Rayco C100R Operator's Manual

Hide thumbs

page of 62

/ 62
Bookmarks

Quick Links

Download this manual

C100R

OPERATOR BOOKLET

PRINTED IN USA

INDEX: OBC100R-14

Need help?

Do you have a question about the C100R and is the answer not in the manual?

Questions and answers

Summary of Contents for Rayco C100R

Page 2 This helps to ensure the best possible performance and service NOTICE: Maintenance and Repairs should ONLY be performed by a trained specialists or qualified person. Please contact Rayco Mfg for a listing of approved maintenance facilities in your area.
Page 3 C100R Operator Booklet Content TABLE OF CONTENTS Forward Safety Operation Specifications 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 Manufacturer Dealer for obtaining engine parts and service.
Page 5 To extend service intervals, the C100R features an advanced forestry cooling system which is easy to maintain and will The Rayco C100R (Crawler 100 hp Rubber Track Machine) is extend service intervals, even when operating in the most designed for your maximum benefit for every dollar spent. The extreme conditions.
Page 6 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.
Page 7 C100R Operator Booklet 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 800.392.2686...
Page 8 C100R Operator Booklet Safety California Proposition Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, 65 Warning and from steps. Diesel engine exhaust and some of its constituents are known...
Page 9 An accident can often be avoided by recognizing Rayco, you must use it only if you have accurately evaluated potentially hazardous situations before an accident occurs. it and found that it threatens no one’s safety. You should A person must be alert to potential hazards.
Page 10 Keep all manuals in a safe place for future reference and Rayco has provided shields, guards, safety decals and other for ordering replacement parts. important safety features to aid in using the machine properly.
Page 11 C100R Operator Booklet Safety Personal Protective Equipment protection. Eye protection includes goggles or a protective face shield. (PPE) 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.
Page 12 • 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.
Page 13 C100R Operator Booklet Safety Coolant 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.
Page 14 Do not operate the machine near any flame. the machine, for crawlers mount on the left side of the cab Extinguish all cigarettes, cigars, pipes and other sources behind the seat. Consult your Rayco dealer for the proper of ignition. procedure of mounting the fire extinguisher.
Page 15 Repair any lines that are loose or damaged. Leaks can speed the engine. The governor controls the maximum safe operating speed of the engine cause fires. Consult your Rayco dealer for repair or for • Never leave this machine unattended with the engine replacement parts.
Page 16 Replacement parts which are authorized site organization is required in order to minimize hazards that by Rayco are the only parts which should be used for are caused by restricted visibility. Job site organization is a repair or replacement on this machine.
Page 17 C100R Operator Booklet Safety Consult your Rayco dealer in order to obtain copies of the Avoid operating the machine across the slope. When possible, material. The information should be reviewed by every person operate the machine up the slopes and down the slopes.
Page 18 A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact Only use work tools that are approved by Rayco for use on on stability. Operator training provides a person with the Rayco machines. Refer to the Operation and Maintenance following abilities: observation of working and environmental Manual, Rayco options”.
Page 19 Welding brackets or drilling holes in the ROPS/FOPS a. Haul the machines between workplaces. Structures can weaken the structures. Consult your Rayco 9. Less operator comfort may be caused by other risk factors. The following guidelines can be effective in dealer for mounting guidelines.
Page 20 Rayco or polycarbonate front guards that are Lock Out Procedure approved by Rayco are available for machines with a cab or 1. All affected persons are to be notified that the equipment an open canopy. On machines that are equipped with cabs, will be off and locked out.
Page 21 C100R Operator Booklet Safety 3. Inform all affected personnel. SIDE to SIDE MOTION (SWAY) THAT BEGINS as you • If a worker who applied the lockout/tag out is not present, reach a certain speed, will likely become WHIPPING at and his supervisor deems it necessary to energize the higher speeds.
