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Rayco RG 1635A User Manual

Rayco RG 1635A
104 pages
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RG 1635A
STUMP CUTTER
OPERATOR & PARTS MANUAL
4255 Lincoln Way East Wooster, Ohio 44691
Nationwide & Canada Phone Toll-Free: (800) 392-2686
FAX: (330) 264-3697
Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A. Index 780305 9/2000

Table of Contents

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Rayco RG 1635A Specifications

General IconGeneral
BrandRayco
ModelRG 1635A
CategoryLawn and Garden Equipment
LanguageEnglish

Summary

Foreword

About This Manual

Manual content overview including safety, operation, maintenance, and parts.

Safety Section Overview

Covers basic safety precautions and warning labels.

Operation Section Overview

Details machine controls, operation, and towing.

Maintenance Section Overview

Guide to equipment care with step-by-step instructions.

Troubleshooting Section Overview

Problem diagnosis and solutions for hydraulic and electrical systems.

Parts Section Overview

Information on identifying and ordering parts.

Machine Description

Design and Features

Durable construction, 35 HP engine, 23" cutting wheel, maneuverability.

How it Works

Stump removal process using a high-speed cutting wheel.

Serial Numbers

Location for recording machine and engine serial numbers.

Safety

Safety Alert Symbol

Explains the universal safety alert symbol and its meaning.

General Hazard Information

Pressure Air Hazards

Risks of using compressed air for cleaning.

Fluid Penetration Risks

Dangers of pressurized fluid leaks.

Crushing and Cutting Prevention

Safety measures to avoid mechanical injury.

Burn and Explosion Prevention

Flammable Materials Safety

Safe handling and storage of fuels and lubricants.

Starting Fluid Hazards

Risks associated with improper use of starting fluid.

Essential Safety Information

Oils and Battery Acid Safety

Precautions for handling hot oils and battery acid.

Lines, Tubes, and Hoses Safety

Safe handling of hydraulic and fuel lines.

Before Starting the Engine Safety

Pre-operation checks and safety considerations.

Operational Safety Procedures

Danger Zone Awareness

Ensuring personnel avoid hazardous operational areas.

Machine Modifications and Controls

Avoiding unauthorized changes and setting controls correctly.

Towing Vehicle and Machine Stability

Ensuring safe towing and machine stability.

Pre-Operation Safety Checks

Verifying machine readiness and identifying site hazards.

Safe Operation Practices

Emergency Shutdown Procedures

How to stop the machine quickly in emergencies.

Operator Precautions During Operation

Rules for safe operator conduct and positioning.

Slope Operation Safety

Guidelines for safe stump cutting on inclines.

Cutting Wheel Usage Guidelines

Proper techniques for effective and safe cutting.

Shutdown and Maintenance Preparation

Normal Shutdown Procedure

Step-by-step process for stopping the machine normally.

Emergency Shutdown Procedure

Steps to take for an immediate engine shutdown.

Machine Securing for Maintenance

Methods to stabilize the machine before servicing.

Transporting and Decal Care

Transporting the Machine Procedures

Steps for safely hitching and transporting the stump cutter.

Safety Decals

Importance of decals and their maintenance.

Operation Overview

Operator's Station Layout

Identification of controls and their location.

Machine Controls Functionality

Explanation of how to operate the machine's controls.

Machine Components and Controls

Cutting Wheel Drive Control

Engaging and disengaging the cutting wheel.

Engine Speed Control

Adjusting engine RPM for operation.

Machine Transport Procedures

Checklist for Transporting Machine

Steps to prepare the machine for towing.

Engine Starting Procedures

Pre-Starting Inspection Steps

Essential checks before starting the engine.

Engine Starting Steps

How to safely start the stump cutter's engine.

Starting with Jumper Cables

Jumper Cable Procedure

Step-by-step guide for jump-starting.

Pre-Operation Warm-up

Warm-up Steps

Procedures to warm the engine and hydraulic oil.

Stump Removal Process

Work Area Preparation

Preparing the site for safe stump removal.

Cutting Wheel Safety Warnings

Critical safety points for using the cutting wheel.

Procedure for Cutting a Stump

Detailed steps for removing a stump.

Stump Cutting Procedure Details

Removing Roots

Method for cutting and removing stump roots.

Cutting Stump Proper

Technique for cutting the main stump body.

Repeating the Cutting Process

How to continue cutting until desired depth.

Machine Stopping and Operating Tips

Normal Stopping Procedure

Steps to safely shut down the machine.

Engine Stopping Procedure

How to turn off the engine.

General Operation Tips

Advice for efficient and safe stump cutting.

