Rayco C275 Operator, Service, Maintenance Manual
The Rayco C275 is a powerful mid-sized stump cutter designed for contractors. It boasts a 260hp Cummins engine for efficient operation and features a comfortable side entry cab with excellent visibility. The C275 also offers a heavy duty undercarriage for long life, multiple track shoe options for various ground conditions, and a single-drive cutter head with a variable displacement motor for optimized cutting power.
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C275 OPERATOR · SERVICE · MAINTENANCE MANUAL RAYCO MANUFACTURING © 2019 ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMC275-19 C275 Operation & Service Manual This manual is published by Rayco Manufacturing, Inc. for the benefit of the users of Rayco products. Rayco Manufacturing, Inc. has made every effort to ensure that this manual is correct and up to date at the time of publication. However, due to continuous improvements, Rayco Manufacturing, Inc. reserves the right to make changes in the contents, at any time, without notice or obligation. Each machine shipped contains operation, maintenance & parts manuals to familiarize the operator with the proper operating, lubricating and maintenance instructions. This helps to ensure the best possible performance and service from the machine. Read and understand all instructions before attempting to operate this machine. This manual should 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 Rayco Manufacturing, Inc., Wooster, Ohio. Due to continuous improvements, Rayco reserves the right to make changes in engineering, design and specifications, or discontinue manufacture, at any time, without notice or obligation. CALIFORNIA PROPOSITION 65 WARNING THIS MACHINE AND ITS CONSTITUENTS ARE KNOWN IN THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRODUCTIVE HARM. VISIT WWW.P65WARNINGS.CA.GOV NOTICE: Maintenance and Repairs should ONLY be performed by a trained specialists or qualified person. Please contact Rayco Mfg for a listing of approved maintenance facilities in your area. 2 C275 Operation & Service Manual TABLE OF CONTENTS Forward 4 Safety 8 Operation 22 Specifications 38 Maintenance 42 Troubleshoot 64 Warranty 99 800.392.2686 3 C275 Operation & Service Manual Foreword Literature Information Maintenance The operators manual should be stored in the operator’s compartment in the literature holder storage area. Rayco provides a binder to hold the Operator Service Manual, Parts Manual, Engine Manual along with other component manuals. 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. These manuals contain safety information, operation instruction, transportation information, lubrication information and maintenance information. Some photographs or illustrations in the publication show details of attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes. Continuing improvement may have caused changes to your machine which may not be included in this publication. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study and keep this manual with the machine. Whenever a question arises regarding your machine, of this publication, please consult your Rayco dealer for the latest available information. Safety The safety section lists basic safety precautions. In addition, this section may include text and locations of warning signs and labels used on the machine. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this machine. Parts Parts are readily found through illustrations with accompanying Rayco part numbers. The machine assembly is listed by basic groups to enable ease 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 includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities. 4 Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 100 service hours, also service those items listed under every 50 service hours and every 10 service hours or daily. C275 Operation & Service Manual Foreword Machine Description Serial Numbers The T260 stumper offers a solution for contractors looking for a mid-sized stump cutter with premium features and top level performance. The 6-cylinder Cummins engine provides 260hp and meets Tier 4 emissions. Operators will appreciate the comfortable, side entry cab with excellent visibility and a rooftop escape hatch. A heavy duty undercarriage provides long life and a smooth ride. Multiple track shoe options allow the T260 to meet a wide range of traction and ground pressure levels. The single-drive cutter head uses a variable displacement motor to maximize cutting power and efficiency. Each crawler track is driven by an independent hydrostatic transmission. All controls, both hydrostatic and hydraulic, are manipulated by joysticks. These controls are self-centering. Whenever communicating with Rayco or your Rayco dealer, have your machine serial number handy, as it can help pinpoint most exactly what information is need­ed in caring for your machine. It is attached to the operator right- hand side of the frame. STANDARD MACHINE FEATURES INCLUDE: • • • • • • • • • • • • • • • • • • • • • • • • • • • Rear Swing-out Door for Primary Radiator Cleaning 2-Speed Ground Travel w/Auto-Shift Pilot Operated Joystick Control Master Electrical Disconnect Switch Remote Grease Point for Track Tension Adjustment Track Tension Monitoring System on LCD Display Lockable Access Panels “Forgiving” Front Bulkhead Connections Front, Rear & Side LED Lighting Air Over Electric High-tone Horn Danfoss® PLUS-1® Controller & Terminal 71 gal Fuel Tank Powder Coat Paint *Warn® 18,000k Winch Side Cab Entry Door Cab top Escape Hatch Danfoss® PLUS-1® Graphical Terminal CANbus Lighted Switch Panel LED Dome Light (2) 12v Auxiliary Power Ports Adjustable Cup/Beverage Holder Side Mirrors GRAMMER Air-ride Suspension Seat w/Heat Power Actuated Tilt-Cab for Service/Maintenance Sealed/Pressurized Cab for Dust-Free Operation Fire Extinguisher Red Dot ® HVAC System 800.392.2686 5 C275 Operation & Service Manual Serial Number Location & Information Serial number is located as shown. Use the below table to record identification numbers and dealer information. Serial Numbers Location Whenever communicating with Rayco or your Rayco dealer, have your machine serial number handy, as it can help pinpoint most exactly what information is needed in caring for your machine. For reference on communication regarding the engine, record its model and serial numbers also in the boxes provided on the next page of this manual. See the Engine Operator Manual for assistance in locating the numbers on the engine. The serial number plate is located on the cab door side of the engine compartment, in front of the DEF tank. Breakdown of the serial number For Example: C275 001 01 19 C275 - 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 001= The three digit number of produced C275=Type of Rayco Equipment Production Date; 01=2 digit month; 19= 2 digit year CRAWLER C275 C275 0010119 275HP (205kw) 27460/12456(kg) 40857 2019 6 C275 Operation & Service Manual 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 800.392.2686 7 C275 Operation & Service Manual Safety California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Certified Engine Maintenance Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road engine owner, you are responsible for the required maintenance listed in the Engine Owner Manual & Machine Operator, Maintenance & Service Manual. Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. Know the width of your equipment in order to maintain proper clearance with you operate the equipment near fences or near boundary obstacles. Be aware of high voltage power lines and power cables that are buried. If the machine comes in contact with these hazards, serious injury or death may occur from electrocution. Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment. Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment. Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only. Do not smoke when you service an air conditioner. Also, do not smoke if refrigerant gas may be present. Inhaling the fumes that are released from a flame that contact air conditioner refrigerant can cause bodily harm or death. Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death. Never put maintenance fluids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position. When you perform maintenance above ground level, use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards. DANGER ZONE STAY BACK 300FT 8 C275 Operation & Service Manual Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WAR N I N G” or “CAUTI O N”. The Safety Alert “WARNING” label is shown below. Safety Warnings To highlight specific safety information the following designations are provided to assist the reader. This is the “Safety Alert” symbol. It is used to ALERT you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury 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. Rayco cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this 800.392.2686 Safety publication and on the product are therefore not all inclusive. If you desire to make use of a tool, procedure, work method, or operating technique not specifically recommended by Rayco, you must use it only if you have accurately evaluated it and found that it threatens no one’s safety. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that you choose. The procedures described in this “Safety” section may not be fully explained here, but a more complete explanation is given in the “Operation”, or in the “Maintenance” section. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Rayco dealers have the most current information available. Rayco Manufacturing, Inc. is greatly concerned with the safety of the operator, as well as all in the vicinity of his work. Rayco has provided shields, guards, safety decals and other important safety features to aid in using the machine properly. In order to further ensure your safety we ask that you properly operate and service your machine. This machine is capable of amputating hands and feet and throwing objects. Failure to observe safety instructions, improper operation, lubrication, maintenance, or repair of this product could result in severe injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product, until you have read, you understand, and you decide to do so in compliance with all of the operation, lubrication, maintenance, and troubleshooting information contained in these Operator and Parts Manuals and that contained in the Engine Operator Manual, which are included with this machine. Additional manuals are available from Rayco or your Rayco dealer. When replacement parts are required for this product Rayco recommends using Rayco replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. FAILURE TO HEED THIS WARNING CAN LEAD TO PREMATURE FAILURES, PRODUCT DAMAGE, PERSONAL INJURY OF DEATH. 9 C275 Operation & Service Manual Safety General Hazard Information (PPE) Head protection must conform to ANSI Z89.1 and DO NOT wear under chin strapping while operating or within the operation area of the Horizontal Grinder. Eye protection must conform to ANSI Z87.1 and be the wrap around style. Always wear the eye protection when operating or working within the operational area of the machine. Hearing Protection - Plug type ear protection or full ear coverage devices (muff type) shall be worn at all times when operating or within the operational area of the machine. 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 replacement parts. Familiarize yourself with all controls in a safe environment before operation. Know how to stop the machine and disengage the controls quickly. Never allow minors to operate this machine. Never allow anyone who has not had proper instruction to operate this machine. Keep bystanders, children and pets away from the machine and work area. Never allow anyone to ride on this machine. Never transport cargo, tools or wood on this machine. Keep the operator zone and adjacent area clear for safe, secure footing. Use the machine in daylight or under good artificial lighting. Use this machine for its intended purpose only, deviation from the machines capabilities could damage the equipment and cause injury or death. Gloves - When operating or handling brush within the operational area of the Horizontal Grinder, loose fitting gloves are the only gloves that should be worn. DO NOT wear gauntlet or strapped gloves. Clothing Protection - Clothes must be close fitting, but not restrictive of movement. DO NOT wear loose fitting clothes, jewelry or long dangling clothing; i.e. neckties, long belts or chains. Hooded sweat shirts may be worn only if the hood is tightly drawn around the face with drawstrings tucked into the outer garment when not in use. If working near traffic, wear reflective clothing. Shoes - (Foot Protection)- Always over the ankle work boots with skid resistant soles. Breathing Protection - When breathing protection is required the use of paper masks that can tear away if caught or entangled in material or machine must be worn. Flying Debris Do not allow anyone to stand in front or directly behind the machine. Flying debris could be thrown past Engine exhaust contains products of combustion which can be harmful to your health. Always start and operate the engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to the outside. Personal Protective Equipment guards and injure bystanders if they are in these areas. Pressurized Air and Water 10 C275 Operation & Service Manual Safety Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. Asbestos Information 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 effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275kPa (40 psi). Trapped Pressure Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines of fittings. High pressure oil that is released can cause a hose to whip. High pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death. Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause sever injury. If fluid is injected into your skin you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Containing Fluid Spillage Care must be taken in order to ensure the fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids. Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Rayco recommends the use of only genuine Rayco replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed: Never use compressed air for cleaning. Avoid brushing materials that contain asbestos. Avoid grinding materials that contain asbestos. Use a wet method in order to clean up asbestos material. A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used. Use exhaust ventilation on permanent machining jobs. Wear an approved respirator if there is no other way to control the dust. 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 Properly Tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids. 800.392.2686 11 C275 Operation & Service Manual Safety Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.Always use leak proof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. Crushing Prevention and Cutting Prevention Always shut-off the engine and wait for all moving parts, belts, fans, rotors, drums, cutting wheels (etc) to come to a complete stop before opening access covers and/or guards. Stay clear of all rotating and moving parts. A moving belt, pulley, sprocket and chain can suddenly pull a limb into them causing loss or severe injury. If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed. Keep objects away from moving fan blades. The fan blade will throw or cut objects. Do not use a kinked wire cable or a frayed wire cable. Wear gloves when you handle wire cable. When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear protective glasses when you strike a retainer pin. If equipment is unhitched from the tow vehicle for operation, always block the wheels and support the tongue weight with blocking to prevent unintended movement. Do not use only the jack stand to support the tongue while in operation. Burn Prevention Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks. Do not perform any work until you have read and followed the proper “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 start the engine. Unexpected machine movement could result. Whenever there are equipment control linkages, the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Avoid contact with the rotating feed wheel, cutter wheel and rotor. Do not touch any part of an operating engine. Allow the engine, radiator, exhaust and hydraulic reservoir to cool before any maintenance is performed. Relieve all pressure in the air system, oil system, lubrication system, fuel system, and/ or in the cooling system before any lines, fittings or related items are disconnected. In addition, avoid contact with other related hot engine 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 12 C275 Operation & Service Manual Safety When the engine is at operating temperature, the engine Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended. Fire Prevention and Explosion Prevention All fuels, most lubricants, and some coolant mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage. coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level only after the engine has been stopped. Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes or the mouth. Oils Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin. Remove the hydraulic tank filler cap only after the engine has been stopped. The filler cap must be cool enough to touch with a bare hand. Follow the standard procedure in this manual in order to remove the hydraulic tank filler cap. Batteries Remove all flammable materials such as fuel, oil, and debris from the machine. Do not allow any flammable materials to accumulate on the machine. Serious personal injury can occur when fuel or oil is spilled on yourself or your clothes, which can ignite. Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Do not operate the machine near any flame. Extinguish all cigarettes, cigars, pipes and other sources of ignition. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in case of a break in a line, in a hose, or in a seal. Exhaust shields must be installed correctly. Do not weld on lines or on tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the machine. Clean all electrical connections and tighten all electrical connections. Dust that is generated from repairing nonmetallic hoods or non metallic fenders can be flammable and/or explosive. Repair such components in a well ventilated area away from open flames or sparks. Inspect all lines and hoses for wear or for deterioration. The hoses must be properly routed. The lines and the hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Use caution when you are refueling a machine. Do not smoke while you are refueling a machine. Do not refuel a machine near open flames or sparks. Always stop the engine before refueling. Fill the fuel tank outdoors. 800.392.2686 13 C275 Operation & Service Manual Safety Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer. Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions. Do not charge a frozen battery. This may cause an explosion. Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate. Lines, Tubes and Hoses Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Rayco dealer for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque. Replace the parts if any of the following conditions are present: End fittings are damaged or leaking Outer coverings are chafed or cut. Wires are exposed. Outer coverings are ballooning. Fire Extinguisher Location Flexible part of the hoses are kinked. Make sure that a fire extinguisher is on the machine. Make sure that you are familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher. Obey the recommendations on the instruction plate. Outer covers have embedded armoring. Mount the fire extinguisher in an easily accessible place on the machine, for crawlers mount on the left side of the cab behind the seat. Consult your Rayco dealer for the proper procedure of mounting the fire extinguisher. Ether Starting Fluid Ether is flammable and poisonous. Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 49 °C (120 °F). Keep ether cylinders away from open flames or sparks. Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel. Do not spray ether into an engine if the machine is equipped with a thermal starting aid for cold weather starting. End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, and excessive hear. Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures: Mount the machine. Dismount the machine. If you are in the operator’s CAB during an electrical storm, stay in the operator’s CAB. If you are on the ground during an electrical storm, stay away from the vicinity of the machine! While Operating the Machine All personnel using this Machine must be trained in the operation, safety and maintenance repair procedures. Careless use of this Equipment could result in serious injury or even death. ALL PROCEDURES IN THE SAFETY AND OPERATION SECTIONS OF THIS MANUAL MUST BE READ AND UNDERSTOOD BEFORE STARTING THIS MACHINE. All operators must be wearing the proper Personal Protective Equipment before attempting to start and operate this machine. Do not allow children or other spectators to standby and watch the machine in operation. Familiarize yourself with all of the controls in a safe environment before starting to work with this machine. 14 C275 Operation & Service Manual Safety Always have more than one person at the job site. If an accident occurs, someone is there to assist or obtain help. Never operate or allow someone to operate the machine while under the influence of alcohol, drugs, or any medication that could affect the operator’s performance and concentration. Maintain a drug-free work place. Always operate this machine with all safety equipment in place and working. Make sure all controls are properly adjusted for safe operation. Do not change the engine governor settings or over speed the engine. The governor controls the maximum safe operating speed of the engine Never leave this machine unattended with the engine running. Use only your hand to operate the controls. Never use a foot, knee, rope or any extension device. Never hand-feed this machine for any reason. Contact with moving parts, belts or rotating cutter wheels can kill, injure or dismember. Turn off engine and wait for all movement to stop before working on this machine. Lock-out/Tag Out all controls. If equipped, the Emergency Stop buttons must be operating properly. These should each be checked and verified to shut down the engine by the operator prior to performing any work. CAUTION! FLYING DEBRIS! NEVER stand or allow anyone else to be directly in front of the In-Feed conveyor or directly behind the discharge conveyor! Stay away from the discharge chute while the rotor is turning. Material being discharged can cause severe injury, blindness or death. Always operate this machine from the operator area. Never stand directly in front or in back of machine as flying objects could be thrown during operation. Never move this machine, or make adjustments or repairs, while the engine is running. While Servicing and Performing Maintenance on the Machine ALWAYS Block the wheels to prevent unintended movement. Adhere to your LOCK-OUT/TAG-OUT procedure when performing maintenance or repairs to this machine. Locking and tagging out equipment safeguards those working on equipment from being injured by its unexpected energized or releasing stored energy. To prevent fires, clean debris and chaff from the engine and muffler areas. Periodically check that all nuts and bolts, hose clamps, and hydraulic fittings are tight. When removing the fuel cap, unscrew it slowly, and hold it firmly. The cap may otherwise be thrown due to pressure buildup caused by an increase in temperature. 800.392.2686 For your safety, repair or replace all damaged or worn parts immediately. Replacement parts which are authorized by Rayco are the only parts which should be used for repair or replacement on this machine. Altering this equipment, or using this equipment in such a way as to circumvent its design capabilities and capacities, could result in serious injury or fatality and WILL VOID THE WARRANTY. Do not alter this machine in any manner. Alterations such as attaching a rope to the control bar may result in personal injury or death. NEVER remove the cap from the hydraulic tank or reservoir while the Horizontal Grinder is running. Hot oil under pressure will cause injury. Relieve hydraulic system pressure before repairing or adjusting fittings, hoses, tubing, or other system components Before Starting Engine Start the engine only from the operator compartment. Never short across the starter terminate or across the batteries. Shorting could damage the electrical system by bypassing the engine neutral start system. Inspect the condition of the seat belt (if equipped) and of the mounting hardware. Replace any parts that are worn or damaged. Regardless of appearance, replace the seat belt after three years of use. Do not use a seat belt extension on a retractable seat belt. Adjust the seat so that full pedal travel can be achieved with the operator’s back against the back of the seat. Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Make sure that all machine lights are working properly. Before you start the engine and before you move the machine, make sure that no one is underneath the machine, around the machine, or on the machine. Make sure that the area is free of personnel. Visibility Information Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine. 