Rayco RG1645S User manual

RG1645S
Sw i n g -Ou t St u m p Cu t t e r
Parts Ma n u a l
pantone
485
pantone
485
pantone
1235
www.raycomfg.com

This manual is published by Rayco
Manufacturing, Inc. for the benet of
the users of Rayco products. Rayco
Manufacturing, Inc. has made every
effort to ensure that this manual is
correct and up to date at the time of
publication. However, due to continuous
improvements, Rayco Manufacturing,
Inc. reserves the right to make changes
in the contents, at any time, without
notice or obligation.
Each machine shipped contains
operation, maintenance & parts manuals
to familiarize the operator with the proper
operating, lubricating and maintenance
instructions. This helps to ensure the best
possible performance and service from
the machine. Read and understand all
instructions before attempting to operate
this machine. This manual should be
readily available for reference at all times.
Additional copies of this manual may be
purchased from Rayco.
This Rayco machine was designed and
manufactured by Rayco Manufacturing,
Inc., Wooster, Ohio. Due to continuous
improvements, Rayco reserves the
right to make changes in engineering,
design and specications, or discontinue
manufacture, at any time, without notice
or obligation.
Always have a record of the model
numbers and serial numbers for your
machine to specify when ordering
parts. Record your machine model and
serial numbers below for your personal
records.
IDENTIFICATION NUMBERS
MODEL NUMBER SERIAL NUMBER
MACHINE
ENGINE
ATTACHMENT 1
ATTACHMENT 2
NOTICE:
MAINTENANCE AND REPAIRS SHOULD ONLY BE PERFORMED BY A TRAINED SPECIALIST
OR QUALIFIED PERSON.
PLEASE CONTACT RAYCO MFG FOR A LISTING OF APPROVED
MAINTENANCE FACILITIES IN YOUR AREA.
DEALER INFORMATION
NAME
ADDRESS
DEALER CONTACT PHONE NUMBER HOURS
SALES
PARTS
SERVICE

Contents 3
Copyright © 2012 Rayco Mfg - All Rights Reserved Rayco RG1645S Stump Cutter
Printed in U.S.A.
Table of Contents
Foreword
About These Manuals
Operator’s Manual...................................................................................................................4
Safety ..................................................................................................................................4
Operation.............................................................................................................................4
Maintenance........................................................................................................................4
Parts Manual ...........................................................................................................................4
Machine Description................................................................................................................5
Serial Number Location...........................................................................................................5
Design .................................................................................................................................5
How it Works .......................................................................................................................5
Serial Numbers....................................................................................................................5
Assemblies
Main Frame Assembly.............................................................................................................6
Boom Assembly.......................................................................................................................8
Idler Assembly ...................................................................................................................10
Swing Cylinder Assembly ..................................................................................................10
Lift Cylinder Assembly .......................................................................................................10
Pivot Assembly .................................................................................................................. 11
Curtain Assembly............................................................................................................... 11
Chip Guard ........................................................................................................................12
Chain Guard ......................................................................................................................13
Cutter Wheel Assembly .....................................................................................................14
Steering Axle Assembly.........................................................................................................15
Tie Rod Assembly..............................................................................................................16
Steering Pivot Assembly....................................................................................................16
Wheel Drive Assembly...........................................................................................................17
Handbrake Release Pump ...............................................................................................17
Dual Wheel Assembly.......................................................................................................18
Coupler Assembly.........................................................................................................18
Swing-out Assembly ..............................................................................................................18
Latch................................................................................................................................22
Blade .....................................................................................................................................23
Engine Assembly...................................................................................................................24
Engine Enclosure Assembly ............................................................................................30
Decal Kit ................................................................................................................................32
Schematics
Electrical Schematic ..................................................................................................................34
Hydraulic Schematic..................................................................................................................40
Adapter Kit.............................................................................................................................42
Hose Kit.................................................................................................................................42
Service
Safety Sales Kit .....................................................................................................................43
Service-Quick Reference.......................................................................................................44
Specications ............................................................................................................................45
Rayco Warranty Certicate........................................................................................................47

