Rayco C120R Operator, Service & Parts Manual Download Page 43

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C120R Operator Service Maintenance Manual

800.392.2686

Maintenance

Service Interval:

10 Hrs

or Daily

First 25

Hrs

First 50

Hrs

Every 100

Hrs

Every 250

Hrs

Every

500 Hrs

Every 1000

Hrs

Every

Year

Needed

Air Cleaner - Check / Replace Cartridges

check

replace

Air Cleaner Ejector Valve- Clean

Air Filter for Air Conditioner - Clean / Replace

check

replace

Air Intake Piping- Check

Back-Up Alarm - Test

Battery & Cables - Check

Brake System - Check

Cab Windows - Remove & Clean

Cooling System - Drain & Clean

Engine Coolant Level- Check

Engine Coolant Hoses- Inspect

Engine Coolant- Anti Freeze Check

Engine Coolant Filter - Replace (if equipped)

replace

Engine Crankcase Breather Tube- Inspect

Engine Injectors - Inspect

Engine Leaks - Check

Engine Mounts - Check

Engine Oil Level - Check

Engine Oil & Filter - Change

Engine Valve Clearance - Check

Engine Vibration Damper- Check

Fan Belt Tension - Check

Fuel Filter - Change

Fuel / Water Separator - Drain

Fuel / Water Separator Element - Change

Fuel Tank - Drain Water & Sediment

Fuel Tank - Fill

Gauges/Warning Lamps/Fault Codes - Check

Grease & Lubricate Moving Parts

Grease & Oil Buildup - Remove

Hydraulic Oil Tank - Check & Fill

Hydraulic Oil Cooler - Clean w/Air

Hydraulic Oil Filters - Change

Hydraulic Oil - Change

Pump/Gearbox Bolt Tightness - Check

Gearbox Oil - Check

Radiator Pressure Cap- Check

Debris Screens - Clean

ROPS - Inspect

Seat Belt - Inspect

Cooler / Radiator - Clean & Inspect

Track Adjustment - Check

Track Adjustment - Adjust

Track Pad Bolts - Re-Torque

Track Motor / Sprocket Bolts - Check

Track Drive Oil - Check

Track Drive Oil - Replace

Walk Around Inspection

Summary of Contents for C120R

Page 2: ...achine Readandunderstandallinstructionsbefore 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 RaycoManufacturing Inc Wooster Ohio Duetocontinuous improvements Rayco reserves the right to make changes in engineering design and specifi...

Page 3: ...C120R Operator Service Maintenance Manual 800 392 2686 3 Content TABLE OF CONTENTS Forward 4 Safety 8 Operation 22 Specifications 38 Maintenance 42 Troubleshoot 64 Warranty 99 ...

Page 4: ...on are basic Skillandtechniquesdevelopastheoperatorgainsknowledge of the machine and its capabilities Maintenance 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 maintena...

Page 5: ... CAT TIER 4 Fuel Type DIESEL Ground Pressure With Mulcher 5 65PSI 38 9KPA Travel Speed Fast Track Travel Work 7 4 7 2 6MPH 11 2 7 5 4 1KMH Mulcher Head Standard FM120 6R Overall Width 83 IN 210 8 CM Cutting Width 71 5 IN 181 6 CM Rotor Diameter 16 75 IN 42 5 CM Teeth 36 36 Hydraulic System LO FLOW OPEN LOOP 20GPM 3 770PSI 75 7LPM 25 993KPA HI FLOW OPEN LOOP 40GPM 3 770PSI 151 4LPM 25 993KPA SUPER ...

Page 6: ...al number For Example C120R 001 01 19 C120R Type of Rayco equipment you have 001 Three digit for the number of produced 02 Two digit month 01 Jan 02 Feb etc 19 Two digit year 19 2019 20 2020 etc It is attached to the machine at the location shown For ready reference record it in the boxes provided on the next page of this manual For reference on communication regarding the engine record its model ...

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

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

Page 9: ...chnique 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 ...

Page 10: ...ctionmustconformtoANSIZ87 1andbethewrap aroundstyle Alwaysweartheeyeprotectionwhenoperating or working within the operational area of the machine Hearing Protection Plug type ear protection or full ear coverage devices muff type shall be worn at all times when operating or within the operational area of the machine Gloves When operating or handling brush within the operational area of the Horizont...

Page 11: ...ned during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluidwithsuitablecontainersbeforeopeninganycompartment or disassembling any component that contains fluids Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Tools that are suitable for containing fluids and equipment that is suitable...

Page 12: ...ome 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 alwaysinstalltheguardsafterthemaintenance is performed Keep objects away from moving fan blades The fan blade will th...

Page 13: ... a fire Fire may cause personal injury and property damage 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 Storefuelsandlubricantsinproperlymarkedcontainersaway fromunauthorizedpersons Storeoilyragsa...

Page 14: ...tarting aid for cold weather starting 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...

Page 15: ...e to pressure buildup caused by an increase in temperature 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 serio...