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. Your machine may be equipped with visual aids. Some examples of visual aids are Closed Circuit Television and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids using the procedures that are located in this Operation and Maintenance manual. 15 C275 Operation & Service Manual Safety It may not be possible to provide direct visibility on large machines to all areas around the machine. Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility. Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area. Examples of job site organization include the following: Safety instructions Controlled patterns of machine movement and vehicle movement Workers that direct traffic to move when it is safe Restricted areas Operator training Warning symbols or warning signs on machines or on vehicles A system of communication Communication between workers and operators prior to approaching the machine Modifications of the machine configuration by the user that result in a restriction of visibility shall be evaluated. Make sure that the machine horn, the backup alarm and all other warning devices are working properly. Fasten the seat belt securely (if equipped). Lower the armrest. Operation Only operate the machine controls when the engine is running. Do not leave the operators station while machine is running. Before you move the machine, you must be certain that no one will be endangered. While you operate the machine and the work tool slowly in an open area, check for proper operation of all controls and all protective devices. Do not allow riders on the machine. Note any needed repairs during machine operation. Report any needed repairs. Use only Rayco Approved Work Tools on this machine. Obey all the lift restrictions. Refer to Operation and Maintenance Manual, “Rayco Approved Work Tools” for the approved work tools and the lift restriction information. Engine Starting If equipped, carry work tools low. Lower the lift arms fully. Tilt back the work tool in order to keep the work tool off of the ground. Do not go close to the edge of a cliff, an excavation, or an overhang. If a warning tag is attached to the start switch or to the controls, do not start the engine. Also, do not move any controls. If the machine begins to sideslip downward on a grade, immediately remove the load and turn the machine downhill. Move all hydraulic controls to the NEUTRAL position before you start the engine. 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. Diesel engine exhaust contains products of combustion which can be harmful to your health. Always start the engine in a well ventilated area. Always operate the engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to the outside. Before Operation Video tapes and safety information are available in English for this machine. A list of some of the material is available in the Operation and Maintenance Manual, “Reference Material”. Consult your Rayco dealer in order to obtain copies of the material. The information should be reviewed by every person that operates the machine. Clear all personnel from the machine and from the area. Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. Make sure that all windows are clean. Secure all doors in the closed position. Secure the windows in the open position or in the shut position. Avoid operating the machine across the slope. When possible, operate the machine up the slopes and down the slopes. Maintain control of the machine. Do not overload the machine beyond the machine capacity. Never straddle a wire cable. Never allow personnel to straddle a wire cable. Know the maximum dimensions of your machine. If equipped with a Rollover Protection Structure (ROPS), always keep the ROPS installed during machine operation. Observe all applicable local government regulations when you use this machine. Parking Park on a level surface. If you must park on a grade, chock the machine. Move the joystick control slowly to the NEUTRAL position in order to stop the machine. Move the throttle control lever to the LOW IDLE position. Lower all implements (if equipped) so that the work tool implement rests firmly on the ground. 16 C275 Operation & Service Manual Safety Move the hydraulic controls to the NEUTRAL position. Turn the engine start switch key to OFF position and remove the key. Disconnect the operator restraint devices (if equipped) and exit the machine. Block the wheels (if equipped), and set manual brake (if equipped) to prevent movement. Slope Operation The crawler should not be operated on slopes that are steeper than 30°. While this may not cause a loss of oil pressure, loss of traction could occur thus creating a rollover condition. NOTE: A 30° slope is equivalent to a 58% grade. A constant grade of 58% represents a 58’ change in elevation across a horizontal distance of 100’. Machines that are operating safely in various applications depend on these criteria: the machine model, configuration, machine maintenance, operating speed of the machine, conditions of the terrain, fluid levels, and tire inflation pressures. The most important criteria are the skill and judgment of the operation. A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability. Operator training provides a person with the following abilities: observation of working and environmental conditions, feel for the machine, identification stability. Rocky surfaces may promote side slipping of the machine. Slippage due to excessive loads – This may cause downhill tracks or downhill tires to dig into the ground, which will increase the angle of the machine. Width of tracks or tires – Narrower tracks or narrower tires further increase the digging into the ground which causes the machine to be less stable. Implements attached to the machine hitch or drawbar – This may decrease the weight on the uphill tracks. This may also decrease the weight on the uphill tires. The decreased weight will cause the machine to be less stable. Height of the working load of the machine – When the working loads are in higher positions, the stability of the machine is reduced. Operated equipment – Be aware of performance features of the equipment in operation and the effects on machine stability. Operating techniques – Keep all attachments or pulled loads low to the ground for optimum stability. Machine systems have limitations on slopes – Slopes can affect the proper function and operation of the various machine systems. These machine systems are needed for machine control on slopes. of potential hazards, and operating the machine safely by making appropriate decisions. Note: Safe operation on steep slopes may require special machine maintenance. Excellent skill of the operator and proper equipment for specific applications are also required. Consult the Operation and Maintenance Manual sections for the proper fluid level requirements and intended machine use. When you work on side hills and when you work on slopes, consider the following important points: Work Tool options - Attachments Speed of travel – At higher speeds, forces of inertia tend to make the machine less stable. Roughness of terrain or surface – The machine may be less stable with uneven terrain. Direction of travel – Avoid operation the machine across the slope. When possible, operate the machine up the slopes and operate the machine down the slopes. Only use work tools that are approved by Rayco for use on Rayco machines. Refer to the Operation and Maintenance Manual, Rayco options”. If you are in doubt about the compatibility of a particular work tool with your machine, consult your Rayco dealer. Make sure that all necessary guarding is in place on the host machine and on the work tool. Place the heaviest end of the machine uphill when you are working on an incline. If equipped, keep all windows and doors closed on the machine. Mounted equipment – Balance of the machine may be impeded by the following components: equipment that is mounted on the machine, machine configuration, weights, and counterweights. Always wear protective glasses. Always wear the protective equipment that is recommended in the work tool’s operation manual. Wear any other protective equipment that is required for the operating environment. Nature of surface – Ground that has been newly filled with earth may collapse from the weight of the machine. To prevent personnel from being struck by flying objects, ensure that all personnel are out of the work area. Surface material – Rocks and moisture of the surface material may drastically affect the machine’s traction and machine’s While you are performing any maintenance, any testing, or any adjustments to the machine, stay clear of the following areas: cutting edges, pinching surfaces, and crushing surfaces. 800.392.2686 17 C275 Operation & Service Manual Safety Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel. The procedure to use will vary with the type of equipment to be lowered. Keep in mind this system use a high pressure fluid to raise or lower equipment. The procedure will cause high pressure hydraulic oil to be released in order to lower the equipment. Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual. Sound Level Information • • • The operator Equivalent Sound Pressure Level is used to measure a work cycle sound exposure level Hearing protection may be needed when the machine is operated with an open operator station for extended periods in a noisy environment. Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment. Vibration Data Information concerning hand/arm vibration level When the machine is operated according to the intended use, the hand/arm vibration of this machine is rated by meter per second squared. Note: Vibration levels are influenced by many different parameters listed below. Operator training, behavior, mode, and stress Job site organization, preparation, environment, weather and material Machine type, quality of the seat, quality of the suspension system, attachments, and condition of the equipment. Guidelines for Reducing Vibration Levels on Equipment Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level: • • 18 Use the right type and size of machine, equipment, and attachments. Maintain machines according to the manufacturer’s recommendations. a: Tire pressures • • • • b: Brake and steering systems c: Controls, hydraulic system and linkages Keep the terrain in good condition. a. Remove any large rocks or obstacles. b. Fill any ditches and holes. c. Provide machines and schedule time in order to maintain the conditions of the terrain. Use a seat that meets “ISO 7096”. Keep the seat maintained and adjusted. a. Adjust the seat and suspension for the weight and the size of the operator. b. Inspect and maintain the seat suspension and adjustment mechanisms. Perform the following operations smoothly. a. Steer b. Brake c. Accelerate d. Shift the gears Move the attachments smoothly. Adjust the machine speed and the route in order to minimize the vibration level. a. Drive around obstacles and rough terrain. b. Slow down when it is necessary to go over rough terrain. Minimize vibrations for a long work cycle or a long travel distance. a. Haul the machines between workplaces. Less operator comfort may be caused by other risk factors. The following guidelines can be effective in order to provide better operator comfort: a. Adjust the seat and adjust the controls in order to achieve good posture. b. Adjust the mirrors in order to minimize twisted posture. c. Provide breaks in order to reduce long periods of sitting. d. Avoid jumping from the cab. e. Minimize repeated handling of loads and lifting of loads. f. Minimize any shocks and impacts during sports and leisure activities. Guards (Operator Protection) There are different types of guards that are used to protect the operator. The machine and the machine application determines the type of guard that should be used. A daily inspection of the guards is required in order to check for structures that are bent, cracked or loose. Never operate a machine with a damaged structure. The operator becomes exposed to a hazardous situation if the machine is used improperly or if poor operating techniques are used. This situation can occur even though a machine is equipment with an appropriate protective guard. C275 Operation & Service Manual Safety Follow the established operating procedures that are recommended for your machine. Rollover Protective Structure (ROPS), Falling Object Projective Structure (FOPS) or Tip Over Protection Structure (TOPS) The TOPS/FOPS Structure (if equipped) on your machine is specifically designed, tested and certified for that machine. Any alteration or any modification to the ROPS/FOPS Structure could weaken the structure. This places the operator into an unprotected environment. Modifications or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment. Excessive weight may inhibit the brake performance, the steering performance and the ROPS. The protection that is offered by the ROPS/FOPS Structure will be impaired if the ROPS/FOPS Structure has structural damage. Damage to the structure can be caused by an overturn, a falling object, a collision, etc. 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: ALWAYS disconnect Electronic Control Unit (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 is given in the “Parts” manual. For your protection, familiarize yourself with each label until you completely understand the warning intended. Do not violate any such warnings! Keep all decals in place and in good condition: Do not mount items (fire extinguishers, first aid kits, work lights, etc.) by welding brackets to the ROPS/FOPS Structure or by drilling holes in the ROPS/FOPS Structure. Use soap and water to keep decals clean. DO NOT use mineral spirits, abrasive cleaners or other similar cleaners which will damage the decals. Welding brackets or drilling holes in the ROPS/FOPS Structures can weaken the structures. Consult your Rayco dealer for mounting guidelines. Replace any damaged or missing decals. Before attaching decals, the surface temperature of the metal must be at least 40 degrees. The metal should also be clean and dry before attaching the decal. The Top Over Protection Structure (TOPS) is another type of guard that is used on crawlers. This structure protects the operator in the even of a tip over. The same guidelines for the inspection, the maintenance and the modification of the ROPS/FOPS Structure are required for the Top Over Protection Structure. Other Guards (If Equipped) Protection from flying object and/or falling objects is required for special applications. Logging applications and demolition applications are two examples that require special protection. A front guard needs to be installed when a work tool that creates flying objects is used. Mesh front guards that are approved by Rayco or polycarbonate front guards that are approved by Rayco are available for machines with a cab or an open canopy. On machines that are equipped with cabs, the windshield should also be closed. Safety glasses are recommended when flying hazards exist for machines with cabs and machines with open canopies. If the work material extends above the cab, top guards and front guards should be used. Additional guards may be required for specific applications or work tools. The Operation and Maintenance Manual 800.392.2686 If a machine component to which a decal is attached is replaced, be sure to replace the decal as well. Replacement decals may be purchased from Rayco Mfg or your Rayco dealer. LOCK-Out / Tag-Out Guidelines Always practice lock out tag out procedures when working on this machine. Locking and tagging out equipment safeguards those working on the equipment from being injured by its unexpected energized or releasing stored energy. This section summarizes the applicable requirements for lockout/ tag out procedures, and its intent to comply with OSHA regulations. Lock Out Procedure 1. All affected persons are to be notified that the equipment will be off and locked out. 2. All energy sources for the equipment should be identified. 3. The equipment shall be shut off or otherwise deenergized, being careful to de-energize all energy sources. This includes all valves, switches, breakers, or other controls 19 C275 Operation & Service Manual Safety that supplies energy to the equipment. In case of mechanical energy, a block may be used to stop the release of stored energy. 3. A lock is to be placed on each energy source disconnect or energy release block. a. The lock is to be placed directly on the equipment if provided with an integral locking device. b. If there is no integral lockout device on the equipment, securely attach an independently manufactured lockout device on the equipment and then place the lock on the lockout device. c. If none of the above are possible, use the tag out procedure. 4. A tag to be secured to the lock indicating that the equipment is not to be energized and who owns the lock. 5. It should be safely tested and verified that the lockout does prevent the release of energy. Tag Out Procedure This procedure is to be used only if it is not reasonable to use the lockout procedure. All affected persons are to be notified that the equipment will be shut off and tagged out. All energy sources for the equipment should be identified. The equipment shall be shut off or otherwise de-energized, being careful to de-energize all energy sources. This includes all valves, switches, breakers, or other controls that supplies energy to the equipment. in case of mechanical energy, a block may be used to stop the release of stored energy. Securely place a tag on each energy source disconnect or energy release 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 it necessary to energize the equipment, the following must be done by the supervisor. 1. Make all reasonable effort to contact the worker who placed the tag. 2. Determine the purpose of the lockout/tag out, and whether it is safe to operate the equipment in its current condition. 3. Remove all non essential items. 4. Inform all affected personnel. 20 5. Check to see that all affected persons are located in a safe position. 6. Inform the worker of the lockout/tag out removal before the worker starts to work for his/her next shift. 7. When more than one person works on the same equipment, multiple lock/tag outs must be used. Only when all locks are removed can the equipment be energized. Pre-Transportation Checks Never allow inexperienced drivers to tow the machine. When towing, always make sure the tow vehicle ball hitch and trailer/machine hitch coupler are the correct matching size and style. Always make sure the tow vehicle and the trailer/machine are on level ground and the wheels are chocked before connecting or disconnecting. Make sure the tow vehicle is of adequate size and has the towing capacity to safely tow the combined weight of trailer/machine. Never tow a machine while it is running. Towing will affect handling, allow for extra stopping distances. Refer to U-Haul’s “Safe Trailering” Driver Education Program that is available at this website: http://www.uhaul.com/guide/ index.aspx?equipment=towing-autotransport Make sure the towing eye is at the proper height so the machine tows level when traveling. A proper amount of tongue weight is required to allow the machine to tow properly. Too little tongue weight will result in wandering, fish-tailing, and/or axle damage. NOTE: Use caution when backing up. Be aware of the length of the equipment while turning, parking, crossing intersections, and in all driving situations. When arriving at the work site, do not set up the equipment under a tree that is being pruned, cut, or worked on. Important Towing Information PREVENT WHIPPING by properly loading the auto transport trailer. Load the heaviest end (engine end) of the vehicle-in-tow to the FRONT of the trailer. Loading heavier in the rear can cause the tow vehicle and transport trailer “combination” to begin WHIPPING, which is violent and uncontrollable sway. SIDE to SIDE MOTION (SWAY) THAT BEGINS as you reach a certain speed, will likely become WHIPPING at higher speeds. If you notice sway beginning SLOW DOWN IMMEDIATELY by letting off the gas pedal. Then stop to reload the vehicle-in-tow heaviest end forward as soon as possible, and remove any cargo from the vehicle-in-tow (vehicle carried on trailer). C275 Operation & Service Manual Safety IF WHIPPING or SWAY OCCURS, DO NOT steer. DO NOT apply your brakes and NEVER speed up. Let off the gas pedal and hold the steering wheel in a straight-ahead position. A “combination disturbance” is improper handling, 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 COMBINATION DISTURBANCE OCCURS, DO NOT steer or brake. Steering or braking during a disturbance can cause a loss of control or crash. If a WHEEL GOES OFF THE PAVED ROADWAY, DO NOT steer sharply and DO NOT brake. Let off the gas pedal and slow down below 25 mph. Then steer gradually back onto the roadway. Proceed with caution entering traffic. Loading Your Combination NEVER load cargo inside the vehicle-in-tow or on the trailer. Cargo inside the vehicle-in tow can cause sway or WHIPPING. NEVER overload your tow vehicle. Do not exceed the Gross Vehicle Weight Rating (GVWR) and the Gross Axle Weight Ratings (GAWR), which are posted on a label inside the driver’s door opening. Make sure the trailer is securely attached to the tow vehicle hitch before loading and unloading. Keep children and others at least 25 feet away during loading and unloading. Slow Down When Towing AVOID CRASHES by slowing down. Reduce your speed from what you would normally drive without a trailer under similar road conditions. The maximum speed is 45 mph when towing a trailer. Do not exceed any posted speed limit. DRIVE DEFENSIVELY – anticipate stops, brake early, and never follow closely. BEFORE going downhill, slow down and shift the transmission into a lower gear. DO NOT RIDE BRAKES on downgrades. Slow down for curves, adverse weather, hazardous road conditions, road construction and expressway exits. 800.392.2686 21 C275 Operation & Service Manual Operation Preparing the cutter boom BEFORE OPERATING, PLEASE CONSULT THE “SAFETY SECTION” FOR VITAL INFORMATION RELATED TO OPERATING THIS POWERFUL MACHINE! NOTICE Remove all loose pieces of wood, stones, wire and other debris from the work area before beginning removal. Wind direction should be considered, as it influences the direction that dust and wood chips will be directed. Always allow a cold engine time to warm up before cutting. Whenever the tracks of the machine raise off the ground while operating, lower the machine to the ground smoothly., DO NOT DROP OR CATCH IT WITH THE HYDRAULICS. Damage to the machine can result. Consult your RAYCO dealer for special cutting wheels and teeth available for a variety of applications. Move the machine whenever the cutting position is not efficient. The machine may be moved forward or backward anytime during the operating cycle. Use smooth, comfortable speeds while operating. For efficient operation, use more than one control at a time when possible. NOTICE The CB260 Cutter Boom is designed to be attached to the T260 Crawler. The cutter boom is not to be attached to any other machine. Consult your Rayco dealer with any Questions about attaching the CB260 Cutter Boom or consult the CB260 Manual. Machine Attachment WHEN ATTACHING THE CUTTER BOOM TO THE CRAWLER ALWAYS TURN THE ENGINE OFF. THE CASE DRAIN HOSE MUST ALWAYS BE CONNECTED FIRST. WHEN DISCONNECTING THE BOOM, THE CASE DRAIN MUST BE DISCONNECTED LAST. THE CASE DRAIN HOSE SHOULD NEVER BECOME PINCHED, REMOVED WHILE IN OPERATION, OR RESTRICTED IN ANY WAY. THIS COULD CAUSE SEVERE HYDRAULIC SYSTEM DAMAGE AND COULD VOID WARRANTY. 22 PREPARATION MUST BE CARRIED OUT WHILE THE BOOM IS ON THE GROUND, AND THE CRAWLER SWITCHED OFF AND LOCKED. NOTICE Before operating the first time (and each time the hydraulic circuit is disconnected), be sure that the hydraulic motor is full of oil. If not, fill with the same type of oil as the hydraulic circuit. Do not change the values on the check valve, or this will end the validity of the warranty. All jobs (connection, starting and movement checks) must be performed by specialized personnel only. The company using the cutter boom must instruct its personnel adequately and make available to them information on the cutter boom and how to operate it. We do not accept any liability in cases of accidents caused by failure to instruct personnel. Before beginning work, make sure the cutter boom is in order: • • • Lubricant oils are at the correct level Guards installed All parts that are subject to wear and tear are in good working order Work preparation and crawler connection must always be carried out with the boom on level ground, and the key removed from the key switch. Connecting the cutter boom to the crawler is dangerous. Be extremely careful and carry out the entire operation according to instructions. C275 Operation & Service Manual Operation Know Your Machine 1. Engine Access 2. Hydraulic Oil Cooler 3. Fuel Tank 4. Hydraulic Tank 5. Cab Door (entry) 6. Cab Escape Hatch & Window 7. Boom Swing Cylinder 8. Chain Guard 9. Final Drive Motor 10. Cutter Drive Belt Guard 11. Exterior Lighting 12. Tilt Cab Lock 13. Tilt Cab Pivot 14. Cutter Wheel 15. Horn 16. Rearview Mirror 26. 15.5k D-rings* 35. Battery and Hydraulic Filter Access 17. Cab Entry (Steps) 27. Back-up Alarm 36. Hydraulic Valve Access 18. Master Electrical Disconnect 28. Cab Tilt Cylinder 37. Right Joystick (Boom Control) 19. Tracks 29. Idler Access 38. Left Joystick (Machine Movement) 20. Cutter Wheel Motor 30. Engine Air Intake 39. Fire Extinguisher 21. Toolbox/Cab Tilt Remote 31. Exhaust 40. Seat belt 22. Electrical Panel Access 32. Hydraulic Fill Cap 41. Display/Control Panel 23. 