Rayco RG25HD Operator, Service, Maintenance, Parts Manual
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Rayco RG25HD Operator, Service, Maintenance, Parts Manual

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RG25HD
OPERATOR • SERVICE • MAINTENANCE • PARTS
MANUAL
RAYCO MANUFACTURING © 2015 ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSPMRG25HD-15

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Summary of Contents for Rayco RG25HD

  • Page 1 RG25HD OPERATOR • SERVICE • MAINTENANCE • PARTS MANUAL RAYCO MANUFACTURING © 2015 ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSPMRG25HD-15...
  • Page 2 RG25DH Operation • Service • Maintenance • Parts Manual 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

    RG25DH Operation • Service • Maintenance • Parts Manual TABLE OF CONTENTS Forward Safety Operation Maintenance Specifications Troubleshoot 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

    RG25DH Operation • Service • Maintenance • Parts Manual Foreword Certified Engine Maintenance If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards. Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty Machine Description off-road engine owner, you are responsible for the required Design...
  • Page 6 Breakdown of the serial number For Example:RG25HD 001 01 15 RG25HD - Type of Rayco equipment you have 001 - Three digit for the number of produced 01 - Two digit month, 01 = Jan., 02 = Feb., etc...
  • Page 7 RG25DH Operation • Service • Maintenance • Parts 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 Name...

  • Page 8: Important Safety Information

    Rayco, you must use it only if you have accurately evaluated precautions. An accident can often be avoided by recognizing it and found that it threatens no one’s safety. You should potentially hazardous situations before an accident occurs.

  • Page 9: Personal Protective Equipment

    RG25DH Operation • Service • Maintenance • Parts Manual Safety General Hazard Information 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. Personal Protective Equipment (PPE) Head protection - must conform to ANSI Z89.1 and DO...
  • Page 10 Pressure can be trapped in a hydraulic system. Releasing Asbestos Information trapped pressure can cause sudden machine movement Rayco recommends the use of only genuine Rayco or attachment movement. Use caution if you disconnect replacement parts. Use the following guidelines when you hydraulic lines of fittings.
  • Page 11 RG25DH Operation • Service • Maintenance • Parts Manual Safety • Obey environmental regulations for the disposal of a sudden change in clearance with machine movement or asbestos. equipment movement. • Stay away from areas that might have asbestos particles Avoid contact with the rotating feed wheel, cutter wheel in the air and rotor.
  • Page 12 RG25DH Operation • Service • Maintenance • Parts Manual Safety Burn Prevention 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 Repair such components in a well ventilated area away from open flames or sparks. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Rayco dealer for repair or for Inspect all lines and hoses for wear or for deterioration. The replacement parts.
  • Page 14 Replacement parts which are and watch the machine in operation. authorized by Rayco are the only parts which should be • Familiarize yourself with all of the controls in a safe used for repair or replacement on this machine.
  • Page 15 Maintenance Manual, “Reference Material”. Consult Parking your Rayco dealer in order to obtain copies of the material. Park on a level surface. If you must park on a grade, chock The information should be reviewed by every person that the machine.
  • Page 16 RG25DH Operation • Service • Maintenance • Parts Manual Safety 6. Disconnect the operator restraint devices (if equipped) • Height of machine working load. When the working loads and exit the machine. are in higher positions, machine stability is reduced. 7.

  • Page 17: Safety Decals

    Rayco or polycarbonate front guards that are on the equipment from being injured by its unexpected approved by Rayco are available for machines with a cab or energized or releasing stored energy. This section summarizes an open canopy. On machines that are equipped with cabs, the applicable requirements for lockout/ tag out procedures, the windshield should also be closed.
  • Page 18 RG25DH Operation • Service • Maintenance • Parts Manual Safety 1. The lock is to be placed directly on the equipment if when all locks are removed can the equipment be energized. provided with an integral locking device. Pre-Transportation Checks 2.
  • Page 19 RG25DH Operation • Service • Maintenance • Parts Manual Safety A “combination disturbance” is improper handling, whipping, NEVER use a cell phone when driving. If you need to use a sway, over-steering or other deviation of the tow vehicle or cell phone find a safe place to exit the roadway.

