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Rayco T415 Operation, Service And Maintenance Instructions
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Rayco T415 Operation, Service And Maintenance Instructions

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T415
OPERATION • SERVICE •MAINTENANCE MANUAL
RAYCO MANUFACTURING © 2019 ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMT415-19

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Summary of Contents for Rayco T415

  • Page 1 T415 OPERATION • SERVICE •MAINTENANCE MANUAL RAYCO MANUFACTURING © 2019 ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMT415-19...
  • Page 2 T415 Operation & Service Manual This manual is published by Rayco Manufacturing, Inc. for the attempting to operate this machine. This manual should be benefit of the users of Rayco products. Rayco Manufacturing, readily available for reference at all times. Additional copies Inc.

  • Page 3: Table Of Contents

    T415 Operation & Service Manual TABLE OF CONTENTS General Information Safety Operation Maintenance Specifications Warranty 800.392.2686...
  • Page 4 Parts Parts are readily found through illustrations with accompanying Rayco part numbers. The machine assembly is listed by basic groups to enable ease of finding parts. Please consult your local Rayco Dealer or local Engine Manufacturer Dealer for obtaining engine parts and service.
  • Page 5 Machine Description • Remote Engine Comparment Light • Horn (standard) The T415 offers a solution for contractors looking for a full • Sauer Danfoss® PLUS-1® Controller size stump cutter and forestry mower with premium features • Sauer Danfoss® PLUS-1® Graphical Terminal and top level performance.
  • Page 6 Use the below table to record identification numbers and dealer 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 T415 Operation & Service Manual 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 800.392.2686...

  • Page 8: Safety

    T415 Operation & Service Manual Safety California Proposition Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, 65 Warning and from steps. Diesel engine exhaust and some of its constituents are known...
  • Page 9 An accident can often be avoided by recognizing Rayco, you must use it only if you have accurately evaluated potentially hazardous situations before an accident occurs. it and found that it threatens no one’s safety. You should A person must be alert to potential hazards.
  • Page 10 Keep all manuals in a safe place for future Rayco has provided shields, guards, safety decals and other reference and for ordering replacement parts. important safety features to aid in using the machine properly.
  • Page 11 T415 Operation & Service Manual Safety Personal Protective Equipment protection. Eye protection includes goggles or a protective face shield. (PPE) The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and personal protective equipment.
  • Page 12 • Obey all local regulations for the disposal of liquids. Asbestos Information Rayco recommends the use of only genuine Rayco replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.
  • Page 13 T415 Operation & Service Manual Safety Coolant 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, always install the guards after the maintenance is performed.
  • Page 14 Do not operate the machine near any flame. the machine, for crawlers mount on the left side of the cab Extinguish all cigarettes, cigars, pipes and other sources behind the seat. Consult your Rayco dealer for the proper of ignition. procedure of mounting the fire extinguisher.
  • Page 15 Always operate this machine with all safety equipment Repair any lines that are loose or damaged. Leaks can in place and working. Make sure all controls are cause fires. Consult your Rayco dealer for repair or for properly adjusted for safe operation. replacement parts.
  • Page 16 Replacement parts which are machines to all areas around the machine. Appropriate job authorized by Rayco are the only parts which should site organization is required in order to minimize hazards that be used for repair or replacement on this machine.
  • Page 17 Operation and Maintenance Manual, “Reference Material”. slopes. Also, the machine can tip when you cross ditches, Consult your Rayco dealer in order to obtain copies of the ridges or other unexpected obstacles. material. The information should be reviewed by every person Avoid operating the machine across the slope.
  • Page 18 • Roughness of terrain or surface – The machine may be less stable with uneven terrain. Only use work tools that are approved by Rayco for use on • Direction of travel – Avoid operation the machine Rayco machines. Refer to the Operation and Maintenance across the slope.
  • Page 19 T415 Operation & Service Manual Safety Sound Level Information b. Brake c. Accelerate The operator Equivalent Sound Pressure Level is used to d. Shift the gears measure a work cycle sound exposure level 6. Move the attachments smoothly. Hearing protection may be needed when the machine is 7.
  • Page 20 Rayco or polycarbonate front guards that are and its intent to comply with OSHA regulations. approved by Rayco are available for machines with a cab or Lock Out Procedure an open canopy. On machines that are equipped with cabs, 1.
  • Page 21 T415 Operation & Service Manual Safety 5. A tag to be secured to the lock indicating that the equipment is not to be energized and who owns the lock. 6. It should be safely tested and verified that the lockout does prevent the release of energy.

