Rayco C275 Operator, Service, Maintenance Manual Download Page 36

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C275 Operation & Service Manual

Maintenance

Summary of Contents for C275

Page 2: ...hine 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 specifica...

Page 3: ...C275 Operation Service Manual 800 392 2686 3 TABLE OF CONTENTS Forward 4 Safety 8 Operation 22 Specifications 38 Maintenance 42 Troubleshoot 64 Warranty 99 ...

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

Page 5: ...t 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 ...

Page 6: ...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 Forreferenceoncommunicationregardingtheengine record its model and serial numbers also in the boxes provided on the next page of this manual See the ...

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

Page 8: ...ectiveguardsandallcoversaresecured 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 hand sign...

Page 9: ... 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 explana...

Page 10: ...wear under chin strapping while operating or within the operation area of the Horizontal Grinder Eye protectionmustconformtoANSIZ87 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 operation...

Page 11: ...amiliar with this type of injury Containing Fluid Spillage Caremustbetakeninordertoensurethefluidsarecontained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluidwithsuitablecontainersbeforeopeninganycompartment or disassembling any component that contains fluids Tools that are suitable for collecting fluids and equipment that is ...

Page 12: ...omplete 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 throw or cut...

Page 13: ...re 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 Storeoilyragsandanyflamm...

Page 14: ...engine if the machine is equipped with a thermal starting 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 us...

Page 15: ... hold it firmly The cap may otherwise be thrown due 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...

Page 16: ...hut position Make sure that the machine horn the backup 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...

Page 17: ...surfacematerial may drastically affect the machine s traction 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...

Page 18: ...ntain 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 ...

Page 19: ... 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 the guards Consult your Rayco dealer for additional informa...

Page 20: ... 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 Transportation Checks N...

Page 21: ...ading 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...

Page 22: ...k 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 NOTICE The ...

Page 23: ...l Disconnect 19 Tracks 20 Cutter Wheel Motor 21 Toolbox Cab Tilt Remote 22 Electrical Panel Access 23 18k Winch 24 Winch Fairlead 25 Winch Line Clevis Hook 26 15 5k D rings 27 Back up Alarm 28 Cab Tilt Cylinder 29 Idler Access 30 Engine Air Intake 31 Exhaust 32 Hydraulic Fill Cap 33 Radiator Cap Access 34 Fuel Fill Engine Compartment 35 BatteryandHydraulicFilterAccess 36 Hydraulic Valve Access 37 ...

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

Page 25: ...oystick back This cycles oilthroughthecontrolvalvesatsystemreliefpressureandwill shortenthetimerequiredtowarmuptheoil Cyclethemower 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 Undercoldconditions thehydraulicfilterrestrictionindicator lamp may come on Under extremely cold conditions the hydraulic filte...

Page 26: ...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 po...

Page 27: ...the intakeairheaterisactivated Theairheaterisautomatically 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 engagingtheattac...

Page 28: ... 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 cush...

Page 29: ...oll head back Move the stick to the right to swing the boom right or roll the head forward The stick may be moved to any combination of these positions to produce simultaneous results 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 o...

Page 30: ...h 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 ...

Page 31: ...raulic 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 ge...

Page 32: ... 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 pull...

Page 33: ...o machines of the same size or larger than the towed machine Connect a machine on each end of the towed machine Be sure all necessary repairs and adjustments have been made before a machine that has been towed to a service area is put back into operation When the towing procedure is completed reengage the track drives Ensure that all instructions that are outlined in the Towing Information are car...

Page 34: ...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 fo...

Page 35: ...ck 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 Grease O...

Page 36: ...C275 Operation Service Manual 36 Maintenance ...

Page 37: ...C275 Operation Service Manual 800 392 2686 37 Maintenance Maintenance Log Date of Service Machine Hours Description of Service Maintenance Notes ...

Page 38: ...I 46 Viscosity 7 7 cSt 100 C 46 cSt 40 C Pour Point 45 C 49 F Shell Tellus T 46 new name Tellus S2 V46 Viscosity 7 95 cSt 100 C 45 9 cSt 40 C Pour Point 42 C 43 F Mobil DTE 15M Viscosity 7 8 cSt 100 C 46 cSt 40 C Pour Point 42 C 43 F Exxon Univis N 46 Viscosity 8 2 cSt 100 C 46 cSt 40 C Pour Point 48 C 54 F Pennzoil Pennzbell AWX MV 46 Viscosity 8 8 cSt 100 C 46 3 cSt 40 C Pour Point 48 C 54 F If ...

Page 39: ...reme cold temperature areas a No 0 grade grease may be used Before lubricating make sure all grease fittings and the nozzle of the grease gun is clean Cold Weather Lubricants Before attempting to start the engine make sure that the oil in the engine the transmission and the hydraulic system are fluid enough to flow Check the oil by removing the dipsticks If the oil will drip from the dipstick then...