Contents
4
Rayco RG1645S Copyright © 2012 Rayco Mfg - All Rights Reserved
Printed in U.S.A.
Foreword
About These Manuals
These manuals contain safety, operating, lubrication, maintenance, troubleshooting and parts information.
Read - study - keep them with the machine - adhere to all of the recommendations.
Where the engine is concerned, this manual
makes frequent reference to the Kubota
Engine Operator Manual, which was packed
in your operator’s kit. Keep it, therefore,
with these RG1645 Stump Cutter Manuals
so that it may be readily used.
NOTICE
Guards and covers may have been removed for illustrative purposes. Some photographs or illustrations in this publication
show details or attachments that may be different from your machine. Continuing improvement and advancement of product
design may have caused changes to your machine which are not included in this publication.
Whenever a question arises regarding your machine, or this publication, please consult Rayco for the latest available
information.
When the NOTICE heading appears in
this publication, what follows is either a
clarification or information that will assist
you in avoiding damage to the machine or
property.
NOTICE
Operator’s Manual
Safety
The “Safety” section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels
used on the machine. Read and understand the basic precautions listed in the “Safety” section beforehand, and apply them
always as you operate, transport, perform maintenance, and repair the product.
Operation
The “Operation” section is a reference for the new operator and a refresher for the experienced one. This section includes a
discussion of machine controls and how to operate the machine.
Photographs and illustrations assist the operator in correct procedures of checking, starting, operating, and stopping the
machine.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of
the machine and its capabilities.
Maintenance
The “Maintenance” section is a guide to equipment care. A combination of step-by-step instructions and helpful illustrations
and photographs accompany maintenance items throughout this section.
Parts Manual
Parts are readily found through illustrations with accompanying Rayco part numbers. The machine is broken down into its
basic systems and assemblies to enable ease of finding parts. A separate engine Spare Parts Catalog is also provided for the
aid in identification and ordering engine parts. Please consult your local Kubota dealer or your local Rayco dealer for obtaining
engine parts and service.

Contents 5
Copyright © 2012 Rayco Mfg - All Rights Reserved Rayco RG1645S Stump Cutter
Printed in U.S.A.
Machine Description
Design
The RG1645S Super Junior stump cutter is designed for your maximum benefit for every dollar spent. The machine is
constructed for durability and easy maneuvering, for those hard to reach tree stumps and roots. Its 20” diameter cutting wheel
with 24 Rayco Superteeth is powerfully driven through a direct drive coupler to a 90 degree gearbox and a nickel plated chain
with a 44 horsepower Kubota turbocharged diesel engine at its source. Cutting boom motion and the self-propel drive are
entirely hydraulic, with 2 speeds. The hydraulic controls each include self-centering fingertip control levers.
The machine chassis features rectangular steel tubing and steel guard construction, mounted on extra grip-
ping deep tread tires. The operator benefits from a swing-out steel control station which allows optimal views
of the cutting action, all while being guarded by shatter resistant Lexan® and heavy rubber curtains.
The RG 1645 Super Junior has the unique ability to pass through a 36” gate under its own power. Other special features of
the RG 1645 include dual cross travel cylinders, a slewing ring that is used to pivot the cutter boom, replaceable composite
bushings on all cylinder ends, separate wheel drives for each wheel, 6.5 gallon fuel tank, steel chain guards, and an easy
access ignition switch on the control panel.
An additional safety feature is the optical eye sensor on the front of the control panel. At the point that the operator steps
away from the control station for more than 2 seconds, the machine will shut down.
Other options that have become standard on the RG 1645 are dual removable travel wheels for increased stability and travel
traction, Command Cut, and additional chip guards.
For further design information see the “Specifications” section of this Operator Manual.
REAR
FRONT
RIGHT
LEFT

