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Rayco RG74DXH Operator, Service, Maintenance Manual
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Rayco RG74DXH Operator, Service, Maintenance Manual

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RG74DXH
OPERATOR · SERVICE · MAINTENANCE MANUAL
RAYCO MANUFACTURING © 2017 - ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMRG74DXH-17

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Summary of Contents for Rayco RG74DXH

  • Page 1 RG74DXH OPERATOR · SERVICE · MAINTENANCE MANUAL RAYCO MANUFACTURING © 2017 - ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMRG74DXH-17...
  • Page 2 RG74DXH Operator · Service · Maintenance Manual Introduction This manual is published by Rayco Manufacturing, Inc. for the This Rayco machine was designed and manufactured by benefit of the users of Rayco products. Rayco Manufacturing, Rayco Manufacturing, Inc., Wooster, Ohio. Due to continuous Inc.
  • Page 3 RG74DXH Operator · Service · Maintenance Manual Table of Contents TABLE OF CONTENTS Foreword Safety Operation Warranty 800.392.2686...
  • Page 4 Parts Parts are readily found 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...
  • Page 5 RG74DXH Operator · Service · Maintenance Manual Foreword Maintenance from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death. The maintenance section is a guide to equipment care. Never put maintenance fluids into glass containers. Drain The Maintenance Interval Schedule lists the items to be all liquids into a suitable container.

  • Page 6: Machine Description

    Machine Description • Cummins QSF3.8 diesel engine meets Tier 4 Final/ Stage IV emissions The Rayco RG74DXH is a high-production stump cutter • Does not require Diesel Exhaust Fluid (DEF) powered by a massive 3.8L Cummins 74hp diesel engine that generates peak torque of 295ft-lbs.
  • Page 7 Cutter Wheel RPM: 1000 RPM @ 2200 RPM Engine Speed Hitch: Adjustable height 2-5/16” (58.7 mm) Ball Drive Belt: MBL GigaTorque® Jack Stand: Hydraulic Cutting Teeth: RAYCO Super tooth™ forged, one piece, with Tires: (2) 235-75R-17.5H 6000LB tungsten carbide tips. Engine Cutter Teeth Quantity: 40 Maximum Model: Cummins 3.8L, Tier 4/Stage IV, Vertical 4-cycle, Turbo-...
  • Page 8 RG74DXH Operator · Service · Maintenance Manual Serial Number Location & Information VIN Numbers Location For reference on communication regarding the engine, record its model and serial numbers also in the boxes Whenever communicating with Rayco or your Rayco dealer, provided on the inside front cover of this manual.
  • Page 9 RG74DXH Operator · Service · Maintenance Manual Serial Number Location & Information Serial number is located as shown. Use the below table to record identification numbers and dealer information. Identification Numbers Model Number Serial Number Machine Engine Implement Implement Dealer Information...
  • Page 10 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...

  • Page 11: Personal Protective Equipment

    RG74DXH Operator · Service · Maintenance Manual Safety General Hazard Information 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.
  • Page 12 Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body Rayco recommends the use of dust masks or respirators tissue. Fluid penetration can cause serious injury and to be worn over the nose and mouth that protect the lungs possible death.
  • Page 13 RG74DXH Operator · Service · Maintenance Manual Safety such as chipping brush, stump grinding, working near old Do not work beneath the cab of the machine unless the cab wood or chip piles, non-toxic nuisance dusts can be harmful. is properly supported.
  • Page 14 RG74DXH Operator · Service · Maintenance Manual Safety Burn Prevention 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.
  • Page 15 Repair any lines that are loose or damaged. Leaks can Do not charge a frozen battery. This may cause an explosion. cause fires. Consult your Rayco dealer for repair or for Fire Extinguisher replacement parts.

