McConnel RoboCut Operator'S & Parts Manual Download

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Publication 679

August 2011
Part No. 22674.79
Revision: 09.10.13

McCONNEL

ROBOCUT

REMOTE CONTROLLED MOWER

Operator & Parts Manual

Summary of Contents for RoboCut

Page 1: ...Publication 679 August 2011 Part No 22674 79 Revision 09 10 13 McCONNEL ROBOCUT REMOTE CONTROLLED MOWER Operator Parts Manual...

Page 2: ...to verify that your machine has been registered with McConnel Limited IMPORTANT During the initial bedding in period of a new machine it is the customer s responsibility to regularly inspect all nuts...

Page 3: ...mal life This warranty does not ap ply to any expendable items such as blades flails flap kits skids soil engaging parts shields guards wear pads or pneumatic tyres 1 05 Temporary repairs an d consequ...

Page 4: ...ct to the goods including but not limited to merchantability and fitness for a particular purpose 3 02 The manufacturer makes no warranty as to the design capability capacity or suitability for use of...

Page 5: ...les BS EN 349 1993 A1 2008 Safety of machinery Minimum distances to avoid the entrapment with human body parts BS EN 953 1998 Safety of machinery Guards General requirements for the design and constru...

Page 6: ...is Assembly 42 Rubber Tracks 44 Equipment Mounting Assembly 46 Engine Cover Assembly 48 Machine Cover Assembly 50 Diesel Engine Assembly 52 Diesel Engine Components 56 Pumps Assembly 58 Actuator Assem...

Page 7: ......

Page 8: ...ich is considered essential to emphasis LEFT AND RIGHT HAND These terms are applicable to the machine when it is viewed from the rear facing forwards Note The illustrations in this manual are for inst...

Page 9: ...tirrups Rubber Stopper Spike Protection for Transport Potentiometer Speed Control from 0 to 100 Independent Cooling System for Hydraulic Circuits Self Cleaning Reversible Fan Electronically Controlled...

Page 10: ...starting key removed In the event of any fault being detected with the machine s operation it must be stopped immediately and not used again until the fault has been corrected by a qualified technici...

Page 11: ...can cause the machine to rear up causing loss of control When operating the machine with the flail head running the operator must remain at least 5 metres away from the machine always switch the flail...

Page 12: ...f and the machine chocked and secured using suitable ropes or chains Check the condition of the flails and fixings on a regular basis never use the machine with damaged missing flails or loose fixings...

Page 13: ...nces 4 DANGER Acid read the user and maintenance manual 5 DANGER Rotating components keep clear 6 DANGER Hot components risk of burns 7 WARNING Do not lubricate or service moving components stop the m...

Page 14: ...he machine itself In all instances stated above emergency stopping of the machine will take a maximum of 0 2 seconds from execution of the automatic or manual command and the following actions will oc...

Page 15: ...ttery Pack Battery Charger 12V CA Antenna Belt for the Radio Control Ignition Key Use and Maintenance Manual for Machine Use and Maintenance Manual for Transmitter Use and Maintenance Manual for Engin...

Page 16: ...de View 1 Hydraulic Motor 2 Electrics 3 Warning Beacon Mount 4 Water Oil Radiator 5 Conveyor Radiator Guard 6 Rubber Tracks 7 Electric Actuator 8 Track Tensioner Access 9 Lubrication Point 10 Hydrauli...

Page 17: ...Radiator Fan 8 Ant vibration Engine Support 9 Exhaust Pipe 10 Alternator 12V 11 Air Filter Engine Left Side View 1 Emergency Stop Switch 2 Warning Beacon Mount 3 Air Filter 4 Radiator Fan Guard 5 Rad...

Page 18: ...11 Ignition Panel Components 1 Temperature Gauge Engine Coolant 2 LED Lights 1 10 see symbols below 3 Hours Counter Engine Running Time 4 Ignition Switch Ignition Panel Warning Symbols...

Page 19: ...5 Yellow LED Light No Air filter blocked Disassemble the filter cartridge and clean with compressed air line 6 Red LED Light Yes Oil filter blocked Replace oil filter cartridge 7 Yellow LED Light No P...

Page 20: ...ont Hood 7 Flail Head Pump Control Rotor Speed 8 Emergency Stop Switch 9 Rotor Direction Selector 10 Gear Selector 11 Direction Swap 12 Fan Reverse Control Radiator Self Clean 13 Left Joystick Drive F...

Page 21: ...ne To operate the machine remotely the control unit must first be linked to the machine so that command signals can be transmitted and received the procedure is as follows NOTE Ignition key must eithe...

