Rayco T415, Operation, Service And Maintenance Instructions

Page 1: ...T415 OPERATION SERVICE MAINTENANCE MANUAL RAYCO MANUFACTURING 2019 ALL RIGHTS RESERVED PRINTED IN USA INDEX OSMT415 19 ...

Page 2: ...ld 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: ...T415 Operation Service Manual 800 392 2686 3 TABLE OF CONTENTS General Information 2 Safety 8 Operation 22 Maintenance 34 Specifications 108 Warranty 110 ...

Page 4: ...se of finding parts Please consult your local Rayco Dealer or local Engine Manufacturer Dealer for obtaining engine parts and service Operation The operation section is a reference for the new operator and a refresher for the experienced operator This section includesadiscussionofgauges switches machinecontrols attachment controls transportation and towing information Photographs and illustrations...

Page 5: ...trols are self centering STANDARD MACHINE FEATURES INCLUDE Rear Swing out Door for Primary Radiator Cleaning Additional Engine Radiator in Limb Riser 2 Speed Ground Travel Electronic Joystick Control Side Access to Batteries Master Electrical Disconnect Switch Remote Grease Point for Track Tension Adjustment Track Tension Monitoring System on LCD Display Lockable Access Panels Front Rear and Side ...

Page 6: ...eakdown of the serial number For Example T415 001 01 19 T415 Type of Rayco equipment you have 001 Three digit for the number of produced 02 Two digit month 01 Jan 02 Feb etc 19 Two digit year 19 2019 20 2020 etc It is attached to the machine at the location shown For ready reference record it in the boxes provided on the next page of this manual For reference on communication regarding the engine ...

Page 7: ...anual 800 392 2686 7 Serial Number Location Information Identification Numbers Model Number Serial Number Machine Engine Implement Implement Dealer Information Name Address Dealer Contact Phone Number Hours Sales Parts Service ...

Page 8: ...urethatallprotectiveguardsandallcoversaresecured in place on the equipment Keep the equipment free from foreign material Remove debris oil tools andotheritemsfromthedeck fromwalkways and from steps Secure all loose items such as lunch boxes tools and other items that are not a part of the equipment Knowtheappropriateworksitehandsignalsandthepersonnel that are authorized to give the hand signals Ac...

Page 9: ...y or death Indicates an imminently hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury A message either written or pictorial follows to explain the hazard Raycocan...

Page 10: ...ivalentspecificationsincluding butnotlimitedto physical dimensions type strength and material Failure to heed this warning can lead to premature failures product damage personal injury of death General Hazard Information Read understand and follow all 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 r...

Page 11: ...ot 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 eye protection 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 effectiv...

Page 12: ...rmanent machining jobs Wear an approved respirator if there is no other way to control the dust Comply with applicable rules and regulations 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 Pr...

Page 13: ...ystem before any lines fittings or related items are disconnected In addition avoid contact with other related hot engine parts such as exhaust manifolds turbochargers and mufflers External exhaust parts become very hot during operation Paper cloth and wooden materials could ignite if they come in contact with these parts Coolant When the engine is at operating temperature the engine coolant is ho...

Page 14: ...ons 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 clamps T...

Page 15: ...tempting 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 ...

Page 16: ...chineisequippedwithalightingsystem that is adequate for the job conditions Make sure that all machine lights are working properly Beforeyoustarttheengineandbeforeyoumovethemachine 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 or...

Page 17: ... 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 Avo...

Page 18: ...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 of the equipment in operation and the effects on machine stability Operating techniques Keep all attachments or pulled loads low to the ground f...

Page 19: ...t and maintain the seat suspension and adjustment mechanisms 5 Perform the following operations smoothly a Steer b Brake c Accelerate d Shift the gears 6 Move the attachments smoothly 7 Adjust the machine speed and the route in order to minimize the vibration level a Drive around obstacles and rough terrain b Slow down when it is necessary to go over rough terrain 8 Minimize vibrations for a long ...

Page 20: ... ECU connectors and engine control system to machine ground before welding on engine or machine High currents or electrostatic discharge in electronic components from welding may cause permanent damage Safety Decals The safety decals located on this machine contain useful and important information which will help you to operate your machine safely The complete decal kit and location of each decal ...

Page 21: ...se block Removal Procedure Lockout tag out equipment must be removed by the worker who placed it Before the removal of a lockout tag out the following must be completed 1 Removal of all non essential items 2 Check to see that all workers and bystanders are located in a safe position 3 Inform all affected personnel If a worker who applied the lockout tag out is not present and his supervisor deems ...

Page 22: ...T415 Operation Service Manual 22 1 2 3 11 6 7 Operation 2 1 7 4 9 8 5 8 8 9 5 5 5 10 21 ...

Page 23: ...ps 6 Cab Escape Hatch Window 7 Final Drive Motor 8 Exterior Lighting 9 Tilt Cab Lock 10 Tilt Cab Pivot 11 Cab Door Entry Cab Ineterior 12 RH Joystick Attachment Function 13 LH Joystick Machine Function 14 Seat Adjustments 15 Seat Belt 16 Display Panel 17 Fire Extinguisher 18 Emergency Escape Hatch 19 Heating Air Conditioning Controls 20 Slope Indicator 21 DEF Tank 17 19 18 20 ...

Page 24: ...ork period Also adjust the seat when you are changing operators Inspect the seat belt mounting hardware Replace any hardware that is damaged or worn Keep the mounting bolts tight Fasten the seat belt before you start the engine Emergency Exit Familiarize yourself with the alternate exit In the event that the primary exit is blocked the top window hatch may be removed This hatch is accessible from ...

