C120R Operator Service Maintenance Manual
64
Troubleshoot
Troubleshooting - Engine
Overheating
1. Check water level.
Fluid levels lower than normal may indicate a leak or
consumption internally. All diesel engines consume oil when
they are worked or idled for long periods of time. A new engine
will consume almost twice the amount of oil as an engine
with hours under the same conditions. Oil consumption is
normally due to the work load on the engine. It also increases
as the oil breaks down from heat; so as the oil change interval
nears, you may see an increase in oil consumption.
Check the oil level daily. Low oil level can cause severe
engine damage.
2. Check Belts
Check the tension of the fan belt or any other belts used
on the machine. Refer to the Maintenance Intervals section
of this manual.
3. Clean the Cooler
Maintenance to the outside of the engine is just as critical
as maintaining the internal fluids. It is extremely important to
keep the cooling system clean and free from debris. If a cooler
is not properly kept clean the result will be a catastrophic
failure to the engine.
Cleaning the condensers and the radiator with pressurized
air may be done on a daily basis, depending on conditions.
Cleaning with a pressure washer will likely need to be done
much less frequently.
If an engine starts to overheat, a warning light will come on
and the temperature gauge will be out of the green and into
the red. At this point two things need to happen:
1. The air intake screens and the cooler must be inspected
and any debris hindering the air flow to the engine must
be removed.
2. The machine should be run at an idle under no load until
it reaches a safe operating temperature. Running under
no load will most effectively cool it down because the
cooling fan will continue to run.
Cleaning the Cooler
If debris is accumulating in the engine area so that you can
no longer see the majority of the floor, it is time to clean. It is
recommended that a de-greasing agent be used to soak the
engine area prior to using a pressure washer (hot water) to
clean out debris. Use the following procedures to properly
clean all Rayco coolers and belly pans:
1. Park on level ground, shut the engine off, remove the
ignition 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. Open all engine compartment doors and hoods and check
to make sure water will not enter the engine internally
from any point.
5. Spray engine de-greaser in every area that is to be
washed. Heavily spray the radiator area and floor pan to
aid in breaking down the dirt and oil. Allow de-greaser
to soak for 10 minutes prior to pressure washing (hot
water). Be careful not to directly spray or wash electrical
components.
6. Wash each row of the radiator in the direction of the
rows, starting at the top and working your way down.
You will notice a debris-free cooler fin will allow all the
water (hot water) to flow through and not spray back at
you. When a plugged area is found, rewash the area until
the water flows through. Repeat this procedure until the
cooler is completely clean. Maintain a safe distance (3”
away from the coolers) and make certain you can spray
the radiators straight on to prevent folding over the fins.
7. Wash out the engine compartment starting at the hood
and working all the dirt down to the belly area. The dirt
in the belly pan should be loosened up enough to wash
out with a regular garden hose. This will keep the heavy
dirt and mud from being sprayed back into the previously
cleaned engine compartment. Once the machine is
clean, re-wash the radiator to clean any mud that may
have been sprayed back into the fins.
8. Start the machine, and monitor all pressures and
temperatures for at least ½ hr at ¾ throttle to aid in
drying off the radiator and engine before returning the
machine to work. The cooler must be completely dry, or
debris could re-enter it, causing the fins to plug again,
causing overheating. DO NOT touch the cooler to see
if it is dry while the machine is running.
9. Remove the machine from the wash area, park on level
ground, shut off the engine, and remove the ignition key.
10.
Reinstall all belly pans and guards. Check fluid
levels, air cleaner, and all electrical functions prior to
returning to work.
If the unit continues to overheat after cleaning the machine
as described above, please consult your Authorized RAYCO
Dealer to discuss other issues that may be causing the
problem.
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