Page 22: ...joystick A on the remote controls push the lever forwards to move the machine forwards pull the lever backwards to move the machine backwards The joystick operates proportionally therefore the further...

Page 23: ...et for operating the machine across slopes adjustment is made using the dial switch D rotate the dial either clockwise or anti clockwise for right or left bios respectively the further it is rotated t...

Page 24: ...ngine speed to run at minimum revs before pressing the switch upwards the switch has a built in time delay to avoid unintentional rotor operation and must be held in position for at least 5 seconds re...

Page 25: ...ily for use when driving the machine between work areas on smooth even terrain where it is safe to use higher speed Potentiometer The potentiometer control rotational switch C determines the maximum t...

Page 26: ...le diverting air flow back through the radiator thus removing dirt and dust particles Although Clean Fix operates automatically at preset periods the operator control allows the user to override the f...

Page 27: ...be connected to the electronic ignition box refer to the following page for details WARNING The manual track control is for emergency situations and troubleshooting purposes only never attempt to use...

Page 28: ...s a signal to the brake system instructing it to release the brakes When using the manual control unit the brake controller must be bypassed to allow the brakes to release this is achieved by disconne...

Page 29: ...ricate machine as per details stated in the maintenance section Work and Work Area Precautions Always inspect the work area prior to operations check for and remove foreign bodies such as large stones...

Page 30: ...ersing uphill do not steer when transferring from the level surface to the slope if this is unavoidable perform the manoeuvre gradually Do not move along the edge of a slope or on uneven ground with o...

Page 31: ...or come of its seat wherever possible avoid turning the machine when it is against an obstacle if unavoidable make manoeuvres slowly and gradually until clear of the object If the machine moves in re...

Page 32: ...pecific section for details Check hydraulic oil level replenish if required Clean radiator matrix use compressed air line Daily Clean radiator using compressed air line Check hydraulic oil level reple...

Page 33: ...st be replaced when they reach their maximum wear limit refer to wear limits page Check brakes are working correctly Check all nuts and bolts for tightness Periodic Checks Check brakes and safety warn...

Page 34: ...d surrounding area using a compressed air line do not use any tools to clean the radiator that may cause damage to the fins Close the cover and secure in place with the rubber hooks Clean air intake g...

Page 35: ...H 46 oil for topping up and oil changes failure to use the specified oil will result in a non compliance of the Warranty Checking Engine Oil Level The procedure for checking and replenishing the machi...

Page 36: ...m Unscrew and remove the engine oil filter Take the new filter and smear some engine oil on the rubber seal before fitting screw the filter hand tight then turn it approximately a further of a turn Re...

Page 37: ...draulic oil filter this is located under the bonnet on the left hand side of the machine the filter can be removed by using either a filter wrench or a hexagonal 19mm spanner Fit new hydraulic oil fil...

Page 38: ...t be adopted to ensure the machine is securely positioned before attempting to access or work on the component WARNING Never attempt to work under any machine that it not safely supported and chocked...

Page 39: ...filter and refit the filet bowl ensuring the sealing ring is fitted Screw the filter bowl securing ring to a point where the sealing ring seats on the housing and tighten further third of a turn Open...

Page 40: ...ed by a flow of fuel Close the drain valve Priming the Fuel System If at any time the machine runs out of fuel it will be necessary to prime the fuel system in order to get it running again the proced...

Page 41: ...ion has the additional option of being fitted with steel spikes To fit the spikes remove every second steel tread by removal of the 3 x M8 Allen headed screws and replace with the steel spike treads u...

Page 42: ...0cm ensure the machine is stable and suitably supported Clean undercarriage components and their surrounding area prior to performing maintenance on them Remove backstay side cover Loosen valve on the...

Page 43: ...ease pump equipped with a manometer is available as an option for use in correctly checking and setting the pressure The correct pressure is 130 Bar Max 150 Bar Wear Limits The track components shown...

Page 44: ...umber of upper rollers per side per machine 1 1 2 Track width 230mm Number of links per side per machine 47 47 94 Chain pitch 72mm Track tensioner pressure Max 150Bar Total weight 444kg Hydraulic moto...

Page 45: ...rol X97 R2 Air Heater optional X99 R3 Beacon lamp X97 R3 Starter relay X99 R4 Clean Fix fan X97 R4 Battery switch X99 R5 Unloading Valve X98 R1 Actuator X99 R6 Manual comand track R H X98 R2 Actuator...