Page 25: ... indicator lamps frequently during warm up and operation Undercoldconditions thehydraulicfilterrestrictionindicator lamp may come on Under extremely cold conditions the hydraulic filter may shut down the track transmissions and all hydraulic functions As the hydraulic oil warms up the track functions should return and the hydraulic filter restriction indicator lamp should go out If after the oil h...

Page 26: ...sts can be folded up if required and the height individually adjusted by turning the adjustment knob 3 Control Carrier 4 The joystick control carrier can be adjusted forward or backward for operator comfort To adjust the carrier loosen the knobs set at desired position and retighten To ease entry exit the left joystick box can be tilted up Seat Belt 5 Backrest Adjustment The backrest can be reclin...

Page 27: ...t of the LH Joystick is the 2 speed selector The crawler final drive has two ranges High range will increase speed but reduce torque Low range is used for optimal torque will performing work High range operation should be reserved for transport and not be used for heavy loads The selector is the single button located on the LH joystick Pressing the button will shift the final drive and the indicat...

Page 28: ...sed to shut down the machine in an emergency situation only Turn button indirection of arrow to release reset the switch Ignition The key switch 13 is used to start the engine stop the engine and activate the electrical system OFF Insert and remove the key from the switch in this position ONLY In the OFF position the electrical system is disabled ON Turn the key to this position to enable the elec...

Page 29: ...p of the operator The automatic locking retractor will adjust the length of the seat belt to the operator Releasing the Seat Belt Depress the button on the buckle to release the seat belt Park Brake The park brake can be applied when it necessary to stop the machine on a hill The button will illuminate once activated NOTE DO NOT ATTEMPT TO MOVE THE MACHINE WITH THE PARK BRAKE ENGAGED AS DAMAGE TO ...

Page 30: ...Indicator 12 Battery Voltage Indicator 13 Coolant Temperature Indicator 14 Hydraulic Filter Restriction Indicator 15 Engine Oil Pressure Indicator 16 Hydraulic Temperature Indicator 17 Engine Oil Temperature Indicator 18 Hydraulic Level Indicator 19 Track Tension Indicator 20 Hydraulic Accumulator Pressure 21 Engine Compartment Temperature 22 Reverse Fan Operation Reverses the fan on the limb rise...

Page 31: ...ndicator General hydraulic pressure consult fault page for problem 39 Cutter Speed 40 Drive Mode Selector Changes selections for forward and reverse speeds 41 Forward Speed Indicator When needed the operator can adjust the rate of forward speed If the operator chooses to creep forward have the turtle slow rabbit fast or can be left blank for standard operation 42 Reverse Speed Indicator When neede...

Page 32: ...reen depress the Right Arrow Key To return to the main screen depress the Door Icon Item 8 To reset the rocker switch calibration depress Item 5 Rocker Switch Calibration Procedure Not applicable for stump cutter attachment When the indicator next to the Flap Joy Sensor NoCal is on check the calibration indicators next to button 5 Once the CEN indicator is on push the rocker to its full forward po...

Page 33: ...To track or monitor fuel consumption depress item 5 to reset the Fuel Used number after each refueling This value displayed is the number of gallons used since the last reset Depress item 8 to return to the Main Screen Selected Operation Screen On the selected operation screen the operator needs to set the machine for the attachment being used To toggle between Mower and Cutter simply use the left...

Page 34: ...re that is involved The strength of the towing line or the bar should be at least 150 of the gross weight of the towing machine This is true for a disabled machine that is stuck in the mud and for towing on a grade For towing only attach the tow line to the tow eyes on the frame if equipped Use a wire rope cable with ends that have loops or rings Put an observer in a safe position in order to watc...

Page 35: ...o machines of the same size or larger than the towed machine Connect a machine on each end of the towed machine Be sure all necessary repairs and adjustments have been made before a machine that has been towed to a service area is put back into operation When the towing procedure is completed reengage the track drives Ensure that all instructions that are outlined in the Towing Information are car...

Page 36: ... you frequently compare the actual service hours to the record you will be properly informed to the maintenance requirements as time passes The maintenance intervals listed in this Maintenance Intervals section of this Operator Manual includes engine care topics For the complete information consult the Cummins Engine Operator Manual Rayco has attempted to accurately predict maintenance intervals f...

Page 37: ... X Seat Belt Inspect X X Cutter Teeth and Bolts Inspect Condition X replace Cutter Tooth Bolt Torque check Track Tension check X Air Cleaner Ejector Valve Clean X Hydraulic Oil Filters Change X X X Engine Mounts Inspect X X Engine Oil Filter Change X X Fan Belt Tension check check Fuel Filter Change X X Fuel Water Separator Element Change X X X Pump Gearbox Bolt Tightness Inspect X X Track Bolts R...

Page 38: ...check Cooling System Drain Clean X Hydraulic Oil Change X X Fuel Tank Drain Water Sediment X ROPS Inspect X Cab Windows Remove Clean X Rear Hood Screen Clean X Throttle Cable Adjust if equipped X MAINTENANCE LOG Date Machine Hrs Description of Service Maintenance Notes ...

Page 39: ...T415 Operation Service Manual 800 392 2686 39 Maintenance MAINTENANCE LOG Date Machine Hrs Description of Service Maintenance Notes ...

Page 40: ...I 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 cSt 100 C 46 3 cSt 40 C Pour Point 48 C 54 F If ...

Page 41: ...reme cold temperature areas a No 0 grade grease may be used Before lubricating make sure all grease fittings and the nozzle of the grease gun is clean Cold Weather Lubricants Before attempting to start the engine make sure that the oil in the engine the transmission and the hydraulic system are fluid enough to flow Check the oil by removing the dipsticks If the oil will drip from the dipstick then...

