Rayco Super Jr RG45X Operator, Service, Maintenance Manual

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RG45X / RG45X-R Super Jr

OPERATOR • SERVICE • MAINTENANCE MANUAL

PRINTED IN USA

INDEX: OSMRG45X-16

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Summary of Contents for Rayco Super Jr RG45X

Page 2 RG45X 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
RG45X 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: Machine Description
RG45X Operation • Service • Maintenance Foreword Certified Engine Maintenance When you perform maintenance above ground level, use appropriate devices such as ladders or man lift machines. Proper maintenance and repair is essential to keep the engine If equipped, use the machine anchorage points and use and machine systems operating correctly.
Page 6: Serial Numbers Location
RG45X 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: Identification Numbers
RG45X 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: Safety
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: General Hazard Information
RG45X 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: Flying Debris
Pressure can be trapped in a hydraulic system. Releasing 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: Dispose Of Waste Properly
RG45X Operation • Service • Maintenance Safety • Obey environmental regulations for the disposal of equipment or the machine. Stay clear of areas that may have asbestos. a sudden change in clearance with machine movement or • Stay away from areas that might have asbestos particles equipment movement.
Page 12: Burn Prevention
RG45X Operation • Service • Maintenance Safety 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: Fire Prevention And Explosion Prevention
Do not operate the machine near any flame. behind the seat. Consult your Rayco dealer for the proper Extinguish all cigarettes, cigars, pipes and other sources procedure of mounting the fire extinguisher.
Page 14: While Operating The Machine
Repair any lines that are loose or damaged. Leaks can • Do not change the engine governor settings or over cause fires. Consult your Rayco dealer for repair or for speed the engine. The governor controls the maximum replacement parts.
Page 15: Before Starting Engine
• For your safety, repair or replace all damaged or worn • A system of communication parts immediately. Replacement parts which are authorized by Rayco are the only parts which should be • Communication between workers and operators prior used for repair or replacement on this machine.
Page 16: Before Operation
A list of some of the material is available in the Operation and Maintenance Manual, “Reference Material”. Consult Observe all applicable local government regulations when your Rayco dealer in order to obtain copies of the material. you use this machine. The information should be reviewed by every person that Parking operates the machine.
Page 17 Work Tool options - Attachments Vibration Data Information concerning hand/arm vibration level Only use work tools that are approved by Rayco for use on When the machine is operated according to the intended Rayco machines. Refer to the Operation and Maintenance use, the hand/arm vibration of this machine is rated by meter Manual, Rayco options”.
Page 18: Safety Decals
Rayco or polycarbonate front guards that are a. Remove any large rocks or obstacles. approved by Rayco are available for machines with a cab or an open canopy. On machines that are equipped with cabs, b. Fill any ditches and holes.
Page 19: Lock-Out / Tag-Out Guidelines
RG45X Operation • Service • Maintenance Safety LOCK-Out / Tag-Out Guidelines Removal Procedure • Lockout/tag out equipment must be removed by the Always practice lock out tag out procedures when working worker who placed it. on this machine. • Before the removal of a lockout/tag out the following Locking and tagging out equipment safeguards those working must be completed: on the equipment from being injured by its unexpected...
Page 20 RG45X Operation • Service • Maintenance Safety Pre-Transportation Checks cross winds, passing vehicles, rough roads, etc). IF A COMBINATION DISTURBANCE OCCURS, DO NOT steer • Never allow inexperienced drivers to tow the machine. or brake. Steering or braking during a disturbance can cause •...
Page 21 Use the checklist at the end of these instructions. If you suspect or detect something is wrong, contact the nearest Rayco Dealer. Safety Chains The purpose of the safety chains is to keep the trailer connected to your tow vehicle in the unlikely event the coupler comes off the ball or the ball comes off the hitch.
Page 22: Lighting Conditions
EYE. ANY ATTEMPT TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. ALWAYS during transport. ENSURE THE PHOTO-EYE IS WORKING Unloading the Machine From the Rayco BEFORE OPERATING THE MACHINE. IF THE Trailer (optional equipment) PHOTO-EYE IS NOT OPERATIONAL, DO NOT OPERATE THE MACHINE! 1.
Page 23 RG45X Operation • Service • Maintenance Safety 3. Start the engine. (See “Starting the Engine” and “Pre- operation Warm up”.) 4. Position the engine throttle on low idle 5. Push the FORWARD/REVERSE lever and slowly back the machine off of the trailer, until the tracks are on the ground.
