Morbark RAYCO 1800 AWL Operator, Service, Maintenance Manual

Articulated wheel loader

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ARTICULATED WHEEL LOADER

OPERATOR • SERVICE • MAINTENANCE MANUAL

PRINTED IN USA

INDEX: OSM1800AWL-19

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Page 2 1800 AWL Operation · Service · Maintenance Manual Introduction This manual is published by Rayco Manufacturing, Inc. for the readily available for reference at all times. Additional copies benefit of the users of Rayco products. Rayco Manufacturing, of this manual may be purchased from Rayco. Inc.
Page 3: Table Of Contents
1800 AWL Operation · Service · Maintenance Manual Table of Contents TABLE OF CONTENTS Foreword Safety Operation Maintenance Specifications Troubleshoot Warranty 800.392.2686...
Page 4: Foreword
1800 AWL Operation · Service · Maintenance Manual Foreword Literature Information Maintenance & Intervals The operators manual should be stored in the operator’s The maintenance section is a guide to equipment care. compartment in the literature holder storage area. Rayco The Maintenance Interval Schedule lists the items to be provides a binder to hold the Operator Service Manual, Parts maintained at a specific service interval.
Page 5 1800 AWL Operation · Service · Maintenance Manual Foreword Machine Description that are released from a flame that contact air conditioner refrigerant can cause bodily harm or death. Inhaling gas The Boxer 1800 articulated loader is designed for your from air conditioner refrigerant through a lighted cigarette maximum benefit for every dol lar spent.
Page 6 1800 AWL Operation · Service · Maintenance Manual Serial Number Location & 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.
Page 7 1800 AWL Operation · Service · Maintenance Manual Serial Number Location & Information Serial number is located as shown. Use the below table to record identification numbers and dealer information. Serial Number Location Identification Numbers Model Number Serial Number Machine Engine Implement Implement...
Page 8: Safety
1800 AWL Operation · Service · Maintenance Manual Safety Important Safety Information that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. Most accidents that involve product operation, maintenance If you desire to make use of a tool, procedure, work method, and repair are caused by failure to observe basic safety rules or or operating technique not specifically recommended by precautions.
Page 9 1800 AWL Operation · Service · Maintenance Manual Safety General Hazard Information engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to the outside. Personal Protective Equipment (PPE) · Read, understand and follow all instructions on the machine and in the manuals before attempting to operate.
Page 10 1800 AWL Operation · Service · Maintenance Manual Safety Flying Debris occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure Do not allow anyone to stand in front or directly behind the Always use a board or cardboard when you check for a leak.
Page 11 1800 AWL Operation · Service · Maintenance Manual Safety Crushing and Cutting Prevention • 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.
Page 12 1800 AWL Operation · Service · Maintenance Manual Safety Coolant 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.
Page 13 1800 AWL Operation · Service · Maintenance Manual Safety Fire and Explosion Prevention Improper jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of All fuels, most lubricants, and some coolant mixtures are this manual for specific instructions.
Page 14 1800 AWL Operation · Service · Maintenance Manual Safety Lines, Tubes and Hoses 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.
Page 15 1800 AWL Operation · Service · Maintenance Manual Safety Clear all obstacles from the path of the machine. Beware verified to shut down the engine by the operator prior to performing any work. of hazards such as wires, ditches, etc. Make sure that all windows are clean.
Page 16 1800 AWL Operation · Service · Maintenance Manual Safety While Servicing and Performing Slope Operation Maintenance on the Machine Machines that are operating safely in various applications • ALWAYS Block the wheels to prevent unintended depend on these criteria: the machine model, configuration, movement.
Page 17 1800 AWL Operation · Service · Maintenance Manual Safety Guidelines for Reducing Vibration • Operated equipment – Be aware of performance Levels on Equipment features of the equipment in operation and the effects on machine stability. Properly adjust machines. Properly maintain machines. •...
Page 18 1800 AWL Operation · Service · Maintenance Manual Safety Guards (Operator Protection) • Use soap and water to keep decals clean. DO NOT use mineral spirits, abrasive cleaners or other similar There are different types of guards that are used to protect cleaners which will damage the decals.
Page 19 1800 AWL Operation · Service · Maintenance Manual Safety LOCK-Out / Tag-Out Guidelines Tag Out Procedure • This procedure is to be used only if it is not reasonable Always practice lock out tag out procedures when working to use the lockout procedure. on this machine.
