Rayco RG100K Operation & Service Manual

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RG100K

tump

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Page 1 RG100K tump utter & S peRatiOn eRvice anual www.raycomfg.com...
Page 2 DEAlER INFORMATION NAME ADDRESS DEAlER CONTACT phONE NUMBER hOURS SAlES pARTS SERvICE 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 3 Connecting Your Trailer ......... 22 Safety Chains ............22 Emergency Brake Chain / Cable ......23 Lighting connections ..........23 Loading ..............23 Secure the Load ............ 23 Towing Checklist ............ 23 Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 4 This section includes a discussion of storage area. Rayco provides a binder to hold gauges, switches, machine controls, attachment the Operator Service Manual, Parts Manual, controls, transportation and towing information.
Page 5 The cutter wheel drive system is equipped is advanced 1-1/2 to 2 inches further into the with the Rayco “Quick Stop” system. By pulling stump, and the procedure is simply repeated the cutter wheel control lever to the far right,...
Page 6 Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 7 Obtain the complete and most current information before you start any job. Rayco dealers have the most current information available. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 8 Operator and parts Manuals and that contained in the Engine Operator Manual, which are included with this machine. Additional manuals are available from Rayco or your Rayco dealer. When replacement parts are required for this product Rayco recommends using Rayco...
Page 9 Do not disas- thrown past guards and injure bystanders if semble any hydraulic components or parts they are in these areas. until pressure has been relieved or personal Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 10 If dust that may contain asbestos is present, nals in order to start the engine. Unexpected there are several guidelines that should be fol- machine movement could result. lowed: · Never use compressed air for cleaning. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 12 Inspect all lines and hoses for wear or for dete- dures are not followed: rioration. The hoses must be properly routed. The lines and the hoses must have adequate • Check for and maintain correct tire pressure. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 13 • Flexible part of the hoses are kinked. the left side of the cab behind the seat. Consult • Outer covers have embedded enamoring. your Rayco dealer for the proper procedure of mounting the fire extinguisher. • End fittings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly.
Page 14 The governor controls the or worn parts immediately. Replacement parts maximum safe operating speed of the engine which are authorized by Rayco are the only parts • Never leave this machine unattended with the which should be used for repair or replacement engine running.
Page 16 WORk TOOl OpTIONS- ATTAChMENTS properly. Only use work tools that are approved by Rayco Fasten the seat belt securely (if equipped). for use on Rayco machines. Refer to the Opera- Lower the armrest.
Page 17 Operation and · Surface material – Rocks and moisture of Maintenance Manual, the surface material may drastically affect the machine’s traction and machine’s stability. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 19 • If a machine component to which a decal is at- tached is replaced, be sure to replace the decal as well. • Replacement decals may be purchased from Rayco Mfg or your Rayco dealer. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 21 Then stop to reload the vehicle-in-tow heaviest end forward as soon as possible, and remove any cargo from the vehicle-in-tow (vehicle carried on trailer). Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 22 The purpose of the safety chains is to keep the owner’s manual, or check with an authorized the trailer connected to your tow vehicle in the dealer. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 23 DO NOT load cargo in your vehicle-in-tow or on SPEED your trailer. Loading cargo in your vehicle-in-tow or on trailer may result in sway or WHIPPING. • WEAR YOUR SEAT BELT Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 24 Make no alterations or modifications to your Rayco 14. To ensure that the machine cannot roll on its stump cutter unless requested or recommended own, the machine should be in at least one of the by Rayco Manufacturing Inc.
Page 25 Correct the emergency situation. purposes. Sudden loss of machine control could result. 17. Always have good visibility of the cutting area. Never turn your back on the machine when it is Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 26 15.76 All lamps should always light up when keyswitch 1. Engine / Hydraulics is moved from OFF to START position. If any 17.22 fail to light up, replace light bulb (Rayco part 2. Wheel drives 18.68 #736133). 19.87 3. Cutter wheel 22.75...
Page 27 This measurement is used in determining when to perform maintenance according to the “Maintenance Intervals” section of this manual and the “Maintenance Schedule” in the Kubota Engine Operation Manual. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 28 BlADE -With the operator’s station located in wheel until it comes to a complete stop the swung in position, the cutter wheel travel before doing anything else. is overridden by the blade function. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 30 Do not operate cutter wheel on this operator and the danger zone associated with the machine without both dual wheels machine’s cutter wheel. installed! Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 33 10. Reinstall the battery caps and battery covers. 11. After completion of the above procedure, perform failure analysis on the starting/charging system of the stalled machine as required. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 34 CALL CENTER LOGO HERE Safe Digging Is No Accident: Always Call 811 Before You Dig Know what’s below. Always call 811 before you dig. Visit call811.com for more information. CALL Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 36 The machine may then be self- propelled to next destination. Shut off the engine by turning the ignition keyswitch to OFF and removing the key when finished using the machine! Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 37 (3), and re-install the bolts (1) in pattern cause injury or death. as shown. The wheel drive is now disconnected. *Repeat this on the other wheel drive. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 38 The preferred method, and forth. however, is towing it on a Rayco trailer (available from Rayco). Comply with all local laws dealing with the Store the battery inside where temperatures do not towing of a trailer.