Page 24: Operation
RG45X Operation • Service • Maintenance Operation Getting to know your machine 1. Operator Panel 7. Engine 2. Fuel Tank 8. Swing Out Arm 3. Blade if Equipped 9. Battery / Hydraulic Tank 4. Safety Curtains 10. Operator Bar 5. Cutter Wheel 11.
Page 25 RG45X Operation • Service • Maintenance Operation b. Engine Air Filter Lamp - indicates that the air filter should be serviced. See the Maintenance Section of the Operator, Service, Maintenance Manual. c. Battery Indicator Lamp - indicates that the battery is not being properly charged or the alternator belt has broken.
Page 26: Pre-Starting Inspection
RAISE position. bed. The preferred method is towing it on a Rayco trailer (available from Rayco). Comply with all local laws dealing 3. Move the engine throttle to the max i mum engine speed. Run the engine for an addition al two minutes while in ter mit tent ly with the towing of a trailer.
Page 27: Machine Movement
Steer machine Left/Right with lever (2). Cutter Boom Raise/Lower with the lever (3). Cutter Boom Swing Left/Right with lever (4). Engine throttle toggle (5). Emergency shut down. (6). Travel speed. (7) Rayco recomends only using the fast speed while traveling between stumps. 800.392.2686...
Page 28: Linking Procedures
RG45X Operation • Service • Maintenance Operation Machine Movement Command Cut ® RG45X-R (Remote) RG45X-R (Remote) To adjust the command cut speed using the remote. Turn the Command Cut dial (9) to the desired swing speed. With the cutter wheel engaged and command cut on, and engine at idle, the boom speed should move at a very slow rate.
Page 29 RG45X Operation • Service • Maintenance Operation green. Once the flashing LED turns solid green, the system is linked together and ready to use. 5. Remove the jumper from the Receiver and release the button on the Transmitter. 6. Place the Receiver back into the enclosure. 7.
Page 30 RG45X Operation • Service • Maintenance Operation Transporting in Limp Mode NOTICE Ensure that all fluids are at the correct level before attempting this procedure. This procedure is meant to transport the machine to a safe area or to load on a trailer.
Page 31: Dual Wheels
RG45X Operation • Service • Maintenance Operation 2. Using the allen wrench, loosen the needle valve screw • Drive the rear inside wheel onto a small wooden board on the hydraulic block by backing it out 2 complete turns. so that the outer wheel is slightly raised off of the ground. Do not remove.
Page 32 RG45X Operation • Service • Maintenance Operation Removing Stumps NOTICE Call 8-1-1 Before You Dig Always allow a cold engine time to warm-up before cutting a stump. NOTICE When swinging the cutting wheel, DO NOT use the cutting wheel or boom to stop the swinging motion.
Page 33 RG45X Operation • Service • Maintenance Operation Stump Removal Procedure 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, advance the machine slightly (about 2”) and repeat •...
Page 34: Stopping The Machine
RG45X 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 ROTATION, THE CUTTING WHEEL MAY Clean all grease, dirt, mud and other foreign matter from the CONTINUE TO ROTATE UNNOTICED, EVEN...
Page 35 RG45X Operation • Service • Maintenance Operation • Mount the battery and connect the cables to the machine. 5. Remove all of the battery caps from the batteries (if not maintenance-free type) on both machines, allowing • Review the machine according to the “Before Start ing the explosive vapors to disperse.
Page 36: Remote Operation
RG45X Operation • Service • Maintenance Operation Remote Operation Linking Procedures In the event that you need to (re)link the transmitter and receiver together follow the steps listed below: 1. POWER ON- Turn remote control power (4) on, located in the lower right corner of the remote control. 1.
Page 37 RG45X Operation • Service • Maintenance Operation b. Turn the Command Cut ON - Move command cut toggle to the ON position. Note: If Command Cut FAST is selected on control panel station, remote control command cut will set to FAST. If command cut SLOW or OFF is selected on the control panel station, the remote control command cut will default to SLOW when turned on from remote control.
Page 38: Maintenance
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 39 RG45X Operation • Service • Maintenance Maintenance Maintenance Log Date of Service Machine Hours Description of Service/ Maintenance Notes 800.392.2686...
Page 40 RG45X Operation • Service • Maintenance Maintenance Every 200 Hrs Maintenance Interval Daily or Every 10 Hrs Maintenance Interval Engine Oil & Filter Change - see Kubota Manual Engine Oil Level Check & Replace if needed Radiator Clamps & Hoses Check &...
Page 41 When any one of these occurs, change the element as soon as possible. Always carry an extra replacement element (Rayco part # 765047), as one tankful of contaminated fuel can plug a fuel filter. NOTICE...
Page 42: Element Replacement Procedure
• To change an element, first loosen the large black • Number of Teeth for Depth of Cut: Rayco’s cutter wheels retaining ring. Pull the element straight down - do not are designed to provide an economical cutting wheel twist, the element is not threaded.