Page 42: ...t Maintenance Maintain freeze point between 15 F and 62 F A 50 mixture has a freeze point of 34 F refer to freeze point above Use commercially available test strips for both nitrate and molybdate Maintain nitrate levels between 800ppm and 2300ppm Check levels of nitrate and molybdate every 250 hrs Add SCA s based upon the engine OEM recommendations Top up low coolant systems with a 50 mixture as r...

Page 43: ...lt Torque Requirements SAE GRADE 8 TORQUE DRY OR LOCTITE 1 4 12 2 LB FT 5 16 26 2 LB FT 3 8 46 2 LB FT 7 16 75 5 LB FT 1 2 115 5 LB FT 9 16 160 5 LB FT 5 8 225 10 LB FT 3 4 400 20 LB FT 7 8 650 25 LB FT 1 975 25 LB FT 1 1 8 1350 25 LB FT 1 1 4 1950 25 LB FT 1 3 8 2550 25 LB FT 1 1 2 3350 50 LB FT METRIC CLASS 10 9 DRY OR LOCTITE M6 12 2 LB FT M8 30 3 LB FT M10 60 3 LB FT M12 105 5 LB FT M14 165 5 ...

Page 44: ...cab has been fully raised insert the safety bar 5 to hold it in the raised position The 12V power unit is located below the engine Air Cleaner Check Replace To gain access to the filter cartridge release the clips on both sides 6 and the cover will then be free for removal To remove the outer filter 6A pull on the filter and it will slide out To remove the inner filter 6B pull on the filter and it...

Page 45: ...r points damage loose clamps or punctures that can damage the engine See the Engine Manual for details Back Up Alarm Test The back up alarm is mounted to the top rear of the cab It is intended to sound whenever either or both tracks move backward or when the engine automatically shuts down To test Make sure that the area behind the machine is clear of personnel and obstacles Start the engine Make ...

Page 46: ...briser as shown below To access remove the two lynch pins and lift the doors upward If coolant is not visible in sight glass check the coolant level inside the purge tank Slowly open the 15 psi cap on the surge tank and add water or coolant as needed Engine Coolant Hoses Pressure Cap Check Check for damaged hoses pipes and loose or damaged hose clamps Replace as required Check both radiators for a...

Page 47: ... oil to the crankcase 7 Start the engine and run for two minutes The engine will distribute an additional quart of oil to fill the top portion of the oil cooler 8 Check the dipstick and top off the engine to the upper full line on the dipstick Fuel System Water Separator and Filter Check Drain The water separator 3 is located on the left hand side of the machine along with the fuel filters mounted...

Page 48: ...eal groves to prevent leeks Inspect all parts of the filter housing for wear and cracks 10 Using clean diesel fuel lubricate the seals and place seal on fuel bowl 11 Install the fuel bowl to the base of the filter and tighten to 11 ft lb 12 Lubricate the fuel filter seal with clean fuel 13 Installthenewfilterontothebaseuntilthesealcontacts the fuel filter base and tighten 1 3 to 1 2 turn 14 Open t...

Page 49: ...hey perform a self test and should turn off if system is okay If one or both do not turn off then a problem has been detected and recorded on the Main Display Panel in the Fault Indicator Screen Diagnose and correct any problems before starting up the engine Look for inoperative gauges and LED s Turn on all of the machine lights Check for proper operation Make any necessary repairs before operatin...

Page 50: ...d on the right side of the machine The filler cap 1 is located on the top of the engine enclosure directlybehindthecab Thiscapcanonlyberemovedwiththe specialwrench Raycopart 19359 includedinyourtoolkit The oil level sight gauge 2 is located inside below the filler on the tank side Check the oil level when the machine is cold and on level ground Re fill the hydraulic oil tank 1 Clean all surroundin...

Page 51: ...Spec i fi ca tions It should be passed through a 10 micron nom i nal non bypass filter prior to entering the reservoir Never reuse fluid Check reservoir drain plug for leaking Install charge pressure gauge 3 Supply 10 PSI Maximum Compressed Air to the reservoir while sealing the reservoir fill neck with a rag held in your hand The pressure will push or force the hydraulic fluid into the system 4 L...

Page 52: ...ure gauge starts climbing steadily showing the system is filling If the charge pressure gauge does not move stop the prime mover and recheck installation 9 Charge Pressure should be steady at approximately 340 to 440 Psi This indicates the system is full 10 If Not at this pressure stop the prime mover and troubleshoot the installation and system 11 Set the Prime Mover at approximately 50 percent o...

Page 53: ...ct the Roll Over Protective Structure ROPS for loose or damaged bolts Replace any damaged bolts and any missing bolts with original replacement parts only Tighten the bolts to 400 ft lbs Do not weld on the ROPS Do not drill holes in the ROPS If the ROPS has any cracks in the welds or in any metal portion consult your Rayco dealer Do not mount fire extinguishers first aid kits lights or other items...

Page 54: ... begins to seep out of the cross hole 2 Retighten the nipple when the desired track tension is reached Track Bolts Re Torque When installing a track torque the 5 8 18 master link bolts the bolts that hold the track pad to the track chain to 224 263 ft lbs Track Drive Mounting Bolts Check Tighten Afterthefirst50servicehours checkthemetricboltsfastening the track drive motors to the frame for tightn...

Page 55: ...ine Injectors Inspect Consult your Engine Manual for details Engine Leaks Check Check for leaks as described in the Engine Operation Manual Engine Mounts Check Check and tighten if necessary all engine mounts Engine Valve Clearance Check The engine features a no adjust overhead Intake valves are set at 0 254mm 0 010 and operate within 0 006 to 0 015 Intake valve lash Exhaust valves are set at 0 50...