Operating Tips Continuation

Sideways Machine Movement Technique

How to move the machine laterally.

Cold Weather Operation Tips

Adjustments for operating in cold temperatures.

Maintenance - System Fluids

Systems Fluids Specifications

Details on engine oil, fuel, and hydraulic oil.

Engine Oil and Fuel Information

Location and type of engine fluids.

Hydraulic Oil Information

Type and selection of hydraulic oil.

Maintenance - Fluids and Belts

Lubricating Grease Procedures

How and where to lubricate.

Fluids Refill Capacities

Quantities of fluids for different systems.

Drive Belts Information

Types of belts and their function.

Belt Tension Notice

Importance of correct belt tension.

Storing the Machine

Preparing the Machine for Storage

Steps for long-term storage.

Maintenance Intervals

Required Maintenance Intervals

Schedule for tasks based on usage.

10 Hour or Daily Intervals

Routine checks and lubrication.

50 Hour Intervals

Tasks at 50-hour intervals.

125 Hour Intervals

Tasks at 125-hour intervals.

250 Hour or 1 Year Intervals

Tasks at 250 hours or 1 year.

500 Hour or 1 Year Intervals

Tasks at 500 hours or 1 year.

3 Month or 3,000 Mile Intervals

Trailer wheel and tire checks.

1 Year or 12,000 Mile Intervals

Wheel bearing and spindle checks.

Maintenance Interval Guidelines

Maintenance Schedule Guidelines

How to interpret the interval schedule.

Usage Considerations for Intervals

Adjusting intervals based on conditions.

Required Maintenance Tasks

Fuel Tank Filling Procedure

How to fill the fuel tank.

Grease and Oil Buildup Removal

Cleaning procedures.

Cutting Wheel Inspection

Checking the cutting wheel for wear.

Changing Cutting Wheel Teeth

Tooth Replacement Procedure

Steps for replacing cutting teeth.

Cutting Wheel Teeth Positioning

SuperTeeth Location Guidelines

Proper placement of SuperTeeth.

Sharpening Cutting Wheel Teeth

Tooth Sharpening Guidelines

How to sharpen teeth correctly.

Daily Maintenance Checks

Engine Oil Level Check

Ensuring proper engine oil level.

Engine Air Cleaner Check

Inspecting the air cleaner.

Hydraulic Oil Level Check

Ensuring proper hydraulic oil level.

Component Lubrication and Checks

Lubricating Fittings

Greasing key points.

Refilling Hydraulic Oil Tank

Adding hydraulic fluid.

Walk-Around Inspection

General machine check before operation.

Periodic Maintenance (After 50 Hours)

Hydraulic Oil Filter Change

Replacing the hydraulic oil filter.

Engine Mountings Check

Verifying engine mounting integrity.

Engine Belt Drives Check and Adjust

Inspecting and adjusting engine belts.

50 Hour Service Intervals

Pivot Head Lubrication

Greasing pivot points.

50 Hour Service Intervals Continued

Cutting Boom Swing Pivot Lubrication

Greasing the boom pivot.

Slide Blocks Lubrication

Greasing engine slide mechanism.

Air Filter Element Cleaning

Cleaning the air filter.

Belt Tension Checks

Cutting Wheel Poly Chain Belt Tension

How to check and adjust poly chain belt.

Belt Tension Adjustment

Procedure for adjusting belt tension.

Belt Tension Checks Continued

Jackshaft V-Belts Tension Check

How to check and adjust V-belts.

V-Belt Tension Adjustment

Procedure for adjusting V-belt tension.

125 Hour Service Intervals

Battery Check and Terminal Cleaning

Inspecting and cleaning battery terminals.

Adjusting Electrolyte Level

Maintaining battery electrolyte.

125 Hour Service Intervals Continued

Telescoping Tongue Lubrication

Greasing the tongue tube.

Hitch Lubrication

Oiling hitch pivot points.

Swing Pivot Inspection

Checking swing pivot components.

250 Hour Service Intervals

Hydraulic Oil Filter Change

Replacing the hydraulic oil filter.

Engine Component Checks

Checking compression, spark plugs, fuel filter, etc.

500 Hour Service Intervals

Engine Belt Drives Check and Adjust

Inspecting and adjusting engine belts.

Fluid Management Procedures

Drain Fuel Tank Water Condensation

Removing water from the fuel tank.

Changing Hydraulic Oil

Process for changing hydraulic oil.

Hydraulic and Trailer Maintenance

Hydraulic Circuit Bleeding

Removing air from the hydraulic system.

