Rayco Super Jr RG27 Operator, Service, Maintenance Manual
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Rayco Super Jr RG27 Operator, Service, Maintenance Manual

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RG27 / RG35 / RG37
Super Jr
®
OPERATOR · SERVICE · MAINTENANCE MANUAL
RAYCO MANUFACTURING © 2017 ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMRG27/35/37-17

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Summary of Contents for Rayco Super Jr RG27

  • Page 1 RG27 / RG35 / RG37 Super Jr ® OPERATOR · SERVICE · MAINTENANCE MANUAL RAYCO MANUFACTURING © 2017 ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMRG27/35/37-17...
  • Page 2 RG27/35/37 Operation • Service • Maintenance Introduction This manual is published by Rayco Manufacturing, Inc. for the readily available for reference at all times. Additional copies benefit of the users of Rayco products. Rayco Manufacturing, of this manual may be purchased from Rayco.

  • Page 3: Table Of Contents

    RG27/35/37 Operation • Service • Maintenance Table of Contents TABLE OF CONTENTS Forward Safety Operation Maintenance 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...

  • Page 5: Machine Description

    Its 17” diameter cutting Know the width of your equipment in order to maintain proper wheel with 18 Rayco Superteeth® is pow er ful ly driven through clearance with you operate the equipment near fences or a electromagnetic clutch and a Gates Poly Chain®...
  • Page 6 RG27/35/37 Operation • Service • Maintenance Serial Number Location & 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 RG27/35/37 Operation • Service • Maintenance 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 Name Address Dealer Contact...
  • Page 8 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 9: Personal Protective Equipment

    RG27/35/37 Operation • Service • Maintenance 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 10 275kPa (40 psi). Never use compressed air for cleaning. Trapped Pressure 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 11 Rayco recommends the use of dust masks or respirators Do not perform any work until you have read and followed to be worn over the nose and mouth that protect the lungs the proper “Lock-Out / Tag-Out”...
  • Page 12 RG27/35/37 Operation • Service • Maintenance Burn Prevention 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.
  • Page 13 Refer to the Operation Section of this manual for specific instructions. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Rayco dealer for repair or for Do not charge a frozen battery. This may cause an explosion. replacement parts.
  • Page 14 Important: ALWAYS disconnect Electronic Control Unit (ECU) and Maintenance Manual, “Reference Material”. Consult connectors, battery and engine control system-to-machine your Rayco dealer in order to obtain copies of the material. ground before welding on engine or machine. The information should be reviewed by every person that High currents or electrostatic discharge in electronic operates the machine.
  • Page 15 NOTICE any needed repairs to certified service technician. The intended use(s) of this machine e.g. Outdoor Use only Rayco Approved Work Tools on this machine. Obey use only, Trained Operators only. all the lift restrictions. Refer to Operation and Maintenance Manual, “Rayco Approved Work Tools”...
  • Page 16 RG27/35/37 Operation • Service • Maintenance Safety • Always operate this machine with all safety equipment in • Speed of travel – At higher speeds, forces of inertia place and working. Make sure all controls are properly tend to make the machine less stable. adjusted for safe operation.
  • Page 17 RG27/35/37 Operation • Service • Maintenance Safety Only use work tools that are approved by Rayco for use on • A lock is to be placed on each energy source disconnect or energy release block. Rayco machines. Refer to the Operation and Maintenance Manual, Rayco options.

  • Page 18: Forward

    Replacement parts which are PREVENT WHIPPING by properly loading the auto transport authorized by Rayco are the only parts which should be trailer. Load the heaviest end (engine end) of the vehicle-in-tow used for repair or replacement on this machine.
  • Page 19 RG27/35/37 Operation • Service • Maintenance Safety NOT steer sharply and DO NOT brake. Let off the gas DO NOT drive when you are fatigued, sleepy or distracted. pedal and slow down below 25 mph. Then steer gradually Avoid driving at night. back onto the roadway.
  • Page 20 If you suspect or Make sure all tow vehicle and trailer lights function properly. detect something is wrong, contact the nearest Rayco Dealer. The connecting wires need slack to allow your tow vehicle Safety Chains to make turns.
  • Page 21  Towing hitch and hitch-ball are tight. during transport.  Coupler is tight. Unloading the Machine From the Rayco Trailer (optional equipment)  Safety chains, tire straps and security chains are properly attached and secure.