Page 56: ...he same voltage for jump starting Use of a welder or higher voltage damages the electrical system Use of Jumper Cables Turn the key switch of the stalled machine to OFF Move the power source machine to a location close to the stalled machine so that the jumper cables will reach DO NOT ALLOW THE MACHINES TO TOUCH Turn off the engine of the power source machine Connect the red cable to the positive ...

Page 57: ...emove all belly pans and guards from the final drives Store bolts and covers away from the machine until finished 3 Move the machine to the designated wash area put the machine on an incline with the front of the machine being higher than the rear to aid in draining while cleaning 4 Open all engine compartment doors and hoods and check to make sure water will not enter the engine internally from a...

Page 58: ...hen patented cast in recesses causes the oil to flow across the spline for wet spline operation DRIVE PLATE DRIVEN This unit mounts directly to the engine flywheel Use extreme care when mounting the drive plate to the engine flywheel to avoid pre loading the crankshaft bearings 1 Install the drive plate onto the engine flywheel drive plate hub is to face AWAY from the engine Bolt the drive plate t...

Page 59: ...er to evenly pry the pump pads loose of the gear box Be careful to lift the pump pads evenly to avoid damaging the pilot To avoid oil leaks all o rings are to be replaced any time the pump pad is removed 5 To access the input shaft retaining ring remove the expansion plug Remove the retaining ring from the input drive shaft and slide the shaft out of the engine adapter side see Figure A NOTE The e...

Page 60: ...housing This can be done by hand as the bearings are a slip fit see Figure C When rotating gears keep hands and fingers clear from the gear mesh 8 With all of the gears removed drive the input seal out towards the engine adapter It is required to change the input seal any time the input gear has been removed from the housing 9 To remove the bearings from the gears use a gear puller or Arbor press ...

Page 61: ... defects With a clean towel or rag wipe the housings clean 3 The gears have retaining ring grooves on the output side and a seal lip on the input side Install the gears into the housing half with the input side of the gear facing down or to where the engine adapter would be attached see Figure F Tip Apply a small coat of oil to the outside of the bearing to allow gear and bearing to slide into hou...

Page 62: ... to the seal O D and press into place 060 below flush with the gear Pressing the seal too far will create a leak or possibly block oil to the bearings see Figure H Do not use sharp objects for pressing in seals Press only on the outer edge of the seal to keep from bending or damaging the seal casing 8 To install the dipstick upright the gear box Apply Loctite 609 to the dipstick tube and insert th...

Page 63: ... failure of the pump drive 2 It is recommended to change oil after the first 500 hours or 3 months of service which ever occurs first Thereafter and under normal operating conditions Durst recommends that the oil be changed every 1000 hours or 6 months of service 3 Stop engine before attempting to check or add oil 4 Clean around dipstick and oil fill hole before checking or adding oil 5 Drain oil ...

Page 64: ...6 are not provided in gear box kit but are required in all vertical installations For replacement gears with bearings assembled order gear as a kit with a K number i e To order a 012010 gear with 2 012016 bearings order as K12010 012236 MAGNETIC DRAIN PLUG 012059 PLUG J84 DOWEL PIN 2 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG 4400 101 VENT D70 WASHER 12 D1353 CAP SCREW 12 A INPUT GEAR 012042 SE...

Page 65: ... plate run out Total TIR should not exceed 0 008 4 Apply Silver Streak 200S to the external splines and slide the input shaft of the pump drive into the drive plate hub until the engine adapter seats against the engine flywheel housing Do not use the engine adapter mounting bolts to seat the pump drive engine adapter housing to the engine flywheel housing This may reduce engine crankshaft endplay ...

Page 66: ... does not track in a straight line the pump displacement limiter will need adjustment This done electronically from the operator control screen setup menu RH Cutter Wheel Pump RH Track Drive Pump Series 90 LH Cutter Wheel Pump LH Track Drive Pump Series 90 ...

Page 67: ...l of fluid The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port A heat exchanger with a bypass valve is required to cool the case drain fluid before it returns to the reservoir Circuit Diagram for Series 90 PV and 90 MF 90000800E The System Circuit Control Handle Displacement Control Valve Orificed Check Valve Heat Exchanger Bypass Valve ...

Page 68: ...rge relief valve on the pump serves to maintain charge pressure at a designated level A direct acting poppet valve relieves charge pressure whenever it sur passes a certain level This level is nominally set refer encing case pressure at 1500 rpm This nominal setting assumes the pump is in neutral zero flow in forward or reverse charge pressure will be lower The charge relief valve setting is speci...

Page 69: ... 1 r o r a b 0 0 0 1 g n i t t i f g n i r O 8 1 6 1 9 3 M 6 M e r u s s e r P e g r a h C i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 4 M 5 M e r u s s e r P o v r e S i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 E 9 5 2 2 0 0 T Outline drawings showing port locations follow the tables below t r o P n o i t c n u F e z i S e g u a G d n a g n i t t i F 1 L 2 L e r u s s e r P e s a C i s p...

Page 70: ...e Gauge Port M5 Servo Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 Top View System Pressure Port B System Pressure Gauge Port M2 System Pressure Gauge Port M1 System Pressure Port A Case Drain Port L2 Left Side View System Pressure Port B Carge Pump Inlet Port S Charge Inlet Pressure External Control Pressure Supply Port X3 Charge Pressure Gauge Port M3 Right Side View Speed Sen...

Page 71: ...000820E System Pressure Gauge Port M2 System Pressure Gauge Port M1 Case Drain Port L2 Left Side View System Pressure Port B Charge Pump Inlet Port S System Pressure Port A Servo Displacement Cylinder Pressure Gauge Port M5 Servo Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 Top View Charge Pressure Gauge Port M3 after the filter Port E from filter Port D to filter Rear View Char...