Page 22 C100R Operator Booklet Operation Know Your Machine: General Identification - Exterior...
Page 23 C100R Operator Booklet Operation 1. Engine Compartment 7. Loader Lift Cylinder 2. Radiator 8. Loader Bucket Roll Cylinder a. Rear Door 9. Final Drive Motor b. Limb Riser 10. Exterior Lighting 3. Fuel Tank Location a. Front Lights 4. Hydraulic Tank Location b.
Page 24 C100R Operator Booklet Know Your Machine: General Identification - Cab Interior 13. Manual Box 18. Rear Window Escape 14. Adjustable Seat with Seatbelt 19. Fuse Strip Case 15. Washer Fluid 20. Fire Extinguisher 16. Joysticks - See 21. Ceiling Escape Hatch...
Page 25 C100R Operator Booklet Operation Instrument Panel Lamps 4) Battery Charging Lamp - If the ALTERNATOR lamp comes on while the ma chine is operating, the battery is not being prop er ly charged or the fan belt has broken. Shut off the engine, and troubleshoot the electrical charging system.
Page 26 C100R Operator Booklet Operation NOTICE Operator should not activate the Auxiliary Flow Pump (4) for extended operation while cutter wheel 10) Hour Meter/Tachometer - The hour meter indicates is engaged. If both are activated for more the 15 the total operating hours of the engine. It should be used to seconds the cutter wheel will stop.
Page 27 Seat Belt • Keep the windows closed at all times. This means This machine was shipped from Rayco with a factory installed that the operator should refrain from smoking during seat belt. Consult your Rayco dealer for all replacement parts.
Page 28 C100R Operator Booklet Operation Escape Hatch Machine Controls Top Hatch Safety Interlocks This machine has a top escape hatch that is accessible from The engine will not start unless the safety interlocks are both outside and inside. To remove top hatch, unscrew the engaged.
Page 29 C100R Operator Booklet Operation The stick may be moved to any combination of these positions • Move the stick to the left to counter-rotate the machine to the left. to produce simultaneous results. • Move the stick to the right to counter-rotate the machine The top buttons on the right joystick (4) (5) control the flow to the right.
Page 30 These hoses should never be disconnected, 6. Make no alterations or modifications to your Rayco crawler unless requested or rec om mend ed by Rayco unless absolutely necessary and after consulting Manufacturing Inc. a certified Rayco service representative. Rayco 7.
Page 31 C100R Operator Booklet Operation Starting Procedure 13. Clear all personnel from the machine and from the area. 14. Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. 15. Make sure that all windows are clean. Secure the door in the closed position.
Page 32 C100R Operator Booklet Operation While in Operation continue pulling the bucket control joystick back. This cycles oil through the control valves at system relief pressure and will • Know how to shut the machine off in an emergency. shorten the time required to warm up the oil. Cycle the bucket •...
Page 33 C100R Operator Booklet Operation Track Transmission Machine Parking This machine has two independent hydrostatic transmissions 1. Move the direction/speed control lever (LH joystick) to its center position and release. for transferring engine power to the tracks. This is not 2. Move the throttle to SLOW.
Page 34 C100R Operator Booklet Operation Towing the Machine Be sure all necessary repairs and adjustments have been made before a machine that has been towed to a service area is put back into operation. Shields must be provided on both machines. This will protect the operator if either the tow line or the bar breaks.
Page 35 C100R Operator Booklet Operation Transportation Information Tying Down the Machine Shipping the Machine NOTICE Investigate the travel route for overpass clearances. Make Obey all state and local laws governing the weight, sure that there is adequate clearance for the ROPS/FOPS width, and length of the load.
Page 36 S - 1/4” STRIPPED AND TINNED L - 3-PIN WEATHER PACK PLUG 12015793 (W/FEMALE TERM. & SEAL) T - 3-WAY YAZAKI CONNECTOR ASSEMBLY AVAILABLE FROM RAYCO (KUBOTA P/N 16678-65830) M - 2-PIN WEATHER PACK SOCKET 12010973 (W/MALE PIN & SEAL) U - 2-WAY YAZAKI CONNECTOR ASSEMBLY AVAILABLE FROM RAYCO (KUBOTA P/N 1C010-65830) V - 2-PIN WEATHER PACK PLUG 12015792 (W/MALE TERM.
Page 37 TYPE 'E' COMMON AT SHRINK 4" PLUG '15' GROUND PRESSURE TYPE 'S' RAYCO (KUBOTA P/N 16678-65830) SENSOR M RAYCO (KUBOTA P/N 1C010-65830) TYPE 'Y' SEAL) IN ALL CAVITIES) AIR FILTER SWITCH YELLOW SP12 MICRO GROUND BLACK ENG. COOLANT TEMP. IN ALL CAVITIES) GRAY/BLACK MANUAL REVERSE SW.
