Rayco RG 1635A Programming manual

RG 1635A
STUMP CUTTER
OPERATOR & PARTS MANUAL
4255 Lincoln Way East • Wooster, Ohio 44691
Nationwide & Canada Phone Toll-Free: [phone]
FAX: [phone]
Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A. Index 780305 9/2000

CALIFORNIA
Proposition 65Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.
This Manual is published by Rayco Manufacturing, Inc. for the benefit of the users of Rayco products. RAYCO
Manufacturing, Inc. has made every effort to ensure that this manual is correct and up to date at the time of
publication. However, due to continuous improvements, Rayco Manufacturing, Inc. reserves the right to make
changes in the contents, at any time, without notice or obligation.
Each machine shipped contains an Operation Maintenance & Parts Manual to familiarize the operator with the
proper operating, lubricating, and maintenance instructions. This helps to ensure the best possible performance
and service from the machine. 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
from Rayco.
This Rayco Stump Cutter 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 notice or obligation.
Always have a record of the model numbers and serial numbers for your machine to specify when ordering parts.
Record your machine model and serial numbers below for your personal records.
IDENTIFICATION NUMBERS
Model Number Serial Number
Stump Cutter
Engine

Maintenance
Systems Fluids Specifications
Engine Oil, Engine Fuel ................................ 25
Hydraulic Oil ................................................. 25
Lubricating Grease........................................ 26
Fluids Refill Capacities (Approximate)........... 26
Drive Belts........................................................... 26
Storing the Machine
Preparing the Machine for Storage ................ 27
Removing the Machine from Storage ............. 27
Maintenance Intervals ...................................... 28
Trouble-Shooting
Hydraulic System
Description of Hydraulic System .................. 50
HC ( Hydraulic Cylinders ) Circuits ......... 51
Symptom - Loss of Hydraulic
Cylinder power........................................ 52
Symptom - Cutting Wheel Travel Weak ........ 52
Symptom - Cutting Boom Moves
Downward Too Fast .................................. 53
Symptom - Cutting Boom Swings
Sideways Uncontrolled ............................ 54
Engine System ...................................................55
Trailer Wheels ..................................................... 55
Electrical System................................................ 55
Symptom - Battery not getting recharged .... 55
Parts .................................................... 56
Specifications ................................... 100
Foreword
About This Manual ................................................ 5
A Description of the Machine
Design ............................................................ 6
How it works ................................................... 6
Serial Number ................................................. 6
Safety
General Hazard Information ................................... 8
Pressure Air ................................................... 8
Fluid Penetration ............................................ 8
Crushing, Cutting Prevention ................................. 8
Burn, Explosion Prevention ................................... 9
Oils............................................................... 10
Batteries .......................................................10
Lines, Tubes, and Hoses .............................. 10
Before Starting the Engine .................................. 10
While in Operation ..............................................12
Normal Shutdown Procedure ............................... 13
Emergency Shutdown Procedure ........................ 13
While Servicing and Performing
Maintenance on the Machine ............................. 13
While Transporting the Machine .......................... 14
Safety Decals ..................................................... 14
Operation
Know Your Machine
General Identification .................................... 15
Operator's Station ......................................... 15
Monitoring System........................................ 15
Machine Controls .......................................... 15
Other Machine Components ......................... 16
Transporting the Machine .................................... 17
Pre - Starting Inspection ...................................... 18
Starting the Engine .............................................18
Starting Without Heating Plug ....................... 18
Starting with Jumper Cables ......................... 19
Pre-operation Warm up ....................................... 20
Removing Stumps ............................................... 21
Machine Stopping ............................................... 23
Helpful Tips for Operating the Machine ................ 23
RAYCO ®
Table of
Contents
RG 1635A STUMP CUTTER

