS CHECK VALVE CLEARANCE REPLACE AIR CLEANER ELEMENT CLEAN WATER JACKET RADIATOR CHANGE CHARGE FILTER BOTTOM OF PUMP STACK REPLACE RADIATOR HOSES CLAMPS CHANGE COOLANT CHANGE BATTERY C...

Page 33: ...jacks and stands that have the proper weight rating Chock tires as needed 1 With engine OFF but still warm remove the rear belly pan using a 9 16 wrench or socket 2 With a pan large enough to contain the drained oil position it under the drain plug and remove the drain plug using 2 2 Remove the oil filter 3 by turning counterclockwise as shown 3 Apply a light oil film on the new filter gasket and ...

Page 34: ...r and outer elements and replace as necessary Hydraulic Oil Check The hydraulic oil tank 4 is located beside the engine The oil level is determined by removing the dipstick 5 The hydraulic oil should be at upper mark of the dipstick Add oil if it is below the level indicated Check the oil level only when the engine and hydraulic oil is cold and with the machine on level ground DO NOT SMOKE OR ALLO...

Page 35: ... 1 Turn machine off and allow machine to completely cool 2 Remove the left rear engine panel to expose the top of the hydraulic tank 3 Using a 10mm wrench remove the three bolts on the top of the filter housing and move filter cover off to the side Note use caution removing the top of the filter housing it is spring loaded to keep the filter seated in the base 4 Locate the wire handle on the top o...

Page 36: ...st possible speed Shut down the engine within 40 seconds if the pump or motor begin making an unusual noise indicating a lack of oil and be sure the reservoir is full and all the hoses are properly connected 4 Settheenginethrottleatapproximately50 ofmaximum throttleforafewminutes Thiswillpurgetrappedairfrom the pump control valve cir cuit 5 Now the hydraulic cylinders circuits may be prepared Run ...

Page 37: ...1800 AWL Operation Service Maintenance Manual 800 392 2686 37 Maintenance ...

Page 38: ...oolant before adding coolant If a large amount of coolant is needed to top off the machine look for leeks and service system as needed Coolant Drain and Fill Before draining any fluid be sure to have a catch pan large enough to contain the fluid being drained With the proper catch pan locate the radiator drain 5 on the right rear of the machine as shown Note facing the rear of the machine the left...

Page 39: ...sing a filter wrench loosen the filter and remove Before installing the new filter lubricate the sealing ring with fuel and fill the filter with clean fuel up to the threads Install the new filter hand tight and with a wrench give an additional 1 4 turn Note When the fuel filter has been changed air enters the fuel system By pre filling the fuel filter it reduces the amount of air that enters the ...

Page 40: ... of grease into the grease fittings on the machine If the fittings do not accept new grease replace an or clean as necessary Maintenance ACCUMULATED GREASE AND OIL ON A MACHINE IS A FIRE HAZARD REMOVE SUCH DEBRIS WITH STEAM CLEAN ING OR HIGH PRESSURE WATER SEE THE NOTE BELOW FOR DETAILS ...

Page 41: ...k control behind a cover B To access the panel remove the two retaining bolts A using a 4mm allen head wrench Once the plate cover has been removed press in the tabs on each side of the plastic cover to expose the fuses and relays When trouble shooting the above decal is located on the back of the access panel for reference A B ...

Page 42: ...G2 M2 A B T1 S M4 M3 Rs1 Rs2 BH T2 C R K L J M 1 B 1 B 3 6 6 7 3 7 8 3 8 D A 5 A B 6 7 1 1 4 I 6 7 3 D A 5 B 3 5 J I A 5 8 6 1 7 4 3 1 B 3 5 J A E 3 3 8 F N 6 O P 0 6 7 3 7 8 3 8 1 A E B 1 B 3 F 0 A 1 B A 6 8 3 1 2 1 3 Q 8 A O P 0 3 K 4 3 3 8 E A 5 7 A D I 3 4 5 3 E F ...

Page 43: ... J g I J e h G N f L e I i I R K Q D E F G R X j k f J K e I d J E L K h G K F d k e h G H E D F I J O Q D E F G N f R e Q G K E D D I G i d f e G E K h e I N G I e I R f R G i E R E J E f l I L I E D P Q D E F G m d D G N G D O G J K P Q D E F G n X o d D E L L p G h I K L G R K E H E Q L G d k R H G G i R d p G D U q F N r h d f D s H L G E R G K d J e E K e P d f D t d K L E I J u P i D E f L I...