Page 38 C100R Operator Booklet Electrical Schematic (21643-D) FRESH AIR FAN HIGH WHITE START SOLENOID WHITE/RED HORN SIGNAL YELLOW SP17 2-SPEED VALVE YELLOW SP18 WARNING ALARM LIGHT GREEN MICRO POWER GREEN SEAT SWITCH SIGNAL ORANGE STARTER POWER RED/WHITE LOW COOLANT LEVEL SEAT SWITCH LIGHT...
Page 39 C100R Operator Booklet Electrical Schematic (21643-D) 5V POWER LIGHT BLUE SP20 RH JOYSTICK POWER RED/WHITE SP15 SENSOR GROUND BROWN SP26 AUX. FLOW DOWN ORANGE USB GROUND BLACK RH JOYSTICK POWER RED/WHITE SP15 NOTE USB “-” DATA WHITE RH JOYSTICK POWER...
Page 40 C100R Operator Booklet CAB ELECTRICAL SCHEMATIC (21208-D) PLUG '68' PLUG '69' PLUG '67' IGN. SW. IGN. SW. PLUG '7 LIGHT FRONT LH 6-TERM. 4-TERM. LIGHT FRO TYPE 'D' TYPE 'M' TYPE 'N' TYPE 'D FRESH AIT FAN 4" 12" SW. (HIGH) TYPE 'F' 7"...
Page 41 C100R Operator Booklet CAB ELECTRICAL SCHEMATIC (21208-D) TRACK ALARM 2" GROUND TYPE 'G' 2" TRACK ALARM SIGNAL TYPE 'G' RH TRACK PRESS. 4" PLUG '73' GROUND TYPE 'F' INSTRUMENT PANEL 4" TYPE 'C' RH TRACK PRESS. 16" SIGNAL TYPE 'F' ONT RH LH TRACK PRESS.
Page 42 C100R Operator Booklet CAB ELECTRICAL SCHEMATIC (21208-D) FROM TEMP. LGT PLUG WIRE DESCRIPTION COLOR PLUG TRACK ALARM POWER ALWAYS HOT SEAT SWITCH SIGNAL ORANGE RH JOYSTICK POWER RED/WHITE SEAT SWITCH SIGNAL ORANGE LH JOYSTICK POWER ORANGE COMMON GROUND BROWN IGN SWITCH START...
Page 43 C100R Operator Booklet CAB ELECTRICAL SCHEMATIC (21208-D) LIGHTS SW OUTPUT YELLOW COMMON GROUND BROWN COMMON GROUND BROWN COMMON GROUND BROWN POWER SWITCHED ON MICRO GROUND BLACK PREHEAT SIGNAL LIGHT BLACK COMMON HOT PURPLE AIR PRE-HEATER PINK COMMON HOT PURPLE AIR PRE-HEATER...
Page 44 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807)
Page 45 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807) 800.392.2686...
Page 46 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807)
Page 47 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807) 800.392.2686...
Page 48 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807)
Page 49 C100R Operator Booklet HYDRAULIC SCHEMATIC (801807) 800.392.2686...
Page 50 C100R Operator Booklet HYDRAULIC ADAPTER KIT (801807A-J) ITEM PART # DESCRIPTION FF6500-6-6 ELBOW-90 DEG -6MFF X -6FFFX FF6801-10-12 ELBOW-90 DEG -10MFF X -12MOR FF6400-6-4 CONNECTOR -6MFF X -4MOR FF2405-8-6 CONNECTOR -8MFF X -6FNPT FF6804-12 RUN TEE -12MFF X -12MOR X -12MFF...
Page 51 C100R Operator Booklet HYDRAULIC HOSE KIT (801807-F) 100R1-4-4FFX-4FFX90-38” ABRASION ITEM PART # DESCRIPTION HOSE RESISTANT(100R16 OR 100R17) 10R12AR-10FFX-10FFX90-22” MANULI 100R2-8-8FFX-8FFX-36” ABRASION HOSE HOSE ROCKMASTER/2SN W/FABRIC GUARD RESISTANT(100R16) 10R12AR-10FFX-10FFX90-29” MANULI 100R1-4-4FFX-6FFX90-46” ABRASION HOSE HOSE ROCKMASTER/2SN W/FABRIC GUARD RESISTANT(100R16 OR 100R17) 10SN2AR-10FFX45-12FFX-47” MANULI 100R2-6-6FFX-8MFF-22”...
Page 52 C100R Operator Booklet AIR CONDITIONING AND HEAT HOSE KIT (18654-A)
Page 53 C100R Operator Booklet AIR CONDITIONING AND HEAT HOSE KIT (18654-A) ITEM PART # DESCRIPTION 762808 FIT-4SEL-8FOR-8HOSE END 762812 FIT-90EL-10MOR-8HOSE END 764179 FIT-STR-6MIO-6HOSE END 762810 FIT-STR-8FOR-8HOSE END 101” 762802 HOSE-AC-#6 GH134 AEROQUIP 104” 762803 HOSE-AC-#8 GH134 AEROQUIP 28” 762804 HOSE-AC-#10 GH134 AEROQUIP...
Page 54 Your Rayco machine is filled at the factory with Chevron Heavy Duty Phosphate Free Coolant formulated to meet the heavy-duty engine coolant specifications of TMC RP329 and ASTM D 6210. This coolant is manufactured from ethylene glycol and a highly effective, heavy duty corrosion inhibitor package that is phosphate free and contains nitrates and molybdates.
Page 55 C100R Operator Booklet 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 56 UBRICATION LUID PECIFICATIONS Rayco Lubrication & Fluid Specifications 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 57 MWF Hydrostat Drive C100R Operator Booklet The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50. Do not mix hydrostat and different lubricants! The Differential Gearbox is shipped with 80-90W performance gear oil. Use this fluid or comparable type when refilling.
Page 58 C100R Operator Booklet Specifications Specifications GENERAL Weight (w/omower) ......... . .12,600 lbs. (5715. kg) Weight (w/ith mower) .
Page 59 C100R Operator Booklet Specifications SERVICE PARTS - QUICK REFERENCE HydRAULIC OIL ENGINE AIR CLEANER CHARGE FILtER - 763287 )& ssEmbLy tRACK dRIvE CUttER - 763292 UtER LEmENt WHEEL PUmP - 763291 NNER LEmENt - 11543 ssEmbLy - 764603 ERvICE NdICAtOR...
Page 60 In no event will Rayco receives warranty from their supplier. the dealer and or Rayco be liable for incidental or B. Sprockets Sheaves have a six month limited consequential damages, including but not limited warranty.
Page 62 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.