  • Page 22: Safety

    Rayco or polycarbonate front guards that are 3. Keep the terrain in good condition. approved by Rayco are available for machines with a cab or an open canopy. On machines that are equipped with cabs, a. Remove any large rocks or obstacles.
  • Page 23 • Securely place a tag on each energy source disconnect • Replacement decals may be purchased from Rayco Mfg or energy release block. or your Rayco dealer.
  • Page 24 Work Tool options - Attachments one will be endangered. Only use work tools that are approved by Rayco for use on While you operate the machine and the work tool slowly in Rayco machines. Refer to the Operation and Maintenance an open area, check for proper operation of all controls and Manual, Rayco options”.
  • Page 25 RG27/35/37 Operation • Service • Maintenance Safety 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.
  • Page 26 RG27/35/37 Operation • Service • Maintenance Operation Getting to know your machine 1. Operator Panel 6. Cutter Wheel 2. Fuel / Hydraulic Tanks 7. Cutter Boom Belt 3. Blade 8. Engine 4. Steer Axle 9.Swing Out Arm 5. Safety Curtains...

  • Page 27: Starting The Engine

    RG27/35/37 Operation • Service • Maintenance Operation Pre-Starting Inspection Inspect the hydraulic system for leaks. Check the hydraulic oil level. Inspect the machine and perform each of the “Daily Inspections listed in the The Maintenance Manual as needed before operating this machine. Pre-Operation Warm-Up 1.
  • Page 28 RG27/35/37 Operation • Service • Maintenance Operation Operating the Machine Steer Right/Left Machine Movement - RG27/35 (2) Steer machine Left/Right with lever (3) Blade/Boom Movement - Raise and Lower NOTICE The control levers will re-center themselves a neutral position when released. No movement should occur, if you observe any movement when controls are in nuetral position, please contact a service technician immediately and follow the...
  • Page 29 RG27/35/37 Operation • Service • Maintenance Operation NOTE: The operator control station must not be in the 3. You may now empty the remaining fluid back into the plastic bottle from the gun. 4. Reconnect hydraulic hose the brake release fitting you removed earlier in step 3.
  • Page 30 RG27/35/37 Operation • Service • Maintenance Operation Cutting Wheel Precautions NOTICE 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 BEFORE ENGAGING THE CUTTER WHEEL, THE adjusting th throttle higher.
  • Page 31 RG27/35/37 Operation • Service • Maintenance 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. 4: Cut another level of the stump: •...
  • Page 32 RG27/35/37 Operation • Service • Maintenance Operation Stopping The Machine damaged. The drive motor must be replaced. Failure to keep the ground-drive brake in working condition can result in a machine moving unexpectedly, causing injury or death. The machine must be taken out of service until the ground-drive motor is repaired or replaced.

  • Page 33: Machine Storage

    RG27/35/37 Operation • Service • Maintenance Operation Machine Storage seal and make sure the valve works smoothly before starting the engine. Preparing for Storage 7. Store the machine in a flat place and remove the key Store the machine in a dry protected place. If the machine from the engine.
  • Page 34 ONLY be performed by a trained specialists or qualified person. CALIFORNIA Proposition 65 Warning Please contact Rayco Mfg for a Diesel engine exhaust and some of its constituents are listing of approved maintenance known to the state of California to cause cancer, birth facilities in your area.
  • Page 35 RG27/35/37 Operation • Service • Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 36 RG27/35/37 Operation • Service • Maintenance Maintenance Daily or Every 10 Hrs Maintenance Interval Every 50 Hrs Maintenance Interval Walk Around Inspection See list Slewing Ring Grease Engine Oil Level Check & Replace if needed SOA Bushings Grease Oil Cooler Clean Pivot Bushings Grease...
  • Page 37 RG27/35/37 Operation • Service • Maintenance Maintenance Engine Oil & Filter - Change Walk-Around Inspection Follow directions in the Engine Operator Manual 1. Inspect the cutting boom cylinders and linkage for damage or excessive wear. Repair if dam aged. 2. Inspect and remove any chip or residue buildup in and around the engine.