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
4

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
5
RAYCO ®RG 1635A STUMP CUTTER
Foreword
About This Manual
This manual contains safety, operating, lubrication,
maintenance, troubleshooting, and parts information.
Read - study - keep it with the machine - adhere to all
of the recommendations.
NOTICE
Where the engine is concerned, this manual
makes frequent reference to the Wisconsin [En-
gine] Operation Manual, which was packed in
your operators kit. Keep it, therefore, with this
RG 1635A STUMP CUTTER Operation,
Maintenance, & Parts Manual so that it may be
readily used.
Where the trailer wheels are concerned, this
manual makes frequent reference to the Trailer
Running Gear - Operation Maintenance Service
manual, which was packed in your operators kit.
Keep it, therefore, with this RG 1635A STUMP
CUTTER Operation, Maintenance, & Parts Manual
so that it may be readily used.
Guards and covers may have been removed for
illustrative purposes. Some photographs or illustra-
tions in this publication show details or attachments
that may be different from your machine. Continuing
improvement and advancement of product design
may have caused changes to your machine which are
not included in this publication.
Whenever a question arises regarding your machine,
or this publication, please consult your RAYCO ® dealer
or RAYCO ® for the latest available information.
NOTICE
When the NOTICE heading appears in this publi-
cation, what follows is either a clarification or in-
formation that will assist you in avoiding damage
to the machine or property.
Safety
The 'Safety' section lists basic safety precautions. In
addition, this section identifies the text and locations of
warning labels used on the machine.
Read and understand the basic precautions listed in the
'Safety' section beforehand, and apply them always as
you operate, transport, perform maintenance, and repair
the product.
Operation
The 'Operation' section is a reference for the new
operator and a refresher for the experienced one. This
section includes a discussion of gauges, switches,
machine controls, how to operate the machine, and
towing information.
Photographs and illustrations assist the operator in
understanding correct procedures of checking, starting,
operating, and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The 'Maintenance' section is a guide to equipment
care. A combination of step-by-step instructions and
helpful illustrations and photographs accompany main-
tenance items throughout this section.
Trouble-Shooting
Possible symptoms are listed with a description of
associated problems and solutions. A description of
how the hydraulic system works is given, as well as
diagrams of the hydraulic and electrical systems.
Knowledge of such can be indispensable in solving
problems.
Parts
Parts are readily found through illustrations with
accompanying RAYCO ® part numbers. The machine
is broken down into basic categories to enable ease of
finding parts. A separate engine Operation and Repair
Manual is also provided for aid in the identification and
ordering of engine parts. Please consult your local
Wisconsin engine representative or local RAYCO ®
dealer for obtaining engine parts and service.

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
6
A Description of the
Machine
Design
The RG 1635A STUMP CUTTER is designed for your
maximum benefit per dollar spent. The machine is
constructed for durability and easy maneuvering, for
those hard to reach tree stumps and roots. Its 23"
diameter x 3/4" thick cutting wheel with 24 replaceable
carbide-tipped teeth is powerfully driven by a Wisconsin
35 horsepower gas engine. The machine chassis
features rectangular steel tubing and steel guard
construction, mounted on light truck tires. The operator
benefits from a steel cutting wheel guard, and self-
centering finger-tip control levers on the hydraulic
controls enhancing the safety and efficiency of his
work. The fuel tank has a 14 gallon capacity and the
hydraulic fluid tank has a capacity of 1.7 gallons.
Other special features of the RG 1635A STUMP
CUTTER include dual cross travel cylinders with an
operator-controlled speed setting, hardened
replaceable bushings on all critical cylinder pins,
tapered bearings in the pivot head, steel guards
surrounding moving parts, and convenient access for
tightening Polychain belt.
NOTICE
The telescoping tongue end is considered to be
the front of the machine, while the cutting end is
the rear. Accordingly, the left and right hand
sides of the machine are considered to be the
same as the operator•s left and right hand side
when he stands at the rear of the machine, facing
towards the front.
How it works
The machine removes tree stumps by the repeated
gradual sweeping of a multi-toothed high-speed rotat-
ing cutting wheel. The cutting wheel has teeth on its
side, in a strategic pattern. The rotating cutting wheel
takes a sweep from one side of the stump to the other,
each tooth rapidly tearing and stripping away small
pieces of stump. After each sweep of 1 to 2 inches of
depth, the cutting wheel is advanced deeper into the
stump, and the procedure is continuously repeated,
under the precise control of the operator, until the
stump is satisfactorily removed.
Serial Numbers
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.
It is stamped on the operator's side of the pivot head.
For ready reference record it in the boxes provided on
the inside front cover of this manual. For reference on
communication regarding the engine, record its model
and serial numbers also in the boxes provided on the
inside front cover of this manual. See the Wisconsin
[Engine] Operation Manual for assistance in locating
the numbers on the engine.
FOREWORD
SERIAL NUMBERS
IR1965473J3G
LEFT
FRONT
RIGHT
REAR

