Rayco RC6D, Operation Manual

Page 1: ...pantone 485 www raycomfg com RC6D 25 35hp Wood Chipper Operation Manual 800 610 4101 ActionRental com ...

Page 2: ...o operate this machine This manual should be readily available for reference at all times Additional copies of this manual may be purchased from Rayco This Rayco machine was designed and manufactured by Rayco Manufacturing Inc Wooster Ohio Due to continuous improvements Rayco reserves the right to make changes in engineering design and specifications or discontinue manufacture at any time without ...

Page 3: ... for Reducing Vibration Levels 18 Guards Operator Protection 18 Roll Over Protection 19 Other Guards 19 Precautions for Welding with ECU 19 Safety Decals 19 Lock Out Tag Out Guidelines 20 Pre Transportation Checks 21 Important Towing Information 21 Loading Your Combination 21 Slow Down When Towing 21 Before Towing and on the Road 22 Your Tow Vehicle 22 Towing Equipment Requirements 22 Tire Pressur...

Page 4: ...ying 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 Operation The operation section is a reference for the new operator and a refresher for the experienced operator This section includes a discussion of gauges switches machine controls...

Page 5: ...ute allowing a more consistent pile formation The discharge chute can be rotated 360 degrees and locked at every 7 5 degree increment as well as elevated or lowered for improved byproduct manage ment The chute also has an adjustable locking deflector at the end of the discharge chute to provide just the right amount of deflection angle you need The In Feed Chute can accommodate material up to 6 in...

Page 6: ...welry that can snag on controls or on other parts of the equip ment Make sure that all protective guards and all cov ers are secured in place on the equipment Keep the equipment free from foreign material Remove debris oil tools and other items from the deck from walkways and from steps Secure all loose items such as lunch boxes tools and other items that are not a part of the equipment Know the a...

Page 7: ...ntly hazardous situation which if not avoided could result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided will result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury A message either written or pictorial follows to explain the hazard Rayco cannot anticipat...

Page 8: ...for this product Rayco recommends using Rayco replacement parts or parts with equivalent speci fications including but not limited to physical dimensions type strength and material Failure to heed this warning can lead to pre mature failures product damage personal injury of death General Hazard Information Read understand and follow all instructions on the machine and in the manuals before attemp...

Page 9: ...aught or entangled in material or machine must be worn Flying Debris Do not allow anyone to stand in front or directly behind the machine Flying debris could be thrown past guards and injure bystanders if they are in these areas Pressurized Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury When pressurized air and or p...

Page 10: ...in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are several guidelines that should be fol lowed Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a wet...

Page 11: ... can fly out The loose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin If equipment is unhitched from the tow vehicle for operation always block the wheels and support the tongue weight with blocking to prevent unin tended movement Do not use only the jack...

Page 12: ...sion Prevention All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage Remove all flammable materials such as fuel oil and debris from the machine Do not allow any flammable materials to accumulate on the machine Serious persona...

Page 13: ...the ma chine is equipped with a thermal starting aid for cold weather starting Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Repair any lines that are loose or damaged Leaks can cause fires Consult your Rayco dealer for repair or for replacement parts Check lines tubes and hoses carefully Do not use your ba...

Page 14: ... hand to operate the controls Never use a foot knee rope or any extension device Never hand feed this machine for any reason Contact with moving parts belts or rotating cutter wheels can kill injure or dismember Turn off engine and wait for all movement to stop before working on this machine Lock out Tag Out all controls If equipped the Emergency Stop buttons must be operating properly These shoul...

Page 15: ...he 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 Your machine may be equipped with visual aids Some examples of visual aids are Closed Circuit Television and mirrors Before operat ing the machine ensure that the visual aids are in proper working condition and that the visua...

Page 16: ... If the machine begins to sideslip downward on a grade immediately remove the load and turn the machine downhill Avoid any conditions that can lead to tipping the machine The machine can tip when you work on hills on banks and on slopes Also the machine can tip when you cross ditches ridges or other unexpected obstacles Avoid operating the machine across the slope When possible operate the machine...

Page 17: ...erfor mance features of the equipment in operation and the effects on machine stability Operating techniques Keep all attachments or pulled loads low to the ground for optimum stability Machine systems have limitations on slopes Slopes can affect the proper function and operation of the various machine systems These machine systems are needed for machine control on slopes Note Safe operation on st...

