Rayco T415 Installation and user guide

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

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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 operation, maintenance
& parts manuals 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 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 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 on page 4 for your personal records.
CALIFORNIA PROPOSITION 65
WARNING THIS MACHINE AND ITS
CONSTIUENTS ARE KNOWN IN THE STATE
OF CALIFORNIA TO CAUSE CANCER AND
REPRODUCTIVE HARM.
VISIT WWW.P65WARNINGS.CA.GOV
NOTICE:
Maintenance and Repairs should ONLY be performed by a trained
specialists or qualified personel.
Please contact Rayco Mfg for a listing of approved maintenance
facilities in your area.

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TABLE OF CONTENTS
General Information 2
Safety 8
Operation 22
Maintenance 34
Specifications 108
Warranty 110

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Foreword
Literature Information
The operators manual should be stored in the operator’s
compartment in the literature holder storage area. Rayco
provides a binder to hold the Operator Service Manual, Parts
Manual, Engine Manual along with other component manuals.
These manuals contain safety information, operation
instruction, transportation information, lubrication information
and maintenance information.
Some photographs or illustrations in the publication show
details of attachments that can be different from your machine.
Guards and covers might have been removed for illustrative
purposes. Continuing improvementmay have caused changes
to your machine which may not be included in this publication.
Continuing improvement and advancement of product
design might have caused changes to your machine which
are not included in this publication. Read, study and keep
this manual with the machine.
Whenever a question arises regarding your machine, of this
publication, please consult your Rayco dealer for the latest
available information.
Safety
The safety section lists basic safety precautions. In addition,
this section may include text and locations of warning signs
and labels used on the machine.
Read and understand the basic precautions listed in the
safety section before operating or performing lubrication,
maintenance and repair on this machine.
Parts
Parts are readilyfound through illustrations with accompanying
Rayco part numbers. The machine assembly is listed by basic
groups to enable ease of finding parts.
Please consult your local Rayco Dealer or local Engine
Manufacturer Dealer for obtaining engine parts and service.
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,
attachment controls, transportation and towing information.
Photographs and illustrations guide the operator through
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.
The Maintenance Interval Schedule lists the items to be
maintained at a specific service interval. The Maintenance
Interval Schedule lists the page number for the step-by-
step instructions required to accomplish the scheduled
maintenance procedure.
Maintenance Intervals
Use the service hour meter to determine servicing intervals.
Calendar intervals shown (daily, weekly, monthly, etc.) can be
used instead of service hour meter intervals if they provide
more convenient servicing schedules and approximate the
indicated service hour meter reading. Recommended service
should always be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating conditions,
more frequent lubrication than is specified in the maintenance
intervals chart might be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 100 service hours, also
service those items listed under every 50 service hours and
every 10 service hours or daily.

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Foreword
Machine Description
The T415 offers a solution for contractors looking for a full
size stump cutter and forestry mower with premium features
and top level performance. The 6-cylinder Caterpillar
engine provides 415hp and meets Tier 4 emissions.
Operators will appreciate the comfortable, side entry cab
with excellent visibility and a rooftop escape hatch. A heavy
duty undercarriage provides long life and a smooth ride. The
dual-drive cutter head uses a variable displacement motor
to maximize cutting power and efficiency. Each crawler track
is driven by an independent hydrostatic transmission. All
controls, both hydrostatic and hydraulic, are manipulated
by joysticks. These controls are self-centering.
STANDARD MACHINE FEATURES INCLUDE:
• Rear Swing-out Door for Primary Radiator Cleaning
• Additional Engine Radiator in Limb Riser
• 2-Speed Ground Travel
• Electronic Joystick Control
• Side Access to Batteries
• Master Electrical Disconnect Switch
• Remote Grease Point for Track Tension Adjustment
• Track Tension Monitoring System on LCD Display
• Lockable Access Panels
• Front, Rear and Side LED Work Lights
• Remote Engine Comparment Light
• Horn (standard)
• Sauer Danfoss® PLUS-1® Controller
• Sauer Danfoss® PLUS-1® Graphical Terminal
• 110 gal (US Gal) Fuel Capacity
• Float Style Fuel Level Sender
• Powder Coat Paint
• 35K Hydraulic Winch
• Side Cab Entry Door
• Cab Escape Hatch
• Rear View Camera
• CANbus Lighted Switch Panel
• LED Dome Light
• Two 12v Auxiliary Power Ports
• Adjustable Cup/Beverage Holder
• Side Mirrors
• Weight Adjustable Suspension Seat
• Tilt-Cab for Service/Maintenance
• Sealed/Pressurized Dust-Free Cab
• Fire Extinguisher
• HVAC System