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
7
RAYCO ®RG 1635A STUMP CUTTER
Safety
Tragic accidents involving machinery operation, main-
tenance, and repair are normally caused by failure to
observe basic safety rules or precautions. A machine
designed for powerful benefit can become an even
more powerful setback when potentially hazardous
situations go unrecognized. RAYCO Manufacturing,
Inc. is greatly concerned with the safety of the opera-
tor, as well as all in the vicinity of his work. RAYCO
has provided shields, guards, safety decals and other
important safety features to aid in using the machine
properly. In order to further ensure your safety we ask
that you properly operate and service your stump
cutter.
Improper operation, lubrication, maintenance, or
repair of this product can be dangerous and
could result in severe injury or death.
Do not operate or perform any lubrication, main-
tenance, or repair on this product, until you have
read, you understand, and you decide to do so in
compliance with all of the operation, lubrication,
maintenance, and troubleshooting information
contained in this Operation and Maintenance
Manual and that contained in the Deutz [Engine]
Operation Manual, which are included with this
machine. Additional manuals are available from
RAYCO ® or your RAYCO ® dealer.
WARNING
The meaning of this safety alert symbol is:
Attention! Become Alert!
Your safety is involved!
A message, either written or pictorial, follows to
explain the hazard. RAYCO ® cannot anticipate every
possible circumstance that might involve a potential
hazard. The warnings in this publication and on the
product are therefore not all inclusive. If you desire to
make use of a tool, procedure, work method, or
operating technique not specifically recommended by
RAYCO ®, therefore, you must use it only if you have
accurately evaluated it and found that it threatens no
one's safety. You should also ensure that the product
will not be damaged or made unsafe by the operation,
lubrication, maintenance, or repair procedures that
you choose.
The procedures described in this 'Safety' section
may not be fully explained here, but a more complete
explanation is given in the 'Operation', in the
'Maintenance', or in the 'Troubleshooting' section.
The information, specifications, and illustrations in
this publication were produced on the basis of infor-
mation available at the time it was written. The
specifications, torques, pressures, measurements,
adjustments, illustrations, and other items may change
at any time. These changes can affect the service
given to the product. Obtain the complete and most
current information before starting any job. RAYCO ®
dealers have the most current information available.

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
8
General Hazard
Information
Wear protective face shield, protective glasses, hearing
protection, a hard hat, and other protective equipment
as required by job conditions.
Always wear protective eyeglasses when using a
grinder or hammer.
Do not wear loose clothing or jewelry that can catch on
controls or other parts of the machine.
Make certain all protective guards and covers are
secured in place on the machine.
Keep the machine free of foreign material, such as
debris, oil, tools, and other items which are not part of
the machine.
Never put maintenance fluids into glass containers.
Complete all needed repairs before operation.
Do not allow unauthorized personnel to use the
machine.
Beware of the possibilities of unsafe practices of
others. Always consider what might have been ne-
glected by a previous operator so that his possible
oversight could not cause death or serious injury
during your use of the machine.
Pressure Air
Pressure air (i.e. from an air compressor) can cause
personal injury.
When using pressure air for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes.
The maximum air pressure used for cleaning pur-
poses must be less than 30 psi (205 kPa).
Fluid Penetration
Never allow your hand or other part of the body get
near a pressurized fluid leak. Instead, use a board or
cardboard when checking for a leak. Escaping fluid
under pressure, especially an invisible pinhole sized
leak, can harmfully penetrate body tissue, or enter
mucus membranes, causing serious injury, and
possible death.
WARNING
The attention of a physician who is specially
trained to treat such an injury, must be
sought immediately if penetration into skin
or any mucus membrane occurs. Serious
infection or reaction will soon result if such
a physician is not immediately consulted.
Crushing, Cutting
Prevention
1. Support cutting boom and machine securely
when working beneath them. Do not depend on
hydraulic cylinders to hold cutting wheel up. It
can fall if a control is moved or if a hydraulic
line breaks.
2. Never attempt adjustments when the machine
is moving or the engine running unless other-
wise specified, and if so, only with extreme
caution.
3. Where there are boom linkages, the clearance
in the linkage area will increase or decrease
with movement of the boom. Even without the
engine running, therefore, a hand, for example
could become severely injured if it were in-
volved in the linkage when the cutting boom is
being swung from left to right. Stay clear of
linkages when movement is occurring.
SAFETY