Page 16: ...p alarm and all other warning devices are working properly Fastentheseatbeltsecurely ifequipped Lowerthearmrest Operation Onlyoperatethemachinecontrolswhentheengineisrunning 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...

Page 17: ...raction and machine s 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 attac...

Page 18: ...ight 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 U...

Page 19: ...d 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 for your machine or your work tool will provide specific requirements for ...

Page 20: ... essential items 4 Inform all affected personnel 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 Transportatio...

Page 21: ...fic 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 ...

Page 22: ...hine General Identification Exterior 1 Engine Compartment 2 Fuel Tank FIll 3 Hydraulic Tank DEF Tank Location 4 Cab 5 Work Lights 6 Mower Head 7 Final Drive 8 Radiator 9 Rubber Track 10 Winch 11 Cab Tilt Remote 12 Limb Riser Cooling Package 5 4 3 1 1 7 8 11 2 6 9 10 12 ...

Page 23: ...tinguisher 3 Control Panel 4 Right Joystick 5 Display Panel 6 Heater AC Controls 7 Escape Hatch Knobs 8 LH Joystick 9 Cup Holder 10 Manual Tube 11 Washer Tank 12 Aux Power Ports 13 Slope Indicator 14 Radio 15 Rear Camera Monitor 16 Cab Fuse Block Operation 2 4 7 8 1 3 5 6 9 10 11 12 13 14 7 15 16 ...

Page 24: ...achine 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 Seat and Seat Belt Inspection Adjust the seat at the beginning of each work period Also adjust the seat when you are changing operators Inspect the seat belt mounting hardware...

Page 25: ...g throttle 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 oilthroughthecontrolvalvesatsystemreliefpressureandwill shortenthetimerequiredtowarmuptheoil Cyclethemower in this fashion for pe...

Page 26: ...forallreplacementparts 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 mou...

Page 27: ...oystick with three positions to provide operator with their preferred setting slow medium fast sensitivity 6 Auxiliary Flow Switch This Switch controls the flow direction for the auxiliary hydraulic ports on the right hand side of the machine This also is a three position switch When using the Rayco head this switch should be in the center Off position When using attachments other than the Rayco h...

Page 28: ...YS CHOCK OR SECURE THE MACHINE IN ADDITION TO PARK BRAKE WHEN SERVICING DO NOT RELY SOLELY ON THE PARKING BRAKE TO THE SECURE THE MACHINE Low DO NOT ATTEMPT TO MOVE THE MACHINE WHILE THE PARKING BRAKE IS ENGAGED DAMAGE TO THE FINAL DRIVES MAY OCCUR 19 18 R 125 TYP TEXT AND SYMBOLS TO BE SOLID BLACK BACKGROUND TO BE WHITE NOTE SPLIT ADHESIVE BACKED DECAL W WHITE BACKGROUND 1 2 MIL WHITE POLYESTER W...

Page 29: ...6 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 50o F 10o C Fresh air can be brought into the cab or recirculated using the mode switch 25 Note to maximize heating or cooling in extreme conditions use ...

Page 30: ...te independently of each other The C120R has an optional Fast Track Mode If equipped the indicator A is located to the left of the seat belt indicator Fast track mode allows quick travel of the machine when the work is done To shift into this mode the machine must first be in travel mode rabbit A Press and hold the fast track button on the keypad located on the console and click the 2 speed button...

Page 31: ... 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 SPN FMI The SPN FMI refers the standard trouble code table that can be referenced on line or in the engine manual OC OC references the number of occurrences that the machine has triggered the fault Active Inactive Faults Active faults are faults ...

Page 32: ...ally shutdown in 15 seconds Check oil level and for any sign of leaks AIR FILTER RESTRICTION The intake air cleaner restriction lamp indicates that the air cleaner needs serviced 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 ENGINE COOLANT TEMPERATURE Too much ...

Page 33: ...equipmenttoadrawbarorahitch Never straddle a wire rope cable Never allow other personnel to straddle a wire rope cable Before you maneuver the machine make sure that no personnel are between the machine and the trailing equipment Blockupthehitchofthetrailingequipmentin order to align the hitch with the draw bar Maneuver the machine Connectthemachinetothetrailingequipment Know the maximum dimension...

Page 34: ...talled radio A The radio is located on the upper left cab corner when sitting in the operators seat and can be controlled by the remote C or the buttons on the face of the radio The radio also supports inputs from a phone or other device through the data ports B located on the operators control panel Operation A B C ...

Page 35: ...r a sturdy anchor to attach the winch cable to Open the access cover by removing the pin F and rotating the cover to the left Dis engage the winch clutch by pushing the clutch tab in and rotating the lever G downward Unwind the cable from winch and hook to tree or anchor Be sure to leave at least one or more wraps on the winch drum so cable does not get pulled from winch When using the winch utili...

Page 36: ... horizontal position and install the secondary lock bar Attaching the Hoses To attach the hoses from the mulcher to the C120R remove the cover panel bolts 8 to gain access to the couplers Before coupling the hoses be sure that all surfaces are clean to prevent dirt and debris from entering the hydraulic system and causing failures Aftercleancouplersareachieved alignthecouplersleevewith the alignme...

