T415 Operation & Service Manual
800.392.2686
57
Maintenance
Troubleshooting - Engine
Overheating
1. Check oil 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 Coolers
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 Coolers
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.