Rayco RG55R Operator, Service, Maintenance Manual
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Rayco RG55R Operator, Service, Maintenance Manual

Stump cutter
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RG55R Stump Cutter
OPERATOR • SERVICE • MAINTENANCE MANUAL
RAYCO MANUFACTURING © 2019 - ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMRG55R-19

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Summary of Contents for Rayco RG55R

  • Page 1 RG55R Stump Cutter OPERATOR • SERVICE • MAINTENANCE MANUAL RAYCO MANUFACTURING © 2019 - ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMRG55R-19...
  • Page 2 RG55R Operation • Service • Maintenance Introduction This manual is published by Rayco Manufacturing, Inc. for the of this manual may be purchased from Rayco. benefit of the users of Rayco products. Rayco Manufacturing, This Rayco machine was designed and manufactured by Inc.

  • Page 3: Table Of Contents

    RG55R Operation • Service • Maintenance Table of Contents TABLE OF CONTENTS Foreword Safety Operation Maintenance Specifications Troubleshoot Warranty 800.392.2686...

  • Page 4: Foreword

    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 Its 20” diameter cutting wheel with Operator, Maintenance & Service Manual. 24 Rayco Super teeth is pow er ful ly driven through a 54 Attach a “Do Not Operate” warning tag or a similar warning horsepower Kubota gasoline engine. Cutting boom motion tag to the start switch or to the controls before you service and the self-propel drive are entirely hydraulic, with 2 speeds.
  • Page 6 Breakdown of the serial number For Example: RG55R 001 01 19 RG55R - 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 RG55R 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...

  • Page 8: Safety

    Safety Important Safety Information or operating technique not specifically recommended by Rayco, you must use it only if you have accurately evaluated Most accidents that involve product operation, maintenance it and found that it threatens no one’s safety. You should...

  • Page 9: Personal Protective Equipment

    RG55R Operation • Service • Maintenance Safety General Hazard Information Personal Protective Equipment Head protection - must conform to ANSI Z89.1 and DO NOT wear under chin strapping while operating or within the • Read, understand and follow all instructions on the machine and in the manuals before attempting to operate.
  • Page 10 Asbestos Information cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective Rayco recommends the use of only genuine Rayco face shield. replacement parts. Use the following guidelines when you The maximum air pressure for cleaning purposes must be...
  • Page 11 Whenever there are equipment control linkages, the clearance in the linkage area will change with the movement of the Rayco recommends the use of dust masks or respirators equipment or the machine. Stay clear of areas that may have to be worn over the nose and mouth that protect the lungs a sudden change in clearance with machine movement or from air-borne dust and irritants.
  • Page 12 RG55R Operation • Service • Maintenance Safety Burn Prevention 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.
  • Page 13 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. 800.392.2686...

  • Page 14: Safety Decals

    • Outer coverings are chafed or cut. approved by Rayco or polycarbonate front guards that are • Wires are exposed. approved by Rayco are available for machines with a cab or an open canopy. On machines that are equipped with cabs, • Outer coverings are ballooning.
  • Page 15 • Warning symbols or warning signs on machines or any needed repairs to certified service technician. on vehicles Use only Rayco Approved Work Tools on this machine. Obey • A system of communication all the lift restrictions. Refer to Operation and Maintenance Manual, “Rayco Approved Work Tools”...
  • Page 16 RG55R Operation • Service • Maintenance Safety Maintain control of the machine. Do not overload the machine could be thrown during operation. beyond the machine capacity. • Never move this machine, or make adjustments or repairs, while the engine is running.
  • Page 17 2. If there is no integral lockout device on the equipment, Only use work tools that are approved by Rayco for use on securely attach an independently manufactured lockout Rayco machines. Refer to the Operation and Maintenance device on the equipment and then place the lock on the Manual, Rayco options.
  • Page 18 Replacement parts which are reach a certain speed, will likely become WHIPPING at authorized by Rayco are the only parts which should be used for repair or replacement on this machine. higher speeds. If you notice sway beginning SLOW DOWN IMMEDIATELY by letting off the gas pedal.
  • Page 19 RG55R Operation • Service • Maintenance Safety (vehicle carried on trailer). BEFORE going downhill, slow down and shift the transmission IF WHIPPING or SWAY OCCURS, DO NOT steer. DO into a lower gear. DO NOT RIDE BRAKES on downgrades. NOT apply your brakes and NEVER speed up. Let off the gas Slow down for curves, adverse weather, hazardous road pedal and hold the steering wheel in a straight-ahead position.
  • Page 20 If you suspect or can affect its ability to tow. These changes can include different detect something is wrong, contact the nearest Rayco Dealer. tires, suspension changes, etc. Check your owner’s manual Safety Chains...
  • Page 21 RG55R Operation • Service • Maintenance Safety securely attached to your tow vehicle hitch. Make sure the safety chains are properly connected. During the loading process, keep bystanders at least 25 feet away. Make sure that the entire width of the tires will be on the ramps before driving on the ramps.