Page 37: ...is designed to be operated with an attachment mounted on the machine In the event that the mulcher or attachment is removed the machine becomes rear heavy and unstable If loading or moving the machine with out the attachment it is necessary take note of the unbalance and plan or work accordingly ...

Page 38: ... 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...

Page 39: ...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 ...

Page 40: ...4 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 recommendat...

Page 41: ...tenance 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 ...

Page 42: ...ill 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 condi...

Page 43: ...ks Check X X X Engine Mounts Check X X Engine Oil Level Check X Engine Oil Filter Change X X Engine Valve Clearance Check X Engine Vibration Damper Check X Fan Belt Tension Check X X Fuel Filter Change X X Fuel Water Separator Drain X Fuel Water Separator Element Change X X Fuel Tank Drain Water Sediment X Fuel Tank Fill X Gauges Warning Lamps Fault Codes Check X Grease Lubricate Moving Parts X Gr...

Page 44: ...C120R Operator Service Maintenance Manual 44 Maintenance Maintenance Log Date of Service Machine Hours Description of Service Maintenance Notes ...

Page 45: ...C120R Operator Service Maintenance Manual 800 392 2686 45 Maintenance Maintenance Log Date of Service Machine Hours Description of Service Maintenance Notes ...

Page 46: ...ull the handle 5 and swing open the radiator screen to gain access To to remove to filter cartridge release the three clips 6 The cover will then be free To remove the outer filter pull on the filter and it will come out To remove the inner filter pull on the filter and it will come out Completely inspect the cleanliness of both filters If they are slightly dirty they may be cleaned by lightly tap...

Page 47: ...rface Replace at stated intervals or when needed Rayco filter element 806306 DO NOT USE COMPRESSED AIR TO CLEAN OUT FILTER In very dusty conditions check this filter daily and clean or replace as needed Batteries Check The battery is located inside the engine enclosure on the left side of the machine It can be accessed by opening up the enclosure side door Whenremovingthebattery loosentheholddowns...

Page 48: ...ngine Coolant Level Check 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 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 16 psi rating every 500 hours to insure it is working properly Inspect...

Page 49: ...nt Anti Freeze Check Use a refractometer to achieve the most accurate reading Refer to pg 36 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 Engine Leaks Check CheckforleaksasdescribedintheEngineOperationManual Engine Mounts Check Check and tighten if necessary all engin...

Page 50: ...y pan Once the belly pane has been removed remove the drain plug 2 and drain the oil Use an approved container to store used oil 2 Remove the oil fill cap 3 to aid in draining 3 Using a heavy duty strap filter wrench remove the oil filter on the machine and replace with a new one 4 4 Using your finger put a light coat of oil on the seal of the new filter Ensure old seal is removed 5 Replace and ti...

Page 51: ...ne Maintenance Manual Fuel System Water Separator Check Drain 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 5 off of the secondary fuel filter Allowing all water to escape into a container Close the drain valve when all water has been removed Refer to the Engine Ma...

Page 52: ...take note of the light on the side of the pendent holder 2a This indicates when the cab pins are in locked position and correspond with the operator control panel 2b The upper white button raises the cab and the lower black button lowers the cab Once the cab has been fully raised insert the safety bar 4 to hold it in the raised position The cab tilt process may take some time as the cab lock pins ...

Page 53: ... is filled to proper level Place Fill Hose back on engine door and replace cap and secure the quick coupler to keep hose clean To drain the hydraulic tank place a catch pan below the machine large enough to catch the oil drained from the tank Remove the engine belly pan cover under the machine The cover has 7 bolts that use a 9 16 wrench to remove Once the cover is removed you can remove the plug ...

Page 54: ...lter The Hydraulic Return Filter and the Hydraulic Fill Filter are bothlocatedin theenginecompartment Toaccessthefilters simply open the left hand engine enclosure door The Hydraulic Return Filter 15 is located directly above the hand operated Hydraulic Fill Pump To remove filter use a heavy duty strap wrench and loosen filter After filter is removed check the filter base and filter to ensure the ...

Page 55: ...need to be removed to tilt the cab Note Do Not reuse fluid this can cause contamination DEF System The C120R is equipped with Diesel Exhaust Fluid DEF treatment system The tank is located in the left rear engine compartment door The DEF system sensors and operating components are sensitive and can be costly to repair and replace care should be taken when working with this system Refer to the engin...

Page 56: ...Under any circumstance the cooler should not be cleaned with a high pressure washer ROPS Inspect 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 originalreplacementpartsonly Tightentheboltsto400ft lbs Do not weld on the ROPS Do not drill holes in the ROPS If the ROPS has a...

Page 57: ...C120R Operator Service Maintenance Manual 800 392 2686 57 Maintenance ...

Page 58: ...n 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 ChargePressureshouldbesteadyatapproximately340 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 Mo...