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Serial Number Location & Information
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.
Serial number is located as shown.
Use the below table to record identification numbers and dealer information.
Serial Numbers Location
Whenever communicating with Rayco or your Rayco dealer, have your machine serial number handy, as it
can help pinpoint most exactly what information is needed in caring for your machine.
Breakdown of the serial number
For Example: T415 001 01 19
T415 - Type of Rayco equipment you have
001 - Three digit for the number of produced
02 - Two digit month, 01 = Jan., 02 = Feb., etc...
19 - Two digit year, 19 = 2019, 20 = 2020, etc
It is attached to the machine at the location shown. For ready reference, record it in the boxes provided on
the next page 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 Engine Operator Manual for assistance in locating the numbers on the engine.
T415
T415 0010119
38969
42,4920(LB)/192741(KG)
2019
HP416 (kw)311
CRAWLER
001= The three digit number of produced
T415 = Type of Rayco Equipment Production Date; 01=2 digit month; 19= 2 digit year

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Serial Number Location & Information
Identification Numbers
Model Number Serial Number
Machine
Engine
Implement
Implement
Dealer Information
Name
Address
Dealer Contact Phone Number Hours
Sales
Parts
Service

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California Proposition
65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Battery posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep the engine
and machine systems operating correctly. As the heavy duty
off-road engine owner, you are responsible for the required
maintenance listed in the Engine Owner Manual & Machine
Operator, Maintenance & Service Manual.
Attach a “Do Not Operate” warning tag or a similar warning
tag to the start switch or to the controls before you service
the equipment or before you repair the equipment.
Know the width of your equipment in order to maintain proper
clearance with you operate the equipment near fences or
near boundary obstacles.
Be aware of high voltage power lines and power cables
that are buried. If the machine comes in contact with these
hazards, serious injury or death may occur from electrocution.
Wear a hard hat, protective glasses, and other protective
equipment, as required.
Do not wear loose clothing or jewelry that can snag on
controls or on other parts of the equipment.
Make sure that all protective guards and all covers are secured
in place on the equipment.
Keep the equipment free from foreign material. Remove
debris, oil, tools, andother 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 theappropriate work site hand signalsand the personnel
that are authorized to give the hand signals. Accept hand
signals from one person only.
Do not smoke when you service an air conditioner. Also, do
not smoke if refrigerant gasmay be present. Inhaling the fumes
that are released from a flame that contact air conditioner
refrigerant can cause bodily harm or death. Inhaling gas
from air conditioner refrigerant through a lighted cigarette
can cause bodily harm or death.
Never put maintenance fluids into glass containers. Drain
all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care. Report all necessary
repairs.
Do not allow unauthorized personnel on the equipment.
Unless you are instructed otherwise, perform maintenance
with the equipment in the servicing position. Refer to
Operation and Maintenance Manual for the procedure for
placing the equipment in the servicing position.
When you perform maintenance above ground level, use
appropriate devices such as ladders or man lift machines.
If equipped, use the machine anchorage points and use
approved fall arrest harnesses and lanyards.
Safety

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Important Safety Information
Most accidents that involve product operation, maintenance
and repair are caused byfailure to observe basic safety rules or
precautions. An accident can often be avoidedby recognizing
potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person
should also have the necessary training, skills and tools to
perform these functions properly.
Improper operation, lubrication, maintenance or repair of this
product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or
repair on this product, until you have read and understood
theoperation, lubrication, maintenanceand repairinformation.
Safety precautions and warnings are provided in this manual
and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol”
and followed by a “Signal Word” such as “DANG ER”,
“WARNING” or “CAUTION”. The Safety Alert
“WARNING” label is shown below.
Safety Warnings
To highlight specific safety information the following
designations are provided to assist the reader.
This is the “Safety Alert” symbol. It is used to ALERT
you to the potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid
possible injury or death.
Indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, will result in death or serious injury.
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 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, 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”, or in the “Maintenance” section.
The information, specifications, and illustrations in this
publication are on the basis of information that was available at
the time that the publication was written. The specifications,
torques, pressures, measurements, adjustments, illustrations,
and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the
complete and most current information before you start any
job. Raycodealers have themost current informationavailable.
Safety