Page 40 23027 SHAFT-ANCHOR, WELD 8095 PIN, PIVOT 728028 PIN-SAFETY SNAP 1/4 X 2 1/2 724919 NUT- HEX M30 X 3.5 760583 STRAP-SLING 2-1/4 X 3 FT 726908 WASHER FLAT 1-1/4-10GA Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 41 (F). It is important to use the strap provided by Rayco because it is balanced in accordance with the machine’s weight and center of gravity. Now that the lifting assembly is...
Page 42 Synthetic vg46 Bio-degradable oil. panolin hlp Synthetic Ester vg46.………………….Viscosity 8.1 cSt @ 100°C / 47 cSt @ 40°C / Pour Point -57°C (-70°F) Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 43 5-10 degrees lower than the coldest ambient temperature. Fluids Refill Capacities (Approximate) Compartment or System U.S. gallons Imperial gallons liters Fuel Tank Engine Crankcase w/Filter Total Engine Coolant including Cooler Hydraulic Reservoir Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 44 Freeze Protection to -24.4°C (-12°F) 40% antifreeze and 60% water Freeze Protection to -36.7°C (-34°F) 50% antifreeze and 50% water Freeze Protection to -52.2°C (-62°F) 60% antifreeze and 40% water Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 45 BY MID-STATES 500 +/-20 lB-FT 850 +/-25 lB-FT 1700 +/-25 lB-FT 3000 +/-50 lB-FT TORqUE SpECIFICATIONS BASED ON 67% OF BOlT YIElD STRENgTh (UppER TOlERANCE NOT TO ExCEED 75% YIElD) Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 47 See “System Fluids Specifications” in this Maintenance section for more information. please contact Rayco Mfg for a listing of approved maintenance facilities in your area. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 48 Rayco Manufacturing Inc. recommends only genuine head bolts to 135 - 145 foot-lbs. Rayco Cutting Tools for use on Rayco Stump Cutters and Forestry Mowers. The use of non-Rayco cutting tools or cutting wheels will void the machine warranty.
Page 50 For further details applicable to the service gauge, Replace the breather cap. filter cartridge, safety cartridge and dust ejector valve, see the “Combustion Air Cleaner” section of the Kubota Engine Operation Manual. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 51 Kubota Engine Operation Manual. Charge pump Oil Filter - Change Change the hydraulic oil filter as described in the “Every 250 Service Hours” interval in this section. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 52 The grease fittings are located on the under side of the rear pins. The front pins are lubricated by two bulkhead fittings and hoses. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 53 Turn the adjusting nut (4) clockwise (viewed from ground), pivoting the hydraulic motor away from the cutting wheel. Check the tension once again, and continue Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 54 Use fluid as noted in the “Fluid Specifications” page in base of the terminal. the Maintenance section of this manual. Replace the cable. Repeat the same procedure for the red positive (+) cable. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 55 A 25 micron filter is used on this machine (Rayco part # 761038). It is located on the external filter head to filter the oil before entering the hydraulic operating components.
Page 56 50 hours and then every 250 soon as possible. Always carry an extra replacement hours. element (Rayco part # 765047), as one tankful of contaminated fuel can plug a fuel filter. Element replacement procedure: - To change an element, first loosen the large black retaining ring.
Page 57 Following the logical box diagrams are “Diagram Action Step Comments” corresponding with the numbers Replace and tighten the fittings. shown in the box diagrams. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 58 This will purge Maintenance” section of the Kubota Engine Operation any remaining trapped air from the system. Turn Manual. off the prime mover and connect the pump control linkages. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 60 Please record the date, the procedure performed and the hourmeter reading in the correct columns for all maintenance performed on your machine. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 61 764682 AIR ClEANER CARTRIDgES 736142 - enGIne fUel fIlter Inner 736115 - 764683 oUter FUEl FIlTER 765049 hyDraUlIc pUmp BOWl oIl fIlter 765048 element ElEMENT 763676 765047 764136 Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 62 Charge pressure @ 435-440 psi E TEST PORT full rpm, cutter wheel engaged R HEAD Wheel drive valve @ engine 3300 psi ORT OF BLOCK idle full flow Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 63 Continue to tighten or loosen adjusting screw and checking pressure until pressure is within and checking pressure until pressure is within the acceptable range. Retighten the jam nut. the acceptable range. Retighten the jam nut. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 65 AUX IN3: (normally the Blade/Swing Selector Valve) OThER lCM FUNCTIONS: The Lamp Test Circuitry is designed to provide a short test of the indicator lamps for a given machine. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 72 No current Bad connection LED not lit Clean & Check for LED not lit Broken wire or Tighten all broken ad key switch connections wiring Replace Start Relay Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 73 Drive N/S switch needs to be adjusted to assure that when the lever is in the neutral position, the switch is also. If the LED still is not on, proceed to next paragraph. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 77 C. Check - Cylinder rod seal leaking. replaced. These are available from Rayco. If all the If when operated, cylinder loses fluid around the circuit pressure readings are bad the integral relief rod, the rod seal is leaking.