Page 72: ...manufacturer for suitability This should be done at latest half way between fluid changes It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contami nated with foreign matter dirt water grease etc or if the fluid has been subjected to temperature levels greater than the recommended maximum Never reuse fluid The filter should be changed whenever th...

Page 73: ...of system Heat exchanger not sufficiently cooling the system Low charge pressure will overwork sys tem High inlet vacuum will overwork sys tem A dirty filter will increase the inlet vacuum Inadequate line size will re strict flow If the system relief settings are too low the relief valves will be overworked Leakage will reduce low side system pressure and overwork the system High system pressure w...

Page 74: ...th pump in neu tral 6 Charge pressure with pump in stroke 7 Pump charge relief valve 8 Charge pump inlet filter 9 Charge pump Insufficient hydraulic fluid to supply system loop Input to control module is operating improperly Control linkages are not secure control orifices are blocked etc If bypass valve s is open the system loop will be depressurized Low charge pressure insufficient to re charge ...

Page 75: ...variable motor displacement control is not functioning correctly variable motor swashplate may be in wrong position Internal leakage will reduce system pressure Fill oil to proper level Measure pump output and check for proper pump speed and see that the pump is in full stroke See if variable motor displacement con trol is responding If not repair or re place control Check for leakage in O rings g...

Page 76: ...ge in O rings gaskets and other fittings Excessive Noise and or Vibration Check Description Action 1 Oil in reservoir 2 Air in system 3 Pump inlet vacuum 4 Shaft couplings 5 Shaft alignment Insufficient hydraulic fluid will lead to cavitation Air bubbles will lead to cavitation High inlet vacuum will create noise A dirty filter will increase the inlet vacuum A loose shaft coupling will cause exces...

Page 77: ... while performing the procedure in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle machine S000007E 1 To measure pump charge pressure install a pres sure gauge in the pump charge pressure gauge port M3 Also install a gauge to measure case pressure tee into L1 or L2 or use servo gauge port Operate the system with the pump in neutr...

Page 78: ...should be torqued to 68 Nm 50 lbf ft Later production Series 90 pumps are equipped with an external screw adjustable charge pressure relief valve Adjustment of the charge pressure is accom plished by loosening the lock nut e z i S e m a r F e z i S h c n e r W 0 0 1 0 3 0 h c n i 6 1 1 1 0 5 2 0 3 1 h c n i 8 5 1 E 7 6 2 2 0 0 T and turning the adjustment plug with a large screw driver or a 1 2 in...

Page 79: ...desired maximum displace ment setting tighten the lock nut on the adjusting screw as follows e z i S e m a r F e u q r o T 0 0 1 0 3 0 t f f b l 8 1 m N 4 2 0 3 1 m N 8 4 t f f b l 5 3 0 5 2 0 8 1 t f f b l 2 9 m N 5 2 1 E 8 7 2 2 0 0 T 4 One turn of the adjusting screw will change the maximum displacement approximately as follows e z i S e m a r F f o v e R r e p p s i D n i e g n a h C x o r p p...

Page 80: ...uid The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port A heat exchanger with a bypass valve is required to cool the case drain fluid before it returns to the reservoir Circuit Diagram for Series 90 PV and 90 MF 90000800E The System Circuit Control Handle Displacement Control Valve Orificed Check Valve Heat Exchanger Bypass Valve Heat Ex...

Page 81: ...The charge relief valve on the pump serves to maintain charge pressure at a designated level A direct acting poppet valve relieves charge pressure whenever it sur passes a certain level This level is nominally set refer encing case pressure at 1500 rpm This nominal setting assumes the pump is in neutral zero flow in forward or reverse charge pressure will be lower The charge relief valve setting i...

Page 82: ... a b 0 0 0 1 g n i t t i f g n i r O 8 1 6 1 9 3 M 6 M e r u s s e r P e g r a h C i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 4 M 5 M e r u s s e r P o v r e S i s p 0 0 0 1 r o r a b 0 5 g n i r O 8 1 6 1 9 E 9 5 2 2 0 0 T Outline drawings showing port locations follow the tables below t r o P n o i t c n u F e z i S e g u a G d n a g n i t t i F 1 L 2 L e r u s s e r P e s a C i s p 0 0 1 r...

Page 83: ...ems eliminating unnecessary machine down time Following the fault logic diagrams are diagram action comments to further help explain the action steps shown in the diagrams Where applicable the action comment number of the statement appears in the action block of the diagram Inspect Repair or Replace Defective 1 Ok Symptom Action Step Comment Number Decision Solution Neutral Difficult or Impossible...

Page 84: ...ief Valve At Pump Low in Forward or Reverse Low in Neutral Forward or Reverse Inspect Inlet Filter 11 Inspect Motor By Pass Valve if Used 10 Check Oil Level in Reservoir 7 Inspect Charge Pump 15 Ok Below Level Clean Inspect Heat Exchanger 8 Clogged Ok Defective Inspect Heat Exchanger By Pass Valve if Used 9 Ok Defective Ok Check Charge Pressure Inspect Charge Relief Valve At Motor 14 Defective Ok ...

Page 85: ... Charge Relief Valve At Pump Low in Forward or Reverse Low in Neutral Forward or Reverse Inspect External Pump Control Linkage if Used 1 Inspect Inlet Filter 11 Inspect Pump Control Valve 2 Check Oil Level in Reservoir 7 Inspect Charge Pump 15 Ok Below Level Defective Ok Ok Defective Inspect Motor By Pass Valve if Used 10 Ok Defective Ok Check Charge Pressure Inspect Charge Relief Valve At Motor 1...

Page 86: ...place Repair or Replace Replace Repair or Replace Repair or Replace Low in Forward or Reverse Low in Neutral Forward or Reverse Check Charge Pressure Inspect Pump Control Valve 2 Inspect System By Pass Valve if Used 10 Inspect Inlet Filter 11 Replace Transmission Pump Motor Inspect Charge Pump 15 Inspect Charge Relief Valve At Pump 13 Defective Ok Ok Ok Defective Ok Defective Clogged Ok Defective ...