Page 18: ...condition a Remove any large rocks or obstacles b Fill any ditches and holes c Provide machines and schedule time in order to maintain the conditions of the terrain 4 Use a seat that meets ISO 7096 Keep the seat maintained and adjusted a Adjust the seat and suspension for the weight and the size of the operator b Inspect and maintain the seat suspension and adjustment mechanisms 5 Perform the foll...

Page 19: ...erator into an unprotected environment Modifica tions or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment Excessive weight may inhibit the brake performance the steering performance and the ROPS The protection that is offered by the ROPS FOPS Structure will be impaired if the ROPS FOPS Structu...

Page 20: ... tested and verified that the lockout does prevent the release of energy Tag Out Procedure a This procedure is to be used only if it is not reasonable to use the lockout procedure b All affected persons are to be notified that the equipment will be shut off and tagged out c All energy sources for the equipment should be identified d The equipment shall be shut off or otherwise de energized being c...

Page 21: ...o SIDE MOTION SWAY THAT BEGINS as you reach a certain speed will likely become WHIPPING at higher speeds If you notice sway beginning SLOW DOWN IMMEDIATELY by letting off the gas pedal Then stop to reload the vehicle in tow heaviest end forward as soon as possible and remove any cargo from the vehicle in tow vehicle carried on trailer IF WHIPPING or SWAY OCCURS DO NOT steer DO NOT apply your brake...

Page 22: ...er Have an authorized repair facility inspect and repair your vehicle BEFORE towing To find the capabilities of the engine transmis sion and axles of your vehicle for towing refer to the owner s manual or check with an authorized dealer TOWING EQUIPMENT REQUIREMENTS Hitches must be able to tow the weight of your trailer and your vehicle in tow When towing a trailer all lights must be op erational ...

Page 23: ...LIGHTING CONNECTIONS Make sure all tow vehicle and trailer lights func tion properly The connecting wires need slack to allow your tow vehicle to make turns Do not allow wires to drag on the roadway LOADING Load the heaviest end engine end of the ve hicle in tow to the FRONT of the trailer Failure to load facing forward may result in sway or WHIP PING and lead to total loss of control DO NOT load ...

Page 24: ...chute The housing that contains the point of operation chipper disc is sectioned and includes a removable hood to allow access to the components for mainte nance and repair Many chippers are equipped with a mechanical feed control bar that activates the feed rollers when it is pulled The bar is mounted across the top and along the sides of the infeed chute for quick and easy access The American Na...

Page 25: ...t the front of the infeed chute may reduce both caught in and struck by accidents The curtains serve as physical warnings to operators to keep their hands away from the infeed chute They also prevent objects from kicking back and striking employees stand ing nearby Discharge Spout Deflector Guard This device reduces the risk of being struck by flying debris It redi rects the discharge of wood chip...

Page 26: ...chippers in accordance with the manufacturer s specifications Employers should inspect and test the chipper at the start of each workshift to ensure that all parts and safety devices are functioning properly This should include looking for broken parts cracks worn hinges and missing parts and pins Before beginning any servicing operation lockout tagout procedures must be utilized to control hazard...

Page 27: ...d rollers can be operated The interlock system will also prevent the winch line from accidentally being pulled into the chipper Recommendations for Use of Chippers with a Winch Assembly Employers should ensure that employees follow all safe work practices for the operation of the winch Employers who own chippers with winch lines should contact their equipment supplier to investigate the ap plicati...

Page 28: ...el Hydraulic operated 7 Discharge Chute 360 degree rotation and lock 8 Feed Wheel Control Bar Forward Stop Reverse 9 Chute Deflector 10 Cutter Wheel Disc 11 Hydraulic tank 12 Fuel Tank 13 Toolbox Fusebox 14 Operators Manual Case 15 Adjustable Jackstand w Caster 16 Adjustable Hitch height only 4 14 8 9 15 2 3 12 11 Engine 1 Choke Lever 2 Start key switch 3 Throttle Lever 4 Engine Oil Level Dipstick...

Page 29: ...each of the 10 Service Hours or Daily see Maintenance Intervals section maintenance inspections and services as required before operating the machine Starting the Engine Read and understand the Safety section of this manual in its entirety before proceeding IMPORTANT DO NOT operate the engine when the oil level is below the ADD mark on the engine dipstick Check the oil level before starting the en...