  • Page 22: Operation

    T415 Operation & Service Manual Operation...
  • Page 23 T415 Operation & Service Manual Operation Know Your Machine Cab Ineterior RH Joystick (Attachment Function) 1. Engine Compartment LH Joystick (Machine Function) 2. Radiator (Primary & Secondary) Seat Adjustments 3. Fuel Tank Seat Belt 4. Hyralic Tank Display Panel 5. Acces Steps Fire Extinguisher 6.
  • Page 24 Get on or off the machine only at locations that brackets or drilling holes in the ROPS/FOPS can are equipped with steps (1) and/or hand holds. weaken the structure. See your Rayco dealer for • Before you get on the machine, clean and inspect the mounting guidelines.
  • Page 25 T415 Operation & Service Manual Operation Starting Procedure Under cold conditions, the hydraulic filter restriction indicator lamp may come on. Under extremely cold conditions, the hydraulic filter may shut down the track transmissions and all hydraulic functions. As the hydraulic oil warms up, the track...
  • Page 26 T415 Operation & Service Manual Operation Seat Adjustment Armrests (3) The armrests can be folded up if required and the height individually adjusted by turning the adjustment knob (3). Control Carrier (4) RISK OF ACCIDENT! DO NOT OPERATE THE The joystick control carrier can be adjusted forward or SEAT ADJUSTMENTS WHILE OPERATING.
  • Page 27 T415 Operation & Service Manual Operation Machine Controls • Letting go of the stick will allow it to center itself. In this position, the machine will not move. • Push the stick forward to move the machine forward. • Pull the stick backward to move the machine backward.
  • Page 28 The implement engagement lever (14) activates the implement rotor or wheel. When engaging the implement, 3. Dome Light the T415 is designed to gradually start so that a load 4. Winch Out shock is not sent through the machine. Be sure that the 5.
  • Page 29 ALWAYS CHOCK OR SECURE THE MACHINE IN ADDITION TO PARK BRAKE WHEN SERVICING. This machine was shipped from Rayco with a factory installed DO NOT RELY SOLELY ON THE PARKING BRAKE seat belt. Consult your Rayco dealer for all replacement parts.
  • Page 30 T415 Operation & Service Manual Operation 6. Seat Belt Indicator Display Indicators Notifies operator when seat belt is fastened or 1. Low DEF Fluid retracted DEF Fluid is low fill tank. 7. Cab Door Indicator 2. Emission System Failure 8. Parking Brake Code will appear in fault screen and contact dealer.
  • Page 31 T415 Operation & Service Manual Operation 34. Protect Warning Indicator P=PROTECT - This indicates that in order to protect your machine, you need to shut down the machine and have it serviced. 35. Stop Warning Indicator S=STOP - This indicates that there is an immediate fault or service issue, and machine shut down is mandatory.
  • Page 32 T415 Operation & Service Manual Operation DP710 Main Display Panel • Pressing button #5 will prompt the user to clear the current calibration values. Re-calibration is Items on the Main Display Screen: recommended after replacing the joystick. 1) Seat belt buckled, wipers on and 2-speed engaged.
  • Page 33 T415 Operation & Service Manual Operation Engine Faults Screen 1) Switch between Active and 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.
  • Page 34 T415 Operation & Service Manual Operation Towing the Machine 5. Repeat the process for the other track drive. 6. Once the brakes have been released, the machine is ready to be towed a short distance. 7. Great care should be taken as not to damage the splines on the transmission shafts that were removed.
  • Page 35 T415 Operation & Service Manual Operation All situation requirements cannot be listed. Minimal towing machine capacity is required on smooth, level surfaces. On inclines or on surfaces in poor condition, maximum towing machine capacity is required. Block the tracks securely so that the machine cannot move.