Page 40: ...4 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 s...

Page 41: ...lt Torque Requirements SAE GRADE 8 TORQUE DRY OR LOCTITE 1 4 12 2 LB FT 5 16 26 2 LB FT 3 8 46 2 LB FT 7 16 75 5 LB FT 1 2 115 5 LB FT 9 16 160 5 LB FT 5 8 225 10 LB FT 3 4 400 20 LB FT 7 8 650 25 LB FT 1 975 25 LB FT 1 1 8 1350 25 LB FT 1 1 4 1950 25 LB FT 1 3 8 2550 25 LB FT 1 1 2 3350 50 LB FT METRIC CLASS 10 9 DRY OR LOCTITE M6 12 2 LB FT M8 30 3 LB FT M10 60 3 LB FT M12 105 5 LB FT M14 165 5 ...

Page 42: ...n access to the filter cartridge loosen the wing nut and remove 6 The cover will then be free for removal 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 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 interva...

Page 43: ...arm 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 Stopontheslopeandobservethemachineslowlycreep backward Shallow slopes ...

Page 44: ...cedures 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 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 drain...

Page 45: ...icted as the element gradually plugs with contaminants resultinginnoticeablepowerlossand orhardstarting 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 th...

Page 46: ...ation section of the Safety Operation manual before checking for leaks If leaking is observed find the source and correct the leak Check the fluid levels more frequently than the recom mend ed periods if leaking is suspected or ob served until the problem may be corrected Hydraulic Oil Cooler Clean Check and clean debris from hydraulic lines and hoses to prevent heat buildup Use low pressurized ai...

Page 47: ...ulic return filter 4 is accessible through the right hand side engine enclosure Charge Filters 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 repla...

Page 48: ...tallation 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 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 an...

Page 49: ... 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 CHECK ...

Page 50: ... is not specifically authorized by Rayco invalidates the certification for the ROPS FOPS The protectionthatisofferedbytheROPS FOPSwillbeimpaired 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 suit...

Page 51: ...eck 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 thegearboxusing235ft lbs 318Nm torquewrenchsetting They should all be checked again after every 500 hours Contact Rayco for furthe...

Page 52: ...RN PILOT PUMP PRESS ORG WORK FUNC PUMP PRESS PUR CW PUMP PRESS RED BLK START RELAY GRN PILOT SOL WHT CW ENABLE SOL BRN 2SPD SOL GRY BRAKE SOL BLU JOYSTICK SOL GRN FLAP UP SOL ORG FLAP DN SOL PUR BACKUP ALARM SIG WHT FAN SPD SOL GRY FAN REV SOL BRN WINCH OUT SOL WHT WINCH IN SOL BLU HYD OIL TEMP SENSOR ORG ENG COMP TEMP GRY FUEL LEVEL WHT MOWER HEAD PRESS BLU HIGH PRESS FILTER SW GRN CW PUMP FILTER...

Page 53: ...K PRESS 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 CW ENABLE SOL BLU WARNING ALARM PUR BACKUP ALARM SIG GRN WIPER BLU WASHER YLW DOME LGT PWR ORG ENG COMP TEMP GRY FUEL LEVEL PRESS ORG ECM FUSE FEED YLW WORK LGT REL PNK BLK HVAC PWR RED LH JOYSTICK PWR PUR FUSE FEED PUR FUSE FEED BLU PARK BRAKE PNK HV...

Page 54: ...C275 Operation Service Manual 54 Cab Electrical Schematic 41206 Service ...

Page 55: ...C275 Operation Service Manual 800 392 2686 55 Service ...

Page 56: ...C275 Operation Service Manual 56 Service Hydraulic Schematic 806429 Page 1 ...

Page 57: ...C275 Operation Service Manual 800 392 2686 57 Service ...

Page 58: ...C275 Operation Service Manual 58 Service Hydraulic Schematic 806429 Page 2 ...

Page 59: ...C275 Operation Service Manual 800 392 2686 59 Service ...

Page 60: ...C275 Operation Service Manual 60 Service Hydraulic Schematic 806429 Page 3 ...

Page 61: ...C275 Operation Service Manual 800 392 2686 61 Service ...

Page 62: ... OR 6407 24 24 AS SUBSTITUTE 33 1 FF6400 12 12 O RING CONNECTOR 12MORFS X 12MORB 34 2 FF6400 12 16 O RING CONNECTOR 12MORFS X 16MORB 35 1 FF6500 12 12 ELBOW 90 DEG 12 FJLC X 12 MJLC 36 1 FF6602 12 12 12 TEE RUN 12MORFS X 12FORFS SWIVEL X 12MORFS 37 4 4601 24 20 ELBOW 90 DEG 24 BEADED TUBE X 20 MORB 38 1 FF6600 12 12 12 TEE RUN 12 MJLC X 12 MJLC X 12 FJLC 39 2 FF6801 12 16 ELBOW 90 DEG 12MORFS X 16...