Page 30: ...DISCHARGED BACKWARD TOWARDS YOU Always stand to the side of the feed chute when feeding material into the feed wheel roller Use a wooden push tool to move short mate rial into the feed wheel Contact with the rotating feed wheel and cutter disk can kill or dismember place the feed control bar in neutral stop the engine and wait for all movement to stop before working around the feed wheel When the ...

Page 31: ...nger vehicles that are following you 6 Make sure the discharge chute is over the chipper for towing Use the manual crank or hydraulic power rotation to position Use the height adjustment handle to return the discharge chute back to the lowest height for towing don t take any chances with overhead obstructions hitting the discharge chute 7 Use extreme caution and drive slowly over terrain that is r...

Page 32: ... must be trained in the operation safety and maintenance repair procedures Careless use of this chipper could result in serious injury or even death ALL PROCEDURES IN THE SAFETY AND OPERATION SECTIONS OF THIS MANUAL MUST BE READ AND UNDERSTOOD BE FORE STARTING THIS MACHINE All operators must be wearing the proper Personal Protective Equipment before attempt ing to start and operate this machine Se...

Page 33: ... and stops at intervals without warning Never approach the material once it has become engaged by the feed rollers In the event the material will not advance in a reasonable amount of time reverse the material completely with the feed control bar and start the material again Insure the throttle is completely advanced for proper operation of the Versa Feed system During chipping operations never po...

Page 34: ...running Use another piece of wood to move short pieces of wood into the feed wheel or lay shorter pieces on top of longer pieces Chipped material may accumulate in the hopper When this happens push this small material into the machine with a long limb Never try to push material through with your hand foot rake shovel or any other object If any wood debris becomes lodged in the chip per intake area...

Page 35: ...eels Use the jack to support the tongue If possible store the machine in a dry protected place If stored outside cover with weatherproof material Clean all mud dirt grease and other foreign material from the machine To inhibit rusting re paint areas where the paint has been worn Repair or replace any worn or damaged parts and decals Refer to the parts manual for ordering replacements Refer to the ...

Page 36: ... purge flammable fumes 5 Remove all of the battery caps from the bat teries if not maintenance free type on both ma chines allowing explosive vapors to dispense 6 Connect jumper cables a Connect the red positive jumper cable to the positive terminal of the starter solenoid of the stalled machine where the battery red posi tive cable is already connected Pull back the rubber boot to gain access Do ...

Page 37: ...lubricating components may also be specified in the Maintenance Section SAE Metric Bolt Torque Requirements SAE Grade 8 Torque Dry or Loctite 1 4 12 2 lb ft 5 16 26 2 lb ft 3 8 46 2 lb ft 7 16 75 5 lb ft 1 2 115 5 lb ft 9 16 160 5 lb ft 5 8 225 10 lb ft 3 4 400 20 lb ft 7 8 650 25 lb ft 1 975 25 lb ft 1 1 8 1350 25 lb ft 1 1 4 1950 25 lb ft 1 3 8 2550 25 lb ft 1 1 2 3350 50 lb ft Metric Class 10 9...

Page 38: ...ster Base vg46 is the only approved Bio Degradable hydraulic oil for this machine All mineral base oils must be completely drained out of system and components before refilling with panolin hlp Synthetic vg46 Bio degradable oil panolin hlp Synthetic Ester vg46 Viscosity 8 1 cSt 100 C 47 cSt 40 C Pour Point 57 C 70 F Track Drive Oil The track drives should be filled with a Synthetic 75w 90 heavy du...

Page 39: ...ce hours to the record you will be properly informed to the maintenance requirements as time passes The maintenance intervals listed in this Maintenance Intervals section of this Chipper Operator Manual in cludes engine care topics For the complete information consult the Engine Operator Manual Rayco has attempted to accurately predict maintenance intervals for this machine However due to varying ...

Page 40: ...If leaking is observed find the source and correct the leak Check the fluid levels more frequently than the recom mend ed periods if leaking is suspected or ob served until the problem may be corrected Walk around Inspection Shields and guards Check that all shields and guards are installed and are fastened securely to the machine Replace or repair and shields or guards that are damaged or have mi...