Page 43 Replacement teeth are available from your Rayco dealer or Read all of the following instructions before direct from Rayco. Refer to the Parts manual for part numbers beginning to change the cutting teeth. The Cutter Wheel on the RG45X uses 6 different types of...
Page 44: Hydraulic Oil
RG45X Operation • Service • Maintenance Maintenance Sharpening Teeth Hydraulic Oil Check NOTICE NOTICE Sharpening cemented carbide cutting teeth requires a special process. Have your teeth sharpened only Replace oil if it smells burnt or appears to be dirty. by a qualified machinist for obtaining a proper edge Use only clean, fresh hydraulic oils, free of bubbles.
Page 45: Start-Up Procedure
RG45X Operation • Service • Maintenance Maintenance 3. Remove the hose from the pump and allow the oil to drain will be smooth and powerful when all of the air is bled into a container (you may use a hose with a threaded off.
Page 46 RG45X 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 47 RG45X Operation • Service • Maintenance Maintenance misalign the coupler on the splines - this will lead to 9. Check the coupler a second time. If it is still aligned, improper alignment in the following steps. torque the gearbox bolts in a star pattern to 120 lb-ft. 10.Insert the spider into the coupling and insert the drive dogs into the coupling leaving an equal gap between them (~0.020”).
Page 48: Slewing Ring
RG45X 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 49 RG45X 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 50 (2) is positioned as shown. • Replace the inner safety filter cartridge (Rayco part number 800277) every 600 hours, or with every other air filter cartridge replacement.
Page 51 RG45X 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 52: Tires And Rims
RG45X Operation • Service • Maintenance Maintenance Steer Wheel Pivot Lubricate Lubricate the grease fittings (2) on the steer axle pivots. One on each side. Brakes This machine is required to have a daily inspection of the ground-drive brake. This check should be done by the operator every day, before using the machine.
Page 53 RG45X Operation • Service • Maintenance Maintenance 800.392.2686...
Page 54: Main Wire Harness
RG45X Operation • Service • Maintenance Main Wire Harness PLUG '81' PLUG '82' RT TRACK LT TRACK TYPE 'E' TYPE 'E' PLUG '80' BOOM U/D PLUG '83' TRACK I/O SWING/BLADE TYPE 'E' TYPE 'E' PLUG '39' REMOTE RECIEVER 4" 2" 2"...
Page 55 RG45X Operation • Service • Maintenance Main WIre Harness PLUG '69' 2-SPEED TYPE 'H' PLUG '68' TRACK EXPANSION TYPE 'H' 2" 4" PLUG '67' TRACK EXPANSION 3" TYPE 'H' PLUG '66' BOOM DOWN/TRACK OUT 2" 4" TYPE 'H' PLUG '65' 3"...
Page 56 RG45X Operation • Service • Maintenance Main Wire Harness TRACK (78) SOLENOID (68) BOOM U/D RIGHT LEFT TRACK I/O TRACK TRACK TRACK SWING/BLADE SWITCH (80) SOLENOID (67) SWITCH (81) SWITCH (82) SWITCH (83) 2-SPEED (79) SOLENOID (69) (BOOM UP/ (76) TRACK IN SOL) (BOOM DN/...
Page 57 RG45X Operation • Service • Maintenance Main WIre Harness BLADE SELECT 12V DC FUSE(40) WATER TEMP. (23) 803814 TRACK IN/OUT SELECT 12V DC RIGHT TRACK REVERSE THROTTLE UP OIL PRESS. (21) LEFT TRACK REVERSE (85) BOOM UP/TRACK IN BOOM RT/BLADE DOWN CAN HI (58) (39)
Page 58: Specifications
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 59: Biodegradable Hydraulic Oil
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 60: Troubleshoot
RG45X Operation • Service • Maintenance Troubleshoot Engine When output is insufficient Use the following information to determine the source and Cause Countermeasures solution to problems you may encounter related to the engine. Carbon stuck •Clean orifices and needle valve being very This information can also be found in the Kubota Engine around orifice of careful not to damage the nozzle orifice..
Page 61 RG45X Operation • Service • Maintenance Troubleshoot When color of exhaust is especially bad When engine must be stopped immediately Cause Countermeasures Cause Countermeasures Fuel governing •Contact dealer for repairs. Engine revolu- •Check the adjustments, injection timing, and device bad tion suddenly fuel system.
Page 62: Machine Specs
RG45X Operation • Service • Maintenance Machine Specs General Data Metric Weight 3,250 lb 1,474 kg Length 144” 366 cm Maximum Height 73” - operators shield / 61” - air filter 185.4 cm / 155 cm Width 50” Expanded / 35” Retracted 127 cm / 89 cm Engine 44 hp Kubota Turbo...
Page 63 RG45X Operation • Service • Maintenance 800.392.2686...
Page 64: Service Parts
RG45X Operation • Service • Maintenance Service Parts ENGINE OIL FILTER - 800275 FUEL FILTER ASSEMBLY - 765049 ELEMENT FUEL FILTER - 765047 HYDRAULIC RETURN FILTER ASSEMBLY- 803604 FILTER ELEMENT - 761908 DIPSTICK - 761910 RESTRICTION INDICATOR - 761909 OUTER AIR FILTER CARTRIDGE - 780270 INNER AIR FILTER CARTRIDGE - 750202 SERVICE INDICATOR - 803607 FUEL CAP - 801682...
Page 65: Warranty
For warranty service, the purchaser is to on any Rayco product are those set forth on this page. In contact manufacturer directly. no event will the dealer and or Rayco be liable for incidental 4.
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.

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