  • Page 22: Operation

    RG55R Operation • Service • Maintenance Operation 1. Operator Panel 4. Cutter Wheel 2. Blade 5. Battery / Hydraulic Tank 3. Safety Curtains 6. Tires (unroll before cutting stump)
  • Page 23 RG55R Operation • Service • Maintenance Operation 7. Cutter Boom Belt 10. Fuel Tank 8. Engine 11. Air FIlter 9. Swing Out Arm 800.392.2686...
  • Page 24 The control switches will re-center themselves in g: Engine throttle toggle. a neutral position when released. No movement h: Travel speed - Rayco recomends only using the fast should occur, if you observe any movement when speed while traveling between stumps.
  • Page 25 12. Battery Indicator Light 13. Engine Throttle 14. Propel Speed High/Low To adjust the command cut speed when using a RG55R, adjust the needle valve (15) below the operator panel. If the cutter boom lunges while cutting the stump the command cut is set too slow.
  • Page 26 (4) at the same time. To turn off the cutter wheel, simply tun the switch off. The cutter wheel on the RG55R has preset parameters to engage and disengage. If the engine RPM’s are too low the cutter wheel will not engage to prevent engine stall. If the engine RPM’s are too high the cutter wheel will not engage...
  • Page 27 RG55R Operation • Service • Maintenance Operation 800.392.2686...
  • Page 28 RG55R Operation • Service • Maintenance Operation Blade Transition for Transporting The RG55R comes equipped with a 50 1/2” wide blade. For convenience of transporting through gates, or to load and unload on and off a trailer, the blade has wings (16) that can swing in to be only 34 1/2”...
  • Page 29 RG55R Operation • Service • Maintenance Operation Transporting in Freewheel Mode Re-engage The Wheel Motors 1. Reopen the valve on the gun(25). This will allow the In the event of a machine malfunction, the stump cutter may be charged hydraulic fluid to drain back into the gun.

  • Page 30: Starting The Engine

    Rear Blade Operation If the key switch is released before the engine starts, wait The RG55R can be started and moved with the Swing Out until the starter and the engine stops turning before trying Arm (SOA) in the transport position with the operator standing again.
  • Page 31 RG55R Operation • Service • Maintenance Operation Starting With Jumper Cables boost machine. c. Connect the black negative (-) jumper cable to the 1. On the stalled machine, turn the start switch to OFF. negative (-) terminal of the boost machine battery.
  • Page 32 RG55R Operation • Service • Maintenance Operation Removing Stumps NOTICE Call 8-1-1 Before You Dig Wind direction should be considered, as it influences the direction that dust and wood chips will be directed. NOTICE Always allow a cold engine time to warm-up before cutting a stump.
  • Page 33 RG55R Operation • Service • Maintenance Operation Stump Removal Procedure cutting wheel is gone. 4: Cut another level of the stump: 1: Prepare the machine at the stump: • Raise the cutting wheel above the stump once again, and starting with the cutting wheel swung to one side, •...
  • Page 34 RG55R Operation • Service • Maintenance Operation Stopping The Machine Machine Storage Preparing for Storage Store the machine in a dry protected place. If the machine must be stored outside, cover it with a waterproof canvas or other material. DUE TO HIGH SPEED LOW-FRICTION...
  • Page 35 COULD CAUSE SERIOUS INJURY OR DEATH CAUSING THE MACHINE TO CRUSH THE OPERATOR. bed. The preferred method is towing it on a Rayco trailer (available from Rayco). Comply with all local laws dealing with the towing of a trailer. Before towing the machine on the Rayco trailer (optional equipment), make sure of the following: 1.
  • Page 36 RG55R Operation • Service • Maintenance Maintenance Maintenance The maintenance section is a guide to equipment care. The Maintenance Interval Schedule lists the items to be Proper maintenance and repair is essential to keep the engine maintained at a specific service interval. The Maintenance and machine systems operating correctly.
  • Page 37 RG55R Operation • Service • Maintenance Maintenance Engine Identification UNDERSTAND AND HEED TO THE INSTRUCTIONS LISTED IN THE SAFTEY SECTION OF THE MANUAL. IN IT’S ENTIRETY, BEFORE SERVICING THE MACHINE. NOTICE Park the machine on stable and level ground before service or maintenance is performed.
  • Page 38 RG55R Operation • Service • Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes...
  • Page 39 RG55R Operation • Service • Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 40 Change the engine oil and filter cartridge after the first 50hrs. ф Indicates to lubricate every two hours. Rayco recomendes this to prevent dirt from entering bearing. *** CHANGE THE AIR CLEANER ELEMENT MORE FREQUENTLY THAN THE ABOVE SCHEDULE INDICATES WHEN OPERATING UNDER DUSTY CONDITIONS***...
  • Page 41 RG55R Operation • Service • Maintenance Maintenance Engine Oil Level sure to tighten the fitting securely back ontot the oil pan before filling engine with new oil. Engine Oil Filter - BE SURE TO SHUT DOWN THE MACHINE, AND ENGINE BEFORE CHANGING ENGINE OIL AND/OR FILTER.