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
9
RAYCO ®RG 1635A STUMP CUTTER
4. Stay clear of all rotating and moving parts! A
moving belt & pulleys or chain & sprockets can
suddenly pull a limb into them, causing loss of
or severe injury to an arm.
A rotating cutting wheel can suddenly cut off
an arm or leg.
5. Wear protective glasses when striking a
machine part, to avoid eye injury.
6. Consult RAYCO or your RAYCO dealer for
lifting instructions.
7. When machine is parked and detached from
towing vehicle, wheels should be securely
chocked to prevent possibility of machine
rolling uncontrolled.
Burn, Explosion
Prevention
SAFETY
1. All fuels and most lubricants are flammable.
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire. Do not
smoke while refueling, while in a refueling
area, or where flammable materials are stored.
Keep all fuels and lubricants stored in properly
marked containers and away from all
unauthorized persons. Store all oily rags or
other flammable material in a protective
container, in a safe place.
2. Do not weld or flame-cut on pipes, tubes, or
tanks that contain flammable fluids. Clean
them thoroughly with nonflammable solvent
before welding or flame-cutting on them.
Remove all flammable materials such as fuel,
oil and other debris before they accumulate on
the machine.
3. Dangerous explosion may occur with improper
use or care of starting fluid!
' Do not attempt to use starting fluid to
help start engine when using heating
plug.
' Do not use starting fluid without a
dispensing apparatus that is approved by
the engine manufacturer.
' Read and follow starting fluid
manufacturer's instructions when using
starting fluid to start a machine.
' Starting fluid is poisonous and
flammable.
' Breathing starting fluid vapors or
repeated contact of starting fluid with
skin can cause personal injury.
' Use starting fluid only in well ventilated
areas.
' Do not smoke when using starting fluid.
' Use starting fluid with care to avoid fires.
' Do not store replacement starting fluid
cylinders in living areas.
' Do not store starting fluid in direct
sunlight or at temperatures above
102°F (39°C).
' Discard cylinders in a safe place. Do
not puncture or burn cylinders.
' Keep starting fluid cylinders out of the
reach of unauthorized personnel.
4. Do not expose the machine to flames, burning
brush, etc. Shields which protect hot exhaust
components from oil or fuel spray in the event
of a fire, tube, or seal failure, must be installed
correctly.

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
10
5. Do not smoke in areas where batteries are
charged. When using jumper cables always
connect positive (+) cable, to positive (+)
terminal of battery (the terminal that is
connected to starter solenoid), and negative (-)
cable from external source, to ground. Make
last connection and first disconnection at a
point away from battery. Always connect
negative (-) cable last, and disconnect it first.
See the 'Operation' section of the manual for
specific instructions.
6. Clean and tighten all electrical connections.
Check daily for loose or frayed electrical wires.
Have all loose or frayed electrical wires
tightened, repaired or replaced before operating
the machine. Never allow a live electrical wire
make contact with your body or with any metal
that is touching your body.
7. Have a fire extinguisher available and know
how to use it. Inspect and have it serviced as
recommended on its instruction plate.
Oils
Hot oils and components can cause personal burns.
Do not allow hot oil or components to contact the skin.
At operating temperature, the hydraulic tank is hot.
Relieve all pressure in hydraulic system before any
lines, fittings, or components are loosened or
disconnected.
Battery Acid
Always wear protective clothing and eyeglasses when
working with battery.
For further important battery safety information, con-
sult the Wisconsin [Engine] Operation Manual.
Lines, Tubes, and Hoses
Do not bend or strike high pressure lines. Do not install
bent or damaged lines, tubes, or hoses.
Repair any loose or damaged fuel and oil lines, tubes,
and hoses. Leaks can cause fires. Contact RAYCO ®
or your RAYCO ® dealer for repair or replacement.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. See 'General
Hazard Information - Fluid Penetration' in this
'Safety' section for more details. Tighten all
connections sufficiently.
Replace if any of the following conditions are
found:
1. End fittings damaged or leaking
2. Outer covering chafed or cut, and fabric or wire
reinforcing exposed.
3. Outer covering ballooning locally.
4. Evidence of kinking or crushing of the flexible
part of the hose.
5. End fittings displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly to prevent vibration, rubbing
against other parts and against excessive heat, dur-
ing operation.
Before Starting the Engine
1. Review all of the safety decals that are placed
on the machine for your safety and conve-
nience. See 'Parts' section for aid in locating
all decals on machine.
2. Make sure that all shields, guards and curtains
are in place, and in good condition prior to
operating the machine.
3. Only responsible, properly instructed individuals
should operate this machine. Inexperienced
operators must always be carefully supervised.
4. Check cutting wheel for damaged or missing
teeth, and replace as necessary.
5. Make sure that no one is working on, under-
neath or close to the machine before starting
the engine or beginning to move the machine.
Make sure that the area is free of personnel.
6. Check stumps to be removed for embedded
nails, wire, metal fence posts, and other
metallic objects, and for rocks or other buried
impediments which may become dangerously
thrown or cause unexpected machine move-
ments when hit by cutting wheel.
SAFETY