Page 59: ...MP AND MOTOR CASES ALLOW CHARGE PRESSURE OR RUN PRIME MOVER CONTROL IN NEUTRAL WHEN FLUID AT LEAST 200 TO 220 PSI CHARGE PRESSURE GAUGE STARTS CLIMBING 40 SECONDS AT LOW SPEED TIGHTEN CASE DRAIN OUTLET AT MOTOR IS UNTIL FOR APPEARS SET PRIMER MOVER CYCLE PUMP CONTROL SLOWLY CHARGE PRESSURE STOP PRIMER MOVER 50 OF MAXIMUM THROTTLE 2 OR 3 TIMES DROP APPROX 40 PSI IN CHARGE REMOVE GAUGE REPLACE PLUG ...

Page 60: ...tire undercarriage system To lift the machine utilize the mower mounted on the machine in its lowest position Avoid sharp projections when traveling Avoid turning fast on hard surfaces Be careful that no oils get on the rubber track Loosen the Track if too Tight Loosen the grease zerk 1 with a wrench twist the zerk out far enough so that the grease begins to seep out Re tighten the zerk when the d...

Page 61: ...Oil Replace section which follows Track drive oil Replace To change the oil in the track drive gearbox follow the following instructions To drain the oil in the track drive position the unit as in above figure The oil drain hole must be positioned straight down 6 with the oil fill hole used as a pressure relief 5 Draining the oil should always be done when the oil is hot this will aid in the drain...

Page 62: ...O MFG INC CAD GENERATED DRAWING DO NOT MANUALLY UPDATE DWG NO DECAL C120 MAINTENANCE CHART DATE SCALE FINISHED WEIGHT SHEET UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES ARE FRACTIONAL 1 32 00 010 000 005 ANGULAR 1 MATERIAL SEE NOTE DO NOT SCALE DRAWINGS C120 40117 OF WOOSTER OHIO 10 29 2018 1 2 0 347 1 1 XXX CHKD DRWN ESW ACCUMULATED GREASE AND OIL ON A MACHINE IS A FIRE HAZARD R...

Page 63: ...he loader in the upper position The lock bar is located inside the right rear engine compartment door Lift loader arms in the upmost position and insert lock bar in the extended cylinder and use supplied bolt and knob to secure it in place Attachment Handle Lock The Attachment Handle Lock 7 ensures the operator that the attachment on the front of the C120R is latched onto the loader attachment pla...

Page 64: ...n key 2 Remove all belly pans and guards from the final drives Store bolts and covers away from the machine until finished 3 Move the machine to the designated wash area put the machine on an incline with the front of the machine being higher than the rear to aid in draining while cleaning 4 Openallenginecompartmentdoorsandhoodsandcheck to make sure water will not enter the engine internally from ...

Page 65: ...C120R Operator Service Maintenance Manual 800 392 2686 65 Troubleshoot Use ULSD Diesel Only ...

Page 66: ...curs If the micro receives a signal from the Engine Oil Pressure Switch Engine Temperature Switch the coolant level switch DEF system or Hydraulic Oil Level Switch the appropriate indicator light will turn on and the micro will alarm for 10 seconds After 10 seconds of continuous signal the engine will shut down Main Circuit Breaker A 50 Amp circuit breaker 1 is located on the right hand side of th...

Page 67: ...ting power for service or storage Note Wait 4 minutes after the ignition key is shut off before shutting off the master connect Main Power Source The following picture shows the main power source for the C120R 1 Frame Logic Control Module LCM 2 Power Distribution Solenoid 3 Circuit Breakers 4 Engine Compartment Light Switch 5 Engine Control Module ECM NOTE Circuit Breakers are equipped with a manu...

Page 68: ...Thetransducerassemblyislocatedinsidetherightrearengine compartment door and houses the test ports for the C120R To check pressures manually through the test ports you will need to have the proper gauge size that is noted on the transducer decal and the test port coupler adapter When testing the pressure at each port the engine needs to be turned off so that there is no pressure at the ports The te...

Page 69: ...M QTY PART DESCRIPTION 1 1 29803 MANIFOLD PRESSURE TRANS 2 4 722107 BOLT HEX 1 4 20 X 1 3 4 3 5 760399 COUPLING MINI CHECK 6 SAE 4 1 762555 VALVE SHUTTLE LSV1 5 2 801203 SENSOR PRESSURE 0 160 BAR 6 1 801204 SENSOR PRESSURE 0 400 BAR 7 2 801435 SENSOR PRESSURE 0 600 BAR 8 4 801525 FIT 4MORFS 6MORB 9 6 801923 FIT EL90 4MORFS 6MOR 10 1 801925 FIT EL90 4MORFS 4FORFS SWIVEL 11 1 804609 HOSE HYD 3R2T 4F...

Page 70: ...C120R Operator Service Maintenance Manual 70 A C Schematic 39965 Rev A ...

Page 71: ...C120R Operator Service Maintenance Manual 800 392 2686 71 A C Schematic 39965 Rev A ...