  • Page 42: Maintenance

    Note: ALWAYS use GASOLINE Fuel. Fuel FIlter Rayco recommends draining the fuel tank once a year, especially if the RG55 will be in storage for longer than a month. To drain the tank, remove the fuel cap (3) to assist in draining.
  • Page 43 Do not mix the different type or brand of L.L.C • Clean or replace the filter cartridges if the indicator (5) is illuminated. Clean the outer air filter cartridge (Rayco part number 800276) every 100 hours and replace it every year.

  • Page 44: Specifications

    & reduce bearing life. • Number of Teeth for Depth of Cut: Rayco’s cutter wheels are designed to provide an economical cutting wheel assembly solution. The teeth are spaced to provide a maximum depth of cut for the number of teeth on the wheel.
  • Page 45 Replacement teeth are available from your Rayco dealer or of the tooth ever contacting the stump. This concept direct from Rayco. Refer to the Parts manual for part numbers reduces drag, which maximizes the use of the machine’s The Cutter Wheel (1) Rayco part# 35244 on the RG55 uses horsepower.

  • Page 46: Hydraulic Oil

    RG55R Operation • Service • Maintenance Maintenance Sharpening Teeth Cutter Wheel Bearings Lubricate NOTICE Sharpening cemented carbide cutting teeth requires a special process. Have your teeth sharpened only by a qualified machinist for obtaining a proper edge BE SURE TO SHUT DOWN THE MACHINE, AND and to avoid injury.
  • Page 47 RG55R Operation • Service • Maintenance Maintenance if it is below this level. clean!) Keep the top breather clean and threaded tightly. A 10 micron 2. Unscrew the filter cap (4) and pull out the filter. return filter (4) is used on this machine. It is located on the Start-Up Procedure hydraulic tank and filters oil entering the tank.
  • Page 48 RG55R Operation • Service • Maintenance Maintenance Clutch Spider Coupler • Optional shim kit (if needed) Procedure NOTICE 1. There should be an equal gap between the coupling Description: It is crucial that the coupler hub is and drive dogs (~0.020”). If a large or uneven gap is properly aligned and shimmed else premature observed proceed to step 3.
  • Page 49 RG55R Operation • Service • Maintenance Maintenance improper alignment in the following steps. torque the gearbox bolts in a star pattern to 120 lb-ft. 6. Install bolts loosely in the gearbox and push the drive 10.Insert the spider into the coupling and insert the drive dogs into the coupling leaving an equal gap between them (~0.020”).
  • Page 50 RG55R Operation • Service • Maintenance Maintenance Slewing Ring Cutting Wheel Belt - Check & Adjust Tension Check BEFORE BEGINNING TO CHECK OR AD- JUST BELTS OR CHAINS: SHUT DOWN THE MACHINE, ENSURE THAT ALL MOV ING PARTS HAVE COME TO A HALT, REMOVE THE KEY FROM THE ENGINE START SWITCH.
  • Page 51 RG55R Operation • Service • Maintenance Maintenance Smart Tension App Attention iPhone users. Mitsuboshi as designed an app for Apple iPhone users to use for checking tension for timing belts, V-Ribbed Belts, Flat Belts, etc. Open your Smart Tension App •...
  • Page 52 RG55R Operation • Service • Maintenance Maintenance PTO Clutch Brake Air Gap Battery - Change Every 2 Years 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 53 Steer Wheel Pivot Cutter Wheel Gear Box Lubricate The cutter wheel gear box on the RG55R is equipped with two drain plugs (2) and one fill plug (3). Lubricate the grease fittings (1) on the steer axle pivots. One on each side.
  • Page 54 RG55R Operation • Service • Maintenance 39670 Main Wiring Schematic BLU/WHT START CLUTCH DELAY BLU/WHT CLUTCH MIL LAMP BLADE DWN SWING SOL BOOM UP BOOM DWN BLADE UP SWING SOL REMOTE/ SOA SWITCH COMM ORG/WHT GRY/BLK THROTTLE WHT/BLK SWIN WHT/GRN...