  • Page 38: Operation

    RG27/35/37 Operation • Service • Maintenance Maintenance Hydraulic Oil - Check 3. Place a container below the hose and fitting located underneath the hydraulic pump. NOTICE 4. Remove the hose from the fitting and allow the oil to Replace oil if it smells burnt or appears to be dirty. drain into the container.
  • Page 39 RG27/35/37 Operation • Service • Maintenance Maintenance Fuel Tank - Fill Replace Both Filters • Check the service indicator (3). • Unfasten the clamps (4) holding the end cap of the air cleaner and remove. After replacing the cartridge(s), replace the end cap of the air cleaner and lock the clamps GASOLINE IS HIGHLY COMUSTIBLE.
  • Page 40 RG27/35/37 Operation • Service • Maintenance Maintenance Tires and Rims - Check Battery - Check • Check tires for correct pressure. Inflate to 22 psi (1.5 bar). • Check tires and rims for damage. • Check lug nuts for tightness. Torque to 85 ft-lb (115 Nm). ALWAYS WEAR PROTECTIVE CLOTHING AND EYEGLASSES WHEN WORK ING WITH BATTERY.
  • Page 41 RG27/35/37 Operation • Service • Maintenance Maintenance Grease / Oil Build-Up - Remove Slewing Ring ACCUMULATED GREASE AND OIL ON A MACHINE IS A FIRE HAZARD. REMOVE SUCH DEBRIS WITH STEAM CLEAN ING OR HIGH PRESSURE WATER. SEE THE NOTE BELOW FOR DETAILS. Lubricate 3-4 shots of grease into the grease fitting NOTICE on the slewing ring (3) (located under the boom asm).
  • Page 42 RG27/35/37 Operation • Service • Maintenance Maintenance 4) Blade Bushings (If Equipped) Cutting Wheel - Lubricate Lubricate 3-4 shots of grease into the grease fittings (1). Note: there should be 4 total fittings. 5) Steering Axle Pivot Knuckles Lubricate the two fittings (5) (one on each side) until you can visually see old grease being purged out of the side of the bearing.
  • Page 43 RG27/35/37 Operation • Service • Maintenance Maintenance • The belt should deflect 1/2” when 12-15 lbs. force is 2. Plunger Gage. The belt tension should be set to deflect applied. 1/2” using 18-20 lbs force with a belt plunger gage. If tension is acceptable, proceed to step 7.

  • Page 44: Changing Teeth

    Replacement teeth are available from your Rayco dealer or • Number of Teeth for Depth of Cut: Rayco’s cutter wheels are designed to provide an economical cutting wheel direct from Rayco. Refer to the Parts manual for part numbers assembly solution.
  • Page 45 22)Cutter Wheel - Part#28515 Qty of 1 performance. Replacement teeth are available from your Rayco dealer or direct from Rayco. The Cutter Wheel on the RG27/35 / RG27/35 uses 6 different NOTICE types of SuperTeeth as shown below: DO NOT hammer the tip of a tooth.

  • Page 46: Maintenance

    RG27/35/37 Operation • Service • Maintenance Maintenance PTO Clutch Brake Air Gap Parts that DO NOT require maintenance • Bearings - sealed for life of the clutch • Armature, Rotors, Brake - wear evenly and can not be replaced individually. •...
  • Page 47 RG27/35/37 Operation • Service • Maintenance Maintenance - Notes 800.392.2686...