Page 78 Find this leaking. procedure in the Tests and Adjustments section of this manual. To determine if the cylinder piston seals are Symptom - Blade will not operate Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 79 If the pressure reading checK preSSUre is low, the valve may be faulty and need to be replaced. Contact your Rayco dealer or the factory. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 81 The proper pressure should be beginning of this section). 435-440 psi at full throttle. If the pressure is below that, the charge pump needs serviced. Contact your Rayco dealer or the factory. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 82 An obstruction or blockage could be hampering pressure flow to the wheel drive. If the hose is clear, there may be a problem with the wheel drive. Contact your Rayco dealer or the factory. Copyright © 2009 Rayco - All Rights Reserved...
Page 83 Check the hydraulic pressure going out of the valve bank. Use the chart in the Tests and Adjustments section of this manual to determine the correct pressure. If the pressure is coming out Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 86 8R16-8FSX-8FSX90-51” HOSE 12R4 (FC619)-12FSX- 12FSX90M-46” HOSE 4R1T-4FSX-4FSX90-31” HOSE 4R2T-4FSX-4FSX45-24” HOSE 4R2T-4FSX-4FSX90-31” HOSE 6R16-6FSX90-6FSX-22” HOSE 4R16-6FSX-4FSX90-15” HOSE 4R1T-4FSX-4FSX-110” HOSE 4R1T-4FSX-4FSX90-46” HOSE 4R1T-4FSX-4FSX-34” HOSE 4R1T-4FSX-4FSX-22” HOSE 4R1T-4FSX-4FSX-45” HOSE 4R1T-6FSX-4FSX90-55” HOSE 4R1T-4FSX-4FSX-56” Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 87 TO 1” MOR FF6400-8-10 CONNECTOR 1/2” MORFS TO 5/8” MOR FF6400-4-8 CONNECTOR 1/4” MORFS TO 1/2” MOR FF6801-4-6 90º ELBOW 1/4” MORFS TO 3/8” MOR FF2603-6 BRANCH TEE 3/8” MORFS Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 90 HARTS PECS Copyright © 2005 Rayco - All R SUPER RG 90 STUMP CUTTER & S Copyright © 2005 Rayco - All Rights Reserved HARTS PECS Printed in U.S.A. Copyright © 2005 Rayco - All Rights Reserved Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 91 Troubleshooting Hydrostatic CW Circuit - RG90 SUPER RG 90 STUMP CUTTER & S HARTS PECS Copyright © 2005 Rayco - All Rights Reserved Printed in U.S.A. Copyright © 2005 Rayco - All Rights Reserved Printed in U.S.A. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 92 SUPER RG 90 STUMP CUTTER RAYCO ® RG100K S tump utteR & S HARTS PECS hYDRAUlIC TROUBlEShOOTINg TROUBlEShOOTINg hYDROSTATIC CW CIRCUIT Copyright © 2005 Rayco - All Rights Reserved Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A. Printed in U.S.A.
Page 93 SUPER RG 90 STUMP CUTTER RAYCO ® RG100K S tump utteR & S HARTS PECS hYDRAUlIC TROUBlEShOOTINg TROUBlEShOOTINg hYDROSTATIC CW CIRCUIT Copyright © 2005 Rayco - All Rights Reserved Printed in U.S.A. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 94 SUPER RG 90 STUMP CUTTER RAYCO ® RG100K S tump utteR & S HARTS PECS hYDRAUlIC TROUBlEShOOTINg TROUBlEShOOTINg hYDROSTATIC CW CIRCUIT Copyright © 2005 Rayco - All Rights Reserved Printed in U.S.A. Copyright © 2009 Rayco - All Rights Reserved Printed in U.S.A.
Page 95 & S HARTS PECS RAYCO ® RG100K S tump utteR hYDRAUlIC TROUBlEShOOTINg TROUBlEShOOTINg hYDROSTATIC CW CIRCUIT Copyright © 2005 Rayco - All Rights Rese Copyright © 2009 Rayco - All Rights Reserved Printed in U Printed in U.S.A.
Page 97 Drive belt ........Gates PolyChain® GT® low maintenance Cutting teeth (36) ....Rayco Supertooth® forged, one pc., w/tungsten carbide tips Belt guard .
Page 98 1. Engines oDIfIcatIon All engines have specific warranties issued Rayco is relieved of its obligation under this by OEM and honored thru their respective warranty if: dealer. Service (other than normal maintenance and replacement of service items) is 2.
Page 99 Rayco, or to modify the terms or than those set forth above, and NO IMPLIED limitations of this warranty in any way.
Page 100 Think Smart, Think Safe……… We care about your safety. When operating your RAYCO ® machinery always wear an approved helmet complete with ear muffs, face shield and the proper eyewear. 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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