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Rayco RG165T-R Operator, Service, Maintenance Manual

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RG165T-R
OPERATOR · SERVICE · MAINTENANCE MANUAL
RAYCO MANUFACTURING © 2019 - ALL RIGHTS RESERVED
PRINTED IN USA
INDEX: OSMRG165T-R-19

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Summary of Contents for Rayco RG165T-R

  • Page 1 RG165T-R OPERATOR · SERVICE · MAINTENANCE MANUAL RAYCO MANUFACTURING © 2019 - ALL RIGHTS RESERVED PRINTED IN USA INDEX: OSMRG165T-R-19...
  • Page 2 RG165T-R Operator · Service · Maintenance 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: Table Of Contents

    RG165T-R Operator · Service · Maintenance Table of Contents TABLE OF CONTENTS Foreword Safety Operation Maintenance Specifications 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 RG165T-R Operator · Service · Maintenance 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 RG165T-R Operator · Service · Maintenance Foreword Machine Description The Rayco RG165T-R is a high-production stump cutter powered by a 6.2L Ford 165hp gas engine that generates peak torque of 355ft-lbs. The large displacement gas engine provides the power demanded for large jobs with out the need for after treatment when comparing to a diesel engine.
  • Page 7 Wheel Drive Pump: Gear Wheel Drive Motors: Axial 2-speed piston motor RG165T-R Operator · Service · Maintenance Control Valve: Manifold Type Electronic Control The following specifications shall constitute minimum requirements for a heavy duty self propelled tree stump cutting machine.
  • Page 8 Breakdown of the serial number For Example: RG165T-R 001 01 20 RG165T-R - Type of Rayco equipment you have 001 - Three digit for the number of produced 01 - Two digit month, 01 = Jan., 02 = Feb., etc...
  • Page 9 RG165T-R Operator · 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 10: Safety

    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 RG165T-R Operator · 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 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 RG165T-R Operator · Service · Maintenance 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 RG165T-R Operator · Service · Maintenance 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 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 RG165T-R Operator · Service · Maintenance 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 Replacement parts which are cause the tow vehicle and transport trailer “combination” to authorized by Rayco are the only parts which should be begin WHIPPING, which is violent and uncontrollable sway. used for repair or replacement on this machine.
  • 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. Refer to the owner’s manual, decal instructions or an Safety Chains...
  • Page 22 RG165T-R Operator · Service · Maintenance Safety Unloading the Machine From the Rayco attach chains to the ball or to a ball mount that is removable. Trailer (optional equipment) The right chain hooks to the left side in the same manner.
  • Page 23 RG165T-R Operator · Service · Maintenance Safety 800.392.2686...

  • Page 24: Operation

    RG165T-R Operator · Service · Maintenance Operation...
  • Page 25 Everyone must avoid the DANGER ZONE at all times when the machine is in operation! 16. Hydraulic Tank 8. Make no alterations or modifications to your Rayco Before Operating the Machine stump cutter unless requested or recommended by Rayco Manufacturing Inc.
  • Page 26 RG165T-R Operator · Service · Maintenance Operation Pre-Starting Inspection heed either direc tive will result in poor machine performance and se vere damage. Inspect the hydraulic system for leaks. Check the hydraulic Start-Up oil level. Inspect the machine and perform each of the “Daily Inspections”...
  • Page 27 RG165T-R Operator · Service · Maintenance Operation Remote Function 12. Cutter Wheel Engagement Switch Turns the cutter wheel on and off. 1. Left Track Switch Moves left track forward or reverse. 2. Right Track Switch Moves right track forward or reverse.
  • Page 28 RG165T-R Operator · Service · Maintenance Operation Remote Display Screen The remote screen displays information regarding remote function and connectivity to the machine. D. Connection Status Notifies the operator when the remote is linked to the machine. E. Connection Strength Shows the signal strength between the remote and the machine.
  • Page 29 Should your remote control fail, or batteries die in the field, the The remote requires three AA batteries that are accessible RG165T-R comes equipped with a remote tether option. To from the bottom of the remote. When replacing the remote...
  • Page 30 RG165T-R Operator · Service · Maintenance 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 RG165T-R Operator · 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.
  • Page 32 RG165T-R Operator · Service · Maintenance Operation Stopping The Machine Transporting the Machine The RG165T-R should only be transported with a proper working trailer. The preferred method, however, is towing it on a Rayco TR100L trailer (available from Rayco). NOTICE...
  • Page 33 RG165T-R Operator · Service · Maintenance Operation Machine Storage • Start the machine according to the “Starting the Engine” and “Pre-Operation Warm-up” sections of this manual 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.
  • Page 34 RG165T-R Operator · Service · Maintenance Operation Starting With Jumper Cables b. Connect the other end of the red positive (+) jumper cable to the positive (+) terminal of the battery of the NOTICE boost machine. Before attempting to start an engine that has been c.
  • Page 35 • Expand tracks to full 51” or retract tracks to less than 36” • Lower machine to ground Blade Transition The RG165T-R 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 (1) that can swing in to be only 34 1/2”...