Page 63: ...81 1 9235 18 04 18MM X 4MNPT 82 6 4404 10 8 CONNECTOR STR 10 BEADED TUBE X 08 MPT 83 1 5406 12 04 BUSHING 12 MPT X 04 FPT 84 1 FF6804 04 06 04 TEE RUN 04MORFS X 06 MORB X 04 MORFS 85 1 5406 P 32 PLUG 32 HEX 86 2 210 608 CONNECTOR STR 08FJX X 10 BARB 87 2 2705 08 08 LN CONNECTOR BULKHEAD 08FPT X 08MJIC W LOCK NUT 88 4 4501 10 08F ELBOW 90DEG 10BEADED TUBE X 08MPT 89 1 4503 10 12F ELBOW 45DEG 10 BEA...

Page 64: ... X 24MOR OR 6407 24 24 AS SUBSTITUTE 33 1 FF6400 12 12 O RING CONNECTOR 12MORFS X 12MORB 34 2 FF6400 12 16 O RING CONNECTOR 12MORFS X 16MORB 35 1 FF6500 12 12 ELBOW 90 DEG 12 FJLC X 12 MJLC 36 1 FF6602 12 12 12 TEE RUN 12MORFS X 12FORFS SWIVEL X 12MORFS 37 4 4601 24 20 ELBOW 90 DEG 24 BEADED TUBE X 20 MORB 38 1 FF6600 12 12 12 TEE RUN 12 MJLC X 12 MJLC X 12 FJLC 39 2 FF6801 12 16 ELBOW 90 DEG 12MO...

Page 65: ...81 1 9235 18 04 18MM X 4MNPT 82 6 4404 10 8 CONNECTOR STR 10 BEADED TUBE X 08 MPT 83 1 5406 12 04 BUSHING 12 MPT X 04 FPT 84 1 FF6804 04 06 04 TEE RUN 04MORFS X 06 MORB X 04 MORFS 85 1 5406 P 32 PLUG 32 HEX 86 2 210 608 CONNECTOR STR 08FJX X 10 BARB 87 2 2705 08 08 LN CONNECTOR BULKHEAD 08FPT X 08MJIC W LOCK NUT 88 4 4501 10 08F ELBOW 90DEG 10BEADED TUBE X 08MPT 89 1 4503 10 12F ELBOW 45DEG 10 BEA...

Page 66: ...C275 Operation Service Manual 66 Service A C Schematic 41266 ...

Page 67: ...C275 Operation Service Manual 800 392 2686 67 ...

Page 68: ... are available with adjustable mechanical displacement stroke limiters located in the servo covers The maximum displacement of the pump can be limited to any value from its maximum displacement to zero in either direction The limiters are factory set slightly beyond the maximum displacement of the pump Displacement limiters may not be suited to all applications Series 42 pump displacement limiters...

Page 69: ...OP FLUSHING VALVE CHARGE PUMP ORIFICED CHECK VALVE MULTI FUNCTION VALVE CHARGE PRESSURE RELIEF VALVE SERVO PRESSURE RELIEF VALVES TO MOTOR CASE TO PUMP CASE P001 175E CONTROL HANDLE DISPLACEMENT CONTROL VALVE HEAT EXCHANGER BYPASS VALVE RESERVOIR VACUUM GAUGE HYDRAULIC TWO POSITION CONTROL BENT AXIS VARIABLE DISPLACEMENT MOTOR OUTPUT SHAFT CONTROL FLUID CASE DRAIN FLUID SUCTION LINE WORKING LOOP H...

Page 70: ...ase Drain Port L1 Charge Pump Inlet Port S Charge Pressure Gauge Port M3 Charge Pressure Supply For No Charge Pump Option Servo Pressure Gauge Port M4 Case Drain Port L2 Servo Pressure Gauge Port M5 System Pressure Port B System Pressure Gauge Port M2 System Pressure Gauge Port M1 System Pressure Port A Case Drain Port L2 Non Feedback Controls Case Drain Port L1 Non Feedback Controls 28cc Base Uni...

Page 71: ...ment screw 28cc 5 mm Hex 41cc 7 mm Hex until the system pressure gauge readings are equal 6 Turn the adjustment screw clockwise until one of the gauges registers an increase in system pres sure 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...

Page 72: ...t 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 5 Install a new outer O ring new backup ring and new inner O ring on each valve seat plug 6 C...

Page 73: ...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 be tween 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...