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
11
RAYCO ®RG 1635A STUMP CUTTER
7. Ensure that everyone in the vicinity is aware of
the DANGER ZONE associated with this
machine. (See diagram above.) You and they
must avoid the DANGER ZONE at all times
when the machine is in operation.
8. Make no alterations or modifications to your
RAYCO ® stump cutter unless requested or
recommended by RAYCO ® Manufacturing Inc.
9. Ensure that towing vehicle is stabilized:
' Engine is off and key removed from engine
start switch and key is in safekeeping.
' Towing vehicle is in PARK gear and
parking brake is set.
' Towing vehicle is properly blocked or
anchored if there would otherwise be a
danger of the stump cutter operation
causing unsafe movement of the towing
vehicle.
10. When starting the engine, the machine controls
which cause machine movements (the valve
bank levers and the cutting wheel engagement
lever) must be in the NEUTRAL or OFF
positions, so that no machine motion, which
may result in death or severe injury, occurs.
SAFETY
The cutting wheel UP/DOWN lever (1), the
tongue IN/OUT lever (2), and the cutting
wheel SWING control lever (3) automatically
return to the center position when left alone
by the operator. No related machine
motions are allowed when they are in the
center position. Ensure that nothing is
leaning against any of the controls and that
each is in the center position when starting
the engine, or uncontrolled machine move-
ment may occur, resulting in possible death
or severe injury.
11. The cutter wheel engagement lever must be in
the neutral position before attempting to start
the engine.
12. Do not start the engine or or move any of the
controls if there is a "DO NOT OPERATE" or
similar warning tag attached to the machine.
13. To ensure that machine cannot roll on its own,
the machine should be properly attached to
towing vehicle with transmission in PARK and
with emergency brake applied. Any other
measures should be taken to disallow the
vehicle and stump cutter to roll or slide
uncontrolled, resulting in injury or death.
14. Check with the local utilities for the locations of
buried pipes and cables where applicable,
before operating the machine.
1
23

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
12
While in Operation
1. Know how to shut the machine off in an emer-
gency.
2. The operator must never leave the controls
while the machine is in operation.
3. The operator must take extreme precaution not
to accidentally bump a control lever, particularly
when any personnel are in the vicinity.
4. Never let clothing, long hair, jewelry, etc. hang
loosely. It is possible that they can become
dangerously entangled in the moving parts or
the controls of the machine.
5. Keep head, hands and feet away from moving
parts at all times.
6. The engine should not be started within a
building unless it is properly ventilated so as to
eliminate the breathing of exhaust fumes, which
can cause death.
7. Warm up the engine and the hydraulic oil
before operating the machine.
8. Check for proper operation of all controls and
protective devices while operating them slowly.
9. Extreme caution must be exercised when
cutting stumps on slopes, as machine may
shift or slide unpredictably. Never attempt to
cut on a slope exceeding 15 degrees.
10. Wear appropriate safety equipment, including
protective eyeglasses, face shield, protective
footwear, and hearing protection.
11. Ensure that everyone in the vicinity is aware of
the DANGER ZONE associated with this
machine. You and they must avoid the
DANGER ZONE at all times when the machine
is in operation.
12. For safety, local or state codes or job site
operating directives may require a greater
distance from obstacles.
13. Do not activate cutting wheel drive until the
boom has been raised so that the cutting wheel
can rotate freely.
14. Keep eye contact with cutting wheel at all times
that it is rotating.
15. Use only the rear lower portion of the cutting
wheel below the shaft. Never undercut the
stump, or use the upper portion of the wheel for
cutting purposes.
16. Occasionally a curtain may become displaced
in such a way as to leave a normally covered
area exposed. Shut down machine immediately
if it occurs, and reposition curtain before
continuing operation.
SAFETY