  • Page 16: Safety Decals

    Maintenance Manual, “Reference Material”. Consult The safety decals located on this machine contain useful your Rayco dealer in order to obtain copies of the material. and important information which will help you to operate The information should be reviewed by every person that your machine safely.
  • Page 17 • Never hand-feed this machine for any reason. any needed repairs to certified service technician. Use only Rayco Approved Work Tools on this machine. Obey • Contact with moving parts, belts or rotating cutter wheels all the lift restrictions. Refer to Operation and Maintenance can kill, injure or dismember.
  • Page 18 When you work on side hills and when you work on slopes, consider the following important points: Only use work tools that are approved by Rayco for use on Rayco machines. Refer to the Operation and Maintenance • Speed of travel – At higher speeds, forces of inertia Manual, Rayco options.
  • Page 19 RG74DXH Operator · Service · Maintenance Manual Safety LOCK-Out / Tag-Out Guidelines 2. Check to see that all workers and bystanders are located in a safe position. Always practice lock out tag out procedures when working on this machine. 3. Inform all affected personnel.
  • Page 20 NOTE: Use caution when backing up. The rear of the components. RG74DXH may not be visible from the towing vehicle. It is recommended to use a spotter outside the vehicle. • Be aware of the length of the EQUIPMENT while turning, parking, crossing intersections, and in all driving situations.
  • Page 21 Use the Your Tow Vehicle checklist at the end of these instructions. If you suspect or detect something is wrong, contact the nearest Rayco Dealer. 800.392.2686...
  • Page 22 RG74DXH Operator · Service · Maintenance Manual Safety Safety Chains Photo-eye (if equipped) The purpose of the safety chains is to keep the trailer connected to your tow vehicle in the unlikely event the coupler comes off the ball or the ball comes off the hitch. Safety chains are attached to the trailer tongue and are equipped with hooks.
  • Page 23 RG74DXH Operator · Service · Maintenance Manual Safety 3. Start the engine. (See “Starting the Engine” and “Pre- operation Warm up”.) 4. Position the engine throttle on low idle 5. Slowly back the machine off of the trailer, until the machine is on the ground.
  • Page 24 RG74DXH Operator · Service · Maintenance Manual Operation...
  • Page 25 DANGER ZONE associated with this machine. (See diagram above.) Everyone 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 BEFORE OPERATING THIS POWERFUL MACHINE, Rayco Manufacturing Inc.

  • Page 26: Starting The Engine

    RG74DXH Operator · Service · Maintenance Manual Operation Pre-Starting Inspection 4. Cycle all the controls to allow warm oil to circulate through all the cylinders and lines. NOTICE Operator’s Station To ensure the long life and economical operation of your stump cutter, we highly recommend that the operator be well instructed in both the operation and maintenance of this machine.
  • Page 27 RG74DXH Operator · Service · Maintenance Manual Operation (4). Cutting Wheel UP/DOWN Lever Pull to raise cutting settling during transportation and when the machine is not in wheel. Push to lower cutting wheel. use. The pin is installed by the following procedure: 1.
  • Page 28 RG74DXH Operator · Service · Maintenance Manual Operation Electric Brake System 5. To insure safe brake performance and synchronization, read the brake controller manufacturer’s instructions completely before attempting any synchronization procedure. BEFORE ROAD TESTING, MAKE SURE THE AREA IS CLEAR OF VEHICULAR AND PEDESTRIAN TRAFFIC.
  • Page 29 RG74DXH Operator · Service · Maintenance Manual Operation Starting With Jumper Cables cable to the positive (+) terminal of the battery of the boost machine. NOTICE c. Connect the black negative (-) jumper cable to the Before attempting to start an engine that has been negative (-) terminal of the boost machine battery.

  • Page 30: Removing Stumps

    RG74DXH Operator · Service · Maintenance Manual Operation Removing Stumps NOTICE Call 8-1-1 Before You Dig (USA Only) The speed at which the blade moves is dependant on the position of the throttle. To increase the rate of blade movement, increase the engine RPM’s by adjusting th throttle higher.
  • Page 31 RG74DXH Operator · Service · Maintenance Manual Operation Stump Removal Procedure • Continue repeating this procedure until all of the amount of stump in the path of the downward swing of the 1: Prepare the machine at the stump: cutting wheel is gone.

  • Page 32: Machine Storage

    RG74DXH Operator · Service · Maintenance Manual Operation Stopping The Machine must be stored outside, cover it with a waterproof canvas or other material. Clean all grease, dirt, mud and other foreign matter from the machine. Wash the machine. Start and operate machine to help rid it of puddled or excess water.
  • Page 33 RG74DXH Operator · Service · Maintenance Manual Operation 800.392.2686...
  • Page 34 RG74DXH Operator · Service · Maintenance Manual Lubrication & Fluid Specifications & F AYCO UBRICATION LUID PECIFICATIONS Engine Oil During the initial break-in period, the engine will consume more oil than usual. Check the engine oil level daily. ONLY USE CH-4 (or better) CLASSIFICATION OILS WITH A 10 TBA OR HIGHER.
  • Page 35 A synthetic 75W-140 or 80W-140 heavy duty GL-5 gear oil could also be used in warm climates to extend gear life. RG74DXH Operator · Service · Maintenance Manual MWF Hydrostat Drive Lubrication & Fluid Specifications The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50.