Page 20 1800 AWL Operation · Service · Maintenance Manual Safety Pre-Transportation Checks trailer from their intended path, due to one or more causes (improper loading, steering inputs, excessive speed, • Never allow inexperienced drivers to tow the machine. cross winds, passing vehicles, rough roads, etc). IF A •...
Page 21 1800 AWL Operation · Service · Maintenance Manual Safety Connecting Your Trailer • NEVER tow without properly installed tire straps and vehicle-in-tow security chains. Lower the coupler onto the hitch-ball and follow the • DO NOT tow the trailer unless the tongue jack is fully instructions below to properly fasten the coupler to the hitch- raised off The ground ball.
Page 22 1800 AWL Operation · Service · Maintenance Manual Safety to prevent the emergency brake from activating on turns or 5. With an attachment fixed to the machine, push the FORWARD/REVERSE lever and slowly back the inclined driveways. machine off of the trailer, until the tires are on the ground. Lighting Conditions 6.
Page 23: Operation
1800 AWL Operation · Service · Maintenance Manual Operation Getting to know your machine 1. Operator Station 9. Operator Switch Panel 2. Work Lights 10. Side Control Console and Joystick 3. ROPS Canopy 11. Hydraulic Tank 4. Loader Boom 12. Fuel Tank 5.
Page 24 1800 AWL Operation · Service · Maintenance Manual Operation Operator Station e. Differential Lock Switch The differential lock switch allows the operator to engage Gauge Display Panel or disengage the axles to gain more traction. When the differential lock is engaged the machine will be more harsh on softer terrain and be harder to maneuver.
Page 25 1800 AWL Operation · Service · Maintenance Manual Operation Foot Controls k. Boom Retract Switch The boom retract switch brings the boom inward. l. Boom Extend Switch The boom extend switch lengthens the boom. Joystick The joystick controls the raise and lower as well as the attachment roll.
Page 26 1800 AWL Operation · Service · Maintenance Manual Operation Pre-Starting Inspection Starting the Engine NOTICE DO NOT operate the starter for more than 10 seconds at a time. If the engine does not start, allow UNDERSTAND AND HEED TO THE a 60 second cool-down period before re-attempting INSTRUCTIONS LISTED IN THE SAFETY to start.
Page 27 1800 AWL Operation · Service · Maintenance Manual Operation Loading Attachment BE SURE ATTACHMENT, HOSES ARE SECURED BEFORE UTILIZING THE ATTACHMENT. FAILURE TO DO SO MAY CAUSE SERIOUS INJURY OR FATALITY, AS WELL AS CATASTROPHIC DAMAGE TO MACHINE After the attachment is seated onto the attachment plate, turn the lock levers outward (3b).
Page 28 1800 AWL Operation · Service · Maintenance Manual Operation Stopping The Machine may have accumulated while in storage (such as debris brought in by mice). 1. When stopping the machine after normal operation, Removal from Storage lower the engine speed to SLOW, and cycle each of the hydraulic controls slowly for about 30 seconds each •...
Page 29 1800 AWL Operation · Service · Maintenance Manual Operation d. Connect the other end of the black negative (-) jumper cable to the negative post of the stalled machine, where the battery black negative (-) cable is already connected. 7. Start the engine on the boost machine and allow it to DO NOT ALLOW JUMPER CABLE CLAMPS TO run at high idling speed for about ten minutes.
Page 30: Maintenance
1800 AWL Operation · Service · Maintenance Manual Maintenance Certified Engine Maintenance ways, and from steps. Secure all loose items such as lunch boxes, tools, and other Proper maintenance and repair is essential to keep the items that are not a part of the equipment. engine and machine systems operating correctly.
Page 31 1800 AWL Operation · Service · Maintenance Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
Page 32 1800 AWL Operation · Service · Maintenance Manual Maintenance SERVICE INTERVAL DAILY ITEM FIRST EVERY EVERY EVERY EVERY EVERY EVERY EVERY YEARLY 100HRS 100HRS 200HRS 500HRS 1000HRS 2000HRS 2YRS 8HRS ● CHECK ENGINE OIL LEVEL ● CHECK & FILL FUEL TANK LEVEL ●...