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
13
RAYCO ®RG 1635A STUMP CUTTER
Normal Shutdown
Procedure
In consideration of your own safety as well as that
of others, you should always use the following
normal shutdown procedures before departing
from the controls for any reason, including clean-
ing, servicing, transporting, or inspecting the
stump cutter. Never deviate from this procedure
unless so instructed in this manual or an emer-
gency requires it.
1. Move the engine throttle (1) to the mid range
position.
2. To disengage the drive belt rotate the belt
tightener (2) clockwise. The engine lock handle
(3) will drop in place locking the engine in the
disengaged position.
WARNING
A rotating cutting wheel is very
DANGEROUS! Stand at controls and ensure
that cutting wheel comes to a complete stop
before doing anything else.
3. Retract telescoping tongue and insert lock pin
and retaining clip. (Or telescoping tongue may
be left as it is if further use of machine is
intended before relocating.)
4. Raise and center cutting boom and insert cutting
boom transport block. (Or cutting boom may be
lowered to the ground if further use of machine is
intended before relocating.)
5. Turn the engine start key to the 'OFF' position.
6. Remove the key from the engine start switch,
and put in safekeeping.
Emergency Shutdown
Procedure
1. Disable engine by turning engine keyswitch to
OFF position (to the left).
2. Be sure to allow all moving parts to come to a
complete stop.
WARNING
A rotating cutting wheel is very
DANGEROUS! Stand at controls and ensure
that cutting wheel comes to a complete stop
before doing anything else.
3. Correct the emergency situation, and return to
normal operation.
While Servicing and
Performing Maintenance
on the Machine
1. The machine should be in at least one of the
following conditions:
' machine properly attached to towing
vehicle with transmission in PARK and
with emergency brake applied
' wheels securely chocked, with front of
machine resting on solid ground via
jackstand or hitch.
2. The boom should be resting on the ground or
otherwise secured. Do not depend on hydraulic
system to hold boom in position; if a hose
becomes ruptured or a lever is moved, the boom
could drop or swing, resulting in personal injury.
SAFETY
1
2
3

Copyright © 2000 Rayco - All Rights Reserved
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RG 1635A STUMP CUTTER
RAYCO ®
14
SAFETY
5. Use extreme caution and drive slowly over terrain
that is rough or uneven.
6 . Obey all local traffic laws, and extend courtesy
to other drivers.
Safety Decals
The safety decals located on this machine contain
useful and important information which will help you to
operate your machine safely. The complete decal kit
and location of each decal is given in the 'Parts'
section of this manual. For your protection, familiarize
yourself with each label until you completely understand
the warning intended. Do not violate any such warnings!
Keep all decals in place and in good condition:
1. Use soap and water to keep decals clean. DO
NOT use mineral spirits, abrasive cleaners or
other similar cleaners which will damage the
decals.
2. Replace any damaged or missing decals.
Before attaching decals, the surface tempera-
ture of the metal must be at least 40 degrees.
The metal should also be clean and dry before
attaching the decal.
3. If a machine component to which a decal is
attached is replaced, be sure to replace the
decal as well.
4. Replacement decals may be purchased from
RAYCO ® or your RAYCO ® dealer.
3. The start key switch should be in the OFF
position and engine and all moveable parts at
rest.
4. The engine start key should be removed and in
safekeeping.
5. Periodically check the machine for missing,
loose or worn bolts, cracked hoses, and loose
connections. The cutting wheel should be
checked closely for worn or broken teeth, loose
pocket bolts, and cracked pockets.
6. Leaking hydraulic fluid that is under high
pressure may escape visual detection and may
have enough force to penetrate the skin
surface. Always use a piece of cardboard or
wood to detect leaks. See 'General Hazard
Information - Fluid Penetration' in this
'Safety' section for more details.
7. Always relieve the pressure in the hydraulic
system before loosening line connections or
working on the system by pressing and releas-
ing each of the hydraulic control valve levers,
with engine OFF. Always loosen fittings slowly
or "crack" them open to relieve any residual
pressure. Before the system is repressurized,
check connections for tightness and hoses for
serviceable condition.
8. When removing fuel cap, unscrew slowly, and
hold firmly. The cap may otherwise be thrown
due to pressure buildup caused by increase in
temperature.
9. Replacement parts which are authorized by
RAYCO ® are the only parts which should be
used for repair or replacement.
While Transporting the
Machine
1. Retract the telescoping tongue, and install the
tongue transport pin.
2. Center and fully raise cutting boom, and insert
transport block.
3. Fully close the cutting wheel cross travel control
valve.
4. Be sure that machine is securely attached to
towing vehicle.

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
15
RAYCO ®RG 1635A STUMP CUTTER
Operator•s Station
The operator's controls are mounted on the left hand
side of the machine. The valve bank, swing speed
control valve, throttle, choke , engagement lever and
keyswitch are all centrally located for easy access.
Operation
WARNING
Before operating, please consult the •Safety•
section for vital information related to oper-
ating this powerful machine!
Know Your Machine
General Identification
(1) Telescoping Tongue
(2) Hydraulic Oil Tank
(3) Fuel Tank
(4) Pivot Head
(5) Engine
(6) Cutting Boom
(7) Cutting Wheel
(1) Cutting Wheel UP/DOWN Lever
Pull to raise cutting wheel. Push to lower
cutting wheel.
(2) Tongue IN/OUT lever
Pull to retract cutting wheel in ( away from
stump). Push to extend cutting wheel out
( toward stump).
(3) Cutting Wheel SWING lever
Pull to move cutting wheel to the left. Push
to move cutting wheel to the right.
(4) Swing SPEED Control
Turning this valve counterclockwise will
decrease the cutting wheel swing speed.
Turning it clockwise will increase the swing
speed.
Machine Controls
NOTICE
WHEN TRANSPORTING, TURN THE VALVE
FULLY CLOCKWISE TO CLOSE.
1
42
3
56
7
1
23
4