  • Page 48: Troubleshooting

    RG27/35/37 Operation • Service • Maintenance Service Troubleshooting When output is insufficient Engine Cause Countermeasures Use the following information to determine the source and Carbon stuck ►Clean orifices and needle valve being very solution to problems you may encounter related to the engine. around orifice of careful not to damage the nozzle orifice..
  • Page 49 RG27/35/37 Operation • Service • Maintenance Service When engine overheats Cause Countermeasures Engine oil ►Check oil level. Refill as necessary insufficient Fan belt broken ►Change belt or adjust belt tension. or elongated Coolant insuf- ►Replenish coolant. ficient Excessive ►Add water only or change to coolant with the concentration specified mixing ratio.
  • Page 50 RG27/35/37 Operation • Service • Maintenance Wiring Schematic...
  • Page 51 RG27/35/37 Operation • Service • Maintenance Wiring Schematic 800.392.2686...
  • Page 52 RG27/35/37 Operation • Service • Maintenance Hydraulic Schematic - RG27 (802591-D) RG27 BLADE OPTION: 802597 - HYD. KIT STANDARD ON RG35 OVER CENTER VALVE (K) + FITTINGS, LIFT CYLINDER (N) + FITTINGS, AND HOSES 8 AND 10 ARE FROM HOSE KIT 802591...
  • Page 53 RG27/35/37 Operation • Service • Maintenance Hydraulic Schematic - RG27 (802591-D) 738004 3 BANK VALVE 12579 HYDRAULIC TANK 12575 FUEL TANK 761906 HYDRAULIC FILTER ASM. 760115 PUMP - HYDRAULIC 738008 VALVE - SWING CONTROL 801152 DUAL COUNTER-BALANCE W/PILOT PORT 802526 MOTOR DRIVE/BRAKE PARKER 738011 VALVE-LOCK SWING...
  • Page 54 RG27/35/37 Operation • Service • Maintenance Hydraulic Schematic - RG37 (802846)
  • Page 55 RG27/35/37 Operation • Service • Maintenance Hydraulic Schematic - RG37(802846) 802819 4 BANK VALVE(RG35) 12579 HYDRAULIC TANK 12575 FUEL TANK 761906 HYDRAULIC FILTER ASM. 764215 PUMP - TANDEM .31/.31 738008 VALVE - SWING CONTROL 801152 DUAL COUNTER-BALANCE W/PILOT PORT 802526 MOTOR DRIVE/BRAKE PARKER 738011 VALVE-LOCK SWING...

  • Page 56: Specifications

    RG27/35/37 Operation • Service • Maintenance Specifications...
  • Page 57 Specifications Lubricating Grease All Rayco products are completely serviced at the factory before shipping. The operator should check all grease fittings to familiarize with the location and correct service schedule plan. Use the normal shutdown procedure (See “Operating Instructions”), before lubricating the machine.

  • Page 58: Specifications

    Hydraulic Oil (Petroleum-Mineral Base) Your Rayco machine is filled at the factory with Conoco Powerflow AW HVI 46 Hydraulic Fluid. This oil is formulated to provide the proper operating characteristics in a wide range of climates. When refilling, always use Conoco Powerflow AW HVI 46 or one of the recommended brands below.
  • Page 59 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 60: Warranty

    Swing Pivot Bearings: 9” diameter slewing ring Jackshaft Bearings: 1.5” Pillow Block Minimum Brakes: Rear - Spring Applied Hydraulic Release Cutting Teeth: RAYCO Super tooth™ forged,One-piece, with tungsten carbide tips. Tires: 18 x 8.5-10 R4 4 ply Cutter Teeth Quantity: 18 Maximum Drive Axle Bearings: 1-1/2”...
  • Page 61 Drive Chain: Gates Polychain GT, Low Maintenance Jackshaft Bearings: 1.5” Pillow Block Minimum Brakes: Rear - Spring Applied Hydraulic Release Cutting Teeth: RAYCO Super tooth™ forged, Tires: 18 x 8.5-10 R4 4 ply One-piece, with tungsten carbide tips. Drive Axle Bearings: 1-1/2” flange roller minimum w/grease fitting...
  • Page 62 Drive Chain: Gates Polychain GT, Low Maintenance Jackshaft Bearings: 1.5” Pillow Block Minimum Brakes: Rear - Spring Applied Hydraulic Release Cutting Teeth: RAYCO Super tooth™ forged, Tires: 18 x 8.5-10 R4 4 ply One-piece, with tungsten carbide tips. Drive Axle Bearings: 1-1/2” flange roller minimum w/grease fitting...
  • Page 63 RG27/35/37 Operation • Service • Maintenance 800.392.2686...
  • Page 64 RG27/35/37 Operation • Service • Maintenance Service Parts - 750200 nginE iltEr - 763494 iltEr - 761906 ydraulic Eturn iltEr ssEmbly - 761908 iltEr lEmEnt - 761910 ipstick - 761909 EstrictiOn ndicatOr - 780270 utEr iltEr artridgE - 750202 nnEr iltEr artridgE - 761600...
  • Page 65 For warranty service, the purchaser is to contact manufacturer directly. connection with the branch of performance on any warranty on any Rayco product are those set forth on this page. In • 4.Various Components no event will the dealer and or Rayco be liable for incidental a.
  • Page 66 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.

This manual is also suitable for:

Super jr rg35Super jr rg37

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