18k Winch 33. Radiator Cap Access 42. Seat Adjustment 24. Winch Fairlead 34. Fuel Fill (Engine Compartment) * Not For Lifting or Towing Machine 25. Winch Line/Clevis Hook 800.392.2686 23 C275 Operation & Service Manual Operation Pre-Start Procedure Seat and Seat Belt Inspection Adjust the seat at the beginning of each work period. Also adjust the seat when you are changing operators. Walk-Around Inspection For maximum service life of the machine, make a thorough walk-around inspection. Inspect the machine for the following: • Loose bolts • Trash buildup • Oil leaks • Broken parts • Worn parts Inspect the overall condition of the machine and its hydraulic components. 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 Check the engine oil level, the hydraulic oil level, and the fuel level. Refer to the Maintenance Interval Schedule for all service recommendations. Mounting and Dismounting Unscrew Knobs to remove top hatch (emergency exit) steps to access cab 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 inside or outside the cab. The escape hatch is fastened with 3 knobs located directly above the operator seat. Rollover Protective Structure (ROPS) • • • Get on or off the machine only at locations that are equipped with steps and/or hand holds. • Before you get on the machine, clean and inspect the steps and the hand holds. Make all necessary repairs. • Face the machine whenever you get on or off the machine. • Maintain a three-point contact with the steps and hand holds. Note: Three-point contact can be two feet and one hand, or one foot and two hands. • • • • 24 Do not get on or off a moving machine. Never jump off the machine. Do not try to get on or off the machine if you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as hand holds when you enter or exit the operator’s compartment. • • To avoid the possible weakening of the ROPS/FOPS structure, do not alter the structure by welding, cutting, adding weight, or drilling holes into the structure. Do not mount fire extinguishers, first aid kits, lights or other items to the ROPS/FOPS structure. Welding brackets or drilling holes in the ROPS/FOPS can weaken the structure. See your Rayco dealer for mounting guidelines. Any alteration that is not specifically authorized by Rayco invalidates the certification for the ROPS/FOPS. The protection that is offered by the ROPS/FOPS will be impaired if the ROPS/FOPS has structural damage. Damage to the structure can be caused by an overturn, falling objects, etc. Use of the ROPS/FOPS in a damaged, modified or abused condition, or with a prior overturn, is unsafe and the operator protection is no longer suitable and must be replaced. ! C275 Operation & Service Manual Operation Starting Procedure UNDERSTAND AND HEED THE “SAFETY” SECTION OF THIS MANUAL, IN ITS ENTIRETY, BEFORE PROCEEDING. Normal Starting Safety Interlocks The safety interlocks are as follows: • • • Operator must be in the seat. Seat belt must be latched. Cutter Wheel is Off. The engine will not start unless the safety interlocks are engaged. Once the engine is running, if any of these interlocks are disengaged, the engine will remain running; however, all machine movement will be interrupted. Set the throttle control to SLOW or medium-slow position. Insert the key and turn the key switch to ON; check indicator lamps for malfunctioning bulbs. Turn the key switch to START; release the key switch once the engine has started. Pre-Operation Warm-Up Allow a cold engine to warm up at a low idle for at least five minutes. To help the hydraulic systems to warm up faster, cycle the controls. Raise the mower to its upper limit and continue pulling the mower control joystick back. This cycles oil through the control valves at system relief pressure and will shorten the time required to warm up the oil. Cycle the mower in this fashion for periods of ten seconds on, ten seconds off. Look at the gauges and indicator lamps frequently during warm-up and operation. Under cold conditions, the hydraulic filter restriction indicator 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 has warmed up, the lamp does not go out, the machine should be shut down and the cause determined. The most likely cause would be that the filter element needs serviced. • • • • Cycle all controls to allow warm oil to circulate into all lines and cylinders. Allow the machine to warm up for 15 minutes in temperatures above 0°C (32°F). Allow the machine to warm up for 30 minutes in temperatures below 0°C (32°F). More time may be required below -18°C (0°F). Allow the engine to warm up before increasing throttle. NOTICE Starting Engine with Air Intake Heater Do not operate the starter for more than 10 seconds at a time. If the engine does not start, allow a 60-second cool-down period between starting attempts. Failure to follow these guidelines may burn out the starter motor. If the key switch is released before the engine starts, wait until the starter and the engine stops turning before trying again. This will prevent pos­si­ ble dam­age to the starter and/or flywheel. Insert the key and turn the key switch to ON; check the indicator lamps for malfunctioning bulbs. Turn the key to the ON position and view the WAIT TO START lamp to see if it is illuminated. If it is illuminated, wait until it turns off before starting. The engine control system will automatically set the heater according to the ambient temperature. DO NOT USE STARTING FLUID AS A STARTING AID! 800.392.2686 25 C275 Operation & Service Manual Operation Machine Controls • Hydraulic Oil Level • Coolant Level • Engine Oil Pressure • Engine Coolant Temperature • Charge Pressure • Accumulator Pressure These have timers that will shutdown the engine 2. Work Lights 3. 4. Winch Out Activates winch out operation. 5. Winch In Activates winch in operation. 6. Windshield Wiper Activates front windshield wiper 7. Windshield Wiper Wash Activates washer fluid spray on the front windshield 8. Dome Light Turns interior dome light on or off 9. Throttle Up Increases engine RPM 10. Throttle Down Decreases engine RPM Backup Alarm Key Switch Panel Engine Starting Conditions: • • • • Operator must be in Seat Fasten Seat belt Cutter Wheel Throttle Lever is Off position Turn Key Warning Alarm Alarm will sound if either track drive is commanded to go in the reverse direction (turning, spot turning or reverse) 11 Keypad Functions 12 13 1. Park Brake The park brake can be applied when it necessary to stop the machine on a hill. The button will illuminate once activated. NOTICE NOTE: DO NOT ATTEMPT TO MOVE THE MACHINE WITH THE PARK BRAKE ENGAGED AS DAMAGE TO THE FINAL DRIVES MAY OCCUR! ALWAYS CHOCK OR SECURE THE MACHINE IN ADDITION TO PARK BRAKE WHEN SERVICING. DO NOT RELY SOLELY ON THE PARK BRAKE TO SECURE THE MACHINE. 26 14 15 16 17 11. Emergency Stop Button The E-Stop button is meant to be used to shut down the machine in an emergency situation only. Turn button indirection of arrow to release/reset the switch. 12. Key Switch The key switch 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 electrical system. The CHECK ENGINE and WAIT TO START warning lamps will self test for a few seconds. When lights go out you may start the engine. • START - Turn the key to this position and hold to crank the engine. Releasing the key will allow it to return to the ON position. The engine will not start unless the safety interlocks are engaged. The safety interlocks are as follows: • Operator must be in the seat. • Seat belt must be latched. • Cutter Throttle is Off position. #3. what is the camera? #13. rev. fan Eng limb Riser? seat? C275 Operation & Service Manual Operation • E-Stop Button is pulled out. Once the engine is running, if any of these interlocks are disengaged, the engine will remain running; however, all machine movement will be interrupted. 13. 14. STOP ENGINE The STOP ENGINE warning light indicate that a major fault has occurred and that the engine must be shut down immediately! The operator must check for any active faults that have been detective on the Main Display Panel in the Fault Indicator screen. Consult your RAYCO Dealer or Service Technician for further instruction. 15. CHECK ENGINE The CHECK ENGINE warning light tells the operator if there are any electrical faults within the system. Active and inactive faults can be viewed on the Main Display Panel in the Faults Indicator screen. When the key first energizes the system, it will perform a self test for a few seconds and the light will turn off telling the operator that it is safe to start the engine. If the light remains illuminated, the operator must check for any active faults that have been detective. Consult your RAYCO Dealer or Service Technician for further instruction. 16. WAIT TO START- (Intake Heater) The WAIT TO START warning lamps indicates that the intake air heater is activated. The air heater is automatically activated by the engine controller. Do not attempt to start the engine when this light is illuminated. When the light turns off, you may turn the key switch to the start position and start the engine. 17. Attachment Engagement The attachment engagement lever starts the attachment and allows the attachment to begin rotating. When engaging the attachment, with the engine at an idle increase the lever (17) until it stops in the forward position. Then increase the engine to full throttle. 800.392.2686 Heating/Cooling System 3 1 2 4 The cab is designed with a Fresh Air / Heater / Air Conditioner system. It is used to pressurize and help keep dust out of the cab. • Fan speed control (1). • Air mixture control (2). Note: If the A/C is switched off, the coolest setting will be the outside ambient air temperature. • Air Conditioning button (3). Note: the fan will continue to operate if the engine is off but the key switch is in the “on position” - the air conditioning will not operate unless the engine is running. It is generally ineffective to use the air conditioning in temperatures below 50oF (10oC) • Fresh air can be brought into the cab or recirculated using the mode switch (4). Note: to maximize heating or cooling in extreme conditions, use the recirculate mode. Because this mode recirculates the air inside the cab, it is also useful when working in excessively dusty conditions. 27 C275 Operation & Service Manual Operation Seat Adjustments & Components RISK OF ACCIDENT! DO NOT OPERATE THE SEAT ADJUSTMENTS WHILE OPERATING. ALWAYS MAKE SURE THE MACHINE IS STOPPED WITH THE PARKING BRAKE ENGAGED. ENSURE THAT ALL SEAT POSITIONS AND ADJUSTMENTS LATCH INTO PLACE WITH AN “AUDIBLE CLICK.” DOING SO WILL PREVENT INJURY AND UNWANTED SEAT MOVEMENT WHILE THE MACHINE IS OPERATING. Seat Depth Adjustment To adjust the depth of the seat cushion, pull the right handle upwards. By moving the seat cushion backwards or forwards the desired seating position can be reached. Note: this adjustment is independent of the seat backrest. Fore/Aft Isolator Under certain driving conditions, it is useful to activate the fore/aft isolator. When activated, the seat absorbs the majority of shock impacts from the driving direction of the machine. The fore/aft isolator is activated by moving the locking lever outward. Fore/Aft Adjustment (seat only) The fore/aft adjustment lever moves the operator closer or further away from the control joysticks. The fore/aft adjustment is released by lifting the locking lever. Fore/Aft Adjustment (entire seat Assembly) The entire seat assembly can be moved forwards or backwards by lifting the locking lever. By moving the entire seat assembly forward, this will allow the seat back to recline (see below for adjustment of the seat back). Lumbar Support By turning the adjustment knob to the left or right, both the height and curvature of the backrest cushion can be individually adjusted. This increases both the seating comfort and the performance of the operator. Armrests The armrests can be folded up if required and the height individually adjusted by turning the adjustment knob. Backrest Adjustment The backrest can be reclined lifting the locking lever. Seat Heater The seat heater can be activated by pressing the switch. 0=OFF and 1=ON Weight Adjustment The seat should be adjusted for the driver’s weight by briefly pulling the actuator lever (1) up. The machine should not be moving and the operator must remain still during the weight adjustment. To prevent operator injury and damage to the seat, the setting for the driver’s weight must be checked and adjusted as necessary before the vehicle is driven. Height Adjustment The seat height can be altered by fully pulling up or pressing down the actuator lever (1). In order to avoid damage, do not operate compressor for more than 1 min. Seat Pan Angle Adjustment The angle of the seat pan can be individually adjusted. To adjust the angle of the seat pan, pull the left handle (2) upwards. By exerting pressure on or off the front or rear part of the seat pan it can be moved to the desired angle position. Note: this adjustment is independent of the seat backrest. 28 Identify seat functions Control Carrier To ease entry/exit, the left joystick box can be tilted up. Seat Belt This machine was shipped from Rayco with a factory installed seat belt. Consult your Rayco dealer for all replacement parts. • Always check the condition of the seat belt and its mounting hardware before operating the machine. • Regardless of the appearance, the seat belt should be replaced every three years. • Inspect the seat belt for worn or frayed webbing. • Check the buckle for wear or damage. If the seat belt is worn or if the buckle is damaged, replace the seat belt and/or the buckle. • Inspect the belt mounting hardware. Replace any hardware that is damaged or worn. Make sure that mounting bolts are tight. C275 Operation & Service Manual Operation REVISIONS 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. Seat Belt Adjustment Boom Control REV. DATE DESCRIPTION BY ECO# A 3/16/2018 REMOVE MOWER FLOAT BUTTON CALLOUT EDT 18-080 The seat belt is equipped with an automatic locking retractor. The automatic retractor will lock the belt in place. Once the belt is locked, it cannot be pulled further out. The belt must return to its fully retracted position to allow it to be pulled out again. Fastening the Seat Belt • Pull the seat belt out of the retractor in a continuous motion. • Insert the belt tab into the belt buckle. Make sure that the seat belt is placed across the lap of the operator. • The automatic locking retractor will adjust the length of the seat belt to the operator. 1.750 Releasing the Seat Belt Depress the button on the buckle to release the seat belt. 4.000 Joystick Controls BACKGROUND TO BE WHITE • Push the stick forward to lower the boom. • Pull the stick backward to raise the boom. • Move the stick to the left to swing the boom left, or roll head back. • Move the stick to the right to swing the boom right, RAYCO MFG, INC. or roll the head forward. The stick may be moved to any combination of these positions 2-801560 to produce simultaneous results. NOTE: 1. SPLIT ADHESIVE-BACKED DECAL W/WHITE BACKGROUND. 2. 2 MIL WHITE POLYESTER W/1 MIL CLEAR POLYESTER OVERLAMINATE. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE: TEXT AND SYMBOLS TO BE SOLID BLACK Machine Movement - Direction & Speed Control The machine’s speed and direction are controlled with the LH joystick. Moving the stick further in any direction will increase the speed of the machine’s movement. • Letting go of the stick will allow it to center itself. In this position, the machine will not move. • Push the stick forward to move the machine forward. • Pull the stick backward to move the machine backward. • Move the stick to the left to counter-rotate the machine to the left. • Move the stick to the right to counter-rotate the machine to the right. • The stick may be moved to any combination of these positions to produce more gradual turns. 800.392.2686 The cutter boom is controlled by the RH joystick. Moving the stick further in any direction will increase the movement speed of the attachment. Letting go of the stick will stop the movement. FRACTIONAL .00 .000 ANGULAR 1/32 .010 .005 1 CAD GENERATED DRAWING, DO NOT MANUALLY UPDATE LGS CHKD SLB 02.11.11 MATL 0.039 DECAL-RH JOYSTICK --- MATERIAL FINISHED WEIGHT SCALE WOOSTER, OHIO DO NOT SCALE DRAWINGS DRWN DATE DWG. NO. 2:1 SHEET 1 OF 1 2-Speed (High Travel Speed) The button located in front (trigger) 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. Pressing the button will shift the final drive and the indicator will light. The final drive defaults to low when the key switch is turned on. The machine also has an auto-shift feature which will automatically downshift the final drive to provide more torque while in high range. This can happen when excessive pressure builds up from load resistance or when climbing a grade. When the pressure decreases, the transmission will shift back up into high range. Horn The horn button is located on the front (trigger) of the RH Joystick. Depressing this button will sound the horn. 29 C275 Operation & Service Manual Operation DP600 Main Display Panel Items on the Main Display Screen: 1) Seat belt buckled, wipers on and 2-speed engaged. 1 5 2 6 4) Fault Indicator Screen 3 7 5, 6 or 7) Engine Data screens 4 8 2) Hydraulic Pressure monitor screen 3) Stump Cutter Engage 8) Reversing Fan Sequence Start (fan will slow to a stop, reverse, slow to a stop and then return spinning forward) ESC OK Hydraulic Pressures Screen Depress “Hydraulic Pressure Icon” (item #2) to view ALL real-time system pressures. To return back to the main screen, Depress “Door Icon” (Item# 8) 1 5 2 6 Fault Indicator Screen 3 7 • 4 8 To view Engine Faults Screen, 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 position and hold until the MIN or Max indicator appears (approx. 5 seconds). Now place the rocker in the full reverse position and hold until the other indicator appears. Once MIN, MAX and CEN are all displayed the switch is calibrated. Pressing button #5 will prompt the user to clear the current calibration values. Re-calibration is recommended after replacing the joystick. ESC OK 1 5 2 6 3 7 4 8 ESC OK Engine Faults Screen 1) Switch between Active and Inactive Faults 5) View the previous fault. 6) View the next fault 8) Return to the Main Screen. Depress the Left Arrow button to return to the Faults Screen. 1 5 2 6 3 7 4 8 ESC 30 Display Screens the same? OK C275 Operation & Service Manual Operation DP600 Main Display Screen (continued) Engine Data Screen From the Main Display Screen, depress Item #5. to view the Engine Data Screen. 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. 1 5 2 6 3 7 4 8 Depress item #8 to return to the Main Screen. Main Display - Warning Characters ESC OK FUEL LEVEL - The fuel level gauge indicates the amount of fuel in the fuel tank. AIR FILTER RESTRICTION - The intake air cleaner restriction lamp indicates that the air cleaner needs serviced. HYDRAULIC OIL FILTER RESTRICTION -This warning lamp indicates that oil is moving through the filter element too slowly. Causes: dirty filter, cold oil or a combination of the two. Service immediately. ENGINE OIL PRESSURE - When the oil level drops, oil pressure drops, and the lamp lights up. If the indicator light comes on, the engine will shut off after 10 seconds. Check the oil level. ENGINE COOLANT LEVEL - When the coolant level drops the lamp lights up. If the indicator light comes on, the engine will shut off after 15 seconds. Check the coolant level and for any leaks. HYDRAULIC OIL LEVEL -This illuminates when hydraulic oil in the reservoir drops below the acceptable level. Shut off the engine immediately! Engine will automatically shutdown in 15 seconds. Check oil level and for any sign of leaks. HYDRAULIC OIL TEMPERATURE -This indicates the temperature of the hydraulic oil . Engine will automatically shutdown in 30 seconds. PARKING BRAKE (ON/OFF) - This illuminates when the Parking Brake is applied to final drive gearbox. BATTERY CHARGE - This illuminates when the battery is not being prop­er­ly charged or the fan belt has broken. Shut off the engine, and troubleshoot the electrical charging system. TRACK TENSION - This illuminates when track tension is too tight. View the Fault Indicator Screen on Main Display Panel for additional information. Loosen up track tension to correct setting. ENGINE COMPARTMENT TEMPERATURE - this illuminates when critical temperatures are sensed in the engine compartment. Shutdown the engine and diagnose cause before running. ENGINE COOLANT TEMPERATURE - Too much heat is a sign of engine trouble, and damage will occur if not corrected. The lamp will come on at (230°F/110°C) and the engine will shut down after 10 seconds. W - WARNING = This indicates that there is potential for engine fault or service issue. P - PROTECT = This indicates that in order to protect your machine, you need to shut down the machine and have it serviced. S - STOP = This indicates that there is an immediate fault or service issue, and machine shut down is mandatory. 800.392.2686 31 C275 Operation & Service Manual Operation Towing the Machine PERSONAL INJURY OR DEATH COULD RESULT WHEN TOWING A DISABLED MACHINE INCORRECTLY. BLOCK THE MACHINE TO PREVENT MOVEMENT BEFORE DISENGAGING THE TRACK DRIVES. THE MACHINE CAN ROLL FREE IF IT IS NOT BLOCKED. This machine is equipped with spring applied brakes. These brakes are also oil pressure released brakes. If the engine or the system for pressure oil is inoperable, the brakes are applied and the machine cannot be moved. The machine can be moved if the track drives are disengaged. These towing instructions are for moving a disabled machine for a short distance at low speed. Move the machine at a speed of 2 km/h (1.2 mph) or less to a convenient location for repair. These instructions are only for emergencies. Always haul the machine if long distance moving is required. To disengage the track drives, follow the following procedure: 1. Block the machine to insure it does not move or roll back on the technician when releasing the internal brake mechanism. 6. Once the brakes have been released, the machine is ready to be towed a short distance. 7. Great care should be taken as not to damage the splines on the transmission shafts that were removed. 8. Reverse the steps 2-5 to re-engage the track drives Shields must be provided on both machines. This will protect the operator if either the tow line or the bar breaks. Do not allow an operator to be on the machine that is being towed. Before towing, make sure that the tow line or the tow bar is in good condition. Make sure that the tow line or the bar has enough strength for the towing procedure 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 watch the pulling procedure. The observer can stop the procedure, if necessary. The procedure should be stopped if the cable starts to break. Also, stop the procedure if the cable starts to unravel. Stop pulling whenever the towing machine moves without moving the towed machine. DO NOT USE A CHAIN FOR PULLING A DISABLED MACHINE. A CHAIN LINK CAN BREAK. THIS MAY CAUSE POSSIBLE PERSONAL INJURY. 2. Remove the back track drive access panel. 3. Thread a M6 puller into the transmission shaft and pull Keep the tow line angle to a minimum. Do not exceed a 30° angle from the straight ahead position. Quick machine movement could overload the tow line or the bar. This could cause the tow line or the bar to break. Gradual, steady machine movement will be more effective. Normally, the towing machine should be as large as the disabled machine. Make sure that the towing machine has enough brake capacity, enough weight, and enough power. The towing machine must be able to control both machines for the grade that is involved and for the distance that is involved. shaft out. 4. Replace the blind cover and torque to 103 ft/lbs (140 Nm) 5. Repeat the process for the other track drive. 