Page 72: ...C120R Operator Service Maintenance Manual 72 Hydraulic Hose Schematic 806134 Rev E ...

Page 73: ...C120R Operator Service Maintenance Manual 800 392 2686 73 Hydraulic Hose Schematic 806134 Rev E ...

Page 74: ...G 4 MORB HEX HEAD 36 2 FF6802 10 12 ELBOW 45 10 MORFS 12 MORB 37 6 FF6802 6 10 ELBOW 45 6 MORFS 10 MORB 38 1 FF6804 4 4 4 RUN TEE 4 MORFS 4 MORB 4 MORFS 39 1 6400 4 6 CONNECTOR 4 MJIC 6 MORB 40 2 FF6804 4 6 4 RUN TEE 4 MORFS 6 MORB 4 MORFS 41 1 FF6500 4 4 ELBOW 90 4 MORFS 4 FORFS SWIVEL 42 1 FF6801 8 8 ELBOW 90 8 MORFS 8 MORB 43 1 FF2408 8 PLUG 8 MORFS 44 2 FF6801 10 10 ELBOW 90 10 MORFS 10 MORB 4...

Page 75: ... HOSE T3010D 10FSX 10FSX90 77 33 1 HOSE T3010D 10FSX 10FSX90 54 34 1 HOSE SR20 BLANK BLANK 110 35 1 HOSE SR20 BLANK BLANK 72 36 1 HOSE SR20 BLANK BLANK 54 37 2 HOSE T3006D 6FSX 6FSX90 55 38 2 HOSE T3006 6FSX 6FSX90 43 39 1 HOSE T3004D 4FSX 4FSX 12 40 1 HOSE T3004D 4FSX 4FSX90 12 41 THIS LINE INTENTIONALLY LEFT BLANK 42 THIS LINE INTENTIONALLY LEFT BLANK 43 1 HOSE T3004D 4FSX 4FSX 13 44 THIS LINE I...

Page 76: ... TYPE B C 39573 03 108 2 RED BATTERY POST POS TYPE A BATTERY NEGITIVE TYPE A 39573 04 32 2 0 BLK FRAME GROUND TYPE A BATTERY NEGITIVE TYPE A D 39573 05 32 2 0 BLK STARTER GROUND TYPE A FRAME GROUND TYPE A FRAME GROUND TYPE A 39573 06 62 2 BLK G 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 M...

Page 77: ... TERMINAL FOR 3 8 STUD W ADH HEAT SHRINK B COPPER RING TERMINAL FOR 5 16 STUD W ADH HEAT SHRINK C VTE SERIES 487 TERMINAL INSULATOR OR EQ RED D VTE SERIES 487 TERMINAL INSULATOR OR EQ BLACK CABLE LENGTH TOLERANCE LESS THAN 12 1 16 0 12 TO 48 1 8 48 TO 100 1 4 GREATER THAN 100 1 2 AND CRIMPED EDT 18 240 RAYCO MFG INC CAD GENERATED DRAWING DO NOT MANUALLY UPDATE DWG NO CABLE BATTERY KIT DATE SCALE F...

Page 78: ...SW PWR BLU SUSP PWR WHT HIGH HEAT RED BLK SWITCHOVER BLK WIPER GRD BLK WIPER GRD WHT WASH WHT WASH WHT ORG RH JS PWR W RH ORG WHT LH JS PWR PUR SW PWR PNK HEAT LOW SEAT PNK BLK ACC FUSE BLK ACC GRD PNK USB FUSE FLEXXAIRE FAN PURGE SWITCH SEAT SWITCH SEATBELT SWITCH SEAT AIR COMPRESSOR SEAT LOW HEAT SEAT HIGH HEAT SEAT HEATER SWITCH THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF ...

Page 79: ...WR PNK HEAT LOW BLK RELAY GRD BLK RELAY GRD RED ACC PWR RED ACC PWR RED ACC PWR PUR SEAT COMP PUR SEAT C O M P PUR WHT DOOR SW PWR PUR WHT DOOR SW PWR PNK BLK HVAC PWR PNK BLK HVAC PWR SENSITIVITY SWITCH FLOW DIRECTION SWITCH YLW RED WORK LGTS FUSE YLW RED WORK LGTS FUSE 50A KEY SIGNAL DIODE G RY HORN RLY GRY HORN RLY ORG FF 1 ORG FF 1 ORG FF 1 PUR FF 2 PUR FF 2 PUR FF 2 PUR FF 2 PNK BLK ACC FUSE ...

Page 80: ... GRD 14 BLK SP8 06 A CAN 18 YLW 07 3 06 B CAN 18 GRN 07 4 06 C CAN SLD 18 GRY 07 5 07 1 MICRO GRD 18 BLK WHT SP2 07 2 MICRO PWR 18 RED WHT SP1 07 6 SAFETY OUT 18 ORG 17 9 07 7 IGN START 18 PNK 10 50 07 10 DOOR OPEN 18 YLW WHT 67 4 07 11 E STOP SIG 18 PUR WHT 13 4 07 12 KEY SIG 18 WHT 69 k 08 1 FLOW FWD 18 TAN 46 3 08 3 FLOW REV 18 GRY 46 1 08 4 LOW SENSITIVITY 18 BLU 50 1 08 5 HIGH SENSITIVITY 18 ...