Page 44: ... PWR RED DASH PWR BRN FUEL SOL BRN FUEL SOL YLW ALT YLW ALT PUR PILOT PUR PILOT PUR SEAT BELT PUR SEAT BELT BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK VALVE GRD 1 BLK VALVE GRD 1 BLK VALVE GRD 1 BLK VALVE GRD 2 YLW START SIG YLW START SIG BRN WHT FUEL SOL BRN WHT FUEL SOL WHT BRAKE WHT BRAKE GRN DIFF LOCK GRN DIFF LOCK GRN DIFF LOCK TAN OIL PRESS TAN OIL PRESS TAN OIL PRE...

Page 45: ...RUN PWR PNK WATER TEMP D WHT BU SIG BLK COMM GRD STARTER WATER TEMP SENSOR OIL PRESS SWITCH GLOW PLUGS ALTERNATOR YLW START SIG PUR WHT PILOT REVISIONS REV DATE DESCRIPTION BY ECO E See Sheet1 RAYCO MFG INC DWG NO HARNESS FRAME WIRING DATE SCALE FINISHED WEIGHT SHEET UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE FRACTIONAL 1 32 00 010 000 005 ANGULAR 1 CAD GENERATED DRAWING DO...

Page 46: ...tick then the oil is fluid enough to start the engine Do not use oil that has been diluted with kerosene Kerosene will evaporate in the engine If the viscosity of the oil is changed for colder weather also change the filter element If the filter is not changed the filter element and the filter housing can become a solid mass Drain all hydraulic cylinders and lines After you change the oil operate ...

Page 47: ...for your machine Conoco Phillips MegaFlow AW HVI 46 Viscosity 7 7 cSt 100 C 46 cSt 40 C Pour Point 45 C 49 F Shell Tellus T 46 new name Tellus S2 V46 Viscosity 7 95 cSt 100 C 45 9 cSt 40 C Pour Point 42 C 43 F Mobil DTE 15M Viscosity 7 8 cSt 100 C 46 cSt 40 C Pour Point 42 C 43 F Exxon Univis N 46 Viscosity 8 2 cSt 100 C 46 cSt 40 C Pour Point 48 C 54 F Pennzoil Pennzbell AWX MV 46 Viscosity 8 8 c...

Page 48: ...GUIDE When troubles occur be sure to check simple causes which at rst may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below and vary by engine speci cation Use these to locate causing factors Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key s...

Page 49: ...air cleaner cover and base for damage or indications of improper t and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow un ltered air into engine A dirty or clogged element could indicate insuf cient or improper maintenance Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioni...

Page 50: ...1800 AWL Operation Service Maintenance Manual 50 806813 Hydraulic Schematic ...

Page 51: ...1800 AWL Operation Service Maintenance Manual 800 392 2686 51 806813 Hydraulic Schematic ...

Page 52: ...B 16 1 4601 12 12 FIT EL90 12BEADED X 12MORB 17 1 6410 08 06 FIT STRAIGHT 08MORB 06FORB 18 2 FF6400 08 06 FIT STRAIGHT 08MORFS 06MORB 19 1 FF2603 08 08 08 FIT TEE 8MORFS 8MORFS 8MORFS 20 1 6410 16 08 FIT STRAIGHT 16MORB 8FORB 21 2 4603 12 12 FIT EL45 12BT 12MORB 22 1 FF6802 08 08 FIT EL45 8MORFS 8MORB 23 1 FF6500 08 08 FIT EL90 8MORFS 8FORFSS 24 7 FF6400 06 08 FIT STRAIGHT 6MORFS 8MORB 25 1 6408 H...

Page 53: ...HT 10MORFS 10MORB 38 1 FF6602 08 08 08 FIT RUN TEE 08MORFS 08FORFS SWIVEL 08MORFS 39 1 FF306 04 NUT BULKHEAD 04 40 4 FF306 06 NUT BULKHEAD 06 41 1 5504 06 04 ELBOW 90 06FNPT X 04FNPT 42 1 205 106 FIT STRAIGHT 05BARBED X 06MNPT 43 1 5504 06 06F ELBOW 90 06FNPT X 06FNPT 44 1 204 104 FIT STRAIGHT 04BARBED X 04MNPT ...