  • Page 36: Specifications

    Your GM powered machine is filled at the factory with GM approved coolant under the GM6277M specification. Rayco does not warrant use [or mixing] of any other glycol-based coolant in your GM engine. DEX-COOL® is orange in color to distinguish it from other coolants.
  • Page 37 RG74DXH Operator · Service · Maintenance Manual Specifications Torque Specifications General Torque Information Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury. Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners. Exceptions to these torques are given in the Maintenance Section, if necessary.
  • Page 38 Troubleshoot ONLY PROPERLY TRAINED PERSONNEL SHOULD PERFORM MAINTENANCE OR REPAIR OF THIS EQUIPMENT. CONSULT RAYCO MANUFACTURING TO PERFORM ANY MAINTENANCE THAT IS NOT COVERED IN THIS MANUAL. IMPROPER MAINTENANCE OR REPAIR MAY VOID ANY WARRANTIES ON THIS EQUIPMENT. • Improper maintenance or repair COULD result in equipment damage or personal injury.
  • Page 39 RG74DXH Operator · Service · Maintenance Manual Troubleshoot Power System Troubleshooting PROBLEM CAUSE SOLUTION Add fuel. No fuel. Use correct fuel. Wrong fuel. Check fuel line and connection. Leak in fuel line. Remove fuel, clean tank, and replace Dirt or water in fuel system.
  • Page 40 RG74DXH Operator · Service · Maintenance Manual Maintenance Certified Engine Maintenance ways, and from steps. Secure all loose items such as lunch boxes, tools, and other Proper maintenance and repair is essential to keep the items that are not a part of the equipment.
  • Page 41 RG74DXH Operator · Service · Maintenance Manual Maintenance Daily or Every 10 Hrs Maintenance Interval Every 250 Hrs Maintenance Interval Walk Around Inspection See list Engine Oil & Filter Change Engine Oil Level Check & Replace if needed Hydraulic Oil Filter...
  • Page 42 RG74DXH Operator · Service · Maintenance Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes...
  • Page 43 RG74DXH Operator · Service · Maintenance Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 44 RG74DXH Operator · Service · Maintenance Manual Maintenance Maintenance Intervals Engine Oil Level NOTICE Check only when the machine is in a level position. BEFORE PERFORMING ANY MAINTENANCE, PLEASE CONSULT THE “SAFETY” SECTION FOR VITAL INFORMATION RELATED TO OPERATING THIS POWERFUL MACHINE! The maintenance section is a guide to equipment care.
  • Page 45 RG74DXH Operator · Service · Maintenance Manual Maintenance Fuel Tank - Check Level, Fill & Drain 1. Place an oil catch pan under the oil drain plug (3) under the engine. Remove the drain plug and drain the oil. Use an approved container to store used oil.
  • Page 46 RG74DXH Operator · Service · Maintenance Manual Maintenance Fuel Tank - Drain Fuel System Water Separator - Element NOTICE Element replacement frequency is determined by the Dispose of any drained fuel according to local contamination level in fuels. Fuel flow to the engine becomes environment protection regulations.
  • Page 47 RG74DXH Operator · Service · Maintenance Manual Maintenance Hydraulic Oil - Drain Always keep the hydraulic oil clean. Hydrostat Charge Pump Oil Filter - 1. Clean the fittings and tank. Change 2. Place the machine on level ground. This filter (8) is located on frame by the engine fuel filter side of the machine.
  • Page 48 RG74DXH Operator · Service · Maintenance Manual Cooling System - Check NOTICE The coolant level should be checked daily. • When the radiator is empty, re-tighten the radiator drain plug (3). • When refilling the radiator, see your Cummins Engine Manual for coolant specifications.
  • Page 49 & reduce bearing life. • Number of Teeth for Depth of Cut: Rayco’s cutter wheels 1. Remove each cap carefully by prying with a screwdriver. are designed to provide an economical cutting wheel 2.