Page 81: ...WASH 14 WHT 39 2 18 2 WIPER GRD 14 BLK SP3 19 1 SW PWR 1 16 PUR SP4 20 1 MICRO GRD 18 BLK WHT SP2 20 2 LH JS PWR 18 ORG WHT 65 E7 20 3 CAN 18 YLW 21 A 20 4 CAN 18 GRN 21 B 20 5 CAN SLD 18 GRY 21 C 22 1 HEAT LOW 18 PNK SP10 22 2 SW PWR 2 18 PUR 65 E9 22 4 CAB GRD 18 BLK SP9 23 1 MICRO GRD 18 BLK WHT SP2 23 2 RH JS PWR 18 WHT ORG 65 D7 23 3 CAN 18 YLW 24 A 23 4 CAN 18 GRN 24 B 23 5 CAN SLD 18 GRY 24...

Page 82: ... 1 16 PUR SP4 50 7 CAB GRD 14 BLK SP9 54 ACC GRD 16 BLK SP6 55 CAB GRD 14 BLK SP9 57 RELAY GRD 14 BLK SP7 58 WIPER GRD 14 BLK SP3 59 HVAC GRD 14 BLK SP8 60 MICRO GRD 18 BLK WHT SP2 62 RELAY GRD 14 BLK SP7 63 KEY SIG 16 WHT SP17 65 A1 WORK LGT PWR 14 YLW 65 E1 65 A9 HEAT LOW 16 PNK SP10 65 A10 KEY PWR 12 RED SP11 65 B1 RELAY GRD 14 BLK SP7 65 B3 WORK LGTS 14 YLW 67 3 65 B4 RELAY GRD 14 BLK SP7 65 B...

Page 83: ... 65 A9 65 B9 SP11 KEY PWR 12 14 RED 01 4 65 A10 65 D11 67 1 68 1 SP12 SEAT FUSE FEED 14 RED BLK 65 B12 65 E10 65 E12 SP13 FF 1 12 ORG 33 65 D12 65 E4 SP14 FF 2 12 PUR 34 65 C10 65 D8 65 E8 SP15 HVAC FUSE 14 PNK BLK 04 1 05 3 65 E5 SP16 WIPER PWR 14 RED WHT 39 1 41 3 65 E3 66 1 SP17 KEY SIG 16 WHT 10 15 63 69 a SP18 JUMPER 16 GRY RED 41 2 41 5 41 8 65 E3 WIPER PWR 14 RED WHT SP16 65 E4 FF 1 12 ORG ...

Page 84: ...H WHT FAN PITCH TAN HYD OIL TEMP GRY RT TRK SPD PUR LT TRK SPD GRY RT TRK SPD PUR LT TRK SPD PUR ENG ECU PWR PUR ENG ECU PWR YLW RED LGTS ON YLW RED LGTS ON GRN FUEL LVL GRN FUEL LVL ORG PROP CRG PSI ORG PROP CRG PSI PNK TRACK PSI PNK TRACK PSI WHT CUTTER GRG PSI WHT CUTTER CRG PSI BRN WORK FUNC PSI BRN WORK FUNC PSI GRN CUTTER HEAD PSI GRN CUTTER HEAD PSI PNK START RLY PNK START RLY PNK LT TRK PS...

Page 85: ...WD WHT RED CUTTER FWD TAN HYD OIL TEMP TAN HYD OIL TEMP ORG ENG COMP TEMP GRN FUEL LVL PNK TRACK PSI RED KEY PWR RED KEY PWR YLW LGT PWR YLW LGT PWR BLK LGT GRD BLK LGT GRD GRN PINS CLSD GRN PINS CLSD ORG HIGH PRESS FTR ORG HIGH PRESS FTR CUTTER CRG FTR BRN CUTTER CRG FTR BLU TRK DRV CRG FTR BLU TRK DRV CRG FTR BLK LOCKPIN GRD BLK YLW PINS NO COM BLK WHT PINS NC NC BLK PUMP GRD BLK MP GRD BLK FRAM...

Page 86: ... A TILT RLY 16 WHT 19 B1 06 B TILT SOL 16 ORG SP14 07 1 SUPER FLOW 18 PUR 34 28 07 3 VALVE GRD 14 BLK SP1 07 4 HI FLOW ENABLE 18 GRY 31 34 08 1 LIFT U D 18 PNK 34 29 08 3 VALVE GRD 14 BLK SP1 08 4 LIFT ENABLE 18 GRY 34 43 09 1 ROLL U D 18 PUR 34 27 09 3 VALVE GRD 14 BLK SP1 09 4 ROLL ENABLE 18 BLU 34 45 10 1 FLAP U D 18 ORG 34 33 10 3 VALVE GRD 14 BLK SP1 10 4 FLAP ENABLE 18 GRN 34 44 11 1 WINCH I...