  • Page 20: Forward

    Use the ramps before driving on the ramps. checklist at the end of these instructions. If you suspect or detect something is wrong, contact the nearest Rayco Dealer. Approach ramps slowly, check angle of machine to insure Safety Chains proper alignment with trailer, then proceed to drive up ramps into trailer.
  • Page 21  Towing hitch and hitch-ball are the right size and tight. during transport.  Coupler is tight. Unloading the Machine From the Rayco  Safety chains, tire straps and security chains are Trailer (optional equipment) properly attached and secure.
  • Page 22 RG25DH Operation • Service • Maintenance • Parts Manual Getting to know your machine Above is an overview of the basic machine components. 3. Battery They are explained in more detail on the following pages. 4. Cutting Wheel 1. Operator Presence Control 5.

  • Page 23: Machine Controls

    Everyone must avoid the DANGER ZONE at all times when the machine is in operation! and locations). 8. Make no alterations or modifications to your Rayco Hardware - Check the machine for loose, worn, or missing stump cutter unless requested or recommended by parts and hardware.

  • Page 24: Safety

    (1) Connect the red positive (+) jumper cable to the positive (+) terminal of battery of the stalled machine, For highway travel a Rayco trailer is available. There are legal where the battery red positive (+) cable is already road requirements for towing equipment and trailers (such as connected.
  • Page 25 RG25DH Operation • Service • Maintenance • Parts Manual Operation Pre-Operation Warm-Up 1. Allow the engine to warm up at low idle for two minutes. 2. Move the engine throttle to the maximum engine speed. Run the engine for an additional two minutes. This will allow the oil to reach relief pressure, which causes it to warm up more rapidly.

  • Page 26: Removing Stumps

    RG25DH Operation • Service • Maintenance • Parts Manual Operation Removing Stumps • 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 27: Storing The Machine

    RG25DH Operation • Service • Maintenance • Parts Manual Operation to another side of the stump to continue removal, or by Lubricate all parts that have grease fittings, as outlined in the filling the hole with chips before continuing. “Maintenance Intervals” section of this manual, to prevent rust. •...
  • Page 28 California to cause cancer, birth defects, and other reproductive harm. 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 29 Burnish maintenance intervals listed this Every 300 Service Hrs “Maintenance Intervals” section of this RG25HD Tires Inspect STUMP CUTTER Operator Manual includes engine Every 500 Hrs or 1 Year Maintenance Interval care topics. For the complete information, consult Bendix Starter Drive Service the Engine Operation Manual.
  • Page 30 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes...
  • Page 31 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 32 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Engine Oil Level Fuel Tank - Fill DO NOT SMOKE OR ALLOW ANYTHING CARE MUST BE TAKEN BY THE SERVICE PERSON FLAMEABLE NEAR MACHINE WHILE REFUELING. TO PREVENT BEING BURNED BY HOT OIL. NOTICE Check only when the machine is in a level position.

  • Page 33: Changing Teeth

    & reduce bearing life. 5. Install new element(s) • Number of Teeth for Depth of Cut: Rayco’s cutter wheels 6. Reinstall end cap(s) with dust ejector valve/screen down: are designed to provide an economical cutting wheel secure with retaining clips.

  • Page 34: Sharpening Of Teeth

    • Position teeth as shown in the drawing above. Straight teeth and bent teeth should be alternated as shown in the drawing. • When using Rayco brand square-shanked teeth, set extreme edge of each tooth 1¼” away from edge of pocket.
  • Page 35 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Grease and Oil Buildup - Remove V-Belt Tension - Check ACCUMULATED GREASE AND OIL ON A MACHINE BEFORE BEGINNING TO CHECK OR ADJUST IS A FIRE HAZARD. REMOVE SUCH DEBRIS WITH THE BELT: SHUTDOWN THE MACHINE, ENSURE STEAM CLEANING OR HIGH PRESSURE WATER.

  • Page 36: Hydrostatic Drive

    RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Hydrostatic Drive NOTICE NOTICE To extend belt life proper tension must be Do not mix hydrostat and differential lubricants. maintained. A loose belt will cause exessive cutting wheel slippage and belt failure. A belt that is too The drive unit, which consists of the hydrostatic transmission tight can cause bearing, shaft and belt failure.
  • Page 37 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance 2. Reinsert into the threaded holes in the hub. to the second slot in lever and engage it into the frame in that second slot. 3. Turn each bolt by small equal amounts until the tapered hub disengages.