  • Page 36: Maintenance

    OR REPAIRS MADE TO THIS MACHINE WITHOUT should be made, and a note should also be made, WRITTEN CONSENT OF RAYCO MFG. WILL VOID on a regularly viewed calendar, of when the next THE PRODUCT’S WARRANTY, LIABILITY AND...
  • Page 37 T415 Operation & Service Manual Maintenance First Every Every Every Every Hours Every Service Interval: 1000 Year Needed Hours Hours Hours Hours Hours Daily Walk Around Inspection-Check for Leaks, Damage, etc. Air Intake Piping- Inspect Back-Up Alarm - Test Brake System - Test...
  • Page 38 T415 Operation & Service Manual Maintenance Radiator Pressure Cap check Cooling System - Drain & Clean Hydraulic Oil - Change Fuel Tank - Drain Water & Sediment ROPS - Inspect Cab Windows - Remove & Clean Rear Hood Screen - Clean...
  • Page 39 T415 Operation & Service Manual Maintenance MAINTENANCE LOG Date Machine Hrs Description of Service/ Maintenance Notes 800.392.2686...
  • Page 40 T415 Operation & Service Manual Maintenance & F AYCO UBRICATION LUID PECIFICATIONS Rayco Lubrication & Fluid Specifications 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.
  • Page 41 A synthetic 75W-140 or 80W-140 heavy duty GL-5 gear oil could also be used in warm climates to extend gear life. MWF Hydrostat Drive T415 Operation & Service Manual The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50. Do not mix hydrostat and different lubricants! Maintenance The Differential Gearbox is shipped with 80-90W performance gear oil.
  • Page 42 T415 Operation & Service Manual Maintenance COOLANT SPECIFICATIONS Rayco Coolant Specifications Coolant / Antifreeze Recommendations Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. These antifreezes are intended for aluminum automotive engines and are unacceptable for diesel engines. Use antifreeze that is formulated with a low silicate level and the proper coolant additives for heavy duty diesel engines.
  • Page 43 T415 Operation & Service Manual Maintenance Torque Specifications Torque Specifications General Torque Information Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Maintenance Section, if necessary.
  • Page 44 T415 Operation & Service Manual Maintenance Accessing the Engine Enclosure The Engine enclosure has 4 access doors that are lockable. To open the engine access door, first twist open the latch. Next, lift lever (1) to open secondary doors (2).
  • Page 45 Replace at stated intervals or when backward, or when the engine automatically shuts down. needed (Rayco filter element # 762823). DO NOT USE To test: COMPRESSED AIR TO CLEAN OUT FILTER! •...
  • Page 46 T415 Operation & Service Manual Maintenance Batteries - Check Follow the instructions listed in the Engine Maintenance Manual for Draining, Flush & Filling the radiator. Engine Coolant Level - Check ALWAYS WEAR PROTECTIVE CLOTHING AND RADIATOR SURGE TANK EYEGLASSES WHEN WORKING WITH A BATTERY.