32 You must provide sufficient control and sufficient braking when you are moving a disabled machine downhill. This may require a larger towing machine or additional machines that are connected to the rear. This will prevent the machine from rolling away out of control. C275 Operation & Service Manual Operation All situation requirements cannot be listed. Minimal towing machine capacity is required on smooth, level surfaces. On inclines or on surfaces in poor condition, maximum towing machine capacity is required. Block the tracks securely so that the machine cannot move. NOTICE When the track drives are disengaged, the machine has NO parking brakes. The machine can roll and cause personal injury or death. The towing connection must be rigid, or towing must be done by two 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 carefully and exactly followed 800.392.2686 33 C275 Operation & Service Manual Maintenance NOTICE: Maintenance and Repairs should ONLY be performed by a trained specialists or qualified person. Please contact Rayco Mfg for a listing of approved maintenance facilities in your area. ANY ALTERATIONS, MODIFICATIONS, ADDITIONS, OR REPAIRS MADE TO THIS MACHINE WITHOUT WRITTEN CONSENT OF RAYCO MFG. WILL VOID THE PRODUCT’S WARRANTY, LIABILITY AND CERTIFICATION CALIFORNIA PROPOSITION 65 WARNING THIS MACHINE AND ITS CONSTITUENTS ARE KNOWN IN THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRODUCTIVE HARM. VISIT WWW.P65WARNINGS.CA.GOV 34 NOTICE The maintenance items shown in this section, when found under two interval options (one in service hours versus one in strict time), should normally be performed at the interval whichever occurs first in the course of the life of the machine. When consulting this manual regarding the longer maintenance intervals, care must be taken to not miss performing the shorter interval service requirements when the shorter intervals happen to coincide with the longer intervals, as, in such a case, it should be noted that the shorter intervals are not listed again along with the longer intervals. The engine hour meter is a reliable tool for measuring actual service hours of the machine. When each maintenance item is performed, a record of the current service hours and the date should be made, and a note should also be made, on a regularly viewed calendar, of when the next interval that requires scheduled maintenance is to occur, based on adding the amount of time for that next interval to the time when performing that maintenance, as suits the occasion. Then, as 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 for this machine. However, due to varying environmental operating conditions such as intense dust or moisture, or due to heavier usage, your machine may require certain maintenance at more frequent intervals than those given in this manual. Thus, whenever variance is found through the actual usage of this machine, the published interval should be disregarded and a more frequent interval applied.Improper maintenance or repair COULD result in equipment damage or personal injury. Always remove ignition keys from the ignition before performing any maintenance. Before performing any maintenance, please consult the “Safety” section in this “Operator Manual” for vital information related to operating this powerful machine! C275 Operation & Service Manual Maintenance Service Interval: Air Cleaner - Check / Replace Cartridges 10 Hrs First 25 First 50 Every 100 Every 250 Every Every 1000 Every As or Daily Hrs Hrs Hrs Hrs 500 Hrs Hrs Year Needed check replace Air Cleaner Ejector Valve- Clean X Air Filter for Air Conditioner - Clean / Replace X check Air Intake Piping- Check X Back-Up Alarm - Test X replace Battery & Cables - Check Brake System - Check X X Cab Windows - Remove & Clean X Cooling System - Drain & Clean Engine Coolant Level- Check X X Engine Coolant Hoses- Inspect X Engine Coolant- Anti Freeze Check X Engine Coolant Filter - Replace (if equipped) Engine Crankcase Breather Tube- Inspect X Engine Injectors - Inspect Engine Leaks - Check X X Engine Mounts - Check Engine Oil Level - Check X X X X X Engine Oil & Filter - Change X X Engine Valve Clearance - Check X Engine Vibration Damper- Check X Fan Belt Tension - Check X Fuel Filter - Change Fuel / Water Separator - Drain X X X X X X Fuel / Water Separator Element - Change Fuel Tank - Drain Water & Sediment X Fuel Tank - Fill X Gauges/Warning Lamps/Fault Codes - Check X Grease & Lubricate Moving Parts X Grease & Oil Buildup - Remove X Hydraulic Oil Tank - Check & Fill X X Hydraulic Oil Cooler - Clean w/Air X Hydraulic Oil Filters - Change X Hydraulic Oil - Change Pump/Gearbox Bolt Tightness - Check Gearbox Oil - Check X replace X X X X X X X X Radiator Pressure Cap- Check X Debris Screens - Clean X ROPS - Inspect X Seat Belt - Inspect X Cooler / Radiator - Clean & Inspect X Track Adjustment - Check X Track Adjustment - Adjust X X Track Pad Bolts - Re-Torque X Track Motor / Sprocket Bolts - Check X Track Drive Oil - Check X Track Drive Oil - Replace Walk Around Inspection 800.392.2686 X X X 35 C275 Operation & Service Manual Maintenance 36 C275 Operation & Service Manual Maintenance Maintenance Log Date of Service Machine Hours 800.392.2686 Description of Service/ Maintenance Notes 37 C275 Operation & Service Manual Maintenance RAYCO LUBRICATION & FLUID SPECIFICATIONS Rayco Lubrication & Fluid Specifications Engine Oil During the initial break-in period, the engine will consume more oil than usual. Check the engine oil level daily. ONLY USE CH-4 (or better) CLASSIFICATION OILS WITH A 10 TBA OR HIGHER. See the Engine Operator Manual for engine lubricating oil specifications. Fuel - Diesel Engine See the Engine Operator Manual for engine fuel specifications. ALWAYS USE ULTRA LOW SULFUR DIESEL FUEL ONLY. DO NOT USE FUELS WITH SULFUR CONTENT HIGHER THAN ULSD (Ultra Low Sulfer Diesel) 0.015% (15ppm Hydraulic Oil (Petroleum-Mineral Base) Your machine is filled at the factory with Conoco Megaflow AW HVI 46 Hydraulic Fluid. This oil is formulated to provide the proper operating characteristics in a wide range of climates. When refilling, always use Conoco Megaflow AW HVI 46 or one of the recommended brands below. Failure to use the proper hydraulic oil can lower performance and shorten the life of critical components. DON’T MIX different types of hydraulic fluids! Oil specifications address the following concerns: • High-temperature viscosity • Low-temperature flow properties • Viscosity lifespan • High-pressure wear characteristics • Filterability • Multi-metal compatibility in the presence of water We recommend the following hydraulic oils 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 cSt @ 100°C / 46.3 cSt @ 40°C / Pour Point -48°C ( -54°F) If choosing an oil other than those recommended above, the following specifications should be used: • Kinematic Viscosity: 7 cSt (min) @ 100°C / 42-50 cSt @ 40°C • Pour point: -35° F (-37° C) or colder • Viscosity stabilizers, excellent resistance to viscosity breakdown (shear). • Anti-wear, Anti-foam formulation, for use in all pump types at all pressures. • Low-zinc additives; zinc levels should not exceed .08% of total weight Clean hydraulic oil is critical to achieve high performance and get long life from your hydraulic system. The oil and filter should be changed in accordance with the instructions contained in the “Maintenance Intervals” section of your manual. The hydraulic oil should be changed immediately if it appears dirty or smells burnt. Biodegradable Hydraulic Oil Panolin HLP Synthetic Ester Base VG46 is the only approved Bio-Degradable Hydraulic oil for this machine. All mineral base oils must be completely drained out of system and components before refilling with Panolin HLP Synthetic VG46 Bio-degradable oil. Panolin HLP Synthetic Ester VG46.………………….Viscosity 8.1 cSt @ 100°C / 47 cSt @ 40°C / Pour Point -57°C (-70°F) 38 The track drives should be filled with a Synthetic 75W-90 heavy duty gear oil. This oil should have an API service classification of GL-5 which has an extreme pressure additive. A synthetic 75W-140 or 80W-140 heavy duty GL-5 gear oil could also be used in warm climates to extend gear life. MWF Hydrostat Drive C275 Operation & Service Manual The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50. Do not mix hydrostat and different lubricants! Maintenance The Differential Gearbox is shipped with 80-90W performance gear oil. Use this fluid or comparable type when refilling. Lubricating Grease All machines are completely serviced at the factory before shipping. The operator should check all grease fittings to familiarize with the location and correct service schedule plan. Use the normal shutdown procedure (See “Operating Instructions”), before lubricating the machine. Apply grease using a standard low pressure/low volume grease gun. Do not use a pneumatic grease gun. Lubricate with a high quality NLGI No.2 multipurpose bearing grease having rust inhibitors, good water resistance, antioxidant additives, and a minimum viscosity of 150 cSt at 40°C and suitable to operate continuously at 212°F / 100°C or higher. We recommend the following bearing grease that meets this spec: Chevron Delo EP2……………....189 cSt @ 40°C / 17.5 cSt @ 100°C / Temperature range -40°C to 177°C (-40°F to 350°F) Texaco Multifak EP2………….…173 cSt @ 40°C / 15.6 cSt @ 100°C / Temperature range -34°C to 121°C (-30°F to 250°F) Citgo Premium Lithium EP2…..173 cSt @ 40°C / 14.9 cSt @ 100°C / Temperature range -15°C to 121°C ( 5°F to 250°F) Shell Alvania EP2…….………….189 cSt @ 40°C / 15.6 cSt @ 100°C / Temperature range -20°C to 100°C ( -4°F to 212°F) Note: for extreme 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 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. Hydraulic and track drive oil should meet all previous specifications and have a pour point at least 7.8°C (14°F) lower than the coldest expected ambient temperature. 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 the equipment in order to circulate the thinner oil. ENGINE• If continuous ambient operating temperatures are below -10°C (+14°F), oil change intervals should be increased. Consult the Engine Operator Manual for details. • When you start an engine or when you operate an engine in ambient temperatures that are below -20°C (-4°F), use base oils that can flow in low temperatures. These oils have lubricant viscosity grade of SAE 0W or SAE 5W. • When you start an engine or when you operate an engine in ambient temperatures that are below -30°C (-22°F), use a Synthetic base stock multigrade oil. The oil should have lubricant viscosity grade of 0W or 5W. Use an oil with a pour point that is 5-10 degrees lower than the coldest ambient temperature. Fluids Refill Capacities (Approximate) Compartment or System U.S. Gallons Imperial Gallons Liters Fuel Tank Engine Crankcase w/Filter Total Engine Coolant including Cooler Hydraulic Reservoir 800.392.2686 39 C275 Operation & Service Manual Maintenance RAYCO COOLANT SPECIFICATIONS Rayco Coolant Specifications Coolant / Antifreeze Recommendations Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. These antifreezes are intended for aluminum automotive engines and are unacceptable for diesel engines. Use antifreeze that is formulated with a low silicate level and the proper coolant additives for heavy duty diesel engines. Your Rayco machine is filled at the factory with Chevron Heavy Duty Phosphate Free Coolant formulated to meet the heavy-duty engine coolant specifications of TMC RP329 and ASTM D 6210. This coolant is manufactured from ethylene glycol and a highly effective, heavy duty corrosion inhibitor package that is phosphate free and contains nitrates and molybdates. It is compatible with other traditional heavy duty coolants containing supplemental coolant additives (SCA’s). Rayco’s coolant specification address the following concerns: • Effective corrosion protection for aluminum, brass, cast iron, steel, solder, and copper. • Low silicate formulation. • Protects against winter freeze up and minimizes the chance of summer boil over. • Phosphate free formula reduces hardwater scale formation. • Suitable for diesel, gasoline and natural gas powered engines. • compatible with other major brands of coolant and heavy duty diesel supplemental additives. Rayco recommends the following coolant type for your Rayco machine: Chevron HD Coolant (Phosphate-Free) Concentrate P/N 227036 / 227043 with bitterant ……..-34°F @ 50% mix / -62°F @ 60% mix Chevron HD Coolant (Phosphate-Free) Diluted P/N 227034 / 227045 with bitterant……….…..-34°F @ 50% mix / -62°F @ 60% mix Coolant 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 required. • Follow the engine OEM procedures when doing a complete change-out. Make Proper Antifreeze Additions Adding pure antifreeze as a makeup solution for cooling system top-up is an unacceptable practice. It increases the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with water to the same freeze protection as your cooling system. Use the chart below to assist in determining the concentration of antifreeze to use. NOTICE: Additives eventually lose their effectiveness and must be recharged with additional supplement coolant additives available in the form of liquid coolant conditioner. See TESTING ENGINE COOLANT and REPLENISHING SUPPLEMENT COOLANT ADDITIVES (SCA’S) BETWEEN COOLANT CHANGES, as described in the Engine Operator’s Manual. For more detailed explanation on the cooling system refer to the Fuels, Lubricants, and Coolant section of the Engine Operator’s Manual shipped with this machine. Chevron HD Coolant Protection Temperature (w/ 15 psi cap) 40 Concentration Boiling Protection to -129.4°C (265°F) 50% antifreeze and 50% water Freeze Protection to -24.4°C (-12°F) 40% antifreeze and 60% water Freeze Protection to -36.7°C (-34°F) 50% antifreeze and 50% water Freeze Protection to -52.2°C (-62°F) 60% antifreeze and 40% water C275 Operation & Service Manual Maintenance Torque Specifications Torque Specifications General Torque Information Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Maintenance Section, if necessary. Prior to installation of any hardware, ensure that components are in near new condition. Bolts and threads must not be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean the hardware with a noncorrosive cleaner. Do not lubricate the fastener threads except for the rust preventative. The rust preventative should be applied by the supplier of that component for purposes of shipping and storage. Other applications for lubricating components may also be specified in the Maintenance Section. SAE & Metric Bolt 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 LB-FT M16 255 +/-10 LB-FT M20 500 +/-20 LB-FT M24 850 +/-25 LB-FT M30 1700 +/-25 LB-FT M36 3000 +/-50 LB-FT 800.392.2686 TORQUE SPECIFICATIONS BASED ON 67% OF BOLT YIELD STRENGTH (UPPER TOLERANCE NOT TO EXCEED 75% YIELD) O-RING FACE SEAL TORQUE VALUES -3 8 TO 10 LB-FT -4 14 TO 16 LB-FT -5 18 TO 20 LB-FT -6 24 TO 26 LB-FT -8 50 TO 60 LB-FT -10 72 TO 80 LB-FT -12 125 TO 135 LB-FT -16 200 TO 220 LB-FT -20 210 TO 280 LB-FT -24 270 TO 360 LB-FT SAE 37JIC TORQUE VALUES -3 8 TO 9 LB-FT -4 11 TO 12 LB-FT -5 14 TO 15 LB-FT -6 18 TO 20 LB-FT -8 36 TO 39 LB-FT -10 57 TO 63 LB-FT -12 79 TO 88 LB-FT -16 108 TO 113 LB-FT -20 127 TO 133 LB-FT -24 158 TO 167 LB-FT -32 245 TO 258 LB-FT WEATHERHEAD SPEC SHEET PROVIDED BY MID-STATE 41 C275 Operation & Service Manual Maintenance Accessing the Engine Enclosure Air Cleaner - Check/Replace ! 6 7 2 To gain access to the filter cartridge, loosen the wing-nut and remove (6). The cover will then be free for removal. The Engine enclosure has 2 access doors that are lockable. To open the engine access door, depress both latches (1) and swing the door upwards. The door will automatically lock in place once it is fully opened. To close, lift the door upwards to unlatch (2) the hinge lock. Once closed, press the latches (1) to lock. To remove the outer filter, pull on the filter and it will come off. To remove the inner filter, pull on the filter and it will come off Accessing the Hydraulic Pumps Air Cleaner - Ejector Valve 5 3 4 The hydraulic pumps and valves are located under the cab. They are accessible by removing the 2 rear cab mount fasteners and raising the cab. Once the (3) cab mount fasteners have been removed, use the (4) electric motor control located inside the tool box (behind hydraulic tank). Once the cab has been fully raised, insert the (5) safety bar to hold it in the raised position (Included in Safety Sales Kit). Electric motor is under engine. 42 Completely inspect the cleanliness of both filters. If they are slightly dirty they may be cleaned by lightly tapping on a hard surface. Replace at stated intervals or when needed. (Additional detail outlined in Service Section) Discharge the rubber dust ejector valve (7) to clean out any trapped contaminates. Air Cleaner for Cab Fresh Air - Clean This cab fresh air cleaner is located on the inside, left hand side of the cab, right behind the seat as shown. Pull outwards on the clasps of the air cleaner to release the bottom section. Completely inspect the cleanliness of the filter. If it is slightly dirty it may be cleaned by lightly tapping on a hard surface. Replace at stated intervals or when needed In very dusty conditions, check this filter daily and clean or replace as needed. C275 Operation & Service Manual Maintenance Air Conditioning - Check • 3 2 1 • • Stop on the slope and observe the machine slowly creep backward. Shallow slopes will not be enough to allow the machine to creep. While observing the machine creep backward down the slope, apply the parking brake. The brakes should lock immediately. If the brakes appear to malfunction, the cause should be repaired immediately. Batteries - Check Visually check the Drier sight glass for bubbles during operation. There should be a green coloration during operation. If there is no green coloration present, have the air conditioning system checked by a certified Air-Conditioning technician. (see Service Section for detail) System contains: 2 lbs, 14 oz. of refrigerant and 3 oz of compressor oil. Location: (1) Compressor pump is on engine - right side engine enclosure. (2) Drier is located inside right side engine compartment. The (3) Condenser is mounted inside the rear door. ! ALWAYS WEAR PROTECTIVE CLOTHING AND EYEGLASSES WHEN WORKING WITH A BATTERY. FOR FURTHER IMPORTANT BATTERY SAFETY INFORMATION, CONSULT THE CUMMINS OWNER’S MANUAL. Air Intake Piping - Check Visually inspect the air intake piping for wear 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 Limb Riser. It is intended to sound whenever either or both tracks move backward, or when the engine automatically shuts down. • • • • • Make sure that the area behind the machine is clear of personnel and obstacles. Start the engine. Make sure you are in the seat, the seat belt is fastened, and the door closed. Slightly, pull the speed/direction control lever (LH joystick) back, as if to back up the machine. The back-up alarm should sound immediately. The back-up alarm should continue to sound until the joystick is released. If the back-up alarm does not function, it should be repaired immediately. Brake System - Test The brakes on your crawler consist of hydrostatic braking and spring applied, hydraulically released parking brakes. If the machine has hydrostatic power to climb a slope, it has sufficient hydrostatic power to stop the machine. • Climb a slope with the machine. 800.392.2686 Clean Terminals 1. Remove the black negative (-) cable. 2. Clean the terminal and clamp of any oxidation buildup with a stiff wire brush. (Stroke the brush away from your body to avoid hazardous particles.) 3. Apply a light coat of petroleum jelly around base of terminal. 4. Reconnect the cable. Cooling System - Drain, Flush 4 The cooling system is made up of a radiator that is cooled by the engine fan and an internal surge tank. To clean, remove the radiator cap and loosen the valve in the bottom of the radiator. Allow to drain into an approved container and dispose according to local laws. Radiator drain (4) is accessible by removing the rear belly pan under the rear of the machine (forward from the winch assembly). 43 C275 Operation & Service Manual Maintenance Engine Coolant Level - Check Engine Leaks - Check Check for leaks as described in the Engine Operation Manual. ! THIS IS A PRESSURIZED SYSTEM. NEVER OPEN THE RADIATOR CAP IF THE RADIATOR IS HOT! WAIT UNTIL IT HAS COOLED DOWN BEFORE OPENING WITH CAUTION. Engine Mounts - Check Check and tighten if necessary all engine mounts. Engine Oil Level - Check NOTICE Always check oil level while machine is parked on level ground. The coolant level should be checked daily prior to startup by visually looking into radiator fill. Coolant level should be at the bottom of the fill neck. NOTICE Always check coolant level while machine is parked on level ground. Overfilling radiator could result in coolant leaking. Always add a premixed solution rather than undiluted antifreeze to the radiator. If pure water must be added in an emergency, the entire cooling system must be drained and flushed, as soon as possible, to prevent damage to the engine. Engine Coolant Hosed & Pressure Cap - Check Check for damaged hoses, pipes and loose or damaged hose clamps. Replace as required. Check radiator for any sign of leaks, damage and buildup of dirt or debris. Clean and replace as needed. Check the radiator pressure cap and seal. Engine Coolant Anti-Freeze - Check Use a refractometer to achieve the most accurate reading. Refer to pg. 38 of this manual for proper dilution. Engine Crankcase Breather Tube Inspect Consult your Engine Manual for details. Engine Injectors - Inspect Consult your Engine Manual for details. 44 2 The engine oil dipstick (1) is accessible through the right engine enclosure door. Follow the directions found in the Engine Operation Manual for correct procedures on how to read the dipstick. During the initial break-in period, the engine will consume more oil than usual. Check the oil level daily. Low oil level can cause severe engine damage. Engine Oil & Filter - Change NOTICE Engine Oil & Filter change is required after the first 50hrs and then every 250 service hrs when usuing oil with a quality grade of API: CH-4. 1. Place an oil catch pan under the oil drain plug on the engine. Remove the drain plug and drain the oil. Use an approved container to store used oil. 2. Remove the oil fill cap (to aid in draining). 3. Using a filter wrench, remove the oil filter on the machine and replace with a new one (2). 4. Using your finger, put a light coat of oil on the seal of the new filter (b). Ensure old seal is removed. 5. Replace and tighten all fittings. 6. Add the correct amount of oil to the crankcase. 7. Start the engine and run for two minutes then shut off. 8. Check the dipstick, and top off the engine to the upper full line on the dipstick. C275 Operation & Service Manual Maintenance 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 (0.508mm) 0.020” and operate within 0.015” to 0.030” Intake valve lash. Fan Belt Tension - Check The belt tension should be set to deflect one belt thickness or less @ 25 ft-lbs. Readjust if belt tension is in excess of one belt thickness. Refer to the Engine Maintenance Manual for details. Fuel Filter - Change Element replacement frequency is determined by the contamination level in fuels. Fuel flow to the engine becomes restricted as the element gradually plugs with contaminants, resulting in noticeable power loss and/or hard starting. When any one occurs, change the element as soon as possible. Always carry an extra replacement element as one tankful of contaminated fuel can plug a fuel filter (a). Element replacement procedure: • To change an element, unscrew the threaded element and remove. • Add a small amount of petroleum jelly to the gasket of the new filter and screw new filter hand tight. Dispose of the old element properly. • Prime the fuel system using the priming device in the Water Separator Head. • Do not vent air on this High Pressure system. • Do not Pre-Fill the filter Follow the instructions found in the Engine Maintenance Manual. Fuel Tank - Drain Water & Sediment 1 Change the fuel filter (1) as described in the Engine Maintenance Manual. 3 Fuel System Water Separator Check /Drain Slowly remove the fuel filler cap. The fuel tank drain plug is located on the LH side of the machine under the fuel tank (3). Position a suitable container large enough to contain the fuel under the drain plug and remove the plug. Allow the remaining fuel, water and sediment to drain and then reinstall the plug. 1 Water is heavier than diesel fuel and will settle to the bottom of the bowl and will appear different in color. WITH THE ENGINE OFF, drain the water by opening the bottom drain valve (2) and allowing all water to escape into a container. Close the drain valve when all water has been removed. Refer to the Engine Maintenance Manual. ! DIESEL FUEL IS COMBUSTIBLE. DO NOT SPILL IT ON THE ENGINE. LET THE ENGINE COOL BEFORE REFUELING. DO NOT SMOKE OR ALLOW ANY HOT OBJECTS NEARBY WHEN REFUELING. Gauges, Switches & Warning Lamps - Check Look for the following: Fuel System Water Separator - Change Element 800.392.2686 • • Broken lenses on the gauges and lights. Broken switches, etc. 45 C275 Operation & Service Manual Maintenance Turn the key switch to ON. The CHECK ENGINE & WAIT TO START indicator lights should come on for a few seconds while they perform a self-test and should both 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 operating the machine. Grease & Lubricate - Lube Apply a good quality grease daily to all fittings on machine and mower. Refer to the Fluid Specifications in this manual for approved lubricants. Apply 2-3 shots of grease for all grease points with zerks. 2 Grease & Oil Buildup - Remove NOTICE Accumulated grease and oil on a machine is a fire hazard. Remove such debris with steam clean­ing or high pressure water. For cleaning with a hot water cleaning de­vice, use a spray steam with a pressure not exceeding 426 psi (2982 kPa) to pre­ vent damage to painted ar­eas of the components. The use of solvents or strong cleaners should be avoided for the first 90 days. Strong cleaners will destroy paint until the paint is fully cured. PRECAUTIONS FOR ELECTRICAL SYSTEM WHEN STEAM CLEANING ENGINE: IMPORTANT DO NOT STEAM CLEAN ANY ELECTRICAL OR ELECTRONIC COMPONENTS WHILE STEAM CLEANING THE ENGINE, AS IT COULD DAMAGE SENSITIVE PARTS. Wipe all fittings, caps, and plugs before servicing. Keep a close watch for leaks. Refer to the “Fluid Penetration” section of the Safety & Operation manual before checking for leaks. If leaking is observed, find the source, and correct the leak. 1 Check the fluid levels more frequently than the recom­ mend­ed periods if leaking is suspected or ob­served, until the problem may be corrected. Door Hinges Hydraulic Oil Cooler - Clean Engine Door Hinges Check and clean debris from hydraulic lines and hoses to prevent heat buildup. Use low pressurized air to clean cooler and radiator. Always blow away from the engine compartment to keep it clean. Note: Cleaning the radiator and cooler with pressurized air may be done on a daily basis, depending on conditions. Cab Pivots Hydraulic Oil Tank - Check & Fill NOTICE Cab Tilt Cylinder Door Hinges 46 Replace oil if it smells burnt or appears to be dirty. Use only clean, fresh hydraulic oil, free of bubbles. (Bubbles indicate trapped air.) C275 Operation & Service Manual Maintenance Pilot Filter 1 3 2 The hydraulic tank is integrated into the right side of the frame. The filler cap (1) is located on the right side of the engine enclosure directly behind the cab. The hydraulic pilot filter (3) is located in the enclosure forward of the fuel tank. To replace, remove the step and battery access panel. Return Filter The oil level sight gauge is located inside the toolbox (2) on the tank side. Check the oil level when the machine is cold, and on level ground. 