Page 87: ...trical Operated Controls A Plugged control orifice B Damaged mounting gasket C Worn stuck or bent control spool D Stuck solenoid valve s E Defective solenoid coil s F Mis adjusted Potentiometer G Defective Potentiometer H Mis adjusted speed sensor on motor when used I Defective speed sensor J Defective electronics module 3 Inspect Servo Piston for A Improper servo piston adjustment 4 Inspect Syste...

Page 88: ...in high pressure standby mode at the PC setting with zero flow until the function is actuated This condition is often called a dead head condition Once the closed center valve is opened the PC control senses the immediate drop in system pressure and increases pump flow by increasing the swash plate angle The pump continues to increase flow until system pressure reaches the PC setting If system pre...

Page 89: ...he slipper retainer The cylinder block rides on a bi metal valve plate optimized for high volumetric efficiency and low noise Tapered roller bearings support the input shaft and a viton lip seal protects against shaft leaks An adjustable one spool PC only not shown or two spool LS and remote PC control senses system pressure and load pressure LS controls The control ports system pressure to the se...

Page 90: ...i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A e v l a v f e i l e r m e t s y s l a n r e t x e k c e h C g n i t t e s g n i t t e s e v l a v f e i l e r l a n r e t x e w o L m e t s y s n w o d w o l s l l i w r e p g n i t t e s e v l a v f e i l e r l a n r e t x e t s u j d A s n o i t a d n e m m o c e r s r e r u t c a f u n a m e v o b a e b t s u m g n i t t e ...

Page 91: ... p e c c a e v o b a y t i s o c s i v d i u l F e r u t a r e p m e t d i u l f w o l r o s t i m i l r o l l i f o t p m u p e h t w o l l a t o n l l i w y l r e p o r p e t a r e p o o t l o r t n o c e r o f e b p u m r a w o t m e t s y s w o l l A e h t h t i w d i u l f e s u r o n o i t a r e p o r o f e d a r g y t i s o c s i v e t a i r p o r p p a s e r u t a r e p m e t g n i t a r e...

Page 92: ... i s o c s i v d i u l f h g i H y t i s o c s i v m u u c a v t e l n i h g i h s e s u a c e r o f e b p u m r a w o t m e t s y s w o l l A n o i t a r e p o n e e r c s t e l n i t c e p s n I n e e r c s t e l n i d e t c i r t s e r r o d e k c o l B m u u c a v t e l n i h g i h e s u a c l l i w e g a k c o l b e v o m e r n e e r c s n a e l C g n i p i p t e l n i k c e h C g n o l r o s...

Page 93: ...gauge in case drain port L1 or L2 to measure case pressure 2 Start the prime mover and allow fluid to reach normal operating temperature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 3 Loosen the PC set screw and turn the PC adjustment screw until the desired setting is indicated on the pressure gauge at port M2 Clockwise rotation will increa...

Page 94: ...achine or disable disconnect the mechanism while servicing CAUTION Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 4 While holding the position of the LS adjustment screw torque the LS set screw to 7 11 N m 6 8 lbf ft 5 Operate a hydraulic function to its full extension loadi...

Page 95: ...amination Polish the sealing area on the shaft if necessary 4 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation 5 Keeping the seal perpindicular to the shaft press the new seal into the housing just far enough to clear the retaining ring groove Install seal with the cupped side toward th...

Page 96: ...ring C106A and LS spool C112 from the control housing discard the O ring Note orientation of the spool for reassembly C117 C118 6mm C116 C117 C114 C115 C113 C200 C138 6mm C136 C135 C134 C133 C132 C103A C112 C106A C106 3 16 in 11 14 N m 8 10 lbf ft C103 3 16 in 11 14 N m 8 10 lbf ft C300 4pl 5mm 15 18 N m 11 13 lbf ft C102 2pl 4mm 7 11 N m 6 8 lbf ft P101 667 C107A C107 3 16 in 11 14 N m 8 10 lbf f...

Page 97: ...d install into the LS bore Place a new O ring and back up rings onto the LS adjustment screw and thread it into the LS bore until flush then make another full turn Install and torque the set screw to 7 11 N m 6 8 lbf ft 17 Using a new O ring install the plug C107 Torque to 11 14 N m 8 10 lbf ft 18 Using petroleum jelly to retain them install the three interface O rings CONTROL continued C117 C118 ...

Page 98: ...ENG COMP TEMP BLU FUEL LEVEL WHT MOWER HEAD PRESS WHT FAN SPD SOL YLW REAR WORK LGT WHT ECM START SIG BLU HORN RELAY GRN RT CUTTER FWD RED CIRCUIT BREAKER RED CIRCUIT BREAKER GRY A C COMP PWR YLW WORK LMP PWR CAN 2 SHIELD RED START SIGNAL BRN COOLANT LEVEL TEST CABLE 39715 02 RED BLK YLW 5VDC GRD BLK YLW 5VDC GRD BRN LT PROP REV GRY RT PROP FWD WHT RT PROP REV BLU 2SPD BLU HYD TEMP RETURN FILTER S...

Page 99: ... YLW REAR WORK LGT RED PWR ALWAYS HOT RED PWR ALWAYS HOT YLW FRT WORK LGT YLW FRT WORK LGT FUSE YLW REAR WORK LGT FUSE WHT ECM START SIG RED RH JOYSTICK PWR WHT MICRO OTHER WHT MICRO OTHER YLW WORK LGT PWR BLU HORN RELAY ORG SEAT SW PNK AUX HOT BLU FRESH AIR BLK WHT BINARY SW GRY A C COMP PWR WR CAN 1 SHIELD YLW CAN 1 GRN CAN 1 PUR DOOR OPEN RED COMM HOT PUR FUSE FEED BLK SENSOR GRD MP RETURN FILT...