  • Page 55 RG55R Operation • Service • Maintenance 39670 Main Wiring Schematic U/WHT SAFETY INTERLOCK BLU/WHT START E-STOP DELAY KEY SW MIL LAMP ORG/BLK BLADE SAFETY 17740 17741 BLADE BLADE BLADE SWING BOOM UP/DWN POWER RELAY 804514 2 SPD CLUTCH RELAY 804514...
  • Page 56 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 57 Hydraulic Oil (Petroleum-Mineral Base) Your Rayco machine is filled at the factory with Conoco Powerflow AW HVI 32 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 32 or one of the recommended brands below.
  • Page 58 RG55R Operation • Service • Maintenance Hydraulic Schematic 805921...
  • Page 59 RG55R Operation • Service • Maintenance Hydraulic Schematic 805921 800.392.2686...
  • Page 60 RG55R Operation • Service • Maintenance Hydraulic Hose Kit 805921H Rev B ITEM PART # DESCRIPTION HOSE 4R1T-6FFX-4FFX90-131” HOSE 4R2T-6FFX-4FFX-133” HOSE 4R1T-4FFX-4FFX-18” HOSE 4R1T-4FFX-4FFX90-60” HOSE 4R1T-4FFX-4FFX90-53” HOSE 4R17-4FFX-4FFX-38” HOSE 4R17-4FFX-4FFX90-30” HOSE 4R17-4FFX-4FFX90-74” W/FABRIC HOSE GUARD HOSE 4R17-4FFX-4FFX-88” W/FABRIC HOSE GUARD HOSE 4R17-4FFX-4FFX-44”...
  • Page 61 RG55R Operation • Service • Maintenance Hydraulic Adapter Kit 805921A ITEM QTY PART # DESCRIPTION FF6602-04-04-04 TEE RUN -4MFFX-4MFFX-4FFFX FF6802-06-10 ELBOW 45 DEG -6MFFX-10MOR FF6802-04-06 ELBOW 45 DEG -4MFFX-6MOR FF6400-04-10 CONNECTOR -4MFFX-10MOR FF6801-06-06 ELBOW 90 DEG - FIT -6MFFX-6MOR FF6500-04-04...
  • Page 62 RG55R Operation • Service • Maintenance Fuel System Assembly 38605 Rev B SENSO & PRE 22" 803432 8" FUEL PUMP NOTE: CUT 730 TO LENGTH AS...
  • Page 63 RG55R Operation • Service • Maintenance Fuel System Assembly 38605 Rev B 9" 803433 SENSOR- TEMP & PRESSURE GM 805776 71" ENGINE 802495 8" 10" FUEL FILTER CUT 730043 FUEL LINE NGTH AS NEEDED FUEL TANK 800.392.2686...
  • Page 64 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 65 RG55R Operation • Service • Maintenance 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. See the Engine Operator Manual for engine lubricating oil specifications.
  • Page 66 RG55R Operation • Service • Maintenance Specifications RAYCO COOLANT SPECIFICATIONS Coolant / Antifreeze Recommendations Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. These antifreezes are intended for aluminum automotive engines and are unacceptable for diesel engines. Use antifreeze that is formulated with a low silicate level and the proper coolant additives for heavy duty diesel engines.
  • Page 67 RG55R Operation • Service • Maintenance Specifications 800.392.2686...

  • Page 68: Troubleshoot

    RG55R Operation • Service • Maintenance Engine Troubleshoot Engine Use the following information to determine the source and solution to problems you may encounter related to the engine. This information can also be found in the Kubota Engine Operator’s Manual that shipped with this machine.
  • Page 69 Drive Belt: Heavy Duty Carbon Cord with Low Sprocket Wear Tires: 18 x 8.5-10 R4 4 ply Rear - (4) Front - (2) Material Swing-out Control Station Cutting Teeth: RAYCO Super tooth™ forged, One-piece, with Viewing area: 18x24” tungsten carbide tips. Height: 45½”...
  • Page 70 RG55R Operation • Service • Maintenance Service Parts - 800275 nginE iLTER - 802495 iLTER - 803604 ydRaULiC ETURn iLTER SSEmbLy - 761908 iLTER LEmEnT - 761910 ipSTiCk - 761909 ESTRiCTiOn ndiCaTOR - 800276 UTER iLTER aRTRidgE - 800277 nnER...

  • Page 71: Warranty

    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 72 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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