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Rayco Manufacturing, Inc. is greatly concerned with
the safety of the operator, 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 machine.
This machine is capable of amputating hands and feet and
throwing objects.
Failure to observe safety instructions, improper operation,
lubrication, maintenance, or repair of this product could
result in severe injury or death.
Do not operate or perform any lubrication, maintenance, 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 these Operator and Parts Manuals
and that contained in the Engine Operator Manual, which are
included with this machine. Additional manuals are available
from Rayco or your Rayco dealer.
When replacement parts are required for this product Rayco
recommends using Rayco replacement parts or parts with
equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures,
product damage, personal injury of death.
General Hazard Information
• Read, understand and follow all instructions on the
machine and in the manuals before attempting to
operate. Keep all manuals in a safe place for future
reference and for ordering replacement parts.
• Familiarize yourself with all controls in a safe
environment before operation. Know how to stop the
machine and disengage the controls quickly.
• Never allow minors to operate this machine.
• Never allow anyone who has not had proper
instruction to operate this machine.
• Keep bystanders, children and pets away from the
machine and work area.
• Never allow anyone to ride on this machine.
• Never transport cargo, tools or wood on this machine.
• Keep the operator zone and adjacent area clear for
safe, secure footing.
• Use the machine in daylight or under good artificial
lighting.
• Use this machine for its intended purpose only,
deviation from the machines capabilities could
damage the equipment and cause injury or death.
• Engine exhaust contains products of combustion
which can be harmful to your health. Always start and
operate the engine in a well ventilated area. If you are
in an enclosed area, vent the exhaust to the outside.
Safety

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Safety
Personal Protective Equipment
(PPE)
Head protection must conform to ANSI Z89.1 and DO
NOT wear under chin strapping while operating or within
the operation area of the Horizontal Grinder.
Eye protection must conform to ANSI Z87.1 and be the wrap
around style. Always wear the eye protection when operating
or working within the operational area of the machine.
Hearing Protection - Plug type ear protection or full ear
coverage devices (muff type) shall be worn at all times when
operating or within the operational area of the machine.
Gloves - When operating or handling brush within the
operational area of the Horizontal Grinder, loose fitting
gloves are the only gloves that should be worn. DO NOT
wear gauntlet or strapped gloves.
Clothing Protection -Clothes must be close fitting, but
not restrictive of movement. DO NOT wear loose fitting
clothes, jewelry or long dangling clothing; i.e. neckties, long
belts or chains.
Hooded sweat shirts may be worn only if the hood is tightly
drawn around the face with drawstrings tucked into the
outer garment when not in use. If working near traffic, wear
reflective clothing.
Shoes - (Foot Protection)- Always over the ankle work boots
with skid resistant soles.
Breathing Protection -When breathingprotection is required
the use of paper masks that can tear away if caught 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 pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective
face shield.
The maximum air pressure for cleaning purposes must be
reduced to 205 kPa (30 psi) when the nozzle is deadheaded
and the nozzle is used with an effective chip deflector and
personal protective equipment. The maximum water pressure
for cleaning purposes must be below 275kPa (40 psi).
Trapped Pressure
Pressure can be trapped in a hydraulic system. Releasing
trapped pressure can cause sudden machine movement
or attachment movement. Use caution if you disconnect
hydraulic lines of fittings. High pressure oil that is released
can cause a hose to whip. High pressure oil that is released
can cause oil to spray. Fluid penetration can cause serious
injury and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after
the engine has been stopped. The pressure can cause
hydraulic fluid or items such as pipe plugs to escape rapidly
if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts until
pressure has been relieved or personal injury may occur.
Do not disassemble any hydraulic components or parts
until pressure has been relieved or personal injury may
occur. Refer to the Service Manual for any procedures that
are required to relieve the hydraulic pressure
Always use a board or cardboard when you check for a leak.
Leaking fluid that is under pressure can penetrate body
tissue. Fluid penetration can cause serious injury and
possible death. A pin hole leak can cause sever injury.
If fluid is injected into your skin you must get treatment
immediately. Seek treatment from a doctor that is familiar
with this type of injury.