Parts Section
6
Rayco RG1645S Copyright © 2012 Rayco Mfg - All Rights Reserved
Printed in U.S.A.
MAIN FRAME ASSEMBLY (28471)
35 44
34
45
25
18
31 30
33
17 46
414849
382023921224036
28 27
26 29
8 55723
32
37
47
43
6 5 8
15
8
6 5 7
16 51
11 12 13
50 10
9
59
533235212 57 5617 42 19
4
54
586061
24 64

Parts Section 7
Copyright © 2012 Rayco Mfg - All Rights Reserved Rayco RG1645S Stump Cutter
Printed in U.S.A.
ITEM QTY. PART # DESCRIPTION
1 2 751019 BOLT WHIZ 3/8-16 X 1-1/2
2 6 750061 NUT-WHIZ 3/8-16 GR5
3 2 750762 BOLT WHIZ 5/16-18 X 3/4
4 1 724203 NUT-WING 5/16-18 NYLOCK
5 4 3963 WASHER, FLAT 1/4” SAE
6 4 722107 BOLT HEX 1/4-20 X 1 3/4
7 4 724508 NUT LOCK 1/4-20 NYLOCK
8 9 750768 NUT WHIZ 1/4”-20
9 12 800613 BOLT- METRIC 10-1.5 X 55
10 12 726954 WASHER METRIC LOCK M10
11 2 801075 ZERK-GREASE 10MM X 1.0
12 2 722202 BOLT HEX 5/16”-18 X 2-1/4” GR8
13 2 750050 NUT LOCK 5/16-18 NYLON
14 1 801569 BOLT HEX 5/16-18 X 4.25” GR8 ZP
15 2 750865 BOLT HEX 1/4-20 X 4
16 1 760853 BOLT HEX 5/16-18 X 4” GR8
17 6 722110 BOLT WHIZ 1/4-20 X 3/4
18 2 751027 BOLT WHIZ 3/8-16 X 1-1/4
19 2 724105 NUT HEX LOCK #10-24
20 1 722303 BOLT-HEX 3/8-16 X 1
21 2 750124 SCREW-FH SLOT 1/4-20 X 1
22 3 801514 BOLT WHIZ 5/16-18 X 1-1/2
23 5 750764 NUT WHIZ 5/16”-18
24 2 750764 NUT WHIZ 5/16”-18
25 1 28374 FRAME WELDMENT 1645SJRS
26 1 27046 RH SWING PIN
27 1 27041 LH SWING PIN
28 1 20396 SWING CYL. ASSY. LH SJRD
29 1 20397 SWING CYL. ASSY. RH SJRD
30 1 25868 HYD TANK RISER
31 1 765049 FUEL FILTER
32 1 764492 PUMP-FUEL, ELECTRIC C100
33 1 801234 VALVE-BLADE-W/CC
34 1 801412 WHEEL DRIVE BLOCK
35 1 730085 ZERK-GREASE 1/4-28 90DEG
36 1 23602 BLOCK SOA
37 1 23829 SWITCH MOUNT
38 1 28384 SOA SUPPORT BRACKET
39 1 23600 SOA BLOCK
40 1 801005 SNAP ACTING
41 1 736030 BATTERY-26R-60 25/35
42 3 736130 RELAY-SWITCHING (87a87)
43 1 761432 CIRCUIT BREAKER-50A
44 1 802207 RECEIVER, REMOTE
45 1 1200015 VALVE-OVERCENTER
46 5 761641 TRIM-EDGE TRIM-LOK 1/4”
47 1 751021 MANUAL-CASE, SMALL
48 1 17740 CABLE-BATTERY RED
49 1 17741 CABLE-BATTERY BLACK
50 1 21775 PIVOT HEAD ASSY. SJRD
51 1 800309 SLEWING RING
52 1 7617 HOLDDOWN ANGLE, BAT
53 1 23588 BATTERY BRACKET
54 1 28563 WRENCH
55 2 724107 SCREW-#6-32 X 1 HH
56 1 801842 BOOT-CIRCUIT BREAKER
57 2 761599 NUT LOCK #6-32 NYLOCKHOLD
58 2 730024 CLAMP-HOSE #4
59 1 15286 SERIAL NUMBER - VIN TAG
60 1 28346 CURTAIN ASM.
61 2 800983 GROMMET-RUBBER 2-1/4” ID 3/8”
THICK
62 1 802296 WRENCH-ALLEN 5/23”
63 5 800857 SEAL-RUBBER RIBBED 3/8” X 1/2”
64 1 28604 PUMP - HAND BRAKE RELEASE
ASM
MAIN FRAME ASSEMBLY (28471)