  • Page 36: Maintenance

    RG165T-R Operator · Service · Maintenance 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 37 RG165T-R Operator · Service · Maintenance Maintenance First Every Every Every Every 10 Hours Every Service Interval: 1000 or Daily Year Needed Hours Hours Hours Hours Hours Walk Around Inspection-Check for Leaks, Dam- age, etc. Clean Cooler Screens Air Intake Piping- Inspect...
  • Page 38 RG165T-R Operator · Service · Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes...
  • Page 39 RG165T-R Operator · Service · Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
  • Page 40 RG165T-R Operator · Service · Maintenance 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 41 RG165T-R Operator · Service · Maintenance Maintenance Fuel Tank - Check Level, Fill & Drain 1. Place an oil catch pan under the oil drain plug (4) under the engine. Remove the drain plug and drain the oil. Use an approved container to store used oil. Remove the oil fill cap (3) to aid in draining.
  • Page 42 RG165T-R Operator · Service · Maintenance Maintenance Fuel Tank - Drain Hydraulic Oil - Check & Fill NOTICE The hydraulic oil tank (2) and fill neck (3) are located in the front of the engine compartment just behind the cutter boom.
  • Page 43 The filters are serviceable, and can be into the container. cleaned. If the housing or O-rings have damage or wear contact a Rayco dealer or Rayco for replacement parts. 5. Loosen the hose fittings on the cylinders, and drain as much fluid as feasible.
  • Page 44 RG165T-R Operator · Service · Maintenance Maintenance 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 45 The battery is located in the left rear of the engine reduce bearing life. compartment (7). • 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 46 RG165T-R Operator · Service · Maintenance Maintenance Cooling Screens The RG165T-R is equipped with two removable cooler screens that can be easily removed to keep the coolers working at their maximum efficiency. One is located at the rear of the machine at the engine radiator and the other is on the cooler door on the right side of the machine.
  • Page 47 RG165T-R Operator · Service · Maintenance Maintenance 800.392.2686...
  • Page 48 4. After reinstalling or replacing the teeth, according to the diagrams which follow, tighten the socket head bolts to 135 - 145 lbs/ft. Replacement teeth are available from your Rayco dealer or direct from Rayco. Refer to the Parts manual for part numbers...
  • Page 49 RG165T-R Operator · Service · Maintenance Maintenance Cutter Wheel Bearings Engine Leaks - Check Lubricate Check for leaks as described in the “After First 50 Hours” interval of the Cummins Engine Operation Manual.Engine Mounts - Check Check and tighten if necessary all engine mounts.
  • Page 50 RG165T-R Operator · Service · Maintenance Maintenance Cutting Wheel Belt - Check & Adjust Tension A MOVING BELT IS VERY POWERFUL AND DANGEROUS. KEEP AWAY FROM A MOVING BELT AT ALL TIMES! EXTREME CAUTION MUST BE USED TO PREVENT DEATH OR SERIOUS INJURY. FOR...
  • Page 51 RG165T-R Operator · Service · Maintenance Maintenance 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 52 RG165T-R Operator · Service · Maintenance Maintenance Track Adjustment - Check Checking Tension • Drive the machine a short distance forward and backwards with the tracks extended. On a flat solid surface use the rear blade and the cutter wheel lift 1.
  • Page 53 RG165T-R Operator · Service · Maintenance Maintenance Track Drive Oil - Check NOTICE Use diesel engine oil SAE-30-CD or equivalent as gear lubricating oil. Any recommended gear oil can be used, but drain old oil completely To check the track drive oil the drive unit must be on flat, level ground and the drive placed in accordance to the below figure and plug (2) removed.
  • Page 54 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 MILL LIGHT 500 OHM IGNITION RESISTOR SWITCH (MILL LGT PWR) (FUEL PUMP PWR) (MILL LGT SIG) (START SIG) (START SIG) DIODE RED/WHT (KEY RELAY SIG) (5V REF FUEL SENDER) MHR27...