Clutch and Gear Housing Oil Change

Following engine manual for oil change.

Trailer Wheel Nut and Bolt Tightening

Securing trailer wheel fasteners.

Trailer Tire Condition Inspection

Checking tire wear and condition.

Wheel Bearing Maintenance

Trailer Wheel Bearings Cleaning and Repacking

Procedure for cleaning and repacking bearings.

Remove Hub Assembly

Steps to remove the wheel hub.

Bearing Inspection

Checking bearings for wear or damage.

Replacing Bearing Cups

Procedure for replacing bearing cups.

Wheel Bearing Maintenance Continued

Bearing Lubrication Procedures

Greasing bearing cones.

Seal Inspection and Replacement

Checking and replacing bearing seals.

Bearing Adjustment and Hub Replacement

Adjusting wheel bearing preload.

Wheel Spindle Inspection

Trailer Wheel Spindles Weld Inspection

Checking welds on wheel spindles.

Trouble-Shooting - Hydraulic System

Hydraulic System Description

Overview of the hydraulic system components.

Hydraulic Circuits Overview

Explanation of hydraulic circuit diagrams.

Pilot Check Valves Function

Role of pilot check valves in boom control.

Hydraulic System Symptoms

Loss of Hydraulic Cylinder Power

Causes and solutions for weak cylinder power.

Cutting Wheel Travel Weakness

Reasons for weak cutting wheel movement.

Hydraulic System Solutions

Adjusting Integral Relief Valve

Procedure for setting system pressure.

Cleaning Integral Relief Valve

Steps to clean the relief valve.

Boom Movement Symptoms

Cutting Boom Moves Downward Too Fast

Causes and solutions for fast boom descent.

Boom Control Troubleshooting

Cutting Boom Swings Sideways Uncontrolled

Diagnosing and fixing uncontrolled boom swing.

System Troubleshooting

Engine System Issues

Refer to engine manual for troubleshooting.

Trailer Wheels Issues

Refer to trailer manual for troubleshooting.

Electrical System Issues

Troubleshooting electrical system problems.

Parts Information

Ordering Replacement Parts

How to obtain replacement parts.

Master Parts Index

Reference to part numbers and locations.

Decal Kit Information

Decal List and Information

Details on the decal kit.

Safety Decals Overview

General Safety Warnings

Common safety labels on the machine.

Operational Safety Warnings

Safety labels related to machine operation.

Safety Decals Continued

Machine Operation Safety Labels

Labels for operation and refueling safety.

Maintenance Safety Labels

Labels related to maintenance precautions.

Branding and Control Labels

RAYCO Branding and Identification

Manufacturer logos and model information.

Control Labels

Labels for machine controls.

Parts Diagrams

Chassis & Boom Assembly Diagram

Exploded view of chassis and boom parts.

Inner Tongue Assembly Diagram

Exploded view of inner tongue parts.

Wheel Assembly Diagram

Exploded view of wheel assembly parts.

Cutting Wheel Drive System Diagram

Exploded view of drive system parts.

Belt Guards Diagram

Exploded view of belt guard parts.

Chip Guards Diagram

Exploded view of chip guard parts.

Engine System Diagram (Sheet 1 of 2)

Exploded view of engine system parts.

Engine System Diagram (Sheet 2 of 2)

Exploded view of engine system parts.

Chip Containment System Diagram

Exploded view of chip containment system parts.

Hydraulic System Diagram (Sheet 1 of 4)

Exploded view of hydraulic system parts.

Hydraulic System Diagram (Sheet 2 of 4)

Exploded view of hydraulic system parts.

Hydraulic System Diagram (Sheet 3 of 4)

Exploded view of hydraulic system parts.

Hydraulic System Diagram (Sheet 4 of 4)

Exploded view of hydraulic system parts.

Hydraulic Systems Part List

List of parts for hydraulic systems.

Hydraulic Circuits Schematic

Schematic of hydraulic circuits.

Fuel Tank Diagram

Exploded view of fuel tank components.

Electrical System Schematic

Schematic of the electrical system.

Specifications

General Machine Specifications

Physical dimensions and weight.

Engine Specifications

Engine model, power, and displacement.

Hydraulic System Specifications

Details on pumps, cylinders, and pressure.

Cutting Wheel Specifications

Details on wheel diameter, speed, and teeth.

Cutting Range Specifications

Cutting depth and width capabilities.

Optional Features

Lists optional features like spark-arresting muffler.

Product Warranty

Warranty Terms and Exclusions

Coverage, limitations, and what is not covered.

Warranty Claims and Remedies

Procedures for making claims and available remedies.

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