  • Page 47 T415 Operation & Service Manual Maintenance Engine Oil Level - Check Fuel System Water Separator and Filter - Check /Drain NOTICE NOTICE Check only when the machine is in a level position. Dispose of any drained fuel according to local environment protection regulations.
  • Page 48 T415 Operation & Service Manual Maintenance Fuel System Water Separator - Remove and discard the filter according to local regulations. Clean the filter base and verify that all old Change Element filter materials are removed. Element replacement frequency is determined by the Clean all of the filter base components and seal groves contamination level in fuels.
  • Page 49 T415 Operation & Service Manual Maintenance Gearbox Oil Level - Check DIESEL FUEL IS HIGHLY COMBUSTIBLE. DO NOT SPILL IT ON THE ENGINE. LET THE ENGINE COOL BEFORE REFUELING. DO NOT SMOKE OR ALLOW ANY HOT OBJECTS NEARBY WHEN REFUELING.
  • Page 50 This cap can only be removed with the Wipe all fittings, caps, and plugs before servicing. special wrench (Rayco part # 19359) included in your tool kit. Keep a close watch for leaks. Refer to the “Fluid Penetration”...
  • Page 51 T415 Operation & Service Manual Maintenance Hydraulic Oil Filters - Change filler tube. Using a strap wrench, remove the oil filter and replace with a new filter. NOTICE Hydraulic Oil - Change Hydraulic filters need to be changed after the first 100 hours of operation.
  • Page 52 T415 Operation & Service Manual Maintenance and motor cases to fill with fluid for instant lubrication 12. Cycle Track Control Slowly. Restart the prime mover, at start-up. and actuate the track control two or three times to purge any trapped air from the system.
  • Page 53 ROPS/FOPS can weaken the structure. Rear Radiator Screen - Clean See your Rayco dealer for mounting guidelines. Any alteration that is not specifically authorized by Rayco invalidates the certification for the ROPS/FOPS. The protection that is offered by the ROPS/FOPS will be impaired if the ROPS/FOPS has structural damage.
  • Page 54 T415 Operation & Service Manual Maintenance Track Adjustment - Check Track Bolts - Re-Torque fig.1 fig.3 Lay a straight edge (1) on the track between the top carrier roller and front idler. Measure the maximum amount of track When installing a track, torque the 5/8-18 master link bolts sag from the high point of the track grouser to the bottom &...
  • Page 55 T415 Operation & Service Manual Maintenance 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 fig. 4. The oil drain hole must be positioned straight down (3) with the oil fill hole used as a pressure relief (4).
  • Page 56 T415 Operation & Service Manual Maintenance Starting with Jumper Cables • Start the engine of the power source machine. • Allow the power source machine to charge the system for two minutes. • Start the engine of the stalled machine.
  • Page 57 If the unit continues to overheat after cleaning the machine If debris is accumulating in the engine area so that you can as described above, please consult your Authorized RAYCO no longer see the majority of the floor, it is time to clean. It is...