Page 33 1800 AWL Operation · Service · Maintenance Manual Maintenance Walk-Around Inspection 1. Inspect the boom cylinders, boom pins, and attachment plate for damage or excessive wear. Repair as needed. 2. Inspect and remove any dirt or residue buildup in and around the engine compartment.
Page 34 1800 AWL Operation · Service · Maintenance Manual Maintenance Fuel Tank - Fill Air Cleaner - Check & Replace Filter NOTICE Operating engine with loose or damaged air cleaner components could cause premature wear and DO NOT SMOKE OR ALLOW ANYTHING failure.
Page 35 1800 AWL Operation · Service · Maintenance Manual Maintenance Changing Hydraulic Oil 2. Remove the left rear engine panel to expose the top of the hydraulic tank. System Drain 1. Place the machine on level ground, and remove the four mid belly pan bolts using a 9/16 wrench.
Page 36 1800 AWL Operation · Service · Maintenance Manual Maintenance Re-fill Hydraulic Oil The hydraulic system is now completely ready for operation. 8. Clean up any spilled hydraulic fluid and check machine for leeks. Note: Hydraulic oil will need monitored if oil is lost while interchanging attachments.
Page 37 1800 AWL Operation · Service · Maintenance Manual Maintenance 800.392.2686...
Page 38 1800 AWL Operation · Service · Maintenance Manual Maintenance Coolant Check Second, check the coolant level in the purge tank. The tank has an upper and lower mark, and the coolant level should be between the two marks. Do not over fill the tank.
Page 39 1800 AWL Operation · Service · Maintenance Manual Maintenance point socket can be used. • Before installing the new filter, lubricate the sealing • After coolant is drained, reinstall the plug and fill with ring with fuel and fill the filter with clean fuel up to coolant following the coolant specifications page.
Page 40 1800 AWL Operation · Service · Maintenance Manual Maintenance Greasing Machine Lubricate 3-4 pumps of grease into the grease fittings on the machine. If the fittings do not accept new grease, replace an/or clean as necessary. ACCUMULATED GREASE AND OIL ON A MACHINE IS A FIRE HAZARD.
Page 41 1800 AWL Operation · Service · Maintenance Manual Maintenance Fuse Panel The fuse panel is located under the joystick control behind a cover (B). To access the panel, remove the two retaining bolts (A) using a 4mm allen head wrench. Once the plate cover has been removed, press in the tabs on each side of the plastic cover to expose the fuses and relays.
Page 42 1800 AWL Operation · Service · Maintenance Manual   Maintenance      M1 G1 € €  ...
Page 43 1800 AWL Operation · Service · Maintenance Manual Maintenance  ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¤ £ ¥ ¢ € ‚ & ƒ „ … † … ‡ ˆ ‰ ‘ ’ “ ”...
Page 44 1800 AWL Operation · Service · Maintenance Manual Main Wire Harness 41005 Rev E 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. FRAME GROUND DASH...
Page 45 1800 AWL Operation · Service · Maintenance Manual Main WIre Harness 41005 Rev E REVISIONS REV. DATE DESCRIPTION ECO# See Sheet1 (BATT +) (START SIG) STARTER BRN/WHT (FUEL SOL) (FUEL SOL) (VALVE GRD #2) (BRAKE) PUR/WHT (PILOT) GLOW (PRE-HEAT) (PRE-HEAT) PLUGS (ALT) ALTERNATOR...
Page 46: Specifications
1800 AWL Operation · Service · Maintenance Manual Specifications Lubricating Grease All Rayco products 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.
Page 47 1800 AWL Operation · Service · Maintenance Manual Specifications & F AYCO UBRICATION LUID PECIFICATIONS 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.
Page 48: Troubleshoot
1800 AWL Operation · Service · Maintenance Manual Troubleshooting Troubleshoot TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at  rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below and vary by engine speci...
Page 49 1800 AWL Operation · Service · Maintenance Manual Troubleshoot Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ●...
Page 50 1800 AWL Operation · Service · Maintenance Manual 806813 Hydraulic Schematic...
Page 51 1800 AWL Operation · Service · Maintenance Manual 806813 Hydraulic Schematic 800.392.2686...