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
16
Other Machine Components
(1) Telescoping Tongue Lock-Pin
Lock-pin (1) must be removed prior to
operation to allow the tongue to extend and
retract. It may be stored in hole (2) when
not in use. The lock-pin must then be
reinserted as shown prior to transporting
the unit. Always insert retaining pin (3) into
hole in end of lock-pin.
(2) Cutting Boom Transport Block
The cutting boom block prevents the cutting
boom from settling during transportation and
when the machine is not in use.The block also
supports the boom & reduces stress on the
king pin during transportation. The block is
installed by the following procedure:
1. Raise the cutting wheel to it's full height.
Align holes in block and holes in chassis
then insert pin.
2. Very gently bleed cutting boom down
until it rests on block. To remove block,
raise the cutting boom and remove pin.
Take off block and store on tongue of
trailer.
OPERATION
(5) CUTTING WHEEL Drive Control
To engage CUTTING WHEEL first check
cutting wheel for obstructions. Lift up on the
engine lock handle (5) and rotate belt tightener
lever (6) CCW. To extend belt life, the engine
should always be at or near an idle when
engaging or disengaging the drive belt.
To stop CUTTING WHEEL DRIVE:
See the "Normal Shutdown Procedure"
section of this manual.
WARNING
A rotating cutting wheel is very
DANGEROUS! Stand at controls and ensure
that cutting wheel comes to a complete stop
before doing anything else.
(7) Engine SPEED Control
The engine speed control is operated by a
throttle on the front of the engine block on the
operator's side. To increase engine
speed pull throttle towards you until desired
speed is obtained. To decrease speed push
throttle away until desired speed is obtained.
The engine should always be at or near an
idle when engaging belt drive.
(8) ENGINE START Switch
See the 'Starting the Engine' section for
instructions on how to start engine.
(9) Hourmeter
The engine hourmeter automatically
measures hours of machine operation. This
measurement is used in determining when to
preform maintenance according to the "
Maintenance Intervals " section of this
manual and the "Maintenance Schedule" in
the Wisconsin Engine manual.
(10) Ammeter
56
9
7
10
8
INSTALLED
POSITION
1
2
3

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
17
RAYCO ®RG 1635A STUMP CUTTER
OPERATION
Transporting the Machine
The stump cutter is designed with a trailer body with
standard towing equipment. Comply with all local laws
dealing with the towing of a trailer.
Checklist for Transporting Machine:
1. Raise and center cutting boom.
2. Install cutting boom transport block.
3. Close cutting wheel swing speed control valve.
4. Fully retract telescoping tongue, and install
transport pin (1) and insert retaining pin through
hole in end of transport pin.
5. Hitch machine to towing vehicle.
' Lift hitch lever (2) to open hitch jaw (3).
Collar will slide, allowing jaw to spring
open.
' With hitch above ball, lower front end of
machine until hitch (4) rests on the ball.
' Close hitch jaw (3) around ball, and hold
closed while releasing spring-loaded
collar (5) until it securely holds jaw
closed. (Keep fingers away from path of
collar to avoid pinching them.)
' Secure hitch lever with hitch safety pin
(6).
(3) Trailer Hitch
The trailer hitch provides a means of securing
the machine to a towing vehicle (most
commonly, a pickup truck) in such a way as
to allow for a wide range of pivoting due to
turning, uneven ground, and hills. See the
'Transporting the Machine' section for
instructions on how to use it.
(4) Safety Chains
The safety chains provide a backup to the
hitch. See the 'Transporting the Machine'
section for instructions on how to use them.
STORED
POSITION
1
2
7
3
5
6
4
3