Page 54: ...T3004D 4FSX 4FSX90 40 15 1 HOSE T3006D 6FSX 6FSX90 65 16 1 HOSE T3012D 12FSX 12FSX 40 17 1 HOSE T3012D 12FSX 12FSX90 28 18 1 HOSE T3012D 12FSX 12FSX90 23 19 1 HOSE SRF12 BLANK BLANK 32 20 1 HOSE T3008D 8FSX 8FSX90 48 21 1 HOSE T3006D 8FSX 8FSX90 86 22 1 HOSE T3008D 6FSX 8FSX90 33 23 1 HOSE T3006D 6FSX 6FSX90 71 24 1 HOSE T3006D 6FSX 6FSX90L 52 25 1 HOSE T3006D 6FSX 6FSX90L 55 26 1 HOSE T3006D 6FSX...

Page 55: ...004D 6FSX 4FSX 44 39 1 HOSE T3004D 4FSX 4FSX90 32 40 1 HOSE T3008D 8FSX 8FSX90 32 41 2 HOSE T3008D 8FSX8FSX 11 42 1 HOSE T3004D 4FSX 4FSX90 32 43 1 HOSE SAE 30R7 04 BLANK BLANK 20 44 1 HOSE SAE 30R7 05 BLANK BLANK 41 45 1 HOSE SAE 30R7 05 BLANK BLANK 12 46 1 HOSE T3008 08FSX 06FSX 26 47 1 WRAP PLWD 16 24 48 1 WRAP PLWD 16 20 ...

Page 56: ...PWR RED RUN PWR RED DASH PWR RED DASH PWR RED DASH PWR BRN FUEL SOL BRN FUEL SOL YLW ALT YLW ALT PUR PILOT PUR PILOT PUR SEAT BELT PUR SEAT BELT BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK COMM GRD BLK VALVE GRD 1 BLK VALVE GRD 1 BLK VALVE GRD 1 BLK VALVE GRD 2 YLW START SIG YLW START SIG BRN WHT FUEL SOL BRN WHT FUEL SOL WHT BRAKE WHT BRAKE GRN DIFF LOCK GRN DIFF LOCK GRN DIFF LOCK TA...

Page 57: ...W START SIG YLW START SIG YLW START SIG TAN OIL PRESS RED RUN PWR RED RUN PWR PNK WATER TEMP BLK COMM GRD WHT BU SIG BLK COMM GRD STARTER WATER TEMP SENSOR OIL PRESS SWITCH GLOW PLUGS ALTERNATOR YLW START SIG PUR WHT PILOT REVISIONS REV DATE DESCRIPTION BY ECO E See Sheet1 RAYCO MFG INC DWG NO HARNESS FRAME WIRING DATE SCALE FINISHED WEIGHT SHEET UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES...

Page 58: ...y Air Filter M29135 772 1 Charge Filter 806848 1 COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART Qty Tool Box Key 762015 1 Ignition Key M29211 929 1 Ignition Switch M29211 935 1 Hydraulic Cap w Dipstick 806655 Fuel Cap 800731 1 Coolant Cap 1 Fan Belt 1 FILTER SERVICE KIT 41200 KIT INCLUDES FILTERS IN THE FILTER SERVICE SECTION MANUALS Parts PM1800AWL 19 Operator Service Maintenance OSMAWL1800 1...

Page 59: ...he product to and from the place at which warranty work is performed 3 Any product that has been altered or modified in ways not approved by Rayco 4 Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow operating instructions misuse lack of proper protection during storage or accident D Unapproved Service Modification Rayco is relieved of its obli...

Page 60: ...hink Smart Think Safe We care about your safety When operating your RAYCO machinery always wear an ap proved helmet complete with ear muffs face shield and the proper eye wear Never operate under the influence of alcohol or drugs Know your RAYCO read and understand your owner s manual cover to cover RAYCO Manufacturing Inc retains the right to make changes in design and specifications engineering ...