  • Page 58: Specifications

    T415 Operation & Service Manual Maintenance Gearbox - Pump Drive DRIVE PLATE DRIVEN This unit mounts directly to the engine flywheel. Use The New Durst pump drives incorporate some of the extreme care when mounting the drive plate to the engine features from both the previous Terrell and Hub City flywheel to avoid pre-loading the crankshaft bearings.
  • Page 59 T415 Operation & Service Manual Maintenance REPAIR & REBUILDING INSTRUCTIONS DISASSEMBLY INSTRUCTIONS 6) Once the input drive shaft is removed, place the 1) Make certain that the power supply is disconnected pump drive on a flat surface with the pump pads before attempting to service or remove any facing up.
  • Page 60 T415 Operation & Service Manual Maintenance 7) Evenly lift the output housing half, being careful not 8) With all of the gears removed, drive the input to lift any of the gears. Inspect the gears and bearings seal out towards the engine adapter. It is required to...
  • Page 61 T415 Operation & Service Manual Maintenance REASSEMBLY INSTRUCTIONS Then inspect both housings for any contaminates or Before reassembling the pump drive gear box, make sure visual defects. With a clean towel or rag wipe the that both housings have been cleaned and inspected.
  • Page 62 T415 Operation & Service Manual Maintenance 6) Press in the two (2) dowel pins to insure proper Do not use sharp objects for pressing in CAUTION alignment. Evenly install and tighten the cap seals. Press only on the outer edge of the seal to keep screws.
  • Page 63 T415 Operation & Service Manual Maintenance LUBRICATION AND OIL FILLING INSTRUCTIONS Oil flow and circulation in a gear box is one of the most OIL CAPACITY important features to give all internal parts the maximum The following charts indicate the quantity of oil that a NEW life.
  • Page 64 T415 Operation & Service Manual Maintenance 2PD08 MODULE PUMP DRIVE 4400-101 VENT 012166 FITTING SEE NOTE FOR DIPSTICK AND PLUG J84 DOWEL PIN (2) D1353 CAP SCREW (12) D70 WASHER (12) 012059 PLUG A - INPUT GEAR 012042 SEAL 012016 BEARING (6)
  • Page 65 T415 Operation & Service Manual Maintenance DRIVE PLATE OPTIONS The following chart lists all available drive plate options for as complete kits only. the Durst pump drives. Drive plates are to be purchased Drive Plate SAE Drive Drive Plate Tapped Engine...
  • Page 66 T415 Operation & Service Manual Maintenance RH Cutter Wheel Pump LH Cutter Wheel Pump LH Track Drive Pump RH Track Drive Pump (Series 90) (Series 90) If machine does not track in a straight line, the pump displacement limiter will need adjustment. This done electronically from...
  • Page 67 T415 Operation & Service Manual Maintenance Series 90 Functional Description The System Circuit System loop (low pressure) Control Handle Displacement Control Valve Case drain fluid Heat Exchanger System loop (high pressure) Bypass Valve Reservoir Orificed Control fluid Check Valve Vacuum Gauge...
  • Page 68 T415 Operation & Service Manual Maintenance Series 90 Functional Description Pump Features Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage.
  • Page 69 T415 Operation & Service Manual Maintenance Series 90 Pressure Measurement Pressure Measurement Required Tools The service procedures described in this manual for Pressure gauges should be calibrated frequently to en- Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect common mechanic's tools.
  • Page 70 T415 Operation & Service Manual Maintenance Series 90 Pressure Measurement Servo / Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 System Pressure Port B Servo / Displacement Cylinder Pressure Gauge Port M5 Top View 90000814E System Pressure External Control Pressure...
  • Page 71 T415 Operation & Service Manual Maintenance Series 90 Pressure Measurement Servo / Displacement Cylinder Pressure Gauge Port M4 System Pressure Case Drain Gauge Port M2 Port L1 System Pressure Port B Charge Pump Inlet Port S System Pressure Port A...