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
18
8. Secure safety chains (7) to towing vehicle.
' Set the length of each chain, and
crisscross them to optimize their purpose
of catching the trailer tongue should the
hitch become detached. There must, at
the same time, be enough slack left to
allow for pivoting during the sharpest
turns.
To change the length of chain (7), lift the
link out of the slot in hitch mount, pull the
chain to desired length, and drop the
nearby link into the slot so that chain is
held at that length. Set length for both left
and right ends of chain; the slack may left
draping over the tongue.
' Be sure the hooks are securely attached
to towing vehicle and cannot vibrate
loose.
WARNING
If any of above tests fail, troubleshoot
lighting system, and correct problem before
towing machine on public roadways.
Pre-Starting Inspection
NOTICE
To ensure the long life and economical operation
of your stump cutter, we highly recommend that
the operator be well instructed in both the opera-
tion and maintenance of this machine.
Inspect the machine and perform each of the '10
Service Hours or Daily' (See 'Maintenance' section)
maintenance inspections and services as found nec-
essary before operating the machine.
OPERATION
Starting the Engine
WARNING
Understand and decide to heed the •Safety•
section of this manual, in its entirety, before
proceeding.
NOTICE
Do not operate the starter for more than 20 sec-
onds at a time. To do so may overheat the starter.
If the key switch is released before the engine
starts, wait until the starter and the engine stops
turning before trying again. This will prevent pos-
sible damage to the starter and/or flywheel.
If the engine does not start the first time, wait at
least 1 minute before trying again. If it does not
start after 2 attempts, see the •Trouble Shooting•
section of the Wisconsin [Engine] Operation
Manual.
Use starting fluid only while simultaneously
cranking engine, and dispense only with an
apparatus approved by the engine manufacturer.
WARNING
DO NOT start cutting wheel drive until
machine is in cutting position, next to stump!
Starting
1. Insert key into start switch.
2. Open engine speed control throttle 1/4 of the
way.
3. Turn the key clockwise, to engage the starter,
and hold it there momentarily as the engine
cranks. Release the key when the engine starts
firing, and the key will automatically return to
the RUN position.
4. Reduce the engine speed as soon as it is
running smoothly.

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
19
RAYCO ®RG 1635A STUMP CUTTER
OPERATION
Starting with Jumper Cables
NOTICE
This machine has a 12 volt starting system. Use only equal voltage for jump starting. Use of welder or
higher voltage will damage electrical system.
When starting from another machine, make sure the machines do not touch each other. This can prevent
damage to engine bearings and electrical circuits.
1. On stalled machine, turn the start switch to OFF.
2. Move boost machine near enough to stalled machine for cables to reach, but DO NOT ALLOW MACHINES
TO TOUCH.
3. Stop the engine on the boost machine.
4. Open the battery covers of both machines to purge flammable fumes.
(Continued on following page)

Copyright © 2000 Rayco - All Rights Reserved
Printed in U.S.A.
RG 1635A STUMP CUTTER
RAYCO ®
20
5. Remove all of the battery caps from the batteries
(if not maintenance-free type) on both machines,
allowing explosive vapors to disperse.
6. Connect jumper cables:
(1) Connect red positive (+) jumper cable to
positive (+) terminal of starter solenoid of
stalled machine, where the battery red
positive (+) cable is already connected.
(Pull back rubber boot to gain access.)
WARNING
Do not allow jumper cable clamp to touch the
other solenoid terminal. Uncontrolled
starting of engine would occur, which could
cause severe injury or death.
(2) Connect other end of red positive (+)
jumper cable to positive (+) terminal of
battery of boost machine.
(3) Connect black negative (-) jumper cable
to negative (-) terminal of boost machine
battery.
(4) Connect other end of black negative (-)
jumper cable to starter mounting bolt of
stalled machine, where the battery black
negative (-) cable is already connected.
(Scrape away any paint or rust, and
make connection to bare metal.)
8. Start the engine on the boost machine and
allow it to run at high idling speed for about ten
minutes. This will partially charge stalled
engine's battery.
9. Start the stalled engine.
10. Immediately after starting the stalled engine,
disconnect the jumper cables, in reverse order.
11. Reinstall the battery caps and battery covers.
12. After completion of above procedure, perform
failure analysis on starting/charging system of
the stalled machine as required.
Pre-operation Warm up
1. Allow the engine to warm up at low idle for two
minutes.
2. To warm up the hydraulic oil, set the engine at
medium speed for about two minutes while
intermittently holding the cutting wheel UP/
DOWN lever in the UP position.
3. Move the engine throttle to the maximum
engine speed. Run the engine for an additional
two minutes while intermittently holding the
cutting wheel UP/DOWN lever in the UP
position.
This will allow the oil to reach relief pressure,
which causes it to warm up more rapidly.
4. Cycle all controls to allow warm oil to circulate
through all cylinders and lines.
OPERATION