Page 100: ...T415 Operation Service Manual 100 A C Hose Kit 40430 ...

Page 101: ...T415 Operation Service Manual 800 392 2686 101 ...

Page 102: ... FAN CONTROL VALVE 801922 FLOW DIVIDER 801931 T 45cc PUMP OPEN LOOP LOAD SENSE PUMP PRES 170 BAR 805818 PVG32 VALVE 801902 CONNECTED SOLID ATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT PERMISSION OF RAYCO MFG INC IS PROHIBITED Hydraulic Schematic 806038 Rev A ...

Page 103: ...00 010 000 005 ANGULAR 1 MATERIAL GREASE AND CAB LIFT CIRCUITS 806038 OF WOOSTER OHIO 06 13 18 1 1 3 5 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF RAYCO MFG INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF RAYCO MFG INC IS PROHIBITED UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE CAD GENERATED DRAWING DO NOT MANUALLY UPDATE DO NOT SC...

Page 104: ...OCK ACCUMULATOR BOOST 802964 180 PSI PRECHARGED TO 12 BAR ACCUMULATOR 2 5 GAL 801892 w C AUX PAD 130cc PUMP EDC 27989 MANIFOLD RETURN 801880 CHECK THERMAL 30 PSI 801543 HYD COOLER GB X GA X X X GC2 GC1 2 1 G1 D2 C2 B2 A2 D1 CH2 C1 B1 CH1 A1 T ACC X 2 1 2 1 Hydraulic Schematic 806038 Rev A ...

Page 105: ... SUCTION TRACK DRIVE 73 7 1 RELEASE PRES 16 50 bar disp min 16 50 bar RELEASE PRES 73 7 1 TRACK DRIVE 805811 CARTRIDGE 80cc MOTOR 801893 PUMP EDC W AUX PAD RH 55cc 805813 PUMP EDC W AUX PAD LH 55cc 805811 CARTRIDGE 80cc MOTOR 1200105 VALVE BRAKE HYDRAULIC RESERVOIR 801892 w C AUX PAD 801543 HYD COOLER disp min R HO 2 XXX Hydraulic Schematic 806038 Rev A ...

Page 106: ...Operation Service Manual 106 80581 801886 GEAR BOX LH TRACK ENGINE 805810 RH TRAC 8018 1 34 1 A1 B1 A2 B2 801892 CUTTER PUMP 2 801892 CUTTER PUMP 1 28702 2870 S S M3 M3 L2 L2 Hydraulic Schematic 806038 Rev A ...

Page 107: ...C 28702 28704 1 2 BULKHEAD CONNECTIONS 3 3 T CH1 CH2 28701 GB X GA X X X GC2 GC1 2 1 G1 D2 C2 B2 A2 D1 CH2 C1 B1 CH1 A1 T ACC X 2 1 2 1 801903 DETAIL 801970 FAN PUMP 802964 2 5GAL 180PSI ACCUMULATOR C2 D2 B2 A2 FRONT TOP VIEW OF 801903 4 3 50 51 52 53 4000psi 5000psi XX 3 4 1 2 45D 45D TOP 5 LS PUMP 805818 A RAYCO MFG INC HOSE ADAPTER KIT T400 806038 XXX ...

Page 108: ...Operation Service Manual 108 80581 801886 GEAR BOX LH TRACK ENGINE 805810 RH TRAC 8018 1 34 1 A1 B1 A2 B2 801892 CUTTER PUMP 2 801892 CUTTER PUMP 1 28702 2870 S S M3 M3 L2 L2 Hydraulic Schematic 806038 Rev A ...

Page 109: ...C 28702 28704 1 2 BULKHEAD CONNECTIONS 3 3 T CH1 CH2 28701 GB X GA X X X GC2 GC1 2 1 G1 D2 C2 B2 A2 D1 CH2 C1 B1 CH1 A1 T ACC X 2 1 2 1 801903 DETAIL 801970 FAN PUMP 802964 2 5GAL 180PSI ACCUMULATOR C2 D2 B2 A2 FRONT TOP VIEW OF 801903 4 3 50 51 52 53 4000psi 5000psi XX 3 4 1 2 45D 45D TOP 5 LS PUMP 805818 A RAYCO MFG INC HOSE ADAPTER KIT T400 806038 XXX ...

Page 110: ...10 ELBOW 45 DEG 10MFF X 10MORB 21 1 FF6801 08 12 ELBOW 90 DEG 08MFF X 12MORB 22 3 4603 20 16F ELBOW 45 DEG 20BEADED X 16MORB 23 1 FF6400 16 20 CONNECTOR 16MFF X 20MORB 24 1 FF6602 16 16 16 TEE RUN 16MFF X 16FFFX X 16MFF 25 8 4601 24 24F ELBOW 90 DEG 24BEADED X 24MORB 26 2 4601 20 20F ELBOW 90 DEG 20BEADED X 20MORB 27 1 FF6400 10 12 CONNECTOR 10MFF X 12MORB 28 3 4603 20 20F ELBOW 45 DEG 20BEADED X ...

Page 111: ...NBULKHEAD UNION 20MFF X 20MFF W LOCKNUT 58 1 FF2700 16 16 W LNBULKHEAD UNION 16MFF X 16MFF W LOCKNUT 59 1 FF2603 12 12 12 TEE 12MORFS 12MORFS 12MORFS 60 14 TBC 200 T BOLT CLAMP 61 8 TBC 188 T BOLT CLAMP 62 1 FF6400 20 24 CONNECTOR 20MFF X 24MORB 63 2 FF2406 06 06 REDUCER 6ORFS SWIVEL X 6MORFS 64 1 4404 16 16 ADAPTER 16BEADED X 16MNPT 65 1 FF2501 12 16 ELBOW 90 12MORFS X 16MNPT 66 1 FF6402 12 12 CO...