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Safety
Containing Fluid Spillage
Care must be taken in order to ensure the fluids are contained
during performance of inspection, maintenance, testing,
adjusting and repair of the equipment. Prepare to collect the
fluid with suitable containers before opening any compartment
or disassembling any component that contains fluids.
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
• Obey all local regulations for the disposal of liquids.
Asbestos Information
Rayco recommends the use of only genuine Rayco
replacement parts. Use the following guidelines when you
handle any replacement parts that contain asbestos or when
you handle asbestos debris.
Use caution. Avoid inhaling dust that might be generated
when you handle components that contain asbestos fibers.
Inhaling this dust can be hazardous to your health.
The components that may contain asbestos fibers are brake
pads, brake bands, lining material, clutch plates, and some
gaskets. The asbestos that is used 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 followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
material.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining jobs.
• Wear an approved respirator if there is no other way
to control the dust.
• Comply with applicable rules and regulations
for the work place, In the United States, refer to
Occupational Safety and Health Administration
(OSHA) requirements.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air
Dispose of Waste Properly
Improperly disposing of waste can threaten the environment.
Potentially harmful fluids should be disposed of according
to local regulations.Always use leak proof containers when
you drain fluids. Do not pour waste onto the ground, down
a drain, or into any source of water.
Crushing Prevention and Cutting
Prevention
Support the equipment properly before you perform any work
or maintenance beneath that equipment. Do not depend on
the hydraulic cylinders to hold up the equipment. Equipment
can fall if a control is moved, or if a hydraulic line breaks.
Do not perform any work until you have read and followed
the proper “Lock-Out / Tag-Out” procedures.
Do not work beneath the cab of the machine unless the cab
is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the engine
is running.
Never jump across the starter solenoid terminals in order to
start the engine. Unexpectedmachine movement couldresult.
Whenever there are equipmentcontrol linkages, the clearance
in the linkage area will change with the movement of the
equipment or the machine. Stay clear of areas that may have
a sudden change in clearance with machine movement or
equipment movement.
Avoid contact with the rotating feed wheel, cutter wheel
and rotor.
Always shut-off the engine and wait for all moving parts,
belts, fans, rotors, drums, cutting wheels (etc) to come to a
complete stop before opening access covers and/or guards.
Stay clear of all rotating and moving parts. A moving belt,

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Safety
pulley, sprocket and chain can suddenly pull a limb into them
causing loss or severe injury.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the maintenance
is performed.
Keep objects away from moving fan blades. The fan blade
will throw or cut objects.
Do not use a kinked wire cable or a frayed wire cable. Wear
gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer pin
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 unintended movement. Do not use
only the jack stand to support the tongue while in operation.
Burn Prevention
Do not touch any part of an operating engine. Allow the
engine, radiator, exhaust and hydraulic reservoir to cool before
any maintenance is performed. Relieve all pressure in the
air system, oil system, lubrication system, fuel system, and/
or in the cooling system before any lines, fittings or related
items are disconnected.
In addition, avoid contact with other related hot engine parts
such as exhaust manifolds, turbochargers and mufflers.
External exhaust parts become very hot during operation.
Paper, cloth, and wooden materials could ignite if they come
in contact with these parts
Coolant
When the engine is at operating temperature, the engine
coolant is hot. The coolant is also under pressure. The
radiator and all lines to the heaters or to the engine contain
hot coolant.
Any contact with hot coolant or with steam can cause severe
burns. Allow cooling system components to cool before the
cooling system is drained.
Checkthe coolant levelonly after theengine has beenstopped.
Ensure that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with a bare
hand. Remove the filler cap slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the
eyes or the mouth.
Oils
Hot oil and hot components can cause personal injury. Do
not allow hot oil to contact the skin. Also, do not allow hot
components to contact the skin.
Remove the hydraulic tank filler cap only after the engine
has been stopped. The filler cap must be cool enough to
touch with a bare hand. Follow the standard procedure in
this manual in order to remove the hydraulic tank filler cap.

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Safety
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury.
Do not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses for servicing batteries. Wash
hands after touching the batteries and connectors. Use of
gloves is recommended.
Fire Prevention and Explosion
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 personal injury can
occur when fuel or oil is spilled on yourself or your clothes,
which can ignite.
Store fuels and lubricants in properly marked containers away
from unauthorized persons. Store oily rags and any flammable
materials in protective containers. Do not smoke in areas
that are used for storing flammable materials.
Do not operate the machine near any flame.
Extinguish all cigarettes, cigars, pipes and other sources
of ignition.
Exhaust shields (if equipped) protect hotexhaust components
from oil spray or fuel spray in case of a break in a line, in a
hose, or in a seal. Exhaust shields must be installed correctly.
Do not weld on lines or on tanks that contain flammable fluids.
Do not flame cut lines or tanks that contain flammable fluid.
Clean any such lines or tanks thoroughly with a nonflammable
solvent prior to welding or flame cutting. Check all electrical
wires daily. Repair any wires that are loose or frayed before
you operate the machine. Clean all electrical connections
and tighten all electrical connections.
Dust that is generated from repairing nonmetallic hoods or
non metallic fenders can be flammable and/or explosive.
Repair such components in a well ventilated area away from
open flames or sparks.
Inspect all lines and hoses for wear or for deterioration. The
hoses must be properly routed. The lines and the hoses
must have adequate support and secure clamps. Tighten
all connections to the recommended torque. Leaks can
cause fires.
Use caution when you are refueling a machine. Do not smoke
while you are refueling a machine. Do not refuel a machine
near open flames or sparks. Always stop the engine before
refueling. Fill the fuel tank outdoors.
Gases from a battery can explode. Keep any open flames
or sparks away from the top of a battery. Do not smoke in
battery charging areas.
Never check the battery charge by placing a metal object
across the terminal posts. Use a voltmeter or a hydrometer.
Improper jumper cable connections can cause an explosion
that can result in injury. Refer to the Operation Section of
this manual for specific instructions.
Do not charge a frozen battery. This may cause an explosion.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar
with the operation of the fire extinguisher. Inspect the fire
extinguisher and service the fire extinguisher regularly. Obey
the recommendations on the instruction plate.
Fire Extinguisher Location
Make sure that a fire extinguisher is on the machine. Make sure
that you are familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire extinguisher.
Obey the recommendations on the instruction plate.
Mount the fire extinguisher in an easily accessible place on
the machine, for crawlers mount on the left side of the cab
behind the seat. Consult your Rayco dealer for the proper
procedure of mounting the fire extinguisher.

