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Rayco C120R User Manual

Rayco C120R
100 pages
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RAYCO MANUFACTURING © 2019 - ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMC120R-19
C120R
OPERATOR  SERVICE  MAINTENANCE  MANUAL
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Rayco C120R Specifications

General IconGeneral
Cutting Height0-4 inches
Drive SystemHydrostatic
Cutting Height Range0-4 inches
Fuel Capacity3.5 gallons
Fuel Tank Capacity3.5 gallons

Summary

Foreword

Literature Information

Details on storing and using the operator's manual and related documents.

Safety

Basic safety precautions and locations of warning signs on the machine.

Parts

Information on how to find and obtain replacement parts for the machine.

Operation

Procedures for checking, starting, operating, and stopping the machine.

Maintenance

Guide to equipment care and maintenance interval schedules.

Maintenance Intervals

Guidelines for determining when service is required based on hours or time.

A Description of the Machine

Overview of the C120R's features, capabilities, and design.

Machine Specs

Serial Number Location & Information

Identification Numbers

Fields for recording machine, engine, and implement identification numbers.

Dealer Information

Fields for recording dealer contact and service information.

Safety

California Proposition 65 Warning

Warning regarding cancer and reproductive harm associated with machine components.

General Hazard Information

Important safety information and hazard warnings for machine operation.

Personal Protective Equipment (PPE)

Recommended protective gear for safe operation of the machine.

Flying Debris

Warning about potential hazards from flying debris during operation.

Pressurized Air and Water

Safety precautions when working with pressurized air or water.

Important Safety Information

Safety Warnings

Explanation of safety alert symbols and signal words used in the manual.

Safety

General Hazard Information

Key safety instructions for machine operation and handling.

Personal Protective Equipment (PPE)

Detailed list of recommended protective equipment for operators.

Flying Debris

Warning about potential hazards from flying debris.

Pressurized Air and Water

Safety precautions when using pressurized air or water for cleaning.

Safety

Trapped Pressure

Hazards associated with trapped pressure in hydraulic systems.

Fluid Penetration

Risks of hydraulic fluid penetration into the body and required treatment.

Containing Fluid Spillage

Procedures for containing and disposing of spilled fluids.

Asbestos Information

Safety guidelines for handling materials that may contain asbestos.

Safety

Crushing Prevention and Cutting Prevention

Hazards and safety measures for crushing and cutting risks.

Burn Prevention

Warnings and precautions related to hot components and engine parts.

Safety

Coolant

Safety precautions when handling hot coolant and cooling system components.

Oils

Safety precautions when handling hot oil and components.

Batteries

Safety precautions when working with batteries and their components.

Fire Prevention and Explosion Prevention

Measures to prevent fires and explosions related to fuels and lubricants.

Safety

Fire Extinguisher

Information on fire extinguishers, their operation, and location.

Ether Starting Fluid

Safety precautions for using ether starting fluid.

Lines, Tubes and Hoses

Safety guidelines for inspecting and maintaining hydraulic lines and hoses.

Electrical Storm Injury Prevention

Safety measures to take during electrical storms.

Safety

While Servicing and Performing Maintenance on the Machine

Safety procedures for performing maintenance and repairs on the machine.

Before Starting Engine

Checks and precautions required before starting the engine.

Visibility Information

Importance of visibility and proper use of visual aids.

Safety

Safety Instructions

General safety instructions for operating the machine.

Engine Starting

Procedures and precautions for starting the engine safely.

Before Operation

Pre-operation checks and safety steps before starting.

Operation

Safe operating practices and procedures for machine use.

Parking

Safe procedures for parking the machine.

Safety

Slope Operation

Critical safety considerations and limitations for operating on slopes.

Work Tool options - Attachments

Guidelines for using approved work tools and attachments safely.

Safety

Equipment Lowering with Engine Stopped

Procedures for safely lowering equipment with the engine stopped.

Sound Level Information

Information on operator sound exposure levels.

Vibration Data Information concerning hand/arm vibration level

Data on hand/arm vibration levels during machine operation.

Operator training, behavior, mode, and stress

Factors affecting operator performance and safety.

Guards (Operator Protection)

Importance and inspection of operator protective guards.

Safety

Other Guards (If Equipped)

Details on additional guards for specific applications.

LOCK-Out / Tag-Out Guidelines

Procedures for safely de-energizing equipment before maintenance.

Safety

Lock Out Procedure

Steps for safely locking out equipment to prevent accidental startup.

Tag Out Procedure

Procedures for using tags when lockout is not feasible.

Removal Procedure

Steps for safely removing lockout/tagout devices.

Pre-Transportation Checks

Checks to perform before transporting the machine.

Important Towing Information

Key advice for safe towing operations.

Safety

Loading Your Combination

Guidelines for safely loading the machine for towing.

Slow Down When Towing

Recommendations for safe towing speeds and practices.

Operation

Know Your Machine: General Identification - Exterior

Labels and locations of external machine components.

Operation

Cab Interior

Identification of controls and features within the operator's cab.

Operation

Pre-Start Procedure Walk-Around Inspection

Steps for a thorough walk-around inspection before operation.