Page 46: ...material by turning the track in both directions while slackening slightly raise machine at same time if possible Oil leakage Hardened seals Gasket seals damaged or worn Clean around component and rec...

Page 47: ...40...

Page 48: ...41 ROBOCUT Parts Section...

Page 49: ...42 CHASSIS ASSEMBLY ROBOCUT McCON NEL...

Page 50: ...HEAD SCREW 21 8 4000353 FLANGED HEAD SCREW 22 4 4000316 FLANGED HEAD SCREW 23 2 4000354 GRUB SCREW 24 20 4000355 LOCK NUT 25 2 4000018 LOCK NUT 26 4 4000032 ROLL PIN 27 2 4000356 COPPER WASHER 28 20 4...

Page 51: ...44 RUBBER TRACKS ROBOCUT McCON NEL...

Page 52: ...BBER TRANSPORT BLOCK 2 138 4000038 BOLT 3 282 4000037 BOLT 4 2 4000263 RUBBER TRACK 250 72 47 5 2 4000289 RUBBER TRACK 280 72 47 6 46 4000034 RIVETED STIRRUP 7 94 4000035 STEEL STIRRUP 8 2 4000290 RUB...

Page 53: ...46 EQUIPMENT MOUNTING ASSEMBLY ROBOCUT McCON NEL...

Page 54: ...HYDRAULIC RAM 17 2 4000135 QR COUPLING 18 2 4000138 PLUG Option 19 2 4000140 PLUG Option 20 2 4000132 QR COUPLING 21 4 4000128 BULKHEAD FITTING 22 4 4000316 FLANGED HEAD SCREW 23 4 4000130 NUT 24 2 9...

Page 55: ...48 ENGINE COVER ASSEMBLY ROBOCUT McCON NEL...

Page 56: ...UPPORT 14 4 4000376 SCREW 15 2 4000377 CYLINDRIC HEAD SCREW 16 8 4000378 COUNTERSUNK HEAD SCREW 17 8 4000176 HEADLESS SCREW 18 2 4000250 CYLINDRIC HEAD SCREW 19 4 4000379 FLANGED HEAD SCREW 20 2 40003...

Page 57: ...50 MACHINE COVER ASSEMBLY ROBOCUT McCON NEL...

Page 58: ...25 32 9100102 WASHER 26 2 9100103 WASHER 27 6 9100104 WASHER 28 8 0100106 WASHER 29 6 9100204 SPRING WASHER 30 8 9100207 SPRING WASHER 31 2 4000385 WASHER LARGE SERIES 32 4 4000251 ANTI VIBRATION BLO...

Page 59: ...52 DIESEL ENGINE ASSEMBLY ROBOCUT McCON NEL...

Page 60: ...00083 ANTI VIBRATION MOUNTING 19 2 4000391 SPACER 20 1 4000046 RADIATOR 21 4 0904106 HOSE CLIP 22 1 4000400 AIR FILTER COMPLETE c w CLIP 23 1 4000392 RADIATOR HOSE LEFT 24 1 4000394 RADIATOR HOSE RIGH...

Page 61: ...54 DIESEL ENGINE ASSEMBLY ROBOCUT McCON NEL...

Page 62: ...LTER 45 1 4000280 FILTER HOUSING CAP 46 1 4000279 RUBBER VALVE 47 1 4000281 CLOGGING SENSOR 48 1 4000063 ALTERNATOR LID 49 2 4000379 FLANGED HEAD SCREW 50 1 4000062 EXHAUST SUPPORT 51 1 4000061 EXHAUS...

Page 63: ...56 DIESEL ENGINE COMPONENTS ROBOCUT McCON NEL...

Page 64: ...TI VIBRATION BLOCK 18 4 4000418 AUTOGRIP NUT 19 2 4000419 LH ENGINE MOUNTING Serial No 00074 2 4000597 ENGINE MOUNTING Serial No 00073 20 2 4000420 RH ENGINE MOUNTING Serial No 00074 2 4000597 ENGINE...

Page 65: ...58 PUMPS ASSEMBLY ROBOCUT McCON NEL...

Page 66: ...00432 GROOVED JOINT 8 1 4000296 ROTOR PUMP 9 2 4000433 PUMP CLAMP 10 6 4000434 LOCK WASHER 11 6 4000435 HEX HEAD SCREW 12 1 4000436 TANDEM PISTON PUMP Serial No 00074 1 4000598 TANDEM PISTON PUMP Seri...

Page 67: ...60 ACTUATOR ASSEMBLY ROBOCUT McCON NEL...

Page 68: ...GED