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Safety
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 bare
hand to check for leaks. Use a board or cardboard to check
forleaks. Tightenall connections tothe recommendedtorque.
Replacethe parts ifany of thefollowing conditionsare present:
• End fittings are damaged or leaking
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced. Make sure that all clamps,
guards, and heat shields are installed correctly.
During machine operation, this will help to prevent
vibration, rubbing against other parts, and excessive
hear.
Electrical Storm Injury Prevention
When lightning is striking in the vicinity of the machine, the
operator should never attempt the following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator’s CAB during an electrical storm,
stay in the operator’s CAB. If you are on the ground during
an electrical storm, stay away from the vicinity of the machine!
While Operating the Machine
All personnel using this Machine must be trained in the
operation, safety and maintenance repair procedures.
Careless use of this Equipment could result in serious injury
or even death.
ALL PROCEDURES IN THE SAFETY AND OPERATION
SECTIONS OF THIS MANUAL MUST BE READ AND
UNDERSTOOD BEFORE STARTING THIS MACHINE.
• All operators must be wearing the proper Personal
Protective Equipment before attempting to start and
operate this machine.
• Do not allow children or other spectators to standby
and watch the machine in operation.
• Familiarize yourself with all of the controls in a safe
environment before starting to work with this machine.
• Always have more than one person at the job site.
If an accident occurs, someone is there to assist or
obtain help.
• Never operate or allow someone to operate the
machine while under the influence of alcohol, drugs,
or any medication that could affect the operator’s
performance and concentration. Maintain a drug-free
work place.
• Always operate this machine with all safety equipment
in place and working. Make sure all controls are
properly adjusted for safe operation.
• Do not change the engine governor settings or over
speed the engine. The governor controls the maximum
safe operating speed of the engine
• Never leave this machine unattended with the engine
running.
• Use only your 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 should each be checked
and verified to shut down the engine by the operator
prior to performing any work.
• CAUTION! FLYING DEBRIS! NEVER stand or allow
anyone else to be directly in front of the In-Feed
conveyor or directly behind the discharge conveyor!
• Stay away from the discharge chute while the rotor is
turning. Material being discharged can cause severe
injury, blindness or death.
• Always operate this machine from the operator area.
Never stand directly in front or in back of machine as
flying objects could be thrown during operation.
• Never move this machine, or make adjustments or
repairs, while the engine is running.