Seat and Seat Belt Inspection

Procedures for inspecting and adjusting the seat and seat belt.

Emergency Exit

Information on emergency exit procedures from the cab.

Operation

Rollover Protective Structure (ROPS)

Safety guidelines related to the ROPS structure and its modifications.

Starting Procedure Safety Interlocks

Safety interlocks required for starting the engine.

Normal Starting

Steps for normally starting the machine's engine.

Pre-Operation Warm-Up

Procedures for warming up the engine and hydraulic systems.

Operation

Seat Adjustment

How to adjust the operator's seat for optimal positioning and comfort.

Seat Belt

Information on the installed seat belt and its maintenance.

Seat Belt Adjustment

How to adjust the seat belt for proper fit and function.

Operation

Machine Controls

Identification and function of various machine controls.

Key Switch

Operation of the key switch for starting and stopping the engine.

Emergency Stop Button

Function and proper use of the emergency stop button.

Machine Operation Panel

Location and purpose of the machine operation panel.

Operation

Joystick Controls

Explanation of joystick functions for machine movement and implement control.

Park Brake

How to apply and disengage the park brake.

Joystick Sensitivity

Adjusting joystick sensitivity for optimal operator control.

Operation

Heating/Cooling System

Operation and controls for the cab's HVAC system.

Operation

DP710 Main Display Panel

Overview of the main display panel and its buttons.

Hydraulic Pressures Screen

Viewing real-time hydraulic system pressures.

Operation

Rayco LCM Fault Indicator Screen

Understanding fault codes from the LCM for diagnostics.

Engine Faults Screen

Viewing and interpreting active and inactive engine faults.

Engine Data Screen

Monitoring engine data, including fuel consumption.

Operation

PARKING BRAKE (ON/OFF)

Meaning of the parking brake indicator light.

FUEL LEVEL

Meaning of the fuel level indicator light.

BATTERY CHARGE

Meaning of the battery charge indicator light.

HYDRAULIC OIL FILTER RESTRICTION

Meaning of the hydraulic oil filter restriction light.

HYDRAULIC OIL TEMPERATURE

Meaning of the hydraulic oil temperature indicator light.

HYDRAULIC OIL LEVEL

Meaning of the hydraulic oil level indicator light.

AIR FILTER RESTRICTION

Meaning of the air filter restriction light.

ENGINE COOLANT LEVEL

Meaning of the engine coolant level indicator light.

ENGINE COOLANT TEMPERATURE

Meaning of the engine coolant temperature indicator light.

ENGINE OIL PRESSURE

Meaning of the engine oil pressure indicator light.

LOW DEF (DIESEL EXHAUST FLUID) INDICATOR

Meaning of the DEF level indicator light.

Operation

While in Operation

General safety practices and procedures during machine operation.

Operating on Slopes

Safety precautions and limitations for operating on slopes.

Machine Parking

Steps for safely parking the machine.

Operation

Radio

Location and operation of the factory-installed radio system.

Operation

Winch

Details on the installed winch and its intended use.

Operation

Attaching the Mulcher

Steps for connecting the mulcher attachment to the machine.

Attaching the Hoses

Procedures for connecting hydraulic hoses to the mulcher.

Operation

Machine Tip Over

Hazards associated with tip-over and operating without attachments.

Specifications

RAYCO LUBRICATION & FLUID SPECIFICATIONS

Recommended oils, greases, and fluids for the machine.

Engine Oil

Engine oil specifications and recommendations.

Fuel - Diesel Engine

Diesel fuel specifications and usage guidelines.

Hydraulic Oil (Petroleum-Mineral Base)

Recommended hydraulic oils and their properties.

Biodegradable Hydraulic Oil

Approved biodegradable hydraulic oil options.

Specifications

Lubricating Grease

Types of grease and application guidelines.

Cold Weather Lubricants

Lubricant recommendations for cold operating temperatures.

Specifications

RAYCO COOLANT SPECIFICATIONS

Recommended coolant types and concentrations.

Coolant Maintenance

Procedures for maintaining the coolant system.

Specifications

General Torque Information

General guidelines for torque specifications.

Maintenance

NOTICE: Maintenance and Repairs

Warning that maintenance must be done by qualified personnel.

Maintenance

Service Interval:

Table detailing maintenance tasks by service interval.

Maintenance

Maintenance Log

Log for recording dates, hours, and services performed.

Maintenance

Maintenance Log

Log for recording dates, hours, and services performed.

Maintenance

Accessing the Engine Enclosure

How to access the engine compartment.

Air Cleaner - Check/Replace

Procedure for checking and replacing engine air filters.

Air Cleaner - Ejector Valve

How to clean the air cleaner ejector valve.

Maintenance

Air Cleaner for Cab Fresh Air - Clean

How to clean the fresh air filter inside the cab.

Batteries - Check

Location and checks for the machine's battery.

Clean Terminals

Steps for cleaning battery terminals.

Maintenance

Cooling System - Drain

Procedure for draining the cooling system.

Engine Coolant Level - Check

How to check the engine coolant level.

Radiator Pressure Cap - Check

How to inspect the radiator pressure cap.