  • Page 55 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 DIODE WHT/BLK (RT PROP REV) (PROP REV) (SWITCH PWR) YLW/BLK RIGHT (RT PROP FWD) (PROP FWD) (COMM GRD) TRACK SWITCH DIODE RED/YLW E-STOP (E-STOP) (E-STOP SW) SWITCH SWING (BOOM UP)
  • Page 56 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 FROM WIRE DESCRIPTION GAUGE COLOR PLUG# PIN# (FUNCTION IMPRINT) PLUG# PIN # ECU CAN + USB + USB - TETHER CAN+ TETHER CAN- ECU CAN - USB GROUND BLK/YLW 5V REF FUEL SENDER...
  • Page 57 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 MILL LGT SIG YLW/WHT SP31 5V REF FUEL SENDER FUEL SEND SIG BLD DN/SWG RT SP14 BLD UP/SWG LT ORG/WHT SP15 BLD DN/SWG RT SP14 BLD UP/SWG LT ORG/WHT SP15...
  • Page 58 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 BOOM UP SP16 TRK EXP 1/BOOM DN ORG/WHT SP10 BOOM DN ORG/BLK SP17 TRK EXP 1/BOOM DN ORG/WHT SP10 TRK EXP SP19 TRK EXP 2/BOOM UP ORG/BLK SP11 TRK EXP...
  • Page 59 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 VALVE GRD SP26 VALVE GRD SP26 2 SPEED ORG/WHT 2 SPEED ORG/WHT VALVE GRD SP26 VALVE GRD SP26 BLD DN/SWG RT SP14 BLD DN/SWG RT SP14 VALVE GRD SP26 VALVE GRD...
  • Page 60 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 COMM GRD SP12 FAN FUSE COMM GRD SP12 KEY RELAY SIG RED/WHT SP13 FUSED RELAY POWER SP33 FUSED RELAY POWER SP33 FUSED RELAY POWER SP33 KEY RELAY SIG RED/WHT SP13...
  • Page 61 RG165T-R Operator · Service · Maintenance Main Wiring Harness 41561 SP13 KEY RELAY SIG RED/ 07-87a, 29-2, 79-B1, 79-B10, 79-E3, 79-E5, 81-6 SP14 BLD DN/SWG RT 14-k, 16-k, 25-B, 27-B, 42-k, 43-1, 60-k, 61-1 SP15 BLD UP/SWG LT ORG/ 15-k, 17-k, 25-A, 27-A, 44-k, 45-1, 62-k, 63-1...
  • Page 62 RG165T-R Operator · Service · Maintenance Hydraulic Schematic 806797...
  • Page 63 RG165T-R Operator · Service · Maintenance Hydraulic Schematic 806797 BOTTOM 800.392.2686...
  • Page 64 RG165T-R Operator · Service · Maintenance Hydraulic Adapter Kit 806797A ITEM QTY PART # DESCRIPTION (6002-04-04)199-FF3800-0404-ORING (4MORFS X 4MBSPP- ORING ONLY NO RETAINING RING) (6002-06-08)199-FF3800-0608-ORING (6MORFS X 8MBSPP- ORING ONLY NO RETAINING RING) FF6400-04-04 04 MORFS X 04 MORB STRAIGHT FF6801-04-06 04 MORFS X 06 MORB ELBOW 90°...
  • Page 65 RG165T-R Operator · Service · Maintenance Hydraulic Hose Kit 806797H ITEM QTY PART # DESCRIPTION 4R17-04FSX90-04FSX-8" 4R17-04FSX- 6R16-06FSX90-06FSX-38" 06FSX90-108" 8R16-08FSX-08FSX-24" 4R17-04FSX- 10R17-12FSX-10FSX-36" 04FSX45-112" 10R17-10FSX90- 6R16-06FSX- 10FSX-41" 06FSX90L-109" 12R17-12FSX-12FSX-19" 4R17-06FSX-04FSX-109" 6R16-06FSX-06FSX90-14" 6R16-06FSX- 06FSX90-116" 4R17-04FSX90-04FSX-34" 4R17-04FSX- 4R17-04FSX90-04FSX-30" 04FSX45-115" 4R17-04FSX90-04FSX-41" 6R16-08FSX90-06FSX-58" 4R17-04FSX90-04FSX-37" 6R16-08FSX-06FSX-73"...

  • Page 66: Specifications

    RG165T-R Operator · Service · Maintenance 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 67 A synthetic 75W-140 or 80W-140 heavy duty GL-5 gear oil could also be used in warm climates to extend gear life. RG165T-R Operator · Service · Maintenance MWF Hydrostat Drive Lubrication & Fluid Specifications The Hydrostat drive is shipped with Mobil 1 synthetic engine oil, SAE 15W-50.
  • Page 68 RG165T-R Operator · Service · Maintenance Lubrication & Fluid 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 69 RG165T-R Operator · Service · Maintenance 800.392.2686...
  • Page 70 RG165T-R Operator · Service · Maintenance Service Parts SERVICE FILTERS COMMON WEAR AND REPLACEMENT PARTS DESCRIPTION PART # Qty. DESCRIPTION PART# Engine Oil Filter Ignition Key 764136 Primary Fuel Filter Fuel Cap 801682 Secondary Fuel filter O-Ring Kit 800186 Inner Air filter...

  • Page 71: Warranty

    Where permitted by law, the purchaser’s only remedies in 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 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.