Page 41: ...maged tongue tube could result in serious injury or death if the tube fails while in transport Wheels Be sure to use the fasteners matched to the cone angle of your wheel 60 degrees The proper procedure for attaching your wheels is as follows 1 Start all bolts by hand to prevent cross threading 2 Tighten bolts in the sequence shown for Wheel Torque Requirements Torque 75 lbs ft 101 N m 3 Wheel nut...

Page 42: ... dipstick or 1 to 2 1 2 from the top of the reservoir Add oil if it is below the level indicated Check the oil level only when the engine is cold and with the machine on level ground Re fill the hydraulic oil tank 1 Clean all surrounding debris and dirt off of the tank fill opening area Hydraulic fluid must be kept completely clean 2 Unscrew the filter cap and pull out the filter 3 Fill the tank u...

Page 43: ...oid death or serious injury Stay clear of belts and cutting discs when they are moving The Hydraulic pump is driven by two matched V belts via the engine shaft The cutting disc is driven by a V belt via the engine shaft Notice To extend belt life proper tension must be maintained A loose belt will cause ex ces sive cutting disc slippage and belt failure A belt that is too tight can cause jackshaft...

Page 44: ... they are too loose repeat step 4 and check again until it is properly set 6 Replace the belt guard cover Cutter Disc V Belt Check Tension The machine must be shut down when checking and adjusting belt tension The cutter disc V belt pressure can be adjusted by turning the threaded rod in the idler assembly This causes the idler to exert more or less pressure on the V belt 1 With the idler disengag...

Page 45: ...ffected Before attempting any maintenance on the cutter disc place the feed control bar in neutral shut off the engine and remove the ignition key and place it in safekeeping Wait for the chipper cutter disc to stop before opening the access covers IMPORTANT Swing the discharge chute over the tongue before removing the access cover bolts If the chute is turned out over the left side of the machine...

Page 46: ...When turning flipping or replacing a bed knife all surfaces should be cleaned of debris and inspected for deformities If this inspection cleaning is not performed knife bed bolts could loosen leading to catastrophic damage Bed Knife Replace Insert the lock pin through the cutter housing into the hole in the cutter disk and through the hole in the other side of the housing This will keep the disk f...

Page 47: ... until the bed knife gauge and knives are slightly pressed together The gap between the bed knife and the disc knives should be 074 Repeat for the second knife 5 Snug the 5 8 bolts securing the bed knife 6 Remove the gauge 7 Torque the 5 8 bolts securing the bed knife to 110 foot pounds 150 Nm 8 Using a flashlight check the approximate clearance between the disc knives and the bed knife 9 Slowly a...

Page 48: ...illed water as needed 4 Replace both caps Clean the Terminals 1 Raise the access cover 2 Remove the black negative cable 3 Clean the terminal and clamp of any oxidation buildup with a stiff wire brush Stroke the brush away from your body to avoid hazardous particles 4 Apply a light coat of petroleum jelly around the base of the terminal 5 Replace the cable 6 Repeat the same procedure for the red p...

Page 49: ...f all hydraulic components clean as they are installed The machine must not be operated without the fil ter in place or severe dam age to the major hy drau lic components will likely occur The suction filter is a spin on type filter located on the left side of the machine behind the cutter disc housing and directly below the feed wheel motor It is used to filter out oil prior to entering into the ...

Page 50: ... pump control valve cir cuit 5 Cycle the self propel drive lever two or three times to purge all remaining trapped air from the self propel motor circuit The hydraulic motor is now ready for operation 6 Now the hydraulic cylinders circuits may be prepared Run the engine at normal operating speed Using the cutting boom motion lever slowly then at normal operating speed cycle the cylinders through a...

Page 51: ... 4 6400 8 8 CONNECTOR 8MJIC X 8MOR 11 1 4501 12 08 ELBOW 90 DEG 12 BEADED X 8MNPT 12 1 4601 12 12 ELBOW 90 DEG 12 BEADED X 12MOR 13 2 6801 8 8 ELBOW 90 DEG 8MJIC X 8MOR 14 1 4501 12 12 ELBOW 90 DEG 12 BEADED X 12MNPT 15 2 6802 8 10 ELBOW 45 DEG 8MJIC X 10MOR 16 1 139 44 1 4 MALE BARB TO 1 4 MNPT 17 1 4503 12 12 ELBOW 45 DEG 12 BEADED X 12MNPT HYDRAULIC HOSE KIT 801856H Shown as SQUARES on schemati...