Parts Section
8
Rayco RG1645S Copyright © 2012 Rayco Mfg - All Rights Reserved
Printed in U.S.A.
BOOM ASSEMBLY (25144)
9
119 1
6
4
14
12
15
3
2
13
8
5 7
1
16
ASSEMBLE WITH LOCTITE 242 (BLUE)
ASSEMBLE WITH LOCTITE 242(BLUE) TORQUE TO 46 FT-LBS
ITEM QTY. PART # DESCRIPTION
1 1 25009 BOOM WELDMENT 2 4 726909 WASHER FLAT 1-1/4-14GA 3 2 760701 RING-RETAIN EXT 1 1/4” 4 4 726301 WASHER FLAT 3/8 USS 5 6 726302 WASHER-LOCK 3/8 6 4 722305 BOLT-HEX 3/8-16 X 1 1/2 7 2 18953 PIVOT WELD, BOOM 8 2 722303 BOLT-HEX 3/8-16 X 1
9 2 722502 BOLT HEX 1/2-13 x 1 10 2 726502 WASHER LOCK 1/2 11 2 4900-77 WASHER 7 GA. X .531 X 2.0 12 5 722114 WHIZ BOLT 3/8-16 X 3/4 13 1 800307 CLAMP-VINYL COVERED1-1/2” 14 2 21662 GEAR BOX SHIM 15 1 25131 PLATE, COVER 16 1 25120 IDLER ASSEMBLY

Parts Section 9
Copyright © 2012 Rayco Mfg - All Rights Reserved Rayco RG1645S Stump Cutter
Printed in U.S.A.
IDLER ASSEMBLY (25120)
7
5
8
9
1012
3
6
4
ITEM QTY. PART # DESCRIPTION
1 5 724801 NUT HEX 3/4-10 GR8
2 2 726502 WASHER LOCK 1/2
3 2 722502 BOLT HEX 1/2-13 x 1
4 1 2536-08 ROD,THREADED
5 1 25119 PLATE ADJUSTER
6 1 21187 ADJUSTER NUT
7 1 802264 TIGHTENER SHAFT
8 1 802263 SPROCKET 17T 50 SERIES
9 2 722539 BOLT CARR 1/2”-13 X 1-1/2
10 2 750057 NUT-WHIZ 1/2-13 Z

Parts Section
10
Rayco RG1645S Copyright © 2012 Rayco Mfg - All Rights Reserved
Printed in U.S.A.
3
1
2
1
4
4
2
ITEM QTY. PART # DESCRIPTION
1 1 20392 CYLINDER WELD-SWING SJRD
2 3 760872 BEARING-GARMAX 1.25X1.00
3 1 750325 RING-RETAIN EXT HVY 1”
4 4 726907 WASHER FLAT 1-14GA
SWING CYL ASSEMBLY LH (20396)
SWING CYL ASSEMBLY RH (20397)
4
2
31
342
24
ITEM QTY. PART # DESCRIPTION
1 1 20395 CYLINDER WELD-SWING SJRD
2 3 760872 BEARING-GARMAX 1.25X1.00
3 2 750325 RING-RETAIN EXT HVY 1”
4 3 726907 WASHER FLAT 1-14GA
LIFT CYL ASSEMBLY(18771)
2
2
1
ITEM QTY. PART # DESCRIPTION
1 1 18772 CYLINDER-WELD 2-1/2 X 4
2 2 763587 BUSHING-1.50 X 1.25 X 1