  • Page 50: Changing Teeth

    135 - 145 lbs/ft. Replacement teeth are available from your Rayco dealer or direct from Rayco. Refer to the Parts manual for part numbers The Cutter Wheel on the RG74DXH uses 4 different types of SuperTeeth as shown below:...
  • Page 51 RG74DXH Operator · Service · Maintenance Manual Sharpening Teeth NOTICE Sharpening cemented carbide cutting teeth requires a special process. Have your teeth sharpened only by a qualified machinist for obtaining a proper edge and to avoid injury. DO NOT allow any tooth to wear too much before sharpening.
  • Page 52 RG74DXH Operator · Service · Maintenance Manual Cutting Wheel Belt - Check & in and drop down into the 12-15 lbs. range at 1/2” Adjust Tension deflection. Smart Tension App Attention iPhone users. Mitsuboshi as designed an app for Apple iPhone users...
  • Page 53 RG74DXH Operator · Service · Maintenance Manual Cutting Wheel PolyBelt - Check Tension The cutting wheel is driven by a low maintenance positive drive belt. To prolong belt life, proper tension must be maintained. A loose belt will cause excessive cutting wheel slippage and belt failure.
  • Page 54 RG74DXH Operator · Service · Maintenance Manual Emergency Stop Function - Check pivot housing facing towards the operator side. Apply 2-3 pumps of grease. Verify the brake emergency stop is working by raising one Lift Pivot wheel off the ground, rotating the wheel and activate the...
  • Page 55 RG74DXH Operator · Service · Maintenance Manual 800.392.2686...
  • Page 56 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B. 11" 11" 11" 11" 11" 11" LOOM PLUG '24' CW PUMP TYPE 'F' PLUG '31' 6" RUN PWR RELAY TYPE 'T' 5" PLUG '23' 14" HYD TEMP TYPE 'F' 8"...
  • Page 57 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B. CUTTER 1" 4" 4" 4" 4" 2" 2" WHEEL ON/OFF 8" TYPE 'X' CUTTER 1" WHEEL 8" ON/OFF TYPE 'X' LCOKOUT LOCKOUT 6" PLUG '43' PLUG '38'...
  • Page 58 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B.
  • Page 59 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B. COLOR LEGEND: RED = RED BLK = BLACK BRN = BROWN ORG = ORANGE YLW = YELLOW TAN = TAN PUR = PURPLE GRN = GREEN...
  • Page 60 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B. FROM WIRE DESCRIPTION GAUGE COLOR PLUG# PIN# (FUNCTION IMPRINT) PLUG# PIN # COM GND CAN (+) 18 *TWISTED CAN (-) 18 *TWISTED SERIAL GND HYD OIL LEVEL SWITCH...
  • Page 61 RG74DXH Operator · Service · Maintenance Manual Main Electrical Wiring Harness 37581 Rev B. COOLANT LVL INPUT ECU GROUND ECU GROUND ECU GROUND ECU GROUND ECM RETURN ECU GROUND INTAKE HEAT RELAY SIG HS RETURN STARTER LOCKOUT SIG ECU GROUND...
  • Page 62 RG74DXH Operator · Service · Maintenance Manual Hydraulic Kit Schematic 805387 ITEM QTY PART# DESCRIPTION 804909 CW MOTOR MANIFOLD 760759 VALVE-CHECK 15 PSI 804908 CUTTER WHEEL PUMP 805309 FIT-08 MORFS X -08 MOR R.125 805215 PUMP- GEAR 8CC RG74DXH 801012...
  • Page 63 RG74DXH Operator · Service · Maintenance Manual Hydraulic Kit Schematic 805387 800.392.2686...
  • Page 64 RG74DXH Operator · Service · Maintenance Manual Adapter Kit 805387A Rev A. ITEM PART # DESCRIPTION FF6400-06-06 06 MORFS X 06 MORB STRAIGHT FF6600-06-06-06 06 MORFS X 06 MORFS X 06 FORFS BRANCH TEE FF6801-06-06 06 MORFS X 06 MORB ELBOW...
  • Page 65 RG74DXH Operator · Service · Maintenance Manual Hose Kit 805387H Rev A. ITEM PART # DESCRIPTION 8R17-8FSX-8FFSX90LONG-110” 4R17-4FSX-4FSX90-53” 4R17-4FSX-4FSX90-104” 4R17-4FSX-4FSX90-152” 4R17-4FSX-4FSX90-146” 4R17-6FSX-4FSX90-142” 4R17-4FSX-6FSX-14” 4R17-4FSX-4FSX-18” 6R16-6FSX-6FSX-23” 6R16-6FSX-6FSX-35” 6R16-6FSX-6FSX-47” 8R16-8FSX-8FSX90-12” 12R4-PLAIN-18” 12R4-PLAIN-78” W/NHS 12R4-PLAIN-60” W/NHS EATON 5/8” EH22510 BLUE HEATER HOSE OR EQUIVILENT-43”...
  • Page 66 RG74DXH Operator · Service · Maintenance Manual Service Parts ENGINE OIL FILTER - 804903 FUEL FILTER ASSEMBLY PRIMARY FUEL FILTER - 804905 SECONDARY FUEL FILTER - 804904 CUTTER PUMP CHARGE FILTER ELEMENT - 805075 RESTRICTION INDICATOR - 805153 HYDRAULIC TANK FILTER ELEMENT - 805123...
  • Page 67 Batteries have a warranty that is honored thru on any Rayco product are those set forth on this page. In manufacturer. For warranty service, the purchaser is to no event will the dealer and or Rayco be liable for incidental contact manufacturer directly.
  • Page 68 We care about your safety. When operating your RAYCO® machinery always wear an ap- proved helmet complete with ear muffs, face shield and the proper eye wear. Never operate under the influence of alcohol or drugs. Know your RAYCO, read and understand your owner’s manual cover to cover.