Page 87: ...EY PWR 14 RED SP6 19 A3 MICRO FUSE FEED 14 ORG 28 19 A4 MICRO PWR 14 RED WHT SP3 19 A5 LGT PWR 14 YLW SP7 19 A6 LGT FUSE 14 YLW 19 B4 19 B3 RLY GRD 14 BLK SP9 19 B6 RLY GRD 14 BLK SP9 19 C4 LGTS ON 18 YLW RED 31 3 19 C6 LGT CB 14 YLW BLK 29 21 MICRO GRD 14 BLK WHT SP2 22 RLY GRD 14 BLK SP9 23 LGT GRD 14 BLK SP8 24 B LGT GRD 14 BLK SP8 24 A WORK LGT 14 YLW 25 26 LGT BATT PWR 14 YLW RED 60 30 A KEY ...

Page 88: ...R 18 PUR 57 10 31 23 COOLANT LVL 18 BLU 83 D 31 24 HYD OIL TEMP 18 TAN 68 31 28 FAN PITCH 18 WHT 44 C 32 MICRO PWR 14 RED WHT SP3 33 MICRO GRD 14 BLK WHT SP2 34 2 MICRO PWR 18 RED WHT SP3 34 3 CAN 1 18 YLW 35 A 34 4 CAN 1 18 GRN 35 B 34 5 CAN 1 SHD 18 BLK 35 C 34 8 5V PWR 18 RED YLW SP4 34 9 5V GRD 18 BLK YLW SP5 34 20 RETURN FTR 18 GRN 64 A 34 30 CAN 1 SHD 18 BLK 36 C 34 31 CAN 2 18 YLW 36 A 34 3...

Page 89: ... SP5 47 2 5V PWR 18 RED YLW SP4 48 1 5V GRD 18 BLK YLW SP5 48 2 5V PWR 18 RED YLW SP4 49 1 5V GRD 18 BLK YLW SP5 49 2 5V PWR 18 RED YLW SP4 50 1 5V GRD 18 BLK YLW SP5 50 2 5V PWR 18 RED YLW SP4 51 1 5V GRD 18 BLK YLW SP5 51 2 5V PWR 18 RED YLW SP4 52 FRAME GRD 14 BLK SP11 53 PUMP GRD 14 BLK SP13 59 1 TILT SOL 16 ORG SP14 54 LOCKPIN GRD 16 BLK 75 55 4 KEY PWR 18 RED SP6 55 5 FRAME GRD 18 BLK SP11 5...

Page 90: ...D 18 BLK SP11 67 B KEY PWR 18 RED SP6 69 PINS CLSD 18 GRN SP12 71 PINS NC NC 16 BLK WHT 74 72 PINS NO COM 16 BLK YLW 73 78 VALVE GRD 14 BLK SP1 76 2 PUMP GRD 14 BLK SP13 76 3 PUMP GRD 14 BLK SP13 80 2 PUMP GRD 14 BLK SP13 80 3 PUMP GRD 14 BLK SP13 81 2 PUMP GRD 14 BLK SP13 81 3 PUMP GRD 14 BLK SP13 82 k PINS CLSD 18 GRN SP12 83 B FRAME GRD 18 BLK SP11 83 C KEY PWR 18 RED SP6 84 KEY PWR 18 RED SP6 ...

Page 91: ... 34 8 40 1 44 A 47 2 48 2 49 2 50 2 51 2 SP5 5V GRD 18 BLK YLW 14 B 34 9 40 4 44 B 47 1 48 1 49 1 50 1 51 1 SP6 KEY PWR 14 18 RED 13 1 16 1 19 A6 30 A 43 4 55 4 58 A 62 1 64 B 65 B 66 B 67 B 83 C 85 SP7 LGT PWR 14 YLW 13 2 15 1 19 A1 63 1 SP8 LGT GRD 14 18 BLK 15 2 16 4 23 24 B 62 4 63 2 SP9 RLY GRD 14 BLK 19 B3 19 B6 22 38 SP10 BATT 8 RED 01 1 37 61 SP11 FRAME GRD 14 18 BLK 41 2 43 5 52 55 5 58 C...

Page 92: ...SP3 01 5 HORN SIG 14 GRY WHT 02 3 01 6 DOME LGT 18 YEL BLK SP4 01 7 TILT 16 ORG 03 3 01 8 CAB GRD 14 BLK SP2 02 1 KEY PWR 14 RED SP1 02 4 CAB GRD 14 BLK SP2 03 4 DOOR OPEN 16 YLW WHT SP3 04 1 KEY PWR 14 RED SP1 04 2 CAB GRD 14 BLK SP2 05 1 LH SPKR 18 GRN 12 05 2 LH SPKR 18 GRN BLK 13 05 3 RH SPKR 18 PUR 10 05 4 RH SPKR 18 PUR BLK 11 06 1 KEY PWR 14 RED SP1 06 2 CAB GRD 14 BLK SP2 07 a DOOR OPEN SP...