4 Re-fill the hydraulic oil tank 1. Clean all surrounding debris and dirt off of tank fill opening area. (Hydraulic fluid must be kept completely clean!) 2. Remove the breather cap (2). 3. Fill tank until oil level reaches appropriate level on the oil level sight gauge in the GREEN zone. 4. Replace the breather cap. The hydraulic return filter (4) is accessible through the righthand side engine enclosure. Charge Filters Hydraulic Oil Filters - Change NOTICE Hydraulic filters need to be changed after the first 25 hours of operation. Change the filters any time the hydraulic filter restriction lamp lights up, and after every 500 hours of operation. Keep the insides of all hydraulic components clean as they are installed. Always keep the hydraulic oil clean. Severe machine damage will likely occur if oil becomes dirty. The machine must not be operated without the filters in place, or severe damage to the major hydraulic components will likely occur. 800.392.2686 5 This machine is equipped with 2 hydraulic oil charge filters (5) located on either side of the machine. The left filter is located in the enclosure forward of the fuel tank. To replace, remove the step and battery access panel. The right filter is located in the enclosure forward of the hydraulic tank. To replace filter, remove the access panel. Replace both access panels and step when finished. Ensure all fasteners are tightened to the torque specs listed on pg. 39. 47 C275 Operation & Service Manual Maintenance Hydraulic Oil - Change NOTICE Prior to filling with fluid, make certain all system components (reservoir, hoses, valves, fittings, pump, etc.) are clean. Care must be taken to not run pump or hydraulic motor without a sufficient amount of fluid in them. Before operating, please consult the “Safety” section for vital information related to operating this powerful machine! 1. Steam clean the pumps, motors, cylinders, hydraulic lines, fittings and tank. 2. Place the machine on level ground. 3. Place a container on the ground under the hydraulic tank drain plug. 4. Open the hydraulic oil fill cap and remove the drain plug on the bottom of the tank. 5. Loosen hose fittings on cylinders and drain as much fluid as feasible. 6. Replace and tighten all fittings, plugs and caps. Clean up all spilled oil, and wipe off fittings. 7. Follow directions on pg. 48 to refill hydraulic tank. NOTICE Dispose of drained oil according environment protection regulations. to local Hydraulics - Start Up Procedure NOTICE Prior to filling with fluid, make certain all system components (reservoir, hoses, valves, fittings, pump, etc.) are clean. Care must be taken to not run pump or hydraulic motor without a sufficient amount of fluid in them. Before operating, please consult the “Safety” section for vital information related to operating this powerful machine! Action Steps Diagram 1. Check All Fittings on hose and tube connections. Make sure all fittings are tight to prevent fluid leakage and keep air from entering the system. 2. Fill Reservoir with the proper fluid (see “System Fluid Spec­ i­ fi­ ca­ tions”). It should be passed through a 10 micron (nom­i­nal) 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. Loosen Case Drain Connection at Motors, to bleed the system of any entrapped air. This allows the pump 48 and motor cases to fill with fluid for instant lubrication at start-up. 5. Fill Pump and Motor Cases of the circuit through the uppermost case drain ports. This gives both units instant lubrication at start-up. Also remove top hose connection of the HC (Hydraulic Cylinders) pump, fill with oil, and reinstall top hose connection. This will provide instant lubrication to HC pump at start-up. 6. Placing the pump Control in Neutral at start-up is essential to prevent any unexpected machine movement. 7. Run the Prime Mover (engine) for a short period of time using the starter. (Crank the engine briefly, repeatedly.) This allows the charge pump to start filling the system. Start the engine and run at lowest speed. Shut the engine down within 40 seconds if the charge pressure does not increase steadily to approximately 340 to 440 Psi. 8. Or run the prime mover until the charge pressure 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 of maximum throttle for a few minutes. This will purge any remaining trapped air from the system. 12. Cycle Track Control Slowly. Restart the prime mover, and actuate the track control two or three times to purge any trapped air from the system. 13. Stop the Prime Mover and remove pressure gauge used at start-up. Replace the plug. Recheck the reservoir fluid level and add fluid if necessary. Replace the reservoir cap. The hydrostatic circuit is now ready for operation. Hydraulic Circuit After the hydrostatic circuit is ready, the hydraulic circuit may be prepared. 1. Check the reservoir level, and add more clean fluid if necessary. Fill all other components in the HC circuit with hydraulic oil as completely as possible. 2. Start the engine and run it at normal operating speed. Using the boom motion controls, slowly, then at normal operating speed, cycle the boom through all its motions until all air is bled off. The motions will be smooth and powerful when all of the air is bled off. 3. Check the reservoir level, and add more clean fluid if necessary. 4. Remove the reservoir fill neck, and inspect strainer, cap, and gaskets. Replace if damaged or worn. Clean the strainer in clean, non­flam­ma­ble solvent, and dry. Install the strainer. Put a light coat of hydraulic oil on the fill neck gasket. Install the fill neck. Inspect the gasket on the breather cap, and replace if damaged. Install the breather cap. 5. Clean up any spilled hydraulic fluid. The entire hydraulic system is now completely ready for operation. 1 800.392.2686 AND TROUBLE SHOOT STOP 10 9 11 DROP APPROX. 40 PSI IN CHARGE 50% OF MAXIMUM THROTTLE 13 CHARGE PRESSURE 7 SHOULD 2 OR 3 TIMES CYCLE PUMP CONTROL SLOWLY 12 40 SECONDS AT LOW SPEED FOR RUN PRIME MOVER AT SET PRIMER MOVER CHARGE PRESSURE GAUGE STARTS CLIMBING AT LEAST 200 TO 220 PSI 8 UNTIL OR IS CHARGE PRESSURE SEALED RESERVOIR PROPER FILTERED FLUID BE TIGHT IF NOT TO SUPPLY 10 PSI MAXIMUM COMPRESSED AIR 3 WITH 2 FILL RESERVOIR MUST CHECK ALL FITTINGS CONTROL IN NEUTRAL 14 5 THEN STOP PRIMER MOVER TIGHTEN CASE DRAIN OUTLET AT MOTOR APPEARS REMOVE GAUGE REPLACE PLUG CHECK FLUID LEVEL SYSTEM READY TO OPERATE 6 WHEN FLUID FLUID TO FILL BOTH PUMP AND MOTOR CASES ALLOW LOOSEN CASE DRAIN OUTLET AT MOTOR 4 C275 Operation & Service Manual Maintenance 49 C275 Operation & Service Manual Maintenance Pump Bolt Tightness - Check The bolts attaching the pumps to the engine, or to each other, should be checked for tightness after the first 50 hours and then every 250 hours. Radiator Pressure Cap -Check The cooling system is designed to use a pressure cap to prevent boiling of the coolant. Pressure test the cap to the stated 13 psi rating every 500 hours to insure it is working properly. Inspect the rubber seal of both Pressure cap and Fill cap to insure they are not damaged or deteriorating. Replace as required Rear Radiator Screen - Clean if the ROPS/FOPS has structural damage. Damage to the structure can be caused by an overturn, falling objects, etc. Use of the ROPS/FOPS in a damaged, modified or abused condition, or with a prior overturn, is unsafe and the operator protection is no longer suitable and must be replaced. Any alterations, modifications, add-ons or repair without the written consent of Rayco Manufacturing will void the product’s warranty, liability and certification. Seat Belt - Inspect Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine. Inspect the belt mounting hardware. Replace any belt mounting hardware that is damaged or worn. Regardless of appearance, replace the seat belt at three year intervals. Track Adjustment - Check The rear radiator screen should be cleaned frequently to guard against overheating. To access, open the rear door and swing the A/C condenser out of the way. Remove and clean as necessary using compressed air or a pressure washer. Replace screen if damaged. Lay a straight edge on the track between the carrier roller and the idler (b). Measure the maximum amount of track sag from the high point of the track grouser to the bottom of the straight edge (a). A properly adjusted track will have approximately 1.5 +/- .25 inches (38 +/- 6.35mm) of slack. Check for wear and excessive dirt and material buildup. ROPS - Inspect If the track appears to be too tight or too loose, refer to the instructions below. The Roll Over Protective Structure (ROPS) is built into the top of the cab assembly. Inspect area 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. Tighten the Track if Too Loose NOTICE Over-tightening of the track can cause excessive track wear or breakage. 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 to the ROPS/FOPS structure. Welding brackets or drilling holes in the ROPS/FOPS can weaken the structure. See your Rayco dealer for mounting guidelines. Any alteration that is not specifically authorized by Rayco invalidates the certification for the ROPS/FOPS. The protection that is offered by the ROPS/FOPS will be impaired 50 1 2 1. Using the special grease fitting that was included with your machine, add grease through the fill valve fittings located inside the engine compartment on each rearward side until the correct track tension is reached (1). C275 Operation & Service Manual Maintenance 2. Operate the machine back and forth in order to equalize the pressure. 3. Recheck the amount of track sag, and adjust as necessary. 4. An over-tight chain will show on the display panel warning light and an alarm will sound. Loosen the Track if Too Tight 1. Loosen the grease zerk with the wrench, located in the tool box, out far enough so that grease begins to seep out of the cross hole (2). Drive machine if necessary. 2. Retighten the zerk when the desired track tension is reached. Track Pad Bolts - Re-Torque When installing a track, torque the 9/16/18UNF bolts that hold the track pad to the track chain to 155 - 183 ft-lbs. (210 - 248 Nm). After the first 50-100 service hours, they should be re-torqued to 199 - 237 ft-lbs. (270 - 321 Nm). Track Drive Gearbox & Sprocket Mounting Bolts - Check/Tighten In addition, check the M16 metric bolts fastening the drive sprocket to the track drive gearbox using 235 ft-lbs (318 Nm) torque wrench setting in a sequence that tightens them diagonally across the perimeter of the bolt ring. Also check the M16 metric bolts fastening the drive motor to the gearbox using 235 ft-lbs (318 Nm) torque wrench setting They should all be checked again after every 500 hours. (Contact Rayco for further information.) Track drive oil - Check/Add To check the track drive oil the drive unit must be placed in accordance to figure 2 below. Loosen and slowly remove plug (2), if oil seeps out of the hole, the unit is full. When the oil level is below the hole, add the correct oil (SAE 80W90 API GL5) by removing the top plug (1) and fill the unit from the top plug hole until oil begins to come out of oil level plug (2) hole. Insert both plugs and tighten. (see Service Section for additional details). Track Drive Oil - Replace To change the oil in the track drive gearbox follow the instructions listed in the Track Drive Gearbox section in the Service Section. (1). Front gear box oil level plug. (2). Front gear box oil fill plug. M16 mounting bolts (for motor to gearbox) Torque: 235 ft-lbs (318 Nm) 2 1 Cutting Wheel Belt - Check Tension For belt tensioning procedures and illustrations, please reference your CB260RX manual. After the first 50 service hours, check the M20 metric bolts fastening the track drive gearbox to the frame. Check bolt tightness using 460 ft-lbs (623 Nm) torque wrench setting in a sequence that tightens them diagonally across the perimeter of the bolt ring.. 800.392.2686 51 C275 Operation & Service Manual Service Main Electrical Schematic 40857 RED (COMM HOT) FRAME GROUND CABLE 24537-10 BLACK ENGINE GROUND GRY/WHT (LH TRACK PRESS) CABLE 24537-05 RED 175 A ALTERNATOR GRY/BLK (RH TRACK PRESS) BLU (LH PROP CHARGE PRESS GRN (RH PROP CHARGE PRESS) BRN (PILOT PUMP PRESS) ORG (WORK FUNC. PUMP PRESS) PUR (CW PUMP PRESS) WHT (MOWER HEAD PRESS) SIDE WORK LAMP WHT (FAN POSITION) RED/YLW (5VDC PWR) BLK (FAN SOL GRD) BLK/YLW (5VDC GRD) REAR WORK LAMP 5VDC PWR BUSSED CONNECTOR 5VDC GRD BUSSED CONNECTOR SHIELD/DRAIN BUSSED CONNECTOR PUR (ENG FAN SOLENOID) BLK (CONV GRD) GRN (ENG COOLANT LEVEL SIG) BLK (DISPLAY GRD) BLK (MICRO GRD #1) BLU/WHT (FLOAT SIG) GRN (FLAP UP SOL) RED/BLK (START RELAY) BRN (2SPD SOL) WHT (FAN SPD SOL) WHT (WINCH IN SOL) BACKUP ALARM FRAME GROUND BLK (2-SPD GRD) BLK (LIMB RISER GRD) ORG (ENG COMP TEMP) WHT (ECM START SIG) BLU (JOYSTICK SOL) GRY (FUEL LEVEL) BLK (MICRO GRD #1) BLK (JS GRD) BLK (F/R GRD) NOT USED NOT USED NOT USED BLK (F/R GRD) BRN (WINCH OUT SOL) BRN (COOLANT LEVEL TEST) BLK (BRAKE GRD) REAR WORK LAMP BLK (MICRO GRD #3) BLK (MICRO GRD #2) GRY (FAN REV SOL) BLK (PILOT GRD) BLK (MICRO GRD #3) PUR (BACKUP ALARM SIG) ORG (FLAP DN SOL) BLK (MICRO GRD #2) GRN (PILOT SOL) GRY (BRAKE SOL) BLU (HYD OIL TEMP SENSOR) FRAME GROUND SIDE WORK LAMP BLK (COMM GRD #2) RED (COMM HOT) WHT (CW ENABLE SOL) HIGH PRESSURE FILTER SWITCH BLU (HIGH PRESS FILTER SW) CUTTER PUMP FILTER SWITCH GRN (CW PUMP FILTER SW) BLK (LIMB RISER GRD) LH TRACK FILTER SWITCH WHT (LH TRACK FILTER SW) RH TRACK FILTER SWITCH BLU (RH TRACK FILTER SW) PILOT PUMP FILTER SWITCH GRN (PILOT PUMP FILTER SW) CABLE 24537-04 RED CABLE 24537-01 RED CABLE 24537-06 RED BLK (TILT GRD) YLW (REAR WORK LGT) CABLE 24537-09 BLACK 12V DC 30 A CABLE 24537-12 BLACK CABLE 24537-11 BLACK BLE CA CABLE 24537-02 RED 12V DC 7-07 2453 RED RED (CIRCUIT BREAKER) RED (CIRCUIT BREAKER) 50A CIRCUIT BREAKER FRAME GROUND ECM ENGINE COMPARTMEN WORK LAMP SW YLW (WORK LMP PWR) BLK (COMM GRD # 125 A POWER DISTRIBUTION ENGINE COMPARTMENT WORK LAMP CABLE 24537-08 RED CABLE 24537-03 RED WHT/RED (TILT PWR) WHT (TILT) 52 C275 Operation & Service Manual Service BLK (CONSOLE GRD) FRAME GROUND GRY/WHT (LH TRACK PRESS) CUTTER WHEEL NEUTRAL SWITCH GRY/BLK (RH TRACK PRESS) GRY (CW NEUTRAL SW) BLU (LH PROP CHARGE PRESS) WHT (MICRO OTHER) GRN (RH PROP CHARGE PRESS) BRN (PILOT PUMP PRESS) BLK (DISPLAY GRD) BACK-UP PRESSURE SWITCH WHT (BACKUP ALARM SW) ORG (WORK FUNC. PUMP PRESS) PUR (FUSE FEED) HYDRAULIC OIL LEVEL SWITCH PUR (CW PUMP PRESS) PNK (HVAC FUSE FEED) ORG (HYD OIL LEVEL SIG) PRESS) WHT (FAN POSITION) AIR FILTER SWITCH BLU (AIR FILTER SIG) BLK (CONSOLE GRD) RED (PWR ALWAYS HOT) PUR (FUSE FEED) WHT (IGN START SW) RED/YLW 5VDC PWR) IGNITION SWITCH K/YLW DC GRD) FRAME GROUND RED (COMM HOT) BLK (CONV GRD) RED (AUX HOT) WHT (ECM START SIG) BLK/YLW (5VDC GRD) RED/YLW (5VDC PWR) GRY (FUEL LEVEL) L SIG) YLW CAN 1 + GRN CAN 1 - SEAT SWITCH ORG (SEAT SW) ORG (SEAT SW) SEAT BELT SWITCH BRN (2SPD SW) JS POCKET SWITCH OPTIONAL EXTERIOR E-STOP SWITCH 2 SPD SWITCH ORG (E-STOP SIG) WHT (IGN START SW) ORG (ENG COMP TEMP) CAN 1 SHIELD ORG (SEAT SW) YLW CAN 2 + GRN CAN 2 CAN 2 SHIELD BLU (TILT RELAY) PUR (DOOR OPEN) DOOR SWITCH RED (RH JOYSTICK PWR) PUR (BACKUP ALARM SIG) HORN SWITCH GRY (HORN) PARK BRAKE GINE ARTMENT K LAMP SEAT WARMER SWITCH BLK (MICRO GRD #2) BLU (WARNING ALARM) WARNING ALARM GRY (HORN) SEAT POWER RELAY PUR/WHT (SEAT PWR) SEAT COMP. FUSE (10A) SEAT WARMER RELAY BLK (LGT GRD) BLK (CONV GRD) SEAT HARNESS BLU (TILT RELAY) FRONT WORK LAMP BLU (PARK BRAKE) WHT (JOYSTICK FLAP INPUT) BLK (MICRO GRD #3) FRONT WORK LAMP E-STOP SWITCH SEAT WARMER FUSE (7.5A) FRONT WORK LAMP PUR/WHT (SEAT PWR) GRN (WIPER) BLU (WASHER) HORN BLK (COMM CAB GRD) BLK (COMM CAB GRD) FRAME GROUND YLW (DOME LGT PWR) FRAME GROUND YLW (WORK LGT REL) WHT (CW ENABLE SOL) DOME LAMP BLK (LGT GRD) BLK (LGT GRD) PUR (MICRO PWR) ORG ECM FUSE FEED COMMON HOT BLK (RELAY GRD) RED (COMM HOT) 10 A ECM-IGNITION FRONT WORK LIGHT RELAY FRONT WORK LAMP 5A FRONT LIGHTS YLW (FRT WORK LGT FUSE) PANEL LAMP BLK (LGT GRD) 30 A JOYSTICK RH 5A RED (CIRCUIT BREAKER) 5A WHT/RED (TILT PWR) ENGINE COMPARTMENT WORK LAMP SWITCH YLW (WORK LMP PWR) MICRO OTHER PUR (FUSE FEED) BLK (RELAY GRD) REAR WORK LIGHT RELAY 15 A HVAC WHT (MICRO OTHER) FRONT WORK LAMP FRAME GROUND JOYSTICK LH 5A BLK (HVAC GRD) REAR LIGHTS YLW (REAR WORK LGT FUSE) PNK/BLK (HVAC PWR) 15 A BLU (FRESH AIR) RED (LH JOYSTICK PWR) BLK/WHT (BINARY SW) FRAME GROUND 30A CIRCUIT BREAKER BLK (FAN GRD) FRAME GROUND RED (PWR ALWAYS HOT) BLK (COMM GRD #2) GRY (A/C COMP PWR) YLW (REAR WORK LGT) 800.392.2686 20 A 30 A WHT (TILT) 50A CIRCUIT BREAKER YLW (FRT WORK LGT) MICRO LCM PNK (HVAC FUSE FEED) YLW WORK LGT PWR BLU (TILT RELAY) NOT USED NOT USED FRONT WORK LAMP WIRE COLOR LEGEND: BLK - BLACK BLU - BLUE BRN - BROWN GRY - GRAY ORG - ORANGE PNK - PINK PUR - PURPLE RED - RED WHT - WHITE YLW - YELLOW /TC - TRACER COLOR ( ) IMPRINT LETTERING 53 C275 Operation & Service Manual Service Cab Electrical Schematic 41206 54 C275 Operation & Service Manual Service 800.392.2686 55 C275 Operation & Service Manual Service Hydraulic Schematic 806429 Page 1 56 C275 Operation & Service Manual Service 800.392.2686 57 C275 Operation & Service Manual Service Hydraulic Schematic 806429 Page 2 58 C275 Operation & Service Manual Service 800.392.2686 59 C275 Operation & Service Manual Service Hydraulic Schematic 806429 Page 3 60 C275 Operation & Service Manual Service 800.392.2686 61 C275 Operation & Service Manual Service ITEM QTY 1 3 2 2 3 1 4 1 5 1 6 2 7 9 8 11 9 4 10 2 11 4 12 2 13 2 14 1 15 1 16 1 17 3 18 1 19 2 20 3 21 3 22 2 23 8 24 4 25 1 26 3 27 4 28 2 29 3 30 1 31 3 32 62 1 RAYCO MFG. C275 HYDRAULIC ADAPTER KIT PART # DESCRIPTION PLUG -4MOR COUNTERSUNK 6408-H-04 HEX DRIVE PLUG -6MOR COUNTERSUNK 6408-H-06 HEX DRIVE 5406-P-08 PLUG -08 MPT HEX HEAD PLUG -12MOR COUNTER6408-H-12 SUNK HEX DRIVE PLUG -16MOR COUNTER6408-H-16 SUNK HEX DRIVE FF6803-12- TEE BRANCH -12 MORFS X 12-12 -12 MORFS X -12MORB O-RING CONNECTOR FF6400-4-4 -04MORFS X -04MORB ELBOW 90 DEG -04MORFS X FF6801-4-4 -04MORB O-RING CONNECTOR FF6400-4-6 -04MORFS X -06MORB TEE-4MORFS X -4MORFS X FF6600-4-4-4 -4FORFS SWIVEL ELBOW-45 DEG-10MORFS X FF6802-10-10 -10MOR O-RING CONNECTOR FF6400-10-12 -10MORFS X -12MORB TBC120 T-BOLT CLAMP ELBOW 90 DEG -12 BEADED 4601-12-12 TUBE X -12MORB ELBOW 90 DEG -06MORFS X FF6801-6-10 -10MORB ELBOW 90 DEG -06MORFS X FF6801-6-12 -12MORB O-RING CONNECTOR FF6400-6-6 -06MORFS X -06MORB ELBOW 90DEG -04MORFS X FF6500-04-04 -04FORFS SWIVEL ELBOW 45 DEG -10 MORFS X FF6802-10-12 -12 MORB TEE-RUN-06MORFS X -06MOR FF6804-6-6-6 X -06MORFS TEE-RUN-06MORFS X FF6602-6-6-6 -06FORFS SWIVEL X -06MORFS ADAPTER -06MOR X -04FEM 6410-6-4 OR ELBOW 90 DEG -06MORFS X FF6801-6-8 -08MORB ELBOW 90 DEG -10MORFS X FF6801-10-12 -12MORB ELBOW 90 DEG -12MORFS X FF6801-12-12 -12MORB FF6804-12- TEE-RUN-12MORFS X -12MOR 12-12 X -12MORFS FF6502-06-06 ELBOW FF6502-06-06 45DEG-06MORFS X -06FORFS SWIVEL O-RING CONNECTOR FF6400-16-20 -16MORFS X -20MORB ELBOW 45 DEG -24 BEADED 4603-24-24 TUBE X -24 MORB ELBOW 90 DEG -20 BEADED 4601-20-24 TUBE X -24 MORB ELBOW 90 DEG -20 BEADED 4601-20-20 TUBE X -20 MORB CONNECTOR -24MOR X 6403-24-24 -24MOR (OR 6407-24-24 AS SUBSTITUTE) 33 1 34 2 35 1 36 1 37 4 38 1 39 2 40 1 41 2 42 2 43 2 44 1 45 5 46 5 47 8 48 8 49 7 50 2 51 2 52 2 53 1 54 1 55 1 56 1 57 1 58 2 59 2 60 2 61 1 62 1 63 1 64 1 65 6 66 1 67 2 68 1 O-RING CONNECTOR -12MORFS X -12MORB O-RING CONNECTOR FF6400-12-16 -12MORFS X -16MORB ELBOW 90 DEG -12 FJLC X FF6500-12-12 -12 MJLC TEE-RUN-12MORFS X FF6602-12-12FORFS SWIVEL X 12-12 -12MORFS ELBOW 90 DEG -24 BEADED 4601-24-20 TUBE X -20 MORB FF6600-12- TEE RUN -12 MJLC X -12 MJLC 12-12 X -12 FJLC ELBOW 90 DEG -12MORFS X FF6801-12-16 -16MORB CONNECTOR -12 BEADED 4604-12-10 TUBE X -10MOR ELBOW 90 DEG -04 MORFS X 6069-04-14 -14 MALE METRIC ELBOW 45 DEG -06 MORFS X FF6502-06-06 -06 FORFS SWIVEL SPLIT FLANGE KIT -20 CODE SFK62-20 62 ELBOW 90 DEG -12 MORFS X FF6500-12-12 -12 FORFS SWIVEL ELBOW 45 DEG -12 MORFS X FF6802-12-12 -12 MORB ELBOW 90 DEG -06 MORFS X FF6801-06-06 -06 MORB FF2700-6- BULKHEAD-STRAIGHT UNION 6-LN -6MORFS W/LOCKNUT T-BOLT CLAMP (FOR -24 TBC212 HOSE) O-RING CONNECTOR FF6400-6-12 -06MORFS X -12MORB FF2603-20- TEE -20MORFS X -20MORFS X 20-20 -20MORFS O-RING CONNECTOR FF6400-16-16 -16MORFS X -16MORB ELBOW 90 DEG -16MORFS X FF6801-16-16 -16MORB FF6602-16- TEE -16MORFS X -16 FORFS X 16-16 -16MORFS FF5406-P-04 PLUG -04 HEX O-RING CONNECTOR FF6400-6-4 -06MORFS X -04MORB ELBOW 90 DEG -06MORFS X FF6500-6-6 -06FORFS SWIVEL O-RING CONNECTOR FF6400-6-8 -06MORFS X -08MORB O-RING CONNECTOR FF6801-8-12 -08MORFS X -12MORB ELBOW 90 DEG -08MORFS FF6500-08-08 SW X -08FORFS SWIVEL FF2700-8- BULKHEAD-STRAIGHT UNION 8-LN -8MORFS W/LOCKNUT O-RING CONNECTOR FF6400-6-10 -06MORFS X -10MORB ELBOW 90 DEG -10MORFS X FF6801-10-10 -10MORB ELBOW 90 DEG -24 BEADED 4601-24-24 TUBE X -24MORB ELBOW 90 DEG -10MORFS X FF6801-10-08 -08MORB T-BOLT CLAMP (FOR -20 TBC175 HOSE) TEE BRANCH -6MORFS X FF6803-6-6-6 -6MORFS X -6MORB ELBOW 45 DEG -20BEADED 4603-20-16 TUBE X -16 MORB ELBOW 90 DEG -06 MORFS X FF6801-06-04 -04 MORB FF6400-12-12 C275 Operation & Service Manual Service 69 1 70 2 71 1 72 1 73 1 74 2 75 4 76 4 77 2 78 1 79 5 80 1 81 1 82 6 83 1 84 1 85 1 86 2 87 2 88 4 89 1 90 2 91 2 92 1 93 4 94 2 95 1 96 1 97 1 CONNECTOR STR -04 FPT X -04 FPT ELBOW 90 DEG -08FPT X 5504-8-6 -06FPT CONNECTOR STR -06 MPT X 4404-06-06 -06 BEADED TUBE CONNECTOR STR -05BARBED 205-104 X -04MPT CONNECTOR STR-04MP X 5404-04-04 -04FP TEE -04MORFS X -04MORFS X FF2603-4-4-4 -04MORFS ELBOW 90 DEG -12 MORFS 694-12-16 X -16 CODE 62 SPLIT FLANGE ADAPTER SPLIT FLANGE KIT -16 CODE 16SFXO-M12 62 M12 BOLTS ELBOW 90DEG -5 BEADED X 4601-5-5 -5 MORB FF2603-12- TEE -12MORFS X -12MORFS X 12-12 -12MORFS ELBOW 90DEG -04MORFS X FF6801-4-6 -06MOR CONNECTOR STR -05BARBED 205-106 X -06MPT 9235-18-04 18MM X -4MNPT CONNECTOR STR -10 BEADED 4404-10-8 TUBE X -08 MPT 5406-12-04 BUSHING -12 MPT X -04 FPT FF6804-04- TEE-RUN -04MORFS X -06 06-04 MORB X -04 MORFS 5406-P-32 PLUG -32 HEX CONNECTOR STR-08FJX X 210-608 -10 BARB 2705-08- CONNECTOR BULKHEAD08-LN 08FPT X -08MJIC W/LOCK NUT ELBOW 90DEG-10BEADED 4501-10-08F TUBE X -08MPT ELBOW 45DEG -10 BEADED 4503-10-12F TUBE X -12 MPT CONNECTOR -06MJIC-12MALE 9068-06-12 METRIC C/W WASHER & O-RING ELBOW 90DEG-06 BARB X 206-S-666 -06FJX90S TEE-RUN -08MPT X -08FPT X 5602-8-8-8F -08FPT ELBOW 90° -06MORFS 6069-06-14 -14MMETRIC W/WASHER & O-RING CONNECTOR -10MORFS 6068-10-18 -18MALE METRIC C/W WASHER & O-RING TEE-RUN-06MORFS X FF6602-06-06FORFS SWIVEL X 06-06 -06MORFS 5604-12-12- BRANCH TEE -12 FPT X -12 12F FPT X -12 MPT 32-126 3/8” TEE BARB FF5000-04-04 800.392.2686 63 C275 Operation & Service Manual Service ITEM QTY 1 3 2 2 3 1 4 1 5 1 6 2 7 9 8 11 9 4 10 2 11 4 12 2 13 2 14 1 15 1 16 1 17 3 18 1 19 2 20 3 21 3 22 2 23 8 24 4 25 1 26 3 27 4 28 2 29 3 30 1 31 3 32 64 1 RAYCO MFG. C275 HYDRAULIC ADAPTER KIT PART # DESCRIPTION PLUG -4MOR COUNTERSUNK 6408-H-04 HEX DRIVE PLUG -6MOR COUNTERSUNK 6408-H-06 HEX DRIVE 5406-P-08 PLUG -08 MPT HEX HEAD PLUG -12MOR COUNTER6408-H-12 SUNK HEX DRIVE PLUG -16MOR COUNTER6408-H-16 SUNK HEX DRIVE FF6803-12- TEE BRANCH -12 MORFS X 12-12 -12 MORFS X -12MORB O-RING CONNECTOR FF6400-4-4 -04MORFS X -04MORB ELBOW 90 DEG -04MORFS X FF6801-4-4 -04MORB O-RING CONNECTOR FF6400-4-6 -04MORFS X -06MORB TEE-4MORFS X -4MORFS X FF6600-4-4-4 -4FORFS SWIVEL ELBOW-45 DEG-10MORFS X FF6802-10-10 -10MOR O-RING CONNECTOR FF6400-10-12 -10MORFS X -12MORB TBC120 T-BOLT CLAMP ELBOW 90 DEG -12 BEADED 4601-12-12 TUBE X -12MORB ELBOW 90 DEG -06MORFS X FF6801-6-10 -10MORB ELBOW 90 DEG -06MORFS X FF6801-6-12 -12MORB O-RING CONNECTOR FF6400-6-6 -06MORFS X -06MORB ELBOW 90DEG -04MORFS X FF6500-04-04 -04FORFS SWIVEL ELBOW 45 DEG -10 MORFS X FF6802-10-12 -12 MORB TEE-RUN-06MORFS X -06MOR FF6804-6-6-6 X -06MORFS TEE-RUN-06MORFS X FF6602-6-6-6 -06FORFS SWIVEL X -06MORFS ADAPTER -06MOR X -04FEM 6410-6-4 OR ELBOW 90 DEG -06MORFS X FF6801-6-8 -08MORB ELBOW 90 DEG -10MORFS X FF6801-10-12 -12MORB ELBOW 90 DEG -12MORFS X FF6801-12-12 -12MORB FF6804-12- TEE-RUN-12MORFS X -12MOR 12-12 X -12MORFS FF6502-06-06 ELBOW FF6502-06-06 45DEG-06MORFS X -06FORFS SWIVEL O-RING CONNECTOR FF6400-16-20 -16MORFS X -20MORB ELBOW 45 DEG -24 BEADED 4603-24-24 TUBE X -24 MORB ELBOW 90 DEG -20 BEADED 4601-20-24 TUBE X -24 MORB ELBOW 90 DEG -20 BEADED 4601-20-20 TUBE X -20 MORB CONNECTOR -24MOR X 6403-24-24 -24MOR (OR 6407-24-24 AS SUBSTITUTE) 33 1 34 2 35 1 36 1 37 4 38 1 39 2 40 1 41 2 42 2 43 2 44 1 45 5 46 5 47 8 48 8 49 7 50 2 51 2 52 2 53 1 54 1 55 1 56 1 57 1 58 2 59 2 60 2 61 1 62 1 63 1 64 1 65 6 66 1 67 2 68 1 O-RING CONNECTOR -12MORFS X -12MORB O-RING CONNECTOR FF6400-12-16 -12MORFS X -16MORB ELBOW 90 DEG -12 FJLC X FF6500-12-12 -12 MJLC TEE-RUN-12MORFS X FF6602-12-12FORFS SWIVEL X 12-12 -12MORFS ELBOW 90 DEG -24 BEADED 4601-24-20 TUBE X -20 MORB FF6600-12- TEE RUN -12 MJLC X -12 MJLC 12-12 X -12 FJLC ELBOW 90 DEG -12MORFS X FF6801-12-16 -16MORB CONNECTOR -12 BEADED 4604-12-10 TUBE X -10MOR ELBOW 90 DEG -04 MORFS X 6069-04-14 -14 MALE METRIC ELBOW 45 DEG -06 MORFS X FF6502-06-06 -06 FORFS SWIVEL SPLIT FLANGE KIT -20 CODE SFK62-20 62 ELBOW 90 DEG -12 MORFS X FF6500-12-12 -12 FORFS SWIVEL ELBOW 45 DEG -12 MORFS X FF6802-12-12 -12 MORB ELBOW 90 DEG -06 MORFS X FF6801-06-06 -06 MORB FF2700-6- BULKHEAD-STRAIGHT UNION 6-LN -6MORFS W/LOCKNUT T-BOLT CLAMP (FOR -24 TBC212 HOSE) O-RING CONNECTOR FF6400-6-12 -06MORFS X -12MORB