Page 112: ... W FAB GUARD 18 2 HOSE 12R13XF 12FSX 12FSX 84 W FAB GUARD 19 2 HOSE 12R13XF 12FSX45 DEG 12FSX 88 W FAB GUARD 20 1 HOSE H15410 10FSX90 12FSX 37 21 1 HOSE H14510 10FSX90 12FSX 73 22 1 HOSE 4R16 4FSX 4FSX 74 23 1 HOSE 4R16 4FSX 4FSX 35 24 2 HOSE 8R16 8FSX45 DEG 8FSX 174 25 2 HOSE 8R16 8FSX90 DEG 8FSX 43 26 1 HOSE 8R16 8FSX90 DEG 8FSX 36 27 1 HOSE 8R16 8FSX90 DEG 8FSX 56 28 1 HOSE 8R16 8FSX90 DEG 8FSX...

Page 113: ...6 6FSX 6FSX45 DEG 15 45 1 HOSE 16R16 16FSX 16FSX90 DEG 90 46 1 HOSE 20XF5000 20FSX 20FSX90 36 47 1 HOSE 20XF5000 20FSX 20FSX90 48 48 1 HOSE 4R16 4FSX90 DEG 4FSX 82 W FAB GUARD 49 1 HOSE 4R16 4FSX 4FSX 122 W FAB GUARD 50 1 HOSE 20R13XF5000 20FSX 20FSX45 35 51 1 HOSE 20R13XF5000 20FSX 20FSX45 31 5 52 1 HOSE 20R12XF4000 20FSX 20FL62 45 35 53 1 HOSE 20R12XF4000 20FSX 20FL62 45 31 Hydraulic Hose Kit 80...

Page 114: ...URN THERMOSTAT OUTLET WATER PUMP LOW SIDE 27 21 23 28 19 19 28 25 22 26 20 24 9 45 18 38 37 17 16 16 10 35 3 3 35 10 12 15 13 14 12 W RELIEF 15 16 11 8 9 1 4 13 CAP VENTED 764739 T U B E 3 8 5 4 5 CHARGE AIR COOLER 801541 RADIATOR LOWER 801540 SHUT OFF VALVES 802287 3 8 4 0 7 2 7 8 4 1 27725 A TUBE T U B E BLEED PORT T U B E UPPER RADIATOR 804628 HVAC UN CAB ASSEMBLY AIR 22 18 19 20 5 FUEL RETURN ...

Page 115: ...4 32 AIR Q D COUPLING 760776 804628 HVAC UNIT SSEMBLY 17 22 6 3 2 21 1 4 7 5 802205 FUEL BREATHER LWR FUEL TANK MAIN FUEL TANK FUEL FILTER ULATOR 88 BREATHER 120022 801886 GEARBOX 40 DEF TANK RETURN 25 26 CLAMP 730022 CLAMP 730022 CLAMP 730022 CLAMP 730022 CLAMP 730022 CLAMP 730022 CLAMP 738978 CLAMP 738978 CLAMP 738978 CLAMP 738978 CLAMP 738978 CLAMP 738978 CLAMP 738978 CLAMP 738978 ...

Page 116: ... 2 1 2 L X 3 8 NPT SCHED 40 20 1 6400 08 10 1 2 FLARE X 5 8 STRAIGHT THREAD ORING SEAL 21 1 5655 8 8 8 8 1 2 NPT X 1 2 FPT X 1 2 FPT X 1 2 FPT 22 1 5602 08 08 08 1 2 NPT X 1 2 FPT X 1 2 FPT 23 1 2501 04 08F 1 4 FLARE X 1 2 NPT 90 DEG 24 1 2501 04 02F 1 4 FLARE X 1 8 NPT 90 DEG 25 1 2404 06 08 3 8 FLARE X 1 2 NPT 26 1 2404 08 08 1 2 FLARE X 1 2 NPT 27 1 1168X4X4 NYLON AND NICKEL PLATED BRASS TUBE F...

Page 117: ... NO CLAMPS 8 1 HOSE EH225 10 BLANK BLANK 185 W FABRIC GUARD NO CLAMPS 9 1 HOSE EH225 10 BLANK BLANK 175 W FABRIC GUARD NO CLAMPS 10 1 HOSE EH225 10 BLANK BLANK 32 11 1 HOSE EH225 10 BLANK BLANK 14 12 1 HOSE EH225 10 BLANK BLANK 12 13 1 HOSE EH225 12 BLANK BLANK 132 W FABRIC GUARD NO CLAMPS 14 1 HOSE EH225 05 BLANK BLANK 118 W FABRIC GUARD NO CLAMPS 15 1 HOSE EH225 05 BLANK BLANK 130 W FABRIC GUARD...

Page 118: ... 802660 2 Bottom Roller 760164 18 Top Roller 760167 4 Track 801939 2 Sprocket 33243 2 Front Rock Guard 31119 2 Middle Rock Guard 31116 2 Rear Rock Guard 31114 2 MANUALS Parts PMT415 19 Operator Service Maintenance OSMT415 19 Operator Booklet OBT415 19 COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART QTY Ignition Key 764136 1 Ignition Switch 735999 1 Fuel Cap 802953 1 Coolant Cap 801335 1 Engine ...

Page 119: ... 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 or Modification Rayco is relieved of its obl...

Page 120: ...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 LLC retains the right to make changes in design and specifications engineering ...