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Safety
While Servicing and Performing
Maintenance on the Machine
• ALWAYS Block the wheels to prevent unintended
movement.
• Adhere to your LOCK-OUT/TAG-OUT procedure
when performing maintenance or repairs to this
machine. Locking and tagging out equipment
safeguards those working on equipment from being
injured by its unexpected energized or releasing
stored energy.
• To prevent fires, clean debris and chaff from the
engine and muffler areas.
• Periodically check that all nuts and bolts, hose
clamps, and hydraulic fittings are tight.
• When removing the fuel cap, unscrew it slowly, and
hold it firmly. The cap may otherwise be thrown
due to pressure buildup caused by an increase in
temperature.
• For your safety, repair or replace all damaged or worn
parts immediately. Replacement parts which are
authorized by Rayco are the only parts which should
be used for repair or replacement on this machine.
• Altering this equipment, or using this equipment in
such a way as to circumvent its design capabilities
and capacities, could result in serious injury or fatality
and WILL VOID THE WARRANTY.
• Do not alter this machine in any manner. Alterations
such as attaching a rope to the control bar may result
in personal injury or death.
NEVER remove the cap from the hydraulic tank or reservoir
while the machine is running. Hot oil under pressure will
cause injury.
Relieve hydraulic system pressure before repairing or
adjusting fittings, hoses, tubing, or other system components
Before Starting Engine
Start the engine only from the operator compartment. Never
short across the starter terminate or across the batteries.
Shorting could damage the electrical system by bypassing
the engine neutral start system.
Inspect the condition of the seat belt (if equipped) and of
the mounting hardware. Replace any parts that are worn or
damaged. Regardless of appearance, replace the seat belt
after three years of use. Do not use a seat belt extension
on a retractable seat belt.
Adjust the seat so that full pedal travel can be achieved with
the operator’s back against the back of the seat.
Make sure that the machine is equipped with a lighting system
that is adequate for the job conditions. Make sure that all
machine lights are working properly.
Before you start the engine and before you move the machine,
make sure that no one is underneath the machine, around
the machine, or on the machine. Make sure that the area is
free of personnel.
Visibility Information
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no hazards
around the 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 operating the machine, ensure that the visual
aids are in proper working condition and that the visual aids
are clean. Adjust the visual aids using the procedures that
are located in this Operation and Maintenance manual.
It may not be possible to provide direct visibility on large
machines to all areas around the machine. Appropriate job
site organization is required in order to minimize hazards that
are caused by restricted visibility. Job site organization is a
collection of rules and procedures that coordinates machines
and people that work together in the same area. Examples
of job site organization include the following:
• Safety instructions
• Controlled patterns of machine movement and vehicle
movement
• Workers that direct traffic to move when it is safe
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines or
on vehicles
• A system of communication
• Communication between workers and operators prior
to approaching the machine
• Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluated.
Engine Starting
If a warning tag is attached to the start switch or to the controls,
do not start the engine. Also, do not move any controls.
Move all hydraulic controls to the NEUTRAL position before
you start the engine.
Diesel engine exhaust contains products of combustion
which can be harmful to your health. Always start the engine
in a well ventilated area. Always operate the engine in a
well ventilated area. If you are in an enclosed area, vent the
exhaust to the outside.
Before Operation

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Safety
Video tapes and safety information are available in English for
this machine. A list of some of the material is available in the
Operation and Maintenance Manual, “Reference Material”.
Consult your Rayco dealer in order to obtain copies of the
material. The information should be reviewed by every person
that operates the machine.
Clear all personnel from the machine and from the area.
Clear all obstacles from the path of the machine. Beware
of hazards such as wires, ditches, etc.
Make sure that all windows are clean. Secure all doors in the
closed position. Secure the windows in the open position
or in the shut position.
Make sure that the machine horn, the backup alarm and all
other warning devices are working properly.
Fasten the seat belt securely (if equipped). Lower the armrest.
Operation
Only operate the machine controls when the engine is running.
Do not leave the operators station while machine is running.
Before you move the machine, you must be certain that no
one will be endangered.
While you operate the machine and the work tool slowly in
an open area, check for proper operation of all controls and
all protective devices.
Do not allow riders on the machine.
Note any needed repairs during machine operation. Report
any needed repairs.
Use only Rayco Approved Work Tools on this machine. Obey
all the lift restrictions. Refer to Operation and Maintenance
Manual, “Rayco Approved Work Tools” for the approved work
tools and the lift restriction information.
If equipped, carry work tools low. Lower the lift arms fully.
Tilt back the work tool in order to keep the work tool off
of the ground. Do not go close to the edge of a cliff, an
excavation, or an overhang.
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 operatingthe machine acrossthe slope. When possible,
operate the machine up the slopes and down the slopes.
Maintain control of the machine. Do not overload the machine
beyond the machine capacity.
Never straddle a wire cable. Never allow personnel to
straddle a wire cable.
Know the maximum dimensions of your machine.
If equipped with a Rollover Protection Structure (ROPS),
always keep the ROPS installed during machine operation.
Observe all applicable local government regulations when
you use this machine.
Parking
Park on a level surface. If you must park on a grade, chock
the machine.
• Move the joystick control slowly to the NEUTRAL
position in order to stop the machine.
• Move the throttle control to the LOW IDLE position.
• Lower all implements (if equipped) so that the work
tool implement rests firmly on the ground.
• Move the hydraulic controls to the NEUTRAL position.
• Turn the engine start switch key to OFF position and
remove the key.
• Disconnect the operator restraint devices (if
equipped) and exit the machine.
• Block the wheels (if equipped), and set manual brake
(if equipped) to prevent movement.
Slope Operation
The crawler should not be operated on slopes that are steeper
than 30°. While this may not cause a loss of oil pressure,
loss of traction could occur thus creating a rollover condition.
NOTE: A 30° slope is equivalent to a 58% grade. A constant
grade of 58% represents a 58’ change in elevation across a
horizontal distance of 100’.