FF2603-20- TEE -20MORFS X -20MORFS X 20-20 -20MORFS O-RING CONNECTOR FF6400-16-16 -16MORFS X -16MORB ELBOW 90 DEG -16MORFS X FF6801-16-16 -16MORB FF6602-16- TEE -16MORFS X -16 FORFS X 16-16 -16MORFS FF5406-P-04 PLUG -04 HEX O-RING CONNECTOR FF6400-6-4 -06MORFS X -04MORB ELBOW 90 DEG -06MORFS X FF6500-6-6 -06FORFS SWIVEL O-RING CONNECTOR FF6400-6-8 -06MORFS X -08MORB O-RING CONNECTOR FF6801-8-12 -08MORFS X -12MORB ELBOW 90 DEG -08MORFS FF6500-08-08 SW X -08FORFS SWIVEL FF2700-8- BULKHEAD-STRAIGHT UNION 8-LN -8MORFS W/LOCKNUT O-RING CONNECTOR FF6400-6-10 -06MORFS X -10MORB ELBOW 90 DEG -10MORFS X FF6801-10-10 -10MORB ELBOW 90 DEG -24 BEADED 4601-24-24 TUBE X -24MORB ELBOW 90 DEG -10MORFS X FF6801-10-08 -08MORB T-BOLT CLAMP (FOR -20 TBC175 HOSE) TEE BRANCH -6MORFS X FF6803-6-6-6 -6MORFS X -6MORB ELBOW 45 DEG -20BEADED 4603-20-16 TUBE X -16 MORB ELBOW 90 DEG -06 MORFS X FF6801-06-04 -04 MORB FF6400-12-12 C275 Operation & Service Manual Service 69 1 70 2 71 1 72 1 73 1 74 2 75 4 76 4 77 2 78 1 79 5 80 1 81 1 82 6 83 1 84 1 85 1 86 2 87 2 88 4 89 1 90 2 91 2 92 1 93 4 94 2 95 1 96 1 97 1 CONNECTOR STR -04 FPT X -04 FPT ELBOW 90 DEG -08FPT X 5504-8-6 -06FPT CONNECTOR STR -06 MPT X 4404-06-06 -06 BEADED TUBE CONNECTOR STR -05BARBED 205-104 X -04MPT CONNECTOR STR-04MP X 5404-04-04 -04FP TEE -04MORFS X -04MORFS X FF2603-4-4-4 -04MORFS ELBOW 90 DEG -12 MORFS 694-12-16 X -16 CODE 62 SPLIT FLANGE ADAPTER SPLIT FLANGE KIT -16 CODE 16SFXO-M12 62 M12 BOLTS ELBOW 90DEG -5 BEADED X 4601-5-5 -5 MORB FF2603-12- TEE -12MORFS X -12MORFS X 12-12 -12MORFS ELBOW 90DEG -04MORFS X FF6801-4-6 -06MOR CONNECTOR STR -05BARBED 205-106 X -06MPT 9235-18-04 18MM X -4MNPT CONNECTOR STR -10 BEADED 4404-10-8 TUBE X -08 MPT 5406-12-04 BUSHING -12 MPT X -04 FPT FF6804-04- TEE-RUN -04MORFS X -06 06-04 MORB X -04 MORFS 5406-P-32 PLUG -32 HEX CONNECTOR STR-08FJX X 210-608 -10 BARB 2705-08- CONNECTOR BULKHEAD08-LN 08FPT X -08MJIC W/LOCK NUT ELBOW 90DEG-10BEADED 4501-10-08F TUBE X -08MPT ELBOW 45DEG -10 BEADED 4503-10-12F TUBE X -12 MPT CONNECTOR -06MJIC-12MALE 9068-06-12 METRIC C/W WASHER & O-RING ELBOW 90DEG-06 BARB X 206-S-666 -06FJX90S TEE-RUN -08MPT X -08FPT X 5602-8-8-8F -08FPT ELBOW 90° -06MORFS 6069-06-14 -14MMETRIC W/WASHER & O-RING CONNECTOR -10MORFS 6068-10-18 -18MALE METRIC C/W WASHER & O-RING TEE-RUN-06MORFS X FF6602-06-06FORFS SWIVEL X 06-06 -06MORFS 5604-12-12- BRANCH TEE -12 FPT X -12 12F FPT X -12 MPT 32-126 3/8” TEE BARB FF5000-04-04 800.392.2686 65 C275 Operation & Service Manual Service A/C Schematic 41266 66 C275 Operation & Service Manual 800.392.2686 67 The Series 42 variable displacement pump is a compact, high power density unit, using the parallel axial piston/slipper concept in conjunction with a tiltable swashplate to vary the pump’s displacement. Series 42 Axial Piston Pumps Track Pumps Reversing theDrive angle of the swashplate reverses the flow of fluid from the pump, and Technical Information Thisthe machine withmotor (2) Danfoss®-Danfoss series reversing directionisofequipped rotation of the output. Series 42 pumps provide an displacement (stroke) limiters located in the servo covers. The 42 pumps that propel the track drive motors. Each maximum displacement of the pump can be limited to any value nfinitely variable speed range between zero and maximum in bothpump forwardisand reverse. Features and options dedicated to a Left and a Right side track motor. The variable from its maximum displacement to zero in either direction. The Series Piston Pumps Seriesdisplacement 42 pumps use apump cradle42 swashplate designhigh withpower a hydraulic servo control cylinder.limiters are factory set slightly beyond the maximum displaceis a Axial compact, density unit, usControl is provided through a compact servo control system. A variety of servo controls ing the parallel axial piston/slipper concept in conjunction with a ment of the pump. Displacement limiters may not be suited to are available.Technical These include mechanicallyor electrically-actuated feedback controls, Information tilt-able swash plate to vary theand pump’s displacement. Revers-These all applications. hydraulic or electric proportional controls, a three-position electric control. ing feature the angle of the swash plate reverses the flow of fluid from controls low hysteresis and responsive performance. Features and options Series 42 pumps are available Series 42 pump displacement limiters the pump, and reversing the direction of rotationwith of the motor output. Series 42 pumps provide an infinitely variable speed adjustable mechanical displacement 3 28/32/41/51 cross-sectional viewmaximum in both forward and reverse. range cm between zero and (stroke) limiters located in the servo Piston covers.Swashplate The maximum displacement of Series 42 pumps are available with Series 42 pump displacement limiters the pump can be limited to any value adjustable mechanical displacement from its maximum displacement to (stroke) limiters located in the servo zero in either direction. The limiters covers. The set maximum are factory slightly displacement beyond the of the pump can be limited of to the anypump. value maximum displacement from its maximum displacement Displacement limiters may not betosuited zero either direction. The limiters to allinapplications. are factory set slightly beyond the Series 42 pumps have an integral loop flushing valve for maximum displacement of the pump. circuits requiring the removal of excessive contamination or withvalve high cooling requirements. We also an orifice Displacement limiters not beloop suited Series 42 pumps have may an integral flushing for circuits requiring theprovide removal of loop flushing relief valve. The orifice controls loop flushing flow in to all applications. excessive contamination or with high coolingmost requirements. We also provide an orificed conditions. A combination of relief setting and orifice size Roller bearing Charge pump controls flushing flow. For proper operation, ensure loop flushing relief valve. The orifice controls loop flushing flow in most conditions. Athe loop Valve plate flushing relief valve is set at or below the charge relief setting. combination of relief setting and orifice CAUTION: Incorrect pressure settings may result in the To prevent premature wear, use only new clean fluid. Use a size controls flushing For proper Looptoflushing valve Series pumps have flow. an integral loop flushing valve for circuits requiring the removal of inability build required system pressure, insufficient filter capable of42 controlling control pressure, and/or inadequate loop flushing flow. fluid cleanliness to ISO 4406 Class 22/18/13 operation,contamination ensure the loop relief excessive or flushing with high cooling requirements. We also provide an orificed Maintain correct charge pressure under all operating convalve is setapplied atrelief or inbelow the charge relief loop flushing valve. The orifice controls loop flushing flow in most conditions. A ditions. All Series 42 pumps closed circuit installations resetting. Contact your setting Sauer-Danfoss quire charge flow to make combination ofuprelief and orifice Lo for internal leakage, to maintain positive pressure in the main representative for application assistance. size controls flushing flow. For proper Loop flushing valve circuit, to provide flow for 11022637 • Rev. CD • June 2010 operation, ensure loop reliefor cooling, to replace any leakagethe losses fromflushing external valved auxiliary systems, and to CAUTION valve is set at or below the charge relief provide flow and pressure for the pump control system. Incorrect pressure settings may result setting. Contact your Sauer-Danfoss Lo in the to build required system The charge reliefinability valve maintains charge pressure at a desigrepresentative for application assistance. nated level. Series 42 pumps pressure, insufficient control pressure, come with direct-acting poppet style charge relief valves. The and/or inadequate loop flushing flow. valve setting is set at the CAUTION factory. Maintain The setting is screw adjustable. correct charge pressure under Incorrect pressure settings may result Caution: Incorrect charge pressure settings may result in operating conditions. inallthe to build required the inability toinability build required system pressure,system inability to control pump, and/or Inadequate loop flushing flows. pressure, insufficient control pressure, Maintain correct charge pressure under all operating Loop flushing flow loop flushing flow. conand/or inadequate ditions. [psi] Series Maintain 42 pumps are available with adjustable mechanical correct charge pressure under 0 100 200 300 400 all operating conditions. P100382E 10 2.5 Loop flushing flow 9 8 min) 68 107 0 [psi] 100 on 4 i t Op 200 300 400 2 69 system circuit diagram PUMP SWASHPLATE INPUT SHAFT REVERSIBLE VARIABLE DISPLACEMENT PUMP CONTROL HANDLE Pictorial Diagram WORKING LOOP (HIGH PRESSURE) SERVO CONTROL CYLINDER SERVO CONTROL CYLINDER ORIFICED CHECK VALVE DISPLACEMENT CONTROL VALVE CHARGE PUMP TO PUMP CASE LOOP FLUSHING VALVE CHARGE PRESSURE RELIEF VALVE RESERVOIR SUCTION LINE LOOP FLUSHING RELIEF VALVE MULTI-FUNCTION VALVE WORKING LOOP (LOW PRESSURE) SERVO PRESSURE RELIEF VALVES MULTI-FUNCTION VALVE HEAT EXCHANGER HEAT EXCHANGER BYPASS VALVE Technical Information System Circuit Description CONTROL FLUID TO MOTOR CASE HYDRAULIC TWO POSITION CONTROL VACUUM GAUGE CASE DRAIN FLUID P001 175E SYNCHRONIZING SHAFT OUTPUT SHAFT BENT AXIS VARIABLE DISPLACEMENT MOTOR Proper servicing of pumps and motors requires that Seriesbe42 pressure measured and monitored at various points in the hydraulic circuit. The Series 42 pump Series 42 3.2 Ports and Pressure Gauges has several locations at which to take these measure- 3.2 Ports and Pressure Gauges Proper servicing of pumps and motors requires that pressure be Series measured42 and monitored at various Gauservicing ge Recomm ended Proper and motors requires that Pof respumps surcircuit. e Me asuThe red Series points in the hydraulic 42 pump P o r t N a m e G a u g e Size pressure belocations measured and to monitored various has several at which take theseatmeasureSeries 42 System Pressure for points inMthe M1 & 2 hydraulic circuit. The Series 600 ba42 r orpump 10 000 psi Ports Aatawhich nd B to take these measurehas several locations ments. The following outlines show the locations of and Locations theComponent various gauge ports. ThePort tables show the recommended gauge size and the fitting size for each port. Component and Port Locations Refer to this page when installing pressure gauges. ments. The following outlines show the locations of Adjustments the various gauge ports.FThe tablesand show Minor the recom-Repairs itting show the locations of ments. The following outlines mended gauge size and the fitting size for each port. 041 the recom028 the various The tablespressure show Refer to thisgauge page ports. when installing gauges. Adjustments and Minor Repairs mended gauge size and the fitting size for each 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting port. Refer to this page when installing pressure gauges. 4. Adjustment and Minor Repair Instructions 60 bar or 1000 psi 3/4-16 O-Ring Fitting 3/4-16 O-Ring Fitting 4. Adjustment and Minor Repair Instructions F i t t i n Servo Pressure 60 bar or 1000 psi 9/16-18 O-Ring Fitting 9g /16-18 O-Ring Fitting M3 Charge Pressure MG4a& ugM e5 Recommended sure Meand asuredTorque for Plugs and Fittings 4.1PresSize PoLr1t & NaLm 41ing Fitting 28ing Fitting 2 e Case Pressure 35 barGoaru5g0e0Spiszie 1-1/16-12 O0-R 1-5/16-12 O-0R Fitting Gauge Recommended S y s t e m P r e s s u r e f o r P r e s s u r e M e a s u r e d Charge ump Inlet 160b0arb, a ara bou srog1 leu0tS e0i0 & 0 psfresh i 1/61-61-812 O-lightly R0-iR n8 g Flubricated iF ttin 1/61-61 O-O R-0iR n g Fjelly, iF ttin PM or1t S NaMm2ePlug G ze 19-/O-ring, O ing ttg ing 19 -/5 -812 ing ttg inwhenever g 41 and fitting are given Place with petroleum a plug 2 P rctusuAm andSize Bsizes and and Fittings Vo a4.1 orTorque 30 here. in Hg V acfor uumaPlugs is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown. S y s t e m P r e s s u r e f o r Charge Pressure 6 3//1 46 -1-1 68OO -R inin ggFF ittitin gg 3//1 46 -1-1 68OO -R inin ggFF ittitin g0g00 025E M1M&3M2 60 00ba braroror10 10 000p 0s 0i psi 9 -R tin 9 -R tiTn Ports A and B M4 & M5 SePlug rvo Pand ressfitting ure sizes6are 0 bagiven r or 10here. 00 psPlace i /16-18O-ring, O-Ring lightly Fitting lubricated 9/16-1with 8 O-R ing Fitting jelly, whenever a plug a9fresh petroleum M3 Charge Pressure 60 bar or 1000 psi 3/4-16 O-Ring Fitting 3/4-16 O-Ring Fitting be torqued as indicated. A 28cc unit with manual displacement (MDC) is shown. L1 & L2 Caisseremoved. Pressure Each should 3 5 b a r o r 5 0 0 p s i 1 1 / 1 6 1 2 O R i n g F i t t i n g 1 5 / 1 6 1 2 O Ring Fitcontrol ting Servo M4 & M5 Servo Pressure 60 bGage ar or 1000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting Port Charge Pump Inlet 1 bM4 ar, absolute 1 gF Fiittttiin 1 16 L1 S & L2 C 3r5 3b0arinoH r5 1--1 1//1 16 6--1 12 2O O--R Riin ng ng g 1--5 5//1 6--1 12 2O O--R Riin ng gF Fiittttiin ng g VaacsueuP mressure o g0V0apcsuium T 0 0 0 025E Servo Gage Charge Pump Inlet 1 bar, absolute S 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting M4 Vacuum 11/16 in Hex or 30Port in H g Vacuum System Pressure Gauge Port M2 27-47 Nm (20-35 ft•lbf) T000 025E Servo Pressure Gauge Port M5 Charge Pressure Servo Pressure 11/16 in Hex Gauge Port M3 Gauge Port M4 27-47 Nm (Charge Pressure System 28cc: 9/16 in Int.(20-35 Hex ft•lbf) Supply For Case Drain Port L2 Pressure 95-135 Nm No Charge Pump (Non-Feedback Port B (70-100 ft•lbf) System Pressure Option) Servo Pressure Controls) Case Drain 5/8 in Int. 9/16Hex in Int. Hex Gauge Port M5 Gauge Port M2 41cc: 28cc: Port L1 System Charge Pressure 125-250 Nm Nm 95-135 System Pressure CasePressure Drain Servo Servo Pressure Pressure Gauge Port M3 (90-190 ft•lbf) ft•lbf) Charge PressurePort Gage (70-100 Gauge Port M2 Gauge Port M4 GaugeCase Port M5 L1 Port A Drain (Charge Pressure Port M3 (Position Varies, Charge Pressure 41cc: 5/8 in Int. Hex System Charge Pump Inlet Pressure PortServo L1Options) Supply For M3 Gauge Port 125-250 NmRefer to Filtration Case Drain Port L2 Pressure Port S Case Drain Port Port M4 L1 Charge Pump Gauge No Charge Pump (Charge Pressure (90-190 ft•lbf) (Non-Feedback Charge Pressure Gage Port B Torque: 115 Nm (85 ft•lbf) (Non-Feedback System Inlet Port S Option) Supply For Controls) Port M3 (Position Case Drain PortVaries, L2 Controls) Pressure Charge Pump Inlet No Charge Pump Refer to Filtration Options) System (Non-Feedback Port B Port S Case Drain Option) Case Drain System Pressure Pressure Controls) Torque: 115 Nm (85 ft•lbf) Port L2 Port L1 Gauge Port M1 Port A System Case Drain Pressure Left Side View (Side "2") Right Side View (Side "1") Case Drain Port L1 Port L1 Charge Pump Port A (Non-Feedback Inlet Port S P100103 E Case Case PortDrain L1 Charge Pump Plug and fitting sizes are given here. Place a Controls) freshDrain O-ring, lightly lubricated with petroleum jelly, whenever plug 11/16 inaHex Port L2 (Non-Feedback Inlet Port S Nm Case Drain 27-47 is System removed. Each should be28cc torqued asUnit indicated. A 28cc unit with manual displacement control (MDC) is shown. Base with MDC and No Filtration Adapter Pressure Controls) Port L2 Port N and fitting sizes are given (20-35 ft•lbf) Gauge Porthere. M1 Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug (Unused)Case Drain Case Drain Servo Gage moved. Each should be torqued 11/16 in Hex System Pressure as indicated. A 28cc unit with manual displacement control (MDC) is shown. Port L2 Port L2 Right Side View (Side "1")Port M5 27-47 Nm Gauge Port M1 Left Side View (Side "2") System Gage Servo O-ring, Gage Port petroleum N and fitting sizes are given here. Place a fresh lightly lubricated with jelly, whenever a plug P100103 ft•lbf) E (20-35 Ports M1 and M2 (Unused) Port M4 Side View (Side "2")unit with manual displacement Right Side View is (Side "1") moved. Each should be torquedLeft as indicated. A 28cc control (MDC) shown. Servo Gage Servo Gage in Hex P100103 E Port M5 11/16 Port M4 28cc Base UnitSystem with MDC Gage and No Filtration Adapter 27-47 Nm Ports M1 and M2 (20-35 ft•lbf) 11/16 in Hex Servo Gage 28cc Base Unit with MDC and No Filtration Adapter 27-47 Nm 11/16 in Hex 11/16 in Hex Port M4 (20-35 ft•lbf) 27-47 NmHex 28cc: 9/16 in Int. 27-47 Nm (20-35Nm ft•lbf) 95-135 (20-35 ft•lbf) (70-100 ft•lbf) 11/16 in Hex 28cc: 9/16 in Int. Hex 41cc: 28cc: 5/8 in Int. 9/16Hex in Int. Hex 95-135 Nm 27-47 Nm 125-250 Nm Nm 95-135 6 (70-100 ft•lbf) (20-35 28cc: 9/16 in Int.ft•lbf) Hex (90-190 ft•lbf) ft•lbf) (70-100 Case Drain 95-135 Nm 41cc: 5/8 in Int. Hex 41cc: 5/8 in Int. Hex Port L1 (70-100 ft•lbf) 125-250 Nm 11/16 in Hex Nm 125-250 Case Drain (90-190 ft•lbf) 41cc: 5/8 in Int. Hex 8cc: 9/16 27-47 Nm Charge Pressure Gage System Ports (90-190 ft•lbf) Port L1 125-250 95-135 NmNm (20-35 ft•lbf) Port M3 (Position Varies, A and B Charge Pump Inlet (90-190 ft•lbf) (70-100 ft•lbf) Charge Pressure Gage Refer to Filtration Options) 115 Nm (85 ft•lbf) 11/16 in Hex Port S Drain Varies, E100001 E M3 (Position 1cc: 5/8 in Int. Hex 6 PortCase 27-47 Nm Torque: 115 Nm (85 ft•lbf) Charge Pump Inlet System Ports Port Refer to L1 Filtration Options) 125-250 Nm (20-35 ft•lbf) Port S A and B (90-190 ft•lbf) 6 Charge Pressure Gage Torque: 115 Nm (85 115 ft•lbf) Nm (85 ft•lbf) Port M3 (Position Varies, E100001 E Charge Pump Inlet Refer to Filtration Options) Port S Torque: 115 Nm (85 ft•lbf) 70 Series 42 eries 42 Adjustments and Minor Repairs Adjustments and Minor Repairs 4. Adjustment and Minor Repair Instructions ries 42 and Minor Repairs 4. Adjustment and MinorAdjustments Repair Instructions 4.1 Size andand Torque for Plugs and Fittings 4. Adjustment Minor Repair Instructions Size and Torque for Plugs and Fittings Size and Torque for Plugs and Fittings 8 Case Drain 11/16 in Hex Series 42 4.2 Adjustments and Minor Repairs Pump “Neutral” Adjustment The pump neutral adjustment sets the position of the servo piston and pump swashplate relative to the controlling mechanism. WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. 1. Disconnect machine function. 2. Connect a hose between gauge ports M4 and M5 to equalize the pressures on both ends of the pump servo piston. Pump "Neutral" Adjustment Screw Pump "Neutral" Adjustment Seal Lock Nut 3. Install pressure gauges in gauge ports M1 and M2 to measure system pressure. 4. Start the prime mover and operate at normal speed. 5. Loosen the pump "neutral" adjustment seal lock nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn the pump "neutral" adjustment screw [28cc 5 mm Hex; 41cc 7 mm Hex] until the system pressure gauge readings are equal. E100002 E Pump Neutral Adjustment Screw (MDC Control Shown) 6. Turn the adjustment screw clockwise until one of the gauges registers an increase in system pressure. Note the position of the adjustment screw. Turn the screw counterclockwise until the other gauge registers an increase in system pressure. Note the position of the adjustment screw. 7. Turn the adjustment screw clockwise to a position halfway between the positions noted above. The system pressure gauges should indicate equal pressures. 8. While holding the adjustment screw in position, torque the seal lock nut [28cc 20-26 Nm (15-19 ft•lbf); 41cc 28-51 Nm (21-37 ft•lbf)] . 9. Stop the prime mover and remove the hose between gauge ports M4 and M5. Remove the pressure gauges installed in gauge ports M1 and M2. Reinstall the plugs in the gauge ports. 10. Reconnect work function. IMPORTANT If the pump is equipped with an MDC or EDC, the CONTROL "neutral" adjustment MUST also be performed before putting the pump into service (see next section). 9 71 Series 42 Adjustments and Minor Repairs 4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) The charge check, high pressure relief, and the loop bypass functions are all contained within the system check relief (SCR) valve assembly. This assembly may be removed for cleaning and installation of fresh O-rings. The model code specifies whether high pressure relief valves, combination charge check/ high pressure relief valves, and/or loop bypass valves are present or not. 1. Remove the valve seat plugs [9 mm Int. Hex] or valve seat/bypass plugs [1 in Hex] from the pump housing. 2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of each conical spring is crimped to retain it on the check poppet or relief valve. Do not remove. With Bypass Without Bypass Valve Seat Plug Outer O-Ring Backup Ring Inner O-Ring Valve Seat Retaining Ring Standard Bypass Plunger O-Ring Valve Seat Plug Outer O-Ring Backup Ring Inner O-Ring 3. Inspect the valves and mating seats in the special plugs for damage or foreign material. CAUTION The relief valves are factory set and should not be tampered with, except for replacing the entire valve. 4. The O-ring on the standard bypass plunger may be replaced by removing the retaining ring and removing the plunger from the special valve seat plug. Remove the O-ring from the plunger and install a new O-ring. Reinstall the plunger and retaining ring. Check Poppet or High Pressure Relief Valve Conical Spring 5. Install a new outer O-ring, new backup ring, and new inner O-ring on each valve seat plug. 6. Check that the conical springs are properly retained on the check poppets or relief valves. Install the check poppet or high pressure relief valve assemblies into the pump housing . CAUTION The conical springs MUST be correctly positioned on the check poppets or relief valves after installation for proper pump operation. E100015 E System Check Relief Valve Components 7. Install the valve seat plugs or valve seat/bypass plugs into the pump housing and torque [40-95 Nm (30-70 ft•lbf)]. 18 72 Series 42 Adjustments and Minor Repairs 4.12 Loop Flushing Valve The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be exchanged for one with a different flow rating, but the relief valve shims should not be changed out unless specifically instructed so by Sauer-Sundstrand. The function also can be defeated. Loop Flushing Relief Plug Loop Flushing Relief Plug (Defeat) O-Ring O-Ring Shims Spring Poppet Loop Flushing Valve 1. Remove the loop flushing valve plug from the pump housing [11/16 in Hex]. Remove the O-ring from the plug. Loop Flushing Plug (Defeat) 2. Remove the loop flushing valve spool assembly from the housing. O-Ring 3. Inspect the parts for damage or foreign material. The centering spring must be securely retained to the spool by the washer. Defeat Spool Loop Flushing Plug O-Ring Loop Flushing Spool Assembly 4. Install the loop flushing valve spool assembly into its bore. Install a new O-ring on the loop flushing plug and install [27-47 Nm (20-35 ft•lbf)]. Loop Flushing Relief Valve 1. Remove the loop flushing relief valve internal hex plug [5/8 in Hex] from the pump housing. Remove the O-ring from the plug. 2. Remove the spring and poppet from the housing. 3. Do not alter the shims which are installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. Inspect the orifice in the valve poppet. 4. Install a new O-ring on the valve plug. Reinstall the poppet, spring, shims, and plug (with O-ring) into the pump housing [15-34 Nm (15-25 ft•lbf)]. E100018 E Loop Flushing Valve and Loop Flushing Defeat Components Defeating Loop Flushing 1. Remove the loop flushing valve from the pump housing. 2. Install the defeat spool into the spool bore in the housing. Install the plain plug with O-ring into the housing [11/16 in Hex], and torque [27-47 Nm (20-35 ft•lbf)]. 3. Remove the charge relief valve (these parts are not necessary). 4. Install the plain hex plug with O-ring into the end cap [5/8 in Hex], and torque [15-34 Nm (15-25 ft•lbf)]. 21 73 Series 42 Adjustments and Minor Repairs 4.11 Charge Relief Valve The charge relief valve may be removed for cleaning and installation of fresh O-rings. The pressure setting may be changed. However, note that the setting will vary for different charge flows which depends on charge pump size and pump speed. The factory setting is set relative to case pressure at 1800 rpm. The actual charge pressure will vary at different speeds. Shim Adjustable Style 1. Remove the shim adjustable charge relief valve plug [1 in Hex] from the pump housing. Remove the O-ring from the plug. Shim Adjustable Charge Relief Valve Plug O-Ring Shims 2. Remove the spring and poppet from the housing. Spring Poppet 3. Do not alter the shims which may be installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. If desired, the charge relief valve setting can be changed. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in). The effective setting will vary. To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached. Series 42 5. Install a new O-ring on the valve plug. Reinstall the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100 ft•lbf)]. Screw Adjustable Style (continued) 1. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the lock nut [1-1/16 in Hex] and unscrewing the plug [8 mm Int. Hex]. Remove the O-ring from the plug. E100016 E Shim Adjustable Charge Relief Valve Components Adjustments Approximate Reliefand Setting Minor vs Shim ThicRepairs kness 4 bar / 1.25 mm (58 psi / 0.050 in) T000 023E Charge Relief Lock Nut O-Ring Screw Adjustable Charge Relief Valve Plug Spring Poppet 2. Remove the spring and poppet from the housing. 3. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. Install a new O-ring on the valve plug. Reinstall the poppet and spring. Reinstall the plug with its lock nut [47-57 Nm (34-42 ft•lbf)], aligning the marks made at disassembly. 5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge relief valves, an approximate rule of thumb is 2.8 bar / quarter turn (40 psi / quarter turn). 