  • Page 38: Operation

    RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Storing the Machine Adjust the tension of the belts in accordance with the instructions contained in this manual’s “Every 50 Service Preparing the Machine for Storage Hours” section. NOTICE Mount the battery and connect the cables to the machine. Do not start or run the engine with the “by-pass”...
  • Page 39 RG25DH Operation • Service • Maintenance • Parts Manual Fluid Specifications MWF Hydrostat Drive The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50. Use this fluid or comparable type when refiling. Lubricating Grease All machines 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.
  • Page 40 Ignition System Poor Compression Should more extensive repair be needed, we recommend you contact a local Rayco Dealer for repair. Repair manuals are also available from your local dealer or direct from www.TecumsehPower.com. A complete list of the available manuals can be found at the end of this book.

  • Page 41: Ignition System

    RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting Four Cycle Troubleshooting - continued To reduce the risk of serious injury or death from fires and/or explosions, NEVER use flammable solvents (e.g., gasoline) to clean serviceable parts. Use a water-based, non-flammable solvent Degreaser Cleaner.
  • Page 42 RG25DH Operation • Service • Maintenance • Parts Manual Maintenance Basic Gear Drive Troubleshooting Preparation NOTE Before troubleshooting any system problem, see instructions. Make your troubleshooting easier by preparing as follows: • Work in a clean, well-lighted place. • Keep proper tools and materials nearby. •...

  • Page 43: Troubleshooting Chart

    3. Check pulley condition and wheels for sheared or damaged keys. TecumsehPower Hydrostatic Transaxle 4. Check drive belt condition, if glazed or worn, replace it. Troubleshooting 5. Possible internal transmission damage. We suggest you contact a local Rayco Dealer. Hydrostatic Transmission Final Drive...
  • Page 44 Check, replace worn bearings Hydrostatic transmission noise Replace hydrostatic transmission Mechanical disconnect not properly engaged, check for obstruction RG25DH Operation • Service • Maintenance • Parts Manual Transaxle clicking Check, replace mechanical disconnect Troubleshooting components (If hydrostatic transmission shaft is damaged, replace transmission) Belt worn, replace Improper belt tension (See O.E.M.
  • Page 45 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting Troubleshooting 3. Leakage: The VST and 1800 Series have two oil reservoirs which can be checked for diagnostic The information on this page has been provided to help purposes. The first is the pump and motor expansion understand the internal operation.
  • Page 46 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting Light Duty Hydrostatic Internal Features Model 6 Reservoir Ball Piston Hydraulic Motor Ball Piston (Fixed Displacement) Hydraulic Pump (Variable Displacement) Cam Ring (for Varying Pump Displacement and Direction of Flow) Input Shaft Wide Band...
  • Page 47 Light Duty Hydrostatic RG25DH Operation • Service • Maintenance • Parts Manual Model 6 Troubleshooting Internal Reservoir/Expansion Tank Air Bleed Plug Coupling and Pulley (Customer Supplied) Output Shaft Input Shaft Dump Valve Cooling Tapered Control Shaft — (Customer for Installation Supplied) of a Customer Control Lever...