Page 52: ...TIFIER DIODE P 12 PIN DEUTSCH PLUG DTMO6 12SB OR EQ W SOCKETS R 2 PIN WEATHER PACK PLUG 12015792 W FEMALE TERMINAL SEAL S 2 PIN WEATHER PACK SOCKET 12010973 W MALE TERMINAL SEAL T 4 PIN WEATHER PACK PLUG 12015797 W FEMALE TERMINAL SEAL U 4 PIN WEATHER PACK SOCKET 12010974 W SEALING PLUGS IN ALL CAVITIES FROM TO PLUG PIN WIRE DESCRIP TION GA COLOR PLUG PIN 01 1 IGNITION SWITCH 16 WHT 07 01 2 FWD FE...

Page 53: ...ACK SOCKET 12010974 W SEALING PLUGS IN ALL CAVITIES T 2 PIN WEATHER PACK PLUG 12015792 W FEMALE TERMINAL SEAL U 2 PIN WEATHER PACK PLUG 12015792 W SEALING PLUGS IN ALL CAVITIES NOTE 1 ALL CONNECTORS SHOWN FROM WIRE INSERTION END 2 120 ohm RESISTOR CONNECTED BETWEEN THE CAN HIGH AND CAN LOW WIRES FROM TO PLUG PIN WIRE DESCRIPTION GA COLOR PLUG PIN 01 1 IGNITION SWITCH 16 WHT 12 A 01 2 FWD FEED SW 1...

Page 54: ...stem Use correct fuel Remove fuel clean tank and replace Remove air from fuel system Drive System Troubleshooting PROBLEM CAUSE SOLUTION Engine stalls when chipping Feed rate too high Manual Feed Slow down feed roller Autofeed See your Rayco dealer Discharging shredded material Knives are dull Replace or sharpen knives Feed material wants to work backward towards operator Knives are dull Replace o...

Page 55: ...before trying to start engine Check main breaker and reset if needed Lack of engine power Wrong fuel Dirt or water in fuel system Air in fuel system Fuel filter is dirty Wrong weight engine oil Restricted air filter Injectors dirty Low engine compression Engine is too hot Use correct fuel Remove fuel clean tank and replace Remove air from fuel system Replace fuel filter Use correct oil Clean or re...

Page 56: ...rator Ear Sound Pressure db A ambient na dB Low Idle na dB High Idle na dB High Idle Cutting na dB Operator Controls Vibration meter sec2 RMS Low Idle na RMS High Idle na RMS High Idle Cutting na RC6D 25 Specifications General Length 103 5 262 9 cm 127 5 323 9 cm Height 93 236 2 cm Width 63 160 cm Weight na lbs na kg Engine Options Make Model Kohler CH730 3237 Gross HP 25 hp 18 6 kw Type of fuel G...

Page 57: ...gine Oil Filter 750117 35hp Engine Oil Filter 750200 Hydraulic Suction Filter 738018 Hydraulic Oil Return Filter 761906 Element 761908 Dipstick 761910 Indicator 761909 25hp Kohler Fuel Filter 750241 35hp Vanguard Fuel Filter 763494 Fuel Cap 760780 25 hp Kohler Air Cleaner Assembly 780269 Outer Cartridge 780270 Inner Cartridge 761397 35 hp Vanguard Air Cleaner Assembly 749999 Outer Cartridge 780270...

Page 58: ...omponents A Beltswillbecoveredunderwarranty only if Rayco receives warranty from their supplier B Sprockets Sheaves have a six month limited warranty C Electric clutches have a six month limited warranty D Hydraulic Cylinders will be covered under warranty only if Rayco receives warranty from their supplier 5 Pockets and Teeth Pockets and Teeth will be covered under warranty only if they are defec...

Page 59: ...loss of profits rental of substitute equipment or other commercial loss H No Dealer Warranty The selling dealer makes no warranty of his own on any item warranted by Rayco and makes no warranty on other items unless he delivers to the purchaser a separate written warranty certificate specially warranting the item A dealer has no authority to make any representation to promise on behalf of Rayco or...

Page 60: ... under the influence of alcohol or drugs Know your RAYCO read and understand your owner s manual cover to cover RAYCO Manufacturing Inc is recognized as the industry leader in environmental equipment Since 1978 RAYCO has continued to Set the Industry Standard with new and innovative features and designs Engineering is done in house by our highly trained staff of professionals using cutting edge te...