74 To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached. E100017 E Screw Adjustable Charge Relief Valve Components Approximate Relief Setting vs Screw Revolution 2.8 bar / 1⁄4 turn 19 (40 psi / 1⁄4 turn) T000 024E Series 42 Adjustments and Minor Repairs 4.13 Shaft Series 42Seal and Shaft Replacement Adjustments and Minor Repairs A 4.13 lip type shaft sealSeal is usedand in Series 42 pumps. This Shaft Shaft Replacement seal and/or the shaft can be replaced without major disassembly of the Replacement generally A lip type shaft sealunit. is used in Series 42 pumps. reThis quires removal of the pump from the machine. seal and/or the shaft can be replaced without major Retaining Ring SealRetaining Carrier Ring Assembly the unit. generally re1.disassembly Position theofpump withReplacement the shaft facing up. quires removal of the pump from the machine. NOTE: If the unit is positioned horizontally when 1. the Position theremoved, pump with thecylinder shaft facing shaft is the blockup. could move out Ifofthe place, shaft horizontally installation diffiNOTE: unit making is positioned when cult. the shaft is removed, the cylinder block could Seal Carrier Assembly move out place, making shaft installation 2. Remove theofretaining ring from the housing. difficult. 3. Pull out seal carrier assembly. 2. Remove the retaining ring from the housing. 4. Remove the O-ring from the seal carrier. To 3. install Pull out sealshaft carrier assembly. a new only, proceed to step 8. Remove the carrier O-ring infrom the seal 5.4. Place the seal an arbor presscarrier. with theTo install a newside shaftdown, only, proceed to out stepthe 8. old shaft bearing and press An the appropriately sized pipe spacer or socket 5. seal. Place seal carrier in an arbor press with the wrench can be side useddown, as a press tool. out Once shaft bearing and press thereold moved, the seal is not reusable. seal. An appropriately sized pipe spacer or socket wrenchthe canseal be used a press tool. seal Oncefor re6. Inspect carrierasand the new moved, Inspect the sealthe is not reusable. damage. sealing area on the shaft for wear,the or contamination. the sealing 6. rust, Inspect seal carrier andPolish the new seal for area on the shaft if necessary. damage. Inspect the sealing area on the shaft for rust, the wear, orseal contamination. theside sealing 7. Press new into the shaftPolish bearing of area the shaft necessary. the sealon carrier. Theifseal lip must face the outside the pump. Be seal careful damage the side seal.of 7. ofPress the new intonot thetoshaft bearing The diameter of the theoutside seal carrier. The seal lipseal mustmay facebe thecoated outside with a sealant (e.g. Loctite Performance of the pump. Be careful not High to damage the seal. Sealant #59231) prior to installation. This in The outside diameter of the seal may beaids coated preventing leaks caused by damage to the seal with a sealant (e.g. Loctite High Performance Series 42seal carrier. bore in the Sealant #59231) prior to installation. This aids in E100019 E Shaft Seal Components E100019 E Shaft Seal Components O-Ring Seal Seal Carrier Inside Lip Seal Carrier Adjustments and Minor(face Repairs down) preventing leaks caused by damage to the seal (continued) bore in the seal carrier. If the shaft isSeries not being42 replaced proceed to step (continued) 11. Adjustments and Minor Repairs Press Seal Retaining Ring to bottom of Seal Carrier Roller Bearing Press Seal Installation Seal to bottomofofShaft Seal Carrier Retaining Ring 8. Remove the shaft and roller bearing assembly themotor. shaft isThe not being replaced proceed to step from the pumpIfor bearing assembly 11. can be transferred to the new shaft (steps 9 and 8. Remove the shaft and roller bearing assembly 10). 9. from the pump or motor. The bearing assembly Remove the retaining ring that secures roller can be transferred to the new shaft (steps 9 and 10). with a snap ring plier. Remove bearing assembly the roller bearing assembly. 9. Remove the retaining ring that secures roller Sealant may be used on outside diameter Sealant may InsideonLip be used (face diameter down) outside O-Ring Seal 10. Place roller bearing assembly on new shaft and E100020 E Roller Bearing Installation of Shaft Seal Shaft Key Shaft Key Shaft Assembly bearing assembly with a snap ring plier. Remove 10. Place roller bearing assembly on new shaft and the roller bearing assembly. secure with the retaining ring. E100020 E OR OR OR Shaft Assembly OR 11. Wrap the spline or key endretaining of shaft with thin secure with the ring. plastic to prevent damage to the seal lip 11. Wrap the spline or key end ofduring shaft with thin installation. Lubricate inside diameter thelip during plastic tothe prevent damage to theofseal shaft seal with installation. petroleumLubricate jelly. the inside diameter of the shaft seal with petroleum jelly. 22 12. Place the O-ring onto the shaft bearing and 12.petroleum Place the O-ring lubricate with jelly. onto the shaft bearing and lubricate with petroleum jelly. 22 13. Slide the seal carrier assembly over the shaft and 13. Slide the seal carrier assembly over the shaft and into the housinginto bore. Press against O-ring. Hold the housing bore. Press against O-ring. Hold inward pressure against the shaft compress inward pressure againsttothe shaft to compress the cylinder block spring whilethe pressing the cylinder block spring while pressing seal the seal carrier into place. carrier into place. 14. Install the retaining ring. 14. Install the retaining ring. E100021 E Shaft Components Shaft Components E100021 E 75 Introduction CloseD CiRCuit Track Drive Motors In a closed circuit, hydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid flows in either direction from the pump to the motor and back to the pump. Either of the hydraulic lines can be under high pressure. This machine is equipped with (2) Danfoss®-Danfoss Series Case 51-1 motor cartridges that bolt into and drive the track drive drain line gearboxes. The Series 51 feature a bent-axis rotating group that provides high starting torque and high speed. The ball end of each piston runs in a bushing pressed into the drive Series 51 and 51-1 Motors shaft. This permits the transfer of hydraulic power directly into Output MV PV Service Manual Input rotary motion at the drive shaft. The pressure balanced spheri51maintain and 51-1 Motors cal pistonSeries rings contact with the cylinder block bores Operation Service Manual providing high volumetric efficiency and low friction. A constant Introduction velocity joint (synchronizing shaft) keeps the rotation of the cylinder block synchronized with the motor output shaft. A servo Series 51 and 51-1Reservoir Motors Flow (Bi-directional) flusHing Series a loop flushing function. piston changes the angle of looP theend rotating group and varies the -1 motoRs Series 51-1 motors feature simplified cap and control components. The servo piston 51 and 51-1 motors are designed to accommodate P101 170E ing function. Installations that require additional fluid removal in the Series 51-1 has a differential area of 2 to 1. The connecting joint is designed to Service Manual Installations that require additional fluid removal from the main hydraulic circuit be displacement of the motor. Decreasing displacement increases decrease the overall length of the motor. from the main hydraulic circuit because of transmission cooling The direction and speed of the fluid flow use (and motor output shaft rotation) depends of transmission cooling requirements a loop flushing function. The loop flushin Operation speed. Increasing displacement decreases speed. The Series requirements use swash a loop flushing Thedisplacement loop flushing on the position of the pump plate. The pumpfunction. flow and motor The Series 51-1 control feeds servo pressure directly to the servo piston. Low system function consists of a shuttle valve and a poppet style relief valve or an orificed reli 51-1 control feeds servo pressure directly to the servo piston. loop pressure for two-position controls, and high system loop pressure for pressure determines motor output shaft The machine thestyle systemrelief function consists of speed. a shuttle valveload anddetermines a poppet valve cartridge. compensating controls actuates thetwo-position servo piston. Low system loop pressure for controls. pressure. valve or an orificed relief valve cartridge. In a closed circuit, hydraulic lines connect the mainSeries ports ofSeries the looP flusHing Series 51 andshuttle 51-1 motors areacts designed accommodate a loop flushing function. Rotating hardware and housing components are common between 51 and The valve as atoresolver, directing fluid only from Installations that acts require additional fluid removal from the main hydraulic circuit becauseside shuttle valve as a resolver, directing fluid only from the low pressure pump to 51-1. the main ports of the motor. Fluid oPen flowsCiRCuit in either The direcA hydraulic linepressure connects theside outletof port of the pump to a directional valve in an openThe the low the loop to the motor relief valve. cooling requirements use a loop flushing function. The loop flushing loopoftotransmission theshuttle motor relief valve. The shuttle valve is spring centered to the closed pos tion from the pump to the motor and back to the pump. Either circuit. The main ports of the motor connect to the working ports of this valve. When the valve is spring centered tostyle therelief closed position to prevent function consists ofisaactuated, shuttle valve and a poppet or an orificed relief Series 51-1 motor cross section directional valve fluid flows first fromcircuit the pump to valve the reversing valve. The directional to prevent high pressure fluid loss from the when directions. high pressure fluid loss from the circuit when reversing direcMinimum displacement limiter valve cartridge. valve then directs the fluid to the motor in either direction. Valve segment Bearing plate tions. Speed pickup ring The shuttle actsstyle as a resolver, fluid only from low pressure side of the The valve poppet relief directing valve regulates the the charge pressure Flow Flow Tapered rollerLoop bearings loop to thecross-section motor relief(Unidirectional) valve. The shuttle valve is spring centered to the closed position flushing showing orificed relief valve (Bi-directional) level in the system circuit when there is a pressure differential to prevent high pressure fluid loss from the circuit when reversing directions. Orificed relief valve DIN-flange Speed sensor Servo piston Piston Electrohydraulic two-position control Charge pressure relief valve Reservoir DIRECTIONAL VALVE Orificed relief valve Loop flushing cross-section MV PUMP orificed relief valve Input showing Shuttle valve Output Shuttle valve Case drain line P101 171E The direction of fluid flow (and motor output shaft rotation) depends on the position of the directional valve. The motor output speed depends on (1) pump output volume, P101 266E Synchronizing shaft (2) the restriction of the valve opening and (3) motor displacement. The machine load determines the system pressure. The directional valve routes fluid returning from the P101 266E motor to the reservoir. Additional components may be necessary to provide dynamic The poppet style valve regulates in the breaking andmain torelief dealloop. with overrunning loads.the charge pressure level in the system cir The poppet style relief regulatesthe the charge levelof inyou the system circuit when there is •aRev pressure differential thepressure mainpressure loop. When this valve, the When you usevalve this setting theuse motor 11008567 AE • November 2009 valve,in 11 when there is a pressure differential in the main loop. When you use this valve, the pressure setting of less the motor must be lesscharge than the pump’s setting. charge pressure setting must be than the pump’s pressure The pressure setting of the motor must be less than the pump’s charge pressure setting. The pressure setting of this valve is critical to achieving the proper loop flushing pressure setting of this valve is critical to achieving the proper pressure setting of this valve is critical to achieving the proper loop flushing flow rate. flow ra loop flushing flow rate. P101 174E of the hydraulic lines can be under high pressure. The direction flushing cross-section showing stylestyle reliefrelief valve valve LoopLoop flushing cross-section showingpoppet poppet and speed of the fluid flow (and motor output shaft rotation) dePoppet style Poppet style pends on the position of the pump swash plate. The pump flow relief valve relief valve Shuttle valve 11008567 • Rev AE • November 2009 and motor displacement determines motor output shaft speed. Shuttle valve The machine load determines the system pressure. P101 267E Series 51 motors are designed to accommodate a loop flush- P101 267E 76 11008567 • Rev AE • November 2009 13 Servo piston Maximum displacement P101 195E limiter Series 51 motors incorporate mechanical displacement limiters. You can set ais specific displacement range by on um displacement of the motor set by a screw and spacers installed limiting the travel of the valve segment/rotating group. he servo piston. The minimum displacement of the motor is set by The an displacement of the motor is set by a screw and op in themaximum motor housing. spacers installed on the end of the servo piston. The minimum displacement of the motor is set by an adjustable stop in the51-1 motor housing. t limiters Series Tamper resistant cap Minimum displacement limiter Valve segment Servo piston Maximum displacement limiter Spacer ents, pages 33-36, for available ranges. Two-position controlssetting shift the motor to only two discrete positions: v AE • November 2009 15 • maximum displacement • minimum displacement. To change motor displacement, the control routes pilot pressure to one end of the servo piston while draining the other. To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when servicing. Inspect vehicle for leaks daily. Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir. Rancid odor indicates excessive heat. Change the fluid immediately if these conditions occur. Correct the problem immediately. Change the hydraulic fluid at 500 hours. High temperatures and pressures result in accelerated fluid aging. More frequent fluid changes may be required. Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater that the recommended maximum. Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid. Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter. Replace all fluid lost during filter change. 77 51C060-1 Two Position Control, N1NN Loop ?ushing shuttle valve Charge pressure relief valve L1 M4 Case drain “L1” 1.0625-12UN-2B [1 1/16 -12UN-2B] B A Speed pick-up Alternate position Case drain “L2” 1.0625-12UN-2B [1 1/16 -12UN-2B] min. angle stop adjustment Two Position Control, N1NN Split ?ange boss “A”+”B” DN 19 typ II 40 MPa series per ISO 6162 [SAE 0.75] 4 thread: 0.375-16UNC-2B [3/8 -16UNC-2B] 19 [0.75] min. full thread depth Loop ?ushing shuttle valve M4 Charge pressure relief valve Gage port “M4” System pressure max. angle 0.5625-18UNF-2B [9/16 -18UNF-2B] B A Speed pick-up gle stop ment Split ?ange boss “A”+”B” DN 19 typ II 40 MPa series per ISO 6162 [SAE 0.75] 4 thread: 0.375-16UNC-2B [3/8 -16UNC-2B] 19 [0.75] min. full thread depth 78 Gage port “M1” System pressure “A” 0.875-14UNF-2B [7/8 -14UNF-2B] Gage port “M2” System pressure “B” 0.875-14UNF-2B [7/8 -14UNF-2B] Gage port “M1” System pressure “A” 0.875-14UNF-2B [7/8 -14UNF-2B] Series 51 and 51-1 Motors Service Manual Troubleshooting sluggisH system Check Cause Corrective action 1. Control orifices Blocked or restricted orifice will cause sluggish response. Orifices installed to the wrong locations will cause PCOR control to be sluggish. Remove, inspect and clean all orifices. Ensure the appropriate orifices are installed. 2. Threshold setting (proportional controls) Inappropriately high threshold setting will shift the motor at the wrong time. Check threshold setting. Adjust if necessary. 3. Control spool or piston A sticky 4-way spool or control piston will cause sluggish response. Clean and inspect the 4-way valve spool and control piston. Replace if necessary. 4. Pressure compensator setting Inappropriately low pressure compensating Check pressure compensator setting. Adjust if setting will shift motor to maximum displacement at lower pressure necessary. 5. Control input signal An improper or erratic input signal to the control may cause sluggish response. Check input signal or electric current and correct if necessary. 6. Charge pressure Inappropriately low pressure setting at loop flushing relief valve may cause improper supply pressure to motor control. Measure change pressure in forward and reverse. Adjust loop flushing relief valve if necessary. 7. System pressure Inappropriately low system pressure setting may cause sluggish response. Measure system pressure. Adjust pump pressure limiter or system relief valve if necessary. 8. Internal leakage Excessive leakage will cause lower charge pressure and affect performance. Install loop flushing defeat option and monitor case flow. If case flow is excessive, motor may require major repair. Contact your Sauer-Danfoss service provider. system oPeRating Hot Check Cause Corrective action 1. Oil level Insufficient hydraulic fluid will cause overheating. Fill reservoir to proper level. 2. Heat exchanger Blocked heat exchanger or low air flow will not sufficiently cool the system. Check temperature upstream and downstream of heat exchanger. Clean, repair, or replace heat exchanger if necessary. 3. Loop flushing charge pressure Inappropriately high loop flushing relief valve setting will reduce or prevent loop flushing flow. Improper orifice size will not give proper flow for cooling purposes. Monitor case drain flow. If low, adjust loop flushing relief valve setting or replace with orificed type relief. 4. System pressure If system relief valve settings are too low, excess heat will be generated. Adjust system relief valve settings. 5. Air in system Entrained air generates heat under pressure and causes cavitation Look for foam or bubbles in reservoir. Check for leaks on inlet side of charge pump. 6. Internal leakage Excessive internal leakage will overheat the system. Install loop flushing defeat option and monitor case flow. If case flow is excessive, motor may require major repair. Contact your Sauer-Danfoss service provider. 28 11008567 • Rev AE • November 2009 79 Series 51 and 51-1 Motors Service Manual Troubleshooting exCessive noise oR vibRation Check Cause Corrective action 1. Oil level in reservoir Insufficient hydraulic fluid will cause cavitation. Fill reservoir to proper level. 2. Air in system Air bubbles may lead to cavitation. Look for foam or bubbles in reservoir. Check for leaks on inlet side of charge pump. 3. Shaft coupling Loose shaft coupling creates excess noise. Replace loose shaft coupling. Replace or repair motor if shaft splines are worn excessively. 4. Shaft alignment Misaligned shafts create excessive noise and damage motor. Correct shaft misalignment. motoR oPeRates noRmally in one DiReCtion only Check Cause Corrective action 1. Charge pressure If charge pressure is low in one direction, the loop flushing shuttle spool may be sticking to one side. Measure charge pressure in forward and reverse. If pressure drops in one direction, inspect and repair loop flushing shuttle spool. 2. Motor control If control shifts motor to minimum displacement in one direction, motor may not have enough torque to operate. Measure maximum and minimum servo pressures to check control operation. Repair control or correct input signal if necessary. 3. Pressure compensator control If pressure compensator operates in one direction only, the motor will stay at minimum displacement in the other direction Check brake pressure defeat spool. It may be sticking or receiving an improper signal. Repair spool or correct input signal. imPRoPeR outPut sPeeD Check Cause Oil level in reservoir Insufficient hydraulic fluid will reduce system efficiency. Fill reservoir to proper level. 2. Threshold setting Improper threshold setting will cause motor to have wrong displacement for given signal. Check threshold setting. Refer to control service manual for adjustment procedure. 3. Pressure compensator setting Improper pressure compensator setting shifts motor displacement at wrong pressure. Check pressure compensator setting. Adjust if necessary. 4. Control spool or piston Pressure compensator piston or spool sticking holds motor at wrong displacement. Check pressure compensator piston or spool. Repair or replace if needed. 5. Control orifices Blocked or restricted orifice causes motor to shift improperly. Remove, inspect, and clean all orifices. 6. Control piston Sticky control piston causes motor to shift Check control piston for proper operation. Repair if improperly. necessary. 7. Control input signal Improper input signal causes motor to shift improperly. Correct control input signal. 8. Internal leakage Excess internal leakage causes lower charge Install loop flushing defeat option and monitor case pressure and affects system performance including output speed. flow. If case flow is excessive, motor may require major repair. Contact your Sauer-Danfoss Service Provider. 11008567 • Rev AE • November 2009 80 Corrective action 1. 29 Series 51 and 51-1 Motors Service Manual Troubleshooting low outPut toRque Check Cause Corrective action 1. System pressure Low system pressure at motor reduces output torque. Measure system pressure at the motor. If the pressure limiter or relief valve setting is low, increase setting to the proper level. 2. Charge pressure Low loop flushing relief valve setting may cause improper supply pressure to motor control. Measure charge pressure in forward and reverse. Adjust loop flushing relief valve setting if necessary. 3. Pressure compensator setting High pressure compensator setting causes improper motor displacement for torque required. Check and adjust pressure compensator setting. 4. Control orifices Blocked or restricted orifice causes motor to shift Remove, inspect and clean all orifices. improperly. 5. Pressure compensator piston or spool Sticking pressure compensator piston or spool causes control to hold motor at minimum displacement. Remove and inspect control spool and sensing piston. Repair or replace if necessary. 6. Control spool or piston Sticking 4-way spool or control piston causes motor to shift improperly. Remove and inspect 4-way spool and control piston. Repair or replace if necessary. 7. Two position solenoid Two position control not shifting motor to maximum displacement. Inspect solenoid valve for bent stem or bad coil. Repair or replace if necessary. 8. Control input signal Improper control input signal causes motor to stay at minimum displacement. Correct control input signal. 9. Threshold setting Improper threshold setting causes improper motor displacement for torque required. Check and adjust threshold setting. 10. Internal leakage Excess internal leakage causes charge pressure to decay, reducing output torque. Install loop flushing defeat option and monitor case flow. If case flow is excessive, motor may require major repair. Contact your Sauer-Danfoss Service Provider. 30 11008567 • Rev AE • November 2009 81 oveRview (continued) Series 51 and 51-1 Motors Service Manual Adjustments oveRview WARNING This service procedure may require disabling the vehicle / machine (raising the wheels off the ground, disconnecting the work function, and so forth) while performing, in order to prevent injury to the technician and bystanders. Take the necessary safety precautions adjusting charge pressure 1. Loosen the lock nut using a 11/16 hex wrench. 2. Turn the adjustment plug with a large screwdriver or 1 WARNING Incorrect charge pressure Clockwise rotation of the plug increases the setting, and co settings may result in the decreases the setting. The charge pressure setting will be re Adjust components of the Series 51required and Seriesof 51-1 motors per following approximately 3.4 bar [50procedures psi] per turn. inability to build (where necessary, refer to Pressure pages 23-24, for gauge port locations system pressureMeasurement, and / or and sizes): inadequate loop flushing 3. After adjusting the plug, torque the locknut to 52 N•m flows. You must maintain Charge pressure relief valve the correct charge pressure 4. Remove the gauges. Set the charge pressure relief to the model order code specifications. In most undervalve all operation applications, the motor charge relief valve is set5.2 to 4 bar [29 toport 58 psi] below the setting Reinstall the plugs. conditions to maintain of the pump charge reliefpump valve (measured with the pump in its neutral or zero-angle performance position). This setting assumes a reservoir temperature of 50° C [122° F]. Charge pressure Motors with loop flushing defeated, or equipped with an or is referenced (additive) to case pressure. valve (see charge relief valve, orificed style on page 44) do no measuring charge pressure 1. Install a 0 to 60 bar [0 to 1000 psi] pressure gauge in port M1 or M2 (use which ever is at low loop pressure). Series51-1 51 charge pressure relief valve Series charge pressure relief valve Adjustment plug 1 1 /16 inch 52 Nm [38 lbf•ft] 11/16 lock nut 2. Install a 0 to 60 bar [0 to 1000 psi] gauge in port L1 or L2 to measure case pressure. Series 51 and 51-1 Motors 3. Operate the system with the prime Service Manual mover at normal operating speed Adjustments and the pump at half stroke (forward Adjustment plug P101 208E or reverse). oveRview (continued) WARNING Incorrect charge pressure settings may result in the inability to build required system pressure and / or inadequate loop flushing flows. You must maintain the correct charge pressure under all operation conditions to maintain pump performance P101 209E Older Seriescharge 51 andpressure Series 51-1 motors may be equipped with an external screw adjusting 1/ hex adjustable charge pressure relief shown). 