Maintenance

Engine Coolant Hose & Pressure Cap - Check

Checking coolant hoses, clamps, and pressure cap.

Engine Coolant Anti-Freeze - Check

How to check engine coolant antifreeze concentration.

Engine Crankcase Breather Tube - Inspect

Inspect the engine crankcase breather tube.

Engine Injectors - Inspect

Inspect the engine injectors.

Engine Mounts - Check

Check and tighten engine mounts.

Engine Oil Level - Check

How to check the engine oil level.

Maintenance

Engine Oil & Filter - Change

Step-by-step guide to changing engine oil and filter.

Maintenance

Fuel Tank - Drain Water & Sediment

Procedure for draining water and sediment from the fuel tank.

Fuel Filter - Change

How to change the engine fuel filter.

Fuel System Water Separator - Check / Drain

Checking and draining the fuel system water separator.

Fuel System Water Separator - Change Element

When and how to change the water separator element.

Maintenance

Accessing the Hydraulic Pumps

How to access the hydraulic pumps and valves.

Hydraulic Oil Tank - Check & Fill

How to check and fill the hydraulic oil tank.

Maintenance

NOTICE

Important notices regarding hydraulic oil replacement.

Maintenance

Charge Filters

Location and procedure for changing hydraulic charge filters.

High Pressure Charge Filter

How to change the high pressure charge filter.

Maintenance

Cab Tilt Power Unit

Details on the cab tilt system.

DEF System

Information about the Diesel Exhaust Fluid system.

Control Manifold

Description of the control manifold's function.

Maintenance

Limb Riser Screens Access

How to access the limb riser screens for cleaning.

Limb Riser Screens Clean

Procedures for cleaning limb riser screens.

ROPS - Inspect

Guidelines for inspecting the Rollover Protective Structure.

Maintenance

Hydraulic Oil - Change

Steps for changing the hydraulic oil.

Hydraulics - Start Up Procedure

Procedures for starting the hydraulic system.

Maintenance

Track Adjustment

How to adjust the track tension for optimal performance.

Maintenance

Track Drive Gearbox & Sprocket Mounting Bolts - Check/Tighten

Checking and tightening drive gearbox and sprocket bolts.

Track drive oil - Check

How to check the track drive oil level.

Track drive oil - Replace

Procedure for changing the track drive oil.

Brake System - Test

How to test the machine's brake system.

Maintenance

Grease & Oil - Buildup & Replace

Cleaning accumulated grease and oil and checking for leaks.

Maintenance

Loader Lock Bar

How to use the loader lock bar.

Attachment Handle Lock

Ensuring the attachment is securely latched.

Troubleshoot

Troubleshooting - Engine Overheating

Steps to diagnose and resolve engine overheating.

Troubleshoot

When engine suddenly stops

Causes and solutions for sudden engine stops.

When color of exhaust is especially bad

Diagnosing issues based on exhaust color.

When engine overheats

Causes and solutions for engine overheating.

When engine must be stopped immediately

Troubleshooting immediate engine shutdown causes.

Troubleshoot

Electrical Information

Overview of electrical components and troubleshooting.

Engine Fuse Panel Information

Location and identification of engine fuses.

Troubleshoot

Master Electrical Switch

Function of the master electrical switch for service.

Main Power Source

Identification of the machine's main power components.

Troubleshoot

Cab Access Panel

Access panel for cab controls and power distribution.

Frame Relay and Fuse Panel

Location of frame-mounted relays and fuses.

Transducer Assembly

Information on the transducer assembly and test ports.

Troubleshoot

Transducer Assembly 39619 Rev B

Exploded view and part list for the transducer assembly.

A/C Schematic 39965 Rev A

A/C Schematic 39965 Rev A

Hydraulic Hose Schematic 806134 Rev E

Hydraulic Hose Schematic 806134 Rev E

Hydraulic Hose Adapter Kit 806134A Rev E

Hydraulic Hose Kit 806134H Rev E

Battery Cable Kit 39573 Rev A

Battery Cable Kit 39573 Rev A

Cab Wiring Harness Schematic 39568 Rev E

Cab Wiring Harness Schematic 39568 Rev E

Cab Wiring Harness Schematic 39568 Rev E

Cab Wiring Harness Schematic 39568 Rev E

Cab Wiring Harness Schematic 39568 Rev E

Cab Wiring Harness Schematic 39568 Rev E

SPLICE CIRCUITS

Splice circuit connections for the cab wiring harness.

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

Frame Wiring Harness Schematic 39569 Rev D

SPLICE CIRCUITS

Splice circuit connections for the frame wiring harness.

Upper Cab Harness Schematic 39567 Rev A

Upper Cab Harness Schematic 39567 Rev A

SPLICE CIRCUITS

Splice circuit connections for the upper cab harness.

Jumper Harness Schematic 39570

Jumper Harness Schematic 39570

Jumper Harness Schematic 39570

Jumper Harness Schematic 39570

SERVICE PARTS - SAFETY SALES KIT

RAYCO WARRANTY CERTIFICATE

RAYCO Manufacturing, Inc.

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