Page 74: ...tments 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 differe...

Page 75: ...retaining ring Retaining Ring Roller Bearing Key Shaft Assembly OR OR Shaft Shaft Components E100021 E 2 2 Series 42 Adjustments and Minor Repairs 4 13 Shaft Seal and Shaft Replacement A lip type shaft seal is used in Series 42 pumps This seal and or the shaft can be replaced without major disassembly of the unit Replacement generally re quires removal of the pump from the machine 1 Position the p...

Page 76: ...e opening and 3 motor displacement The machine load determines the system pressure The directional valve routes fluid returning from the motor to the reservoir Additional components may be necessary to provide dynamic breaking and to deal with overrunning loads oPen CiRCuit PUMP MV Flow Unidirectional Flow Bi directional Input Output Case drain line Reservoir DIRECTIONAL VALVE P101 171E Series 51 ...

Page 77: ...d 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 servic ing 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 cloud...

Page 78: ...0625 12UN 2B 1 1 16 12UN 2B Alternate position Case drain L2 1 0625 12UN 2B 1 1 16 12UN 2B Speed pick up Two Position Control N1NN A B M 4 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 Loop ushing shuttle valve Charge pressure relief valve gle stop ment Split ange boss A B DN 19 typ II 40 MPa series per ISO 6162 SAE 0 75 4 thr...

Page 79: ...tely 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 provide...

Page 80: ...on 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 Check Cause Corrective action 1 Oil level in reservoir Insufficient hydraulic fluid will reduce system efficiency Fill reservoir to proper level 2 Threshold setting Improper threshold setting will cause ...

Page 81: ...ton 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 Tw...

Page 82: ... pressure and or inadequate loop flushing flows You must maintain the correct charge pressure under all operation conditions to maintain pump performance P101 209E Series 51 1 charge pressure relief valve 1 1 16 inch Adjustment plug 52 Nm 38 lbf ft oveRview continued 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 Cl...

Page 83: ... the sealing area on the shaft for wear Common parts of a cartridge flanged motor L40 Shaft seal L75 Seal carrier L50 L40 L75 L80 P101225 Series 51 and 51 1 Motors Service Manual Minor repair sHaft seal RePlaCement continued Reassembl y 1 Orient the new shaft seal L40 so the cupped side faces inward 2 Press new shaft seal L40 into the seal carrier L75 3 Press until the shaft seal bottoms out in th...

Page 84: ...t the new shaft seal L40 so the cupped side faces inward 2 Press new shaft seal L40 into the seal carrier L75 3 Press until the shaft seal bottoms out in the cavity 4 Using petroleum jelly to lubricate install new O ring L50 to the groove in the housing bore 5 Using a seal protection sleeve on the shaft push the seal carrier L75 into the housing bore until it clears the snap ring groove 6 Install ...

Page 85: ... rt s fo r w e a r o r d a m a g e 2 C le a n th e c a v it y a n d p a rt s R e a ss e m b ly 1 R e p la c e p a rt s a s n e c e ss a ry a ft e r in sp e c ti n g th e n e w o n e to m a k e c e rt a in th a t e a c h fi ts 2 D is c a rd re p la c e d p a rt s 3 In st a ll O r in g s K 5 0 K 9 5 A to p lu g s K 1 0 K 9 5 4 R e a ss e m b le th e c a rt ri d g e 5 T o rq u e p lu g K 9 5 to 3 7 N...

Page 86: ... 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 quar...

Page 87: ...crew 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 q...

Page 88: ...bs 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 E...

Page 89: ...nual 800 392 2686 89 Specifications cally downwards fig 3 step2 unscrew both the front plugs 8 and leave out the exhaust oil step3 follow the steps described at pag 18 to refill the gearbox Fig 3 Front Gearbox Oil drain plug 2 ...

Page 90: ...C275 Operation Service Manual 90 ...

Page 91: ...2 2686 91 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 Compli ant ...

Page 92: ...64406 1 TRACK ASSEMBLY PARTS DESCRIPTION PART QTY Front Idler Assembly 801719 2 Bottom Roller 803807 16 Top Roller 801772 2 Track Single Bar 801838 2 Sprocket 40168 2 Front Rock Guard 26205 2 Middle Rock Guard 26204 2 Rear Rock Guard 32505 2 MANUALS Parts PMC275 19 Operator Service Maintenance OSMC275 19 Operator Booklet OBC275 19 COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART QTY Ignition Key...

Page 93: ...product to and from the place at which warranty work is performed 3 Any product that has been altered or modified in ways not approved by Rayco 4 Depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow operating instructions misuse lack of proper protection during storage or accident D Unapproved Service or Modification Rayco is relieved of its obli...

Page 94: ...hink 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 alco hol 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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