1. Loosen the lock nut using a 1valve wrench. 16 (not 2. Turn the adjustment plug with a large screwdriver or 13mm hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting. The charge pressure setting will be reduced or increased at a rate of approximately 3.4 bar [50 psi] per turn. 3. After adjusting the plug, torque the locknut to 52 N•m [38 lbf•ft]. Do not overtorque 4. Remove the gauges. 5. Reinstall the port plugs. Motors with loop flushing defeated, or equipped with an orificed charge pressure relief valve (see charge relief valve, orificed style on page 44) do not require adjustment. Series 51-1 charge 32pressure relief valve 11008567 • Rev AE • November 2009 1 1 /16 inch 52 Nm [38 lbf•ft] 11008567 • Rev AE • November 2009 82 31 Series 51 and 51-1 Motors Service Manual Series 51 and 51-1 Motors Minor repair Service Manual Minor repair sHaft seal RePlaCement (continued) sHaft seal RePlaCement (continued) Cartridge flanged motors Disassembly 1. Thoroughly clean all external surfaces before disassembly. Cartridge flanged motors Disassembly 2. the clean seal carrier snap ring (L80)before from the motor housing, using appropriate 1. Remove Thoroughly all external surfaces disassembly. snap ring pliers. 2. Remove the seal carrier snap ring (L80) from the motor housing, using appropriate 3. Carefully the seal carrier (L75) from the housing. snap ringpull pliers. 3. Caution Carefully pull the seal carrier (L75) from the housing. Do not damage the housing bore or shaft. Caution 4. Remove the the O-ring (L50C)bore from housing bore. Do not damage housing orthe shaft. 5. thebore. new one to make certain that it fits. 4. Discard Removethe theO-ring O-ring(L50C) (L50C)after frominspecting the housing 6. press the (L50C) shaft seal (L40) from thethe seal carrier. 5. Carefully Discard the O-ring after inspecting new one to make certain that it fits. sHaft seal RePlaCement (continued) 7. shaft (L40) the sealthe carrier after making certain that the 6. Discard Carefullythe press theseal shaft sealfrom (L40) from seal (L75) carrier. new one fits. 7. Discard the shaft seal (L40) from the seal carrier (L75) after making certain that the Caution new one fits. Series 51 and Motors Do not damage the51-1 seal carrier during removal. Service CautionManual Series 51 51-1 Motors inspection Do not damage theand seal carrier during removal. Minor repair Manual 1. InspectService the seal carrier (L75) and housing bore for damage. Minor repair inspection 2. area(L75) on the for wear. 1. Inspect the sealing seal carrier andshaft housing bore for damage. sHaft seal Cartridge flanged motors Reassembl;y RePlaCement Disassembly (continued)Common 1. the Thoroughly cleanarea all external surfaces before disassembly. parts ofsealing a cartridge flanged motor 2. Orient Inspect on(L40) the shaft wear. side faces inward. L80 1. the new shaft seal so theforcupped 2. Remove the seal carrier snap ring (L80) from the motor housing, using appropriate snap ring pliers. Common of a cartridge flanged motor 2. Press parts new shaft seal (L40) into the seal carrier (L75). L75 L80 3. Carefully pull the seal carrier (L75) from the housing. Caution L40 3. Press until the shaft seal bottoms out in the cavity. Do not damage the housing bore or shaft. L75 4. Remove the O-ring (L50C) from the housing bore. L40 4. Using petroleum jelly to lubricate, install new O-ring (L50) to the groove in the 5. Discard the O-ring (L50C) after inspectingL50 the new one to make certain that it fits. housing bore. 6. Carefully press the shaft seal (L40) from the seal carrier. L50 5. Using a7. seal protection sleeve the (L75) shaft, the seal Discard the shaft seal (L40) from the on seal carrier after push making certain that thecarrier (L75) into the new one fits. housing bore until it clears the snap ring groove. Caution Do not damage the seal carrier during removal. 6. Install snap ring (L80) into the grove in the housing bore, using the appropriate snap inspection ring pliers. 1. Inspect the seal carrier (L75) and housing bore for damage. 2. Inspect the sealing area on the shaft for wear. 7. Remove the shaft seal protection sleeve. L40 Shaft L80seal Common parts of a cartridge flanged motor L75 L40 L40 Shaft seal L75 Seal carrier looP flusHing sHuttle valve L50 Disassembly P101225 surfaces before disassembly. 1. Thoroughly clean all external L75 Seal carrier 11008567 • Rev AE • November 2009 41 11008567 • Rev AE • November 2009 41 2. Using an 11/16 inch hexP101225 wrench, remove the two hex plugs (G20) from the endcap. 3. Remove the O-rings (G20A) from theL40 hex Shaft seal plugs. Common parts of loop flushing shuttle valve G20 L75 Seal carrier 83 P101225 11008567 • Rev AE • November 2009 41 7. Remove the shaft seal protection sleeve. looP flusHing sHuttle valve Disassembly Series 51 and 51-1 Motors 1. Thoroughly clean all external surfaces before disassembly. Service Manual 2. Usingrepair an 11/16 inch hex wrench, remove the two hex plugs (G20) from the endcap. Minor 3. Remove the O-rings (G20A) from the hex plugs. looP flusHing sHuttle valve (continued) 51the and 51-1 Motors 4.Series Discard (G20A) after inspecting the new ones to make certain they fit. Common parts ofO-rings loop flushing shuttle valve Service Manual Minor repair 5. Remove the springs G20 (K14) and seats (K16) or spring / seat assembly from the cavity. 6. Remove the spool (K18) from the cavity. sHaft seal RePlaCement (continued) G20A Inspection Reassembl;y K14 1.1. Inspect thenew spool (K18) and cavity for cupped wear orside damage. Orient the shaft seal (L40) so the faces inward. K16 Press new shaft and seal (L40) 2.2. Clean the spool cavity.into the seal carrier (L75). K18 3. Press until the shaft seal bottoms out in the cavity. Reassembly K16 1. Aafter making certain that you have the exact replacement parts, replace parts as 4. necessary. Using petroleum jelly to lubricate, install new O-ring (L50) to the grooveG20A in the housing bore. G20 2. Install the spring seat (K16) or spring/seat assembly to one end of the spool. 5. Using a seal protection sleeve on the shaft, push the sealK14 carrier (L75) into the housing bore until itwith clears the hydraulic snap ring groove. 3. Lubricate the spool clean oil. P101226 Installthe snap ring (L80) into into the grove in the housing bore, using the appropriate snap 4.6. Slide lubricated spool the cavity. ring pliers. 5. Legend Installfor the other spring seat (K14) or spring/seat assembly to the spool from the G20 7. opposite Remove the end.shaft seal protection sleeve. h use an 11/16 inch wrench t 41 N•m [30 lbf•ft] 42 looP flusHing sHuttle valve 6. Install new O-rings (G20A) to the hex plugs (G20). 11008567 • Rev AE • November 2009 7. Place the K14 springs in to the hex plugs. Disassembly 1. Thoroughly clean all external surfaces before disassembly. 8. Install the hex plugs. 2. Using an 11/16 inch hex wrench, remove the two hex plugs (G20) from the endcap. 9. Torque the hex plugs to 41 N•m [30 lbf•ft] using an 11/16 hex wrench. 3. Remove the O-rings (G20A) from the hex plugs. Caution Do not overtorque hexflushing plugs shuttle valve Common parts of loop G20 G20A K14 K16 K18 K16 G20A G20 K14 P101226 11008567 • Rev AE • November 2009 Legend for G20 h use an 11/16 inch wrench t 41 N•m [30 lbf•ft] 84 42 11008567 • Rev AE • November 2009 43 valve Relief ued) Service Manual Minor repair )deunitnoc .)57L( reirrac laes eht otni )04L( laes tfahs wen sserP .2 .ytivac eht ni tuo smottob laes tfahs eht litnu sserP .3 eht ni evoorg eht ot )05L( gnir-O wen llatsni ,etacirbul ot yllej muelortep gnisU .4 .erob gnisuoh CHaRge Relief valve (continued) em . re disass wrench d style es befo ch hex orifice l surfac ng a 1 in externa mbly cap usi Disasse ughly clean all the end ro avity in 1. Tho m the c 000) fro ridge (K ove cart ridge. it fits. 2. Rem the cart in that 0) from ke certa ing (K5 e to ma ove O-r new on ches. 3. Rem ting the ex wren r inspec 6 inch h ing afte and 11/1 card O-r g 1 inch 4. Dis 00) usin dge (K0 le cartri assemb lve 5. Dis K95 relief va charge g (K95). Orificed ove plu K95A 6. Rem 5A). ing (K9 K70 ove O-r g 7. Rem spectin K80 after in it K000 in that e O-ring card th to make certa K10 8. Dis one the new fits. ). K50 ng (K70 ove spri 9. Rem 0). pet (K8 ove pop 10. Rem ar s for we on nd part 7 P101 22 Inspecti cavity a ect the 1. Insp . e g a or dam each ain that d parts. ake cert avity an ne to m an the c e new o 2. Cle ecting th fter insp bly essary a Reassem ce parts as nec la 1. Rep fits. orificed style eht otni )57L( reirrac laes eht hsup ,tfahs eht no eveels noitcetorp laes a gnisU .5 Disassembly .evoorg gnir pans eht sraelc ti litnu erob gnisuoh 1. Thoroughly clean all external surfaces before disassembly. pans etairporppa eht gnisu ,erob gnisuoh eht ni evorg eht otni )08L( gnir pans llatsnI .6 all O-rin 3. Inst ssem 4. Rea ue p 5. Torq all cart 6. Inst ue ca 7. Torq card re 2. Dis .sreilp gnir 2. Remove cartridge (K000) from the cavity in the endcap using a 1 inch hex wrench. .eveels noitcetorp laes tfahs eht evomeR .7 dge tion Cau ertorque cartri ov Do not 67 • Rev 110085 3. Remove O-ring (K50) from the cartridge. placed parts. gs (K50 5) lug (K9 to ridge in gniHsulf Poo evlav elttuH ylbmessasiD .ylbmessasid erofeb secaf rus lanretxe lla naelc ylhguorohT .1 ) (K95A cartridg .pacdne eht morf )02G( sgulp xeh owt eht evomer ,hcnerw xeh hcni 61/11 na gnisU .2 6. Remove plug (K95). .sgulp xeh eht morf )A02G( sgnir-O eht evomeR .3 evlav elttuhs gnihsufl pool fo strap nommoC Orificed charge relief valve ) (K95). ng a 1 in f•ft] usi ng an 1 f•ft] usi 7. Remove O-ring (K95A). gs (K10 ) to plu e. ity. the cav 2009 •m [27 lb to 37 N 5. Disassemble cartridge (K000) using 1 inch and 11/16 inch hex wrenches. •m [38 lb to 52 N vember AE • No rtridge ble the 4. Discard O-ring after inspecting the new one to make certain that it fits. x wrenc 1/16 he ch hex . 10. Remove poppet (K80). h. wrench 9. Remove spring (K70). K95 02G 8. Discard the O-ring after inspecting the new one to make certain that it fits. A02G K000 K95A K70 41K 61K K80 K10 81K 61K A02G 02G K50 Inspection 41K 1. Inspect the cavity and parts for wear or damage. 622101P P101 227 45 2. Clean the cavity and parts. 02G rof dnegeL hcnerw hcni 61/11 na esu h ]tf•fbl 03[ m•N 14 t Reassembly 9002make rebmevoNcertain • EA veR • 76that 580011each 1. Replace parts as necessary after inspecting the new one to fits. 2 2. Discard replaced parts. 3. Install O-rings (K50) (K95A) to plugs (K10) (K95). 4. Reassemble the cartridge. 5. Torque plug (K95) to 37 N•m [27 lbf•ft] using an 11/16 hex wrench. 6. Install cartridge into the cavity. 7. Torque cartridge to 52 N•m [38 lbf•ft] using a 1 inch hex wrench. Caution Do not overtorque cartridge 11008567 • Rev AE • November 2009 45 85 Track Drive Gearbox PMC 3000 is a travel drive unit, expressly designed to be used for the application on tracked units requiring maximum constructive stiffness . PMC 3000 is equipped with an extremely compact rotating body that allows an optimal torque transmission and an effective resistance to axial and radial loads. The unit is equipped with a parking brake with hydraulic release. Can also be coupled with appropriate flange to plug-in motors. The design and the development was based on the optimization of: a) Lubrication; b) Thermal exchange; c) Durability of brake system; d) Durability of bearings and mechanical seals; PAY ATTENTION ! : Under normal working conditions the gearbox shall never exceed a temperature of 100°C. If this temperature limit is exceeded it is recommendable to suspend usage and allow the gearbox to cool down. Min. temperature gearbox not running or running without load: -40 °C Min. running temperature of gearbox: -15 °C Gearbox weight: 353 lbs. (160 kg) Gearbox oil type: SAE 80W 90-API GL5 (3.0-3.5 quart) Brake disc assembly is spring applied, requires 174 psi (12 bar) hydraulic pressure to fully release brakes. Brake assembly (internal assembly M16 mounting bolts (for mo- inside gearbox) tor to gearbox) Torque: 235 ft-lbs (318Sectional Nm) Cross view of mounting GEARBOX DRIVE MOTOR M20 MOUNTING BOLT (for gearbox to track frame) Torque: 460 ft-lbs (623 Nm) 86 M16 MOUNTING BOLT (for chain sprocket to gearbox) Torque: 235 ft-lbs (318 Nm) Draining For oil-drainig operation, follow these steps: Maintenance: • step4 screw in orderreplacement the level plug The routine maintenance includes only: the timely (2) and the filling plug (1). of the oil! (NOTE: a NEW reduction gearbox is supplied without After 50 working hours it’s advisable to oil!) check the oil level. For correct use of the unit you are use oilpleIf therecommended oil level is lower thantoexpected, type: SAE 80W90 - API GL5 ase restore it! • step 5 : screw in order the level plugRespect (2) andthe theenviroment! filling plug (1). Don’t let the oil drop on the floor! After 50 working hours it’s advisable to check the oil level. If the step1 restore : rotateit! the gearbox until one o oil level is lower than expected,• please two front plugs (8)1 is set vertiOil should be changed every 500the working hours! • Oil should be changed every 500 working hours! To check and add oil, follow these steps: Respect the environment! Don’t let the oil drop on the floor! • Front Gearbox oil fill plug (1) cally downwards (fig. 3). . step2 : unscrew both the front plug (8) and leave out the exhaust oil. step3 : follow the steps described a pag.18 to refill the gearbox. Fig 2 Fig 3 Front Gearbox oil level plug (2) • step 1 : rotate the gearbox until the drive is set as shown with one of the two front lling plugs (2) set horizontally (figure2). The other plug (1) is placed nearly vertically. • step 2 : unscrew both the front plugs (1&2). • step 3 : use a good quality SAE 80W90 - API GL5 oil and fill gearbox through the top front plug (1) using a volume of 3.0 3.5 qts (2.8 - 3.2 liters) oil. The oil introduced is still correct when level touches the middle of the level plug (2). • step 4 : screw in order the level plug (2) and the filling plug (1). After 50 working hours it’s advisable to check the oil level. If the oil level is lower than expected, please restore it! Oil should be changed every 500 working hours! To drain and refill the gearbox oil, follow these steps: Respect the environment! Don’t let the oil drop on the floor! • step1 : rotate the gearbox until one of the two front plugs is set vertically downwards (fig. 3). • step 2 : unscrew both the front plugs (1&2) and leave out the exhaust oil into an approved container to hold approx 4 qt oil. • step 3 : rotate the gearbox until the drive is set as shown with one of the two front lling plugs (2) set horizontally (figure2). The other plug (1) is placed nearly vertically. • step 4 : use a good quality SAE 80W90 - API GL5 oil and fill gearbox through the top front plug (1) using a volume of 3.0 3.5 qts (2.8 - 3.2 liters) oil. The oil introduced is still correct when level touches the middle of the level plug (2). Front Gearbox Oil drain plug (2) 87 Air Conditioning System R-8545 BACK WALL HD Air Conditioner Unit/Heat Compact and powerful are the best words to describe the R-8545. Inch for inch the R-8545 has the highest output of any unit its size in the off road. The R-8545 is constructed of heavy gauge coated steel and engineered to filter in-cab air as well as incoming outside air when pressurization is required. The R-8545’s high-performance, rugged construction and serviceability make it ideal for all off road applications where space is a minimum and dependability essential. R-8545 SPECIFICATIONS BTU’s Heating: 28,600 BTU/Hr @ 100°F (8.4 kW @ 37.8°C) air temperature rise BTU’s Cooling: 18,000 BTU/Hr with 36°F (5.3 kW with 2.2°C) refrigerant temp. and 80°F (26.7°C) wet bulb entering air Air Flow: 265 CFM (450 m3/h) Weight: Heater & A/C= 39 lbs.(18 kg) A/C Only= 34 lbs.(15 kg) Motor: Totally sealed, 12 or 24 VDC permanent magnet type with long life brushes, and heavy duty pre-lubricated sealed ball bearings Current Draw: 16.1 amps @ 13.6 VDC (includes 4 amps for A/C clutch), 8 amps @ 27.2 VDC (includes 2 amps for A/C clutch) Controls: Mode selector switch (heat or A/C), three-speed fan switch, fixed setting A/C thermostat, cable controlled water valve Final Assembly and Check 1) Evacuate the system, add 3 oz of compressor oil, then charge with 2 lbs 6 ozs of R134a refrigerant. 2) Turn the ignition switch to the “On” position and place the fan speed switch on the highest position. 3) Place the Heat-A/C switch to the “A/C” position and the temperature control lever on the coldest position. a. The clutch should click on and be engaged. b. The evaporator blower should be turning at high speed. 4) Turn the fan switch to the “Off” position and compressor clutch should disengage. 5) Move the Heat-A/C switch to the “Heat” position and compressor should disengage. 6) Start engine and run at 1200-1500 rpm. Place the Heat-A/C switch to the “A/C” position and the fan speed on high. Check sight glass on receiver drier for bubbles. Add 6 to 8 ounces more R-134a after the sight glass just clears. NOTE: Be aware that the sight glass may appear “milky” when charging with R-134a. Be careful not to overcharge the system. Total system holds 2 lbs 14 oz of R134a refrigerant. 7) Make sure clutch cycles off and on as system is operating. F. Unit Wiring NOTE: See Figure 6 for wiring diagram. 1. Disconnect battery. 2. Black W/White - Route to A/C clutch through low pressure protection switch if included. 3. Red Wire - Connect to an ignition switch supply through a 30 amp circuit breaker for 12 volt system; a 15 amp circuit breaker for 24 volt system. 4. Black Wire - Unit grounding wire. 5. Brown Wire - Route to condenser fan relay (remote mount condenser). 88 • • cally downwards (fig. 3). . step2 : unscrew both the front plugs (8) and leave out the exhaust oil. step3 : follow the steps described at C275 Operation & Service Manual pag.18 to refill the gearbox. Specifications Fig 3 Front Gearbox Oil drain plug (2) 800.392.2686 89 C275 Operation & Service Manual 90 C275 Operation & Service Manual Fluid Capacities CAPCITY TYPE ENGINE OIL 17 QTS See Chart In Engine Manual FUEL 95 GAL Ultra Low Sulfur Diesel HYDRAULIC 25 GAL w/System 35 GAL AW HVI Hyd Oil 46 COOLANT 76 QTS Phosphate Free HD Antifreeze (ASTM D6210 Compliant) 800.392.2686 91 SERVICE PARTS SERVICE FILTERS TRACK ASSEMBLY PARTS DESCRIPTION PART # QTY. DESCRIPTION PART# Fresh Air Filter 762823 1 Front Idler Assembly 801719 QTY 2 Foam Cab Filter 802762 1 Bottom Roller 803807 16 Engine Air Filter-Primary 806180-10 1 Top Roller 801772 2 Engine Air Filter-Secondary 806180-11 1 Track (Single Bar) 801838 2 Primary Engine Fuel Filter 806180-7 1 Sprocket 40168 2 Secondary Engine Fuel Filter 806180-9 1 Front Rock Guard 26205 2 Engine Oil Filter 806180-5 1 Middle Rock Guard 26204 2 Track Drive/Cutter Pump Charge Filter 762462 1 Rear Rock Guard 32505 2 Hydraulic Return Filter 802681 1 Hydraulic Pilot Filter 764406 1 COMMON WEAR AND REPLACEMENT PARTS MANUALS DESCRIPTION PART# QTY Ignition Key 764136 1 735999 1 Parts PMC275-19 Operator Service Maintenance OSMC275-19 Ignition Switch Operator Booklet OBC275-19 Fuel Cap 1 Coolant Cap 1 Engine Serpentine Belt 1 Engine Fan Belt O-Ring Kit FILTER SERVICE KIT KIT INCLUDES FILTERS IN THE “FILTER SERVICE” SECTION 1 800186 1 RAYCO WARRANTY CERTIFICATE A. General Outline D. Unapproved Service or Modification Rayco Manufacturing, Inc. warrants to the first user that the products it supplies will be free from defects in material and workmanship under normal and proper usage for a period of 365 days from the date of delivery to the first user. In addition, with respect to “Mini Work-Force” models, the mainframe and control bar will be free from defects in material and workmanship under normal and proper usage for a period of two (2) years from said date of delivery. Rayco is relieved of its obligation under this warranty if: This warranty does not cover and Rayco makes no warranties with respect to (i) any product that has been subject to abuse, misuse, misapplication, neglect, alteration or accident; to improper or incorrect repair or maintenance; or to abnormal conditions of use, temperature, moisture, dirt or corrosive matter; and (ii) any material, parts or other components that are manufactured by someone other than Rayco, which items carry only the manufacturer’s warranty, if any. Furthermore, this warranty does not cover expendable parts. Individual components such as engines, engine drive systems, batteries, and hydraulic components, etc. shall be covered by standard warranties of their respective manufacturers. Any claims must be submitted within 30 days of the repair. B. Individual Components 1. Engines All engines have specific warranties issued by OEM and honored thru their respective dealer. 2. Hydraulic Components Hydraulic components have variable warranties. Rayco must preauthorize all hydraulic component product warranties prior to removal from the machine, and all warranty considerations are the sole responsibility of the manufacturer. 3. Batteries Batteries have a warranty that is honored thru manufacturer. For warranty service, the purchaser is to contact manufacturer directly. 4. Various Components A. Belts will be covered under warranty only if Rayco receives warranty from their supplier. B. Sprockets Sheaves have a six month limited warranty. C. Electric clutches have a six month limited warranty. D. Hydraulic Cylinders will be covered under warranty only if Rayco receives warranty from their supplier. 5. Pockets and Teeth 1. Service (other than normal maintenance and replacement of service items) is performed by someone other than an authorized Rayco dealer; or 2. The product is modified or altered in ways not approved by Rayco. E. Obtaining Warranty Service To obtain performance of this warranty, the original retail purchaser must request warranty service from a Rayco dealer authorized to sell the product to be serviced. When making such a request, the purchaser must present evidence of the product’s delivery date, make the product available at the dealer’s place of business, and inform the dealer in what way the purchaser believes the product to be defective. Warranty repairs can be made in the field if the purchaser and servicing dealer so desire. However, travel time expense to and from the job site will be purchaser or dealer responsibility. F. No Implied Warranty or Other Representation Where permitted by law, neither Rayco nor any company affiliated with it makes any warranties, representations or promises, expressed or implied, as to the quality or performance, or freedom from defect of its products other than those set forth above, and NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS IS MADE. G. Limitation of Purchaser’s Remedies Where permitted by law, the purchaser’s only remedies in connection with the branch of performance on any warranty on any Rayco product are those set forth on this page. In no event will the dealer and or Rayco be liable for incidental or consequential damages, including but not limited to: loss of profits, rental of substitute equipment, or other commercial loss. H. No Dealer Warranty The selling dealer makes no warranty of his own on any item warranted by Rayco, and makes no warranty on other items unless he delivers to the purchaser a separate written warranty certificate specially warranting the item. A dealer has no authority to make any representation to promise on behalf of Rayco, or to modify the terms or limitations of this warranty in any way. If you have a situation where you are not sure if a component is covered under warranty, please do not hesitate to contact us. Rayco wants you and your customer to be 100% satisfied with our products and service. Pockets and Teeth will be covered under warranty only if they are defective before they are mounted on a stump grinder. Once they are used, all warranty stops. C. Items not Covered Rayco is not responsible for the following: 1. Premiums charged for overtime labor requested by the purchaser. 2. Transporting the 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. 93 Read and understand all instructions before attempting to operate this machine. This manual should be readily available for reference at all times. Additional copies of this manual may be purchased. Contact your Authorized Rayco Dealer or Rayco Manufacturing Inc. RAYCO Manufacturing, Inc. 4255 E Lincoln Way Wooster, OHIO 44606 U.S.A. 800.392.2686 raycomfg.com Think Smart, Think Safe……… We care about your safety. When operating your RAYCO® machinery always wear an approved 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; add or remove features; add improvements; or discontinue manufacturing at any time without notice or obligation. Thank you for buying and using RAYCO Equipment. ">

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Key features
- 260hp Cummins engine
- Side entry cab
- Heavy duty undercarriage
- Multiple track shoe options
- Single-drive cutter head
- Variable displacement motor
Frequently asked questions
The serial number plate is located on the cab door side of the engine compartment, in front of the DEF tank.
Use the service hour meter to determine servicing intervals. Refer to the Maintenance Interval Schedule for specific items and procedures.
Consult the Troubleshooting section of the manual for common issues and solutions.