  • Page 72 T415 Operation & Service Manual Maintenance Series 90 Fluid and Filter Maintenance Fluid and Filter Maintenance To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be per- formed. Contaminated fluid is the main cause of unit failure.
  • Page 73 T415 Operation & Service Manual Maintenance Series 90 Toubleshooting Troubleshooting This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced.
  • Page 74 T415 Operation & Service Manual Maintenance Series 90 Toubleshooting Transmission Operates Normally in One Direction Only Check Description Action Input to control module is operating Check control input and repair or re- 1. Input to pump control. improperly. place as necessary.
  • Page 75 T415 Operation & Service Manual Maintenance Series 90 Toubleshooting 10. Pump displacement control. Control linkages are not secure, control Repair or replace control module as orifices are blocked, etc. necessary. 11. System pressure. Low system pressure will not provide Measure system pressure. Continue power necessary to move load.
  • Page 76 T415 Operation & Service Manual Maintenance Series 90 Toubleshooting Excessive Noise and/or Vibration Check Description Action 1. Oil in reservoir. Insufficient hydraulic fluid will lead to Fill reservoir to proper level. cavitation. 2. Air in system. Air bubbles will lead to cavitation.
  • Page 77 T415 Operation & Service Manual Maintenance Series 90 Inspections and Adjustments Inspections and Adjustments This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read through the entire related section before beginning a service activity. Refer to the corresponding section for location of gauge ports and suggested gauge size.
  • Page 78 T415 Operation & Service Manual Maintenance Series 90 Inspections and Adjustments 3. Earlier production Series 90 pumps are equipped with a shim adjustable charge pressure relief valve. Shim kits are available from SAUER-SUNDSTRAND. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring.
  • Page 79 T415 Operation & Service Manual Maintenance Series 90 Inspections and Adjustments Displacement Limiter Adjustment The maximum displacement can be limited in either direction. 1. Loosen the seal lock nut retaining the displacement limiter adjusting screw. 2. Rotate the adjusting screw.
  • Page 80 T415 Operation & Service Manual Maintenance Series 90 Functional Description The System Circuit System loop (low pressure) Control Handle Displacement Control Valve Case drain fluid Heat Exchanger System loop (high pressure) Bypass Valve Reservoir Orificed Control fluid Check Valve Vacuum Gauge...
  • Page 81 T415 Operation & Service Manual Maintenance Series 90 Functional Description Pump Features Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage.
  • Page 82 T415 Operation & Service Manual Maintenance Series 90 Pressure Measurement Pressure Measurement Required Tools The service procedures described in this manual for Pressure gauges should be calibrated frequently to en- Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect common mechanic's tools.
  • Page 83 T415 Operation & Service Manual Maintenance Troubleshooting Fault-Logic Tables This Fault-Logic Trouble Shooting Guide is designed as a diagnostic aid in locating possible transmission problems by the user. Match the transmission Symptom: symptoms with the problem statements and follow the action steps shown in the box diagrams.
  • Page 84 T415 Operation & Service Manual Maintenance Troubleshooting Fault-Logic Tables System Operating Hot Check Oil Inspect Inspect Heat Check Level in Heat Exchanger By−Pass Charge Reservoir Exchanger Valve (if Used) Pressure Clogged Below Level Defective Fill to Repair Low in Low in...
  • Page 85 T415 Operation & Service Manual Maintenance Troubleshooting Fault-Logic Tables System Will Not Operate in Either Direction Check Oil Inspect External Inspect Motor Check Level in Pump Control By−Pass Valve Charge Reservoir Linkage (if Used) (if Used) Pressure Defective Below Level...
  • Page 86 T415 Operation & Service Manual Maintenance Troubleshooting Fault-Logic Tables System Response Sluggish Replace Inspect System Check Inspect Transmission By−Pass Valve Charge Pump Control (if Used) (Pump & Motor) Pressure Valve Defective Defective Repair Repair Replace Replace Low in Low in...