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Safety
Machines that are operating safely in various applications
depend on these criteria: the machine model, configuration,
machine maintenance, operating speed of the machine,
conditions of the terrain, fluid levels, and tire inflation
pressures. The most important criteria are the skill and
judgment of the operation.
A well trained operator that follows the instructions in the
Operation and Maintenance Manual has the greatest impact
on stability. Operator training provides a person with the
following abilities: observation of working and environmental
conditions, feel for the machine, identification
of potential hazards, and operating the machine safely by
making appropriate decisions.
When you work on side hills and when you work on slopes,
consider the following important points:
• Speed of travel – At higher speeds, forces of inertia
tend to make the machine less stable.
• Roughness of terrain or surface – The machine may
be less stable with uneven terrain.
• Direction of travel – Avoid operation the machine
across the slope. When possible, operate the
machine up the slopes and operate the machine
down the slopes.
• Place the heaviest end of the machine uphill when you
are working on an incline.
• Mounted equipment – Balance of the machine
may be impeded by the following components:
equipment that is mounted on the machine, machine
configuration, weights, and counterweights.
• Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
machine.
• Surface material – Rocks and moisture of the surface
material may drastically affect the machine’s traction
and machine’s stability. Rocky surfaces may promote
side slipping of the machine.
• Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
• Width of tracks or tires – Narrower tracks or narrower
tires further increase the digging into the ground
which causes the machine to be less stable.
• Implements attached to the machine hitch or drawbar
– This may decrease the weight on the uphill tracks.
This may also decrease the weight on the uphill tires.
The decreased weight will cause the machine to be
less stable.
• Height of the working load of the machine – When
the working loads are in higher positions, the stability
of the machine is reduced.
• Operated equipment – Be aware of performance
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 steep slopes may require special
machine maintenance. Excellent skill of the operator and
proper equipment for specific applications are also required.
Consult the Operation and Maintenance Manual sections for
the proper fluid level requirements and intended machine use.
Work Tool options - Attachments
Only use work tools that are approved by Rayco for use on
Rayco machines. Refer to the Operation and Maintenance
Manual, Rayco options”.
If you are in doubt about the compatibility of a particular work
tool with your machine, consult your Rayco dealer.
Make sure that all necessary guarding is in place on the host
machine and on the work tool.
If equipped, keep all windows and doors closed on the
machine.
Always wear protective glasses. Always wear the protective
equipment that is recommended in the work tool’s operation
manual. Wear any other protective equipment that is required
for the operating environment.
To prevent personnel from being struck by flying objects,
ensure that all personnel are out of the work area.
While you are performing any maintenance, any testing, or any
adjustments to the machine, stay clear of the following areas:
cutting edges, pinching surfaces, and crushing surfaces.
Equipment Lowering with Engine
Stopped
Before lowering any equipment with the engine stopped,
clear the area around the equipment of all personnel. The
procedure to use will vary with the type of equipment to be
lowered. Keep in mind this system use a high pressure fluid
to raise or lower equipment. The procedure will cause high
pressure hydraulic oil to be released in order to lower the
equipment. Wear appropriate personal protective equipment
and follow the established procedure in the Operation and
Maintenance Manual.
100’
58’
30°