Page 93: ...er Cab Harness Schematic 39567 Rev A SPLICE CIRCUITS SPLICE WIRE DESCRIPTION GAUGE COLOR CONNECTED TO SP1 KEY PWR 14 RED 01 1 02 1 04 1 06 1 SP2 CAB GRD 14 18 BLK 01 8 02 4 04 2 06 2 09 SP3 DOOR OPEN 16 YLW WHT 01 4 03 4 07 a SP4 DOME LGT 18 YEL BLK 01 6 07 k 08 ...

Page 94: ...E A HEAT LOW 1 TYPE D 02 05 PLUG CAB HARNE TYPE PLUG CAB HARNE TYPE 2 9 3 64 56 PLUG 01 CAN BUS HARNESS TYPE A PLUG 02 CAN BUS LCM TYPE A PLUG 01 CAN BUS KEYPAD TYPE A PLUG 02 CAN BUS LCM TYPE A PLUG 01 CAN BUS KEYPAD TYPE A PLUG 02 CAN BUS RH JOYSTICK TYPE B PLUG 02 CAN BUS RH JOYSTICK TYPE A PLUG 01 CAN BUS LH JOYSTICK TYPE A 50 CIRC BREA OU TYPE 39570 02 39570 03 39570 04 PL FR HA TY SOLE O TYP...

Page 95: ...YPAD PE A UG 01 N BUS YPAD PE A UG 01 N BUS OYSTICK PE A 01 50A CIRCUIT BREAKER OUT TYPE H 02 50A CIRCUIT BREAKER IN TYPE H 39570 17 39570 16 6 8 28 SEE NOTE 1 PLUG 01 FRAME HARNESS TYPE J PLUG 01 GREEN INDICATOR LIGHT TYPE K 39570 11 01 SOLENOID OUT TYPE G 39570 12 KEYED BUSS STUD TYPE G 02 PLUG 01 WORK LIGHT TYPE E PLUG 02 FRAME HARNESS TYPE L 48 EXTENDED LENGTH 02 01 03 02 PLUG 01 FRAME HARNESS...

Page 96: ...CAN SHIELD NOTE 1 02 C 01 A CAN NOTE 1 YLW 02 A 01 B CAN NOTE 1 GRN 02 B 01 C CAN SHIELD NOTE 1 02 C 39570 06 01 1 HEAT LOW 18 PNK 05 01 2 SW PWR 18 PUR 04 01 3 HEAT HIGH 18 WHT 03 01 4 SW GRD 18 BLK 02 39570 07 01 1 FRESH AIR 16 BLU 03 01 2 HVAC GRD 16 BLK 02 39570 08 01 1 ALARM 16 ORG 02 01 2 GROUND 16 BLK 03 39570 09 01 1 LAMP PWR 16 PUR 02 01 2 PINS OPEN 16 RED BLK 03 39570 10 01 POWER 8 RED 0...

Page 97: ... YLW 02 A 01 B CAN NOTE 1 GRN 02 B 01 C CAN SHIELD NOTE 1 02 C 39570 18 01 A CAN NOTE 1 YLW 02 A 01 B CAN NOTE 1 GRN 02 B 01 C CAN SHIELD NOTE 1 02 C 39570 19 01 30A 10 RED 02 01 50A 10 RED 03 39570 20 01 1 SUPPLY 18 BLU 02 1 01 3 SIGNAL 18 ORG 02 3 39570 21 01 1 WIPER PWR 14 RED WHT 02 01 2 WASH 14 WHT 03 39570 22 01 A FRAME GRD 16 BLK 02 01 B KEY PWR 16 ORG 03 01 C SIG 16 RED 04 Jumper Harness S...

Page 98: ... TRACK ASSEMBLY PARTS DESCRIPTION PART Qty Front Idler 803148 2 Idler Spring and Piston RH 803149 1 Idler Spring and Piston LH 803183 1 Bottom Roller 2 Flange 803150 2 Bottom Roller 3 Flange 803514 10 Track 804437 2 Sprocket 39576 2 MANUALS Parts PMC120R 19 Operator Service Maintenance OSMC120R 19 Operator Booklet OBC120R 19 COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART Qty Door Key 762015 1 ...

Page 99: ...e place at which warranty work is performed 3 Any product that has been altered or modified in ways not approved by Rayco 4 Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow operating instructions misuse lack of proper protection during storage or accident D Unapproved Service or Modification Rayco is relieved of its obligation under this warr...

Page 100: ...hink Smart Think Safe We care about your safety When operating your RAYCO machinery always wear an ap proved helmet complete with ear muffs face shield and the proper eye wear Never operate under the influence of alcohol or drugs Know your RAYCO read and understand your owner s manual cover to cover RAYCO Manufacturing Inc retains the right to make changes in design and specifications engineering ...

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Rayco C120R, Operator, Service & Parts Manual

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