  • Page 48: Maintenance

    RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting...
  • Page 49 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting 800.392.2686...
  • Page 50 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting...
  • Page 51 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting 800.392.2686...
  • Page 52 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting...
  • Page 53 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting 800.392.2686...
  • Page 54 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting...
  • Page 55 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting 800.392.2686...
  • Page 56 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting...
  • Page 57 RG25DH Operation • Service • Maintenance • Parts Manual Troubleshooting 800.392.2686...
  • Page 58 RG25DH Operation • Service • Maintenance • Parts Manual RG25HD - Full Assembly Rev. ITEM QTY. PART # DESCRIPTION 26965 TAG- SN/VIN RAYCO 5565 WELDMENT FRAME 26967 TAG- EPA GAS, EMISSION INFO 3294 DRIVE ASSY-CUTTER WHEEL 750463 RIVET-3/16 X 3/8 STLMAND...
  • Page 59 RG25DH Operation • Service • Maintenance • Parts Manual RG25HD - Full Assembly Rev. 800.392.2686...
  • Page 60 RG25DH Operation • Service • Maintenance • Parts Manual 3294 Drive Asm - Rev.A 16 18 17 ITEM QTY. PART # DESCRIPTION 722505 BOLT HEX 1/2-13 x 1 3/4 1495 SHAFT,CW 724501 NUT HEX 1/2-13 GR8 1502 CUTTER WHEEL ASSY. 724507 NUT LOCK 7/16-20 GR8 2581-05 1/4 keystock x 1 3/4 726501 WASHER FLAT 1/2...
  • Page 61 RG25DH Operation • Service • Maintenance • Parts Manual 12404 Curtain Kit - Rev. ITEM QTY. PART # DESCRIPTION 2905 CURTAIN-REAR 12395 REAR,CHIP WELDMENT 1526 CURTAIN 12397 BRKT-MTG, CURTAIN WELD. 1521 CURTAIN 4024 CURTAIN-SIDE FRONT LEFT 4023 BUFFER, BELT GUARD 1524 CURTAIN 12781...
  • Page 62 17646 Engine Asm - Rev. C 20 21 ITEM QTY. PART # DESCRIPTION 610020 CLUTCH-ELECTRIC 1-7/16 ID 803383 ENGINE-25HP KOHLER RG25HD 4900-57 WASHER-FLAT 2.230 OD x 0.656 ID 803385 AIR CLEANER, KOHLER 25HP 726702 WASHER LOCK 5/8 GR8 764484 MUFFLER-25HP COMMAND...
  • Page 63 RG25DH Operation • Service • Maintenance • Parts Manual 28198 Fuel Tank Assembly 21898- ITEM QTY. PART # DESCRIPTION 738216 FIT-EL90 -2MP -2FP FUEL TANK WELDMENT 750040 FIT- -4MB -2MP 801682 CAP-FUEL FULL TURN EPA 724508 NUT LOCK 1/4-20 NYLOCK 801681 GROMMET-ROLL OVER VENT 722103 BOLT HEX 1/4-20 X 3/4 GR8 801680 VENT-ROLL OVER...
  • Page 64 RG25DH Operation • Service • Maintenance • Parts Manual 5567 Handle Bar Assembly - Rev. B 14 15 16 ITEM QTY. PART # DESCRIPTION 726101 WASHER FLAT 1/4 USS 5568 WELDMENT HANDLE BAR 722109 BOLT HEX 1/4-20 X 3 GR8 1501 LOCK PIN ASSEMBLY 724101...
  • Page 65 RG25DH Operation • Service • Maintenance • Parts Manual 4909 Bail Assembly - ITEM QTY PART # DESCRIPTION 630011 SPRING, DEADMAN SWITCH 728014 PIN, CLEVIS 4916 TAB, ADJUST 726101 WASHER, FLAT 1/4” 4907 KILL SWITCH ROD 724500 NUT 1/4-20 728000 PIN, COTTER 724101 NUT HD 1/4-20 GR8 1601 HANDLE, BAIL...
  • Page 66 RG25DH Operation • Service • Maintenance • Parts Manual Hydraulic Drive Assembly...
  • Page 67 RG25DH Operation • Service • Maintenance • Parts Manual Hydraulic Drive Assembly ITEM # QTY. PART # DESCRIPTION 722337 BOLT CARRIAGE 3/8−16 X 1−1/2 WELDMENT FRAME 620001 PULLEY − IDLER BRACKET, ADJ., ENGINE, WELD- 620002 PULLEY − TRANSMISSION 3387 MENT 620004 TRANSMISSION −...
  • Page 68 RG25DH Operation • Service • Maintenance • Parts Manual Decal Kit 26949- ITEM QTY PART # DESCRIPTION 640056 WARNING 1.DO NOT 30175 RAYCO HORIZONTAL LOCKUP 13”W 640058 EXCESSIVE BELT TENSION 30177 RAYCO VERTICAL LOCKUP 6”H 732008 CAUTION EAR & EYE 30190 MINI WORK-FORCE...
  • Page 69 RG25DH Operation • Service • Maintenance • Parts Manual Decal Kit 26949- 800.392.2686...
  • Page 70 RG25DH Operation • Service • Maintenance • Parts Manual Service Parts ENGINE OIL FILTER ENGINE FUEL FILTER 750117 750241 FUEL CAP 760780 AIR CLEANER CARTRIDGES 803385 - 803387 NNER - 803386 UTER...
  • Page 71 For warranty service, the purchaser is to connection with the branch of performance on any warranty contact manufacturer directly. 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 72: Specifications

    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.

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