  • Page 87 T415 Operation & Service Manual Maintenance Troubleshooting Tips Inspect External Pump Control Linkage for: 3. Inspect Servo Piston for: Manual Operated Controls A. Improper servo piston adjustment A. Mis-adjusted or disconnected 4. Inspect System Relief Valves for: B. Binding, bend or broken A.
  • Page 88 T415 Operation & Service Manual Maintenance Hydraulic Circut Load Sense Pump system pressure and increases pump flow by increasing the swash plate angle. The pump continues to increase flow until The Load Sense pump is mounted on the side of the engine system pressure reaches the PC setting.
  • Page 89 T415 Operation & Service Manual Maintenance Series 45 Axial Piston Open Circuit Pumps Technical Information Frames L and K Design Series 45 Frame L and K pumps have a single servo piston design with a cradle- type swashplate set in polymer-coated journal bearings. A bias spring and internal forces increase swashplate angle.The servo piston decreases swashplate angle.
  • Page 90 T415 Operation & Service Manual Maintenance Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Troubleshooting EXCESSIVE NOISE AND / OR VIBRATION c i f i l u l l i . r i l l i .
  • Page 91 T415 Operation & Service Manual Maintenance Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Troubleshooting SYSTEM OPERATING HOT c i f c i l l i F y f i . r i l l i n i l .
  • Page 92 T415 Operation & Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Maintenance Service Manual Troubleshooting PRESSURE OR FLOW INSTABILITY (continued) i l i . y t s u j n i l l l i...
  • Page 93 T415 Operation & Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Maintenance Service Manual Adjustments PC CONTROL PC setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston PumpsTechnical Information Manual, BLN-10128, for more information.
  • Page 94 T415 Operation & Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Maintenance Service Manual Adjustments LS CONTROL The LS setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual, BLN-10128, for more information.
  • Page 95 T415 Operation & Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Maintenance Service Manual Minor repair SHAFT SEAL A lip type shaft seal is used in the Series 45 open circuit variable pumps.This seal can be REPLACEMENT replaced without major disassembly of the unit.
  • Page 96 T415 Operation & Service Manual Maintenance Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair NTROL Disassembly 1. Remove the four screws (C300) Control assembly holding the control housing onto the  C118 end cap.
  • Page 97 T415 Operation & Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Maintenance Service Manual Minor repair CONTROL Reassembly (continued) 13. Install the PC spool, spherical end Control assembly first, into the PC bore.The PC spool is ...
  • Page 98 T415 Operation & Service Manual Main Wire Harness Schematic 38969 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. BLK/YLW...
  • Page 99 T415 Operation & Service Manual Main Wire Harness Schematic 38969 (LH JS GRD) (DISP GRD) (RH JS GRD) FRAME FRAME FRAME GROUND GROUND GROUND (KEYPAD GRD) P CHARGE PSI) (MICRO OTHER) (HVAC FUSE FEED) HYDRAULIC OIL (FUSE FEED) LEVEL SWITCH...
  • Page 100 T415 Operation & Service Manual A/C Hose Kit 40430...
  • Page 101 T415 Operation & Service Manual 800.392.2686...
  • Page 102 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A ATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF , INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT PERMISSION OF RAYCO MFG, INC. IS PROHIBITED. MOTORS 0.453cir 764614 FLOW...
  • Page 103 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A REVISIONS 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. REV. DATE...
  • Page 104 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A...
  • Page 105 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A SUCTION MANIFOLD 28170 800.392.2686...