Page 52 1800 AWL Operation · Service · Maintenance Manual 806813A Adapter Kit ITEM PART # DESCRIPTION FF6801-10-12 FIT-EL90-10MORFS-12MORB FF6802-10-10 FIT-EL45-10MORFS-10MORB FF6400-10-12 FIT-STRAIGHT-10MORFS-12MORB FF6801-12-16 FIT-EL90-12MORFS-16MORB FF6801-08-08 FIT-EL90-8MORFS-8MORB FF6400-08-08 FIT-STRAIGHT-8MORFS-8MORB FF6802-06-08 FIT-EL45-6MORFS-8MORB FF6802-06-06 FIT-EL45-6MORFS-6MORB FF6803-12-12-12 FIT-TEE-12MORFS-12MORFS-12MORB FF6801-12-12 FIT-EL90-12MORFS-12MORB FF6564-04-04-04 FIT-TEE -04MORFS-04FORFS SWIVEL-04FORB FF6400-04-04 FIT-STRAIGHT-4MORFS-4MORB FF6801-06-08 FIT-EL90-6MORFS-8MORB...
Page 53 1800 AWL Operation · Service · Maintenance Manual 806813A Adapter Kit FF6400-10-10 FIT-STRAIGHT-10MORFS-10MORB FF6602-08-08-08 FIT-RUN TEE -08MORFS-08FORFS SWIVEL -08MORFS FF306-04 NUT-BULKHEAD -04 FF306-06 NUT-BULKHEAD -06 5504-06-04 ELBOW-90° -06FNPT X -04FNPT 205-106 FIT-STRAIGHT -05BARBED X -06MNPT 5504-06-06F ELBOW-90° -06FNPT X -06FNPT 204-104 FIT-STRAIGHT -04BARBED X -04MNPT 800.392.2686...
Page 54 1800 AWL Operation · Service · Maintenance Manual 806813H Hose Kit ITEM PART # DESCRIPTION HOSE T3008D-8FSX90-8FSX-19” HOSE H5010D-10FSX45-10FSX-48” HOSE H5010D-10FSX-10FSX-50” HOSE H5010D-10FSX-10FSX90-62” HOSE H5010D-10FSX-10FSX-54” HOSE T3008D-8FSX-8FSX90-77” HOSE H5010A-10FSX-10FSX45-24” HOSE T5006D-6FSX-6FSX-12” HOSE H5010A-10FSX-10FSX90-28” HOSE T5008D-8FSX-8FSX45-20” HOSE H5010A-10FSX-10FSX45-24” HOSE H5010A-10FSX-10FSX45-33” HOSE T3008D-6FSX-6FSX90-43”...
Page 55 1800 AWL Operation · Service · Maintenance Manual 806813H Hose Kit HOSE T3006D-6FSX-6FSX90L-52” HOSE T3004D-6FSX-4FSX-44” HOSE T3004D-4FSX-4FSX90-32” HOSE T3008D-8FSX-8FSX90-32” HOSE T3008D-8FSX8FSX-11” HOSE T3004D-4FSX-4FSX90-32” HOSE SAE 30R7-04-BLANK-BLANK-20” HOSE SAE 30R7-05-BLANK-BLANK-41” HOSE SAE 30R7-05-BLANK-BLANK-12” HOSE T3008-08FSX-06FSX-26” WRAP PLWD-16-24” WRAP PLWD-16-20” 800.392.2686...
Page 56 1800 AWL Operation · Service · Maintenance Manual 41005 Electrical Schematic Rev E 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. FRAME GROUND DASH...
Page 57 1800 AWL Operation · Service · Maintenance Manual 41005 Electrical Schematic Rev E REVISIONS REV. DATE DESCRIPTION ECO# See Sheet1 (BATT +) (START SIG) STARTER BRN/WHT (FUEL SOL) (FUEL SOL) 18 PIN HARNESS COUPLER (BATT +) (VALVE GRD #2) (BRAKE) (DIFF LOCK) PUR/WHT (PILOT)
Page 58 1800 AWL Operation · Service · Maintenance Manual Service Parts SERVICE FILTERS COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART # Qty. DESCRIPTION PART# Engine Oil Filter 800275 Tool Box Key 762015 Hydraulic Filter (In Tank) M26838-326 Ignition Key M29211-929 Fuel Filter M29211-037 Ignition Switch M29211-935...
Page 59: Warranty
RAYCO WARRANTY CERTIFICATE 2. Transporting the product to and from the place at which A. General Outline warranty work is performed. Rayco Manufacturing, Inc. warrants to the first user that the products it supplies will be free from defects in material and 3.
Page 60 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.