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800.392.2686 19
Safety
Sound Level Information
The operator Equivalent Sound Pressure Level is used to
measure a work cycle sound exposure level
Hearing protection may be needed when the machine is
operated with an open operator station for extended periods
in a noisy environment. Hearing protection may be needed
when the machine is operated with a cab that is not properly
maintained or when the doors and windows are open for
extended periods or in a noisy environment.
Vibration Data Information concerning
hand/arm vibration level
When the machine is operated according to the intended
use, the hand/arm vibration of this machine is rated by meter
per second squared.
Note: Vibration levels are influenced by many different
parameters listed below.
• Operator training, behavior, mode, and stress
• Job site organization, preparation, environment,
weather and material
• Machine type, quality of the seat, quality of the
suspension system, attachments, and condition of the
equipment.
Guidelines for Reducing Vibration Levels
on Equipment
Properly adjust machines. Properly maintain machines.
Operate machines smoothly. Maintain the conditions of the
terrain. The following guidelines can help reduce the whole
body vibration level:
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the manufacturer’s
recommendations.
a: Tire pressures
b: Brake and steering systems
c: Controls, hydraulic system and linkages
3. Keep the terrain in good 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 following operations smoothly.
a. Steer
b. Brake
c. Accelerate
d. Shift the gears
6. Move the attachments smoothly.
7. Adjust the machine speed and the route in order to
minimize the vibration level.
a. Drive around obstacles and rough terrain.
b. Slow down when it is necessary to go over rough
terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance.
a. Haul the machines between workplaces.
9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective in
order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order to
achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
f. Minimize any shocks and impacts during sports
and leisure activities.
Guards (Operator Protection)
There are different types of guards that are used to protect
the operator. The machine and the machine application
determines the type of guard that should be used.
A daily inspection of the guards is required in order to check
for structures that are bent, cracked or loose. Never operate
a machine with a damaged structure.
The operator becomes exposed to a hazardous situation if the
machine is used improperly or if poor operating techniques
are used. This situation can occur even though a machine is
equipment with an appropriate protective guard.
Follow the established operating procedures that are
recommended for your machine.
Rollover Protective Structure
(ROPS), Falling Object Projective
Structure (FOPS) or Tip Over
Protection Structure (TOPS)
The TOPS/FOPS Structure (if equipped) on your machine is
specifically designed, tested and certified for that machine.
Any alteration or any modification to the ROPS/FOPS
Structure could weaken the structure. This places the
operator into an unprotected environment. Modifications or

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Safety
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 Structure has
structural damage. Damage to the structure can be caused
by an overturn, a falling object, a collision, etc.
Do not mount items (fire extinguishers,first aid kits, work lights,
etc.) by welding brackets to the ROPS/FOPS Structure or
by drilling holes in the ROPS/FOPS Structure.
Welding brackets or drilling holes in the ROPS/FOPS
Structures can weaken the structures. Consult your Rayco
dealer for mounting guidelines.
The Top Over Protection Structure (TOPS) is another type
of guard that is used on crawlers. This structure protects
the operator in the even of a tip over. The same guidelines
for the inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Top Over
Protection Structure.
Other Guards (If Equipped)
Protection from flying object and/or falling objects is required
for special applications. Logging applications and demolition
applications are two examples that require special protection.
A front guard needs to be installed when a work tool that
creates flying objects is used. Mesh front guards that are
approved by Rayco or polycarbonate front guards that are
approved by Rayco are available for machines with a cab or
an open canopy. On machines that are equipped with cabs,
the windshield should also be closed. Safety glasses are
recommended when flying hazards exist for machines with
cabs and machines with open canopies.
If the work material extends above the cab, top guards and
front guards should be used.
Additional guards may be required for specific applications
or work tools. The Operation and Maintenance Manual
for your machine or your work tool will provide specific
requirements for the guards. Consult your Rayco dealer for
additional information.
Precautions for Welding on FRAME with
ENGINE/MACHINE Electronic Control
Unit (ECU)
Important: ALWAYSdisconnect Electronic Control Unit (ECU)
connectors and engine control system-to-machine ground
before welding on engine or machine.
High currents or electrostatic discharge in electronic
components from welding may cause permanent damage.
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” 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:
• Use soap and water to keep decals clean. DO NOT
use mineral spirits, abrasive cleaners or other similar
cleaners which will damage the decals.
• Replace any damaged or missing decals. Before
attaching decals, the surface temperature of the metal
must be at least 40 degrees. The metal should also
be clean and dry before attaching the decal.
• If a machine component to which a decal is attached
is replaced, be sure to replace the decal as well.
• Replacement decals may be purchased from Rayco
Mfg or your Rayco dealer.
LOCK-Out / Tag-Out Guidelines
Always practice lock out tag out procedures when working
on this machine.
Locking andtagging out equipment safeguards those working
on the equipment from being injured by its unexpected
energized or releasing stored energy. This sectionsummarizes
the applicable requirements for lockout/ tag out procedures,
and its intent to comply with OSHA regulations.
Lock Out Procedure
1. All affected persons are to be notified that the
equipment will be off and locked out.
2. All energy sources for the equipment should be
identified.
3. The equipment shall be shut off or otherwise
deenergized, being careful to de-energize all
energy sources. This includes all valves, switches,
breakers, or other controls that supplies energy to the
equipment. In case of mechanical energy, a block may
be used to stop the release of stored energy.
4. A lock is to be placed on each energy source
disconnect or energy release block.
a. The lock is to be placed directly on the
equipment if provided with an integral locking
device.
b. If there is no integral lockout device on the
equipment, securely attach an independently
manufactured lockout device on the equipment and
then place the lock on the lockout device.
c. If none of the above are possible, use the tag out
procedure.