  • Page 106 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A 2870 801892 80581 CUTTER PUMP #1 LH TRACK 805810 801886 ENGINE GEAR BOX 1.34 : 1 801892 8018 CUTTER PUMP #2 RH TRAC 28702...
  • Page 107 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A 802964 ACCUMULATOR 28701 2.5GAL, 180PSI 801903 DETAIL 28704 805818 805813 PUMP LH TRACK PUMP 801970 801893 RH TRACK PUMP PUMP BULKHEAD CONNECTIONS 5000psi 28702 4000psi TOP VIEW OF 801903 FRONT RAYCO MFG, INC.
  • Page 108 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A 2870 801892 80581 CUTTER PUMP #1 LH TRACK 805810 801886 ENGINE GEAR BOX 1.34 : 1 801892 8018 CUTTER PUMP #2 RH TRAC 28702...
  • Page 109 T415 Operation & Service Manual Hydraulic Schematic 806038 Rev A 802964 ACCUMULATOR 28701 2.5GAL, 180PSI 801903 DETAIL 28704 805818 805813 PUMP LH TRACK PUMP 801970 801893 RH TRACK PUMP PUMP BULKHEAD CONNECTIONS 5000psi 28702 4000psi TOP VIEW OF 801903 FRONT RAYCO MFG, INC.
  • Page 110 T415 Operation & Service Manual Hydraulic Adapter Kit 806038 Rev A ITEM PART # DESCRIPTION FF6400-08-12 CONNECTOR- 08MFF X -12MORB FF6400-08-10 CONNECTOR- 08MFF X -10MORB FF6400-04-05 CONNECTOR- 04MFF X -05MROB FF6801-16-12 ELBOW, 90 DEG- 16MFF X -12MORB FF6400-12-12 CONNECTOR- 12MFF X -12MORB...
  • Page 111 T415 Operation & Service Manual Hydraulic Adapter Kit 806038 Rev A 694-12-16 90 DEGREE O-RING FACE SEAL SFK62-20 FLANGE KIT FF6502-16-16 45 DEGREE SWIVEL- -16MORFS X -16FORFS FF6801-12-12 ELBOW, 90 DEG- 12MFF X -12MORB FF6804-04-04-04 TEE-RUN -04MORFS X -04MORB X -04MORFS...
  • Page 112 T415 Operation & Service Manual Hydraulic Hose Kit 806038 ITEM QTY PART # DESCRIPTION HOSE 6R16-6FSX-6FSX90 DEG- 71" HOSE 6R16-6FSX45 DEG-6FSX- 142" HOSE 6R16-6FSX45 DEG-6FSX- 126" HOSE 6R16-6FSX-6FSX90 DEG- 29" HOSE 6R16-6FSX-6FSX90 DEG- 69" HOSE 6R16-6FSX-6FSX90 DEG- 94" HOSE 6R16-6FSX-6FSX- 170" W/ FAB. GUARD HOSE H01716-12FSX-BLANK-86"...
  • Page 113 T415 Operation & Service Manual Hydraulic Hose Kit 806038 HOSE 17813047002-BLANK-BLANK- 100" W/FAB. GUARD HOSE 12R16-16FSX-16FSX- 28" HOSE 6R16-6FSX-6FSX90 DEG- 19" HOSE 6R16-6FSX-6FSX- 15" HOSE 6R16-6FSX-6FSX45 DEG- 15" HOSE 16R16-16FSX-16FSX90 DEG- 90" HOSE 20XF5000-20FSX-20FSX90- 36" HOSE 20XF5000-20FSX-20FSX90- 48" HOSE 4R16-4FSX90 DEG-4FSX- 82" W/ FAB. GUARD HOSE 4R16-4FSX-4FSX- 122"...
  • Page 114 T415 Operation & Service Manual Auxiliary Hose Schematic 806047 Rev A CAB ASSEMBLY CAP-NON VENTED #801335 HVAC UN UPPER RADIATOR #804628 #801540 CONTROL 10 35 3 VALVE BLEED PORT #27726 #27725 TUBE TUBE P/N 730024 VENT CAP-VENTED #764739 SURGE TANK...
  • Page 115 T415 Operation & Service Manual Auxiliary Hose Schematic 806047 Rev A SSEMBLY HVAC UNIT #804628 CLAMP 738978 DEF TANK CLAMP 738978 *FUEL BREATHER #802205 *BREATHER CLAMP #120022 730022 CLAMP 738978 CLAMP 730022 RETURN CLAMP 738978 VENT LINES CLAMP 738978 GEARBOX...
  • Page 116 T415 Operation & Service Manual Auxiliary Hose Adapter Kit 806047 Rev A ITEM PART # DESCRIPTION 4404-06-06 3/8” BT X 3/8” NPT 4404-08-08 1/2” BT X 1/2” NPT 4404-10-08 5/8” BT X 1/2” NPT 4501-06-06 3/8” BT X 3/8” NPT, 90 DEG 4601-10-10F 5/8”...
  • Page 117 T415 Operation & Service Manual Auxiliary Hose Adapter Kit 806047 Rev A TBC-250 T-BOLT CLAMP FF6504-10-10 ADAPTER -10 MJIC X -10 FORFS 5402-02-02 HEX NIPPLE -02 MNPT 5602-02-02-02F TEE -02MNPT X -02FNPT X -02FNPT Auxiliary Hose Kit 806047 Rev A...
  • Page 118 SERVICE PARTS SERVICE FILTERS TRACK ASSEMBLY PARTS DESCRIPTION PART # QTY. DESCRIPTION PART# Hydraulic Filter 801554 Front Idler w/ Spring 802660 Outer Cab Filter 762823 Bottom Roller 760164 Hydraulic Filter (Spin On) 802537 Top Roller 760167 Engine Oil Filter 806196 Track 801939 Primary Fuel Filter...

  • Page 119: Warranty

    Rayco product are those set forth on this A. Belts will be covered under warranty only if Rayco page. In no event will the dealer and or Rayco be liable receives warranty from their supplier. for incidental or consequential damages, including but not limited to: loss of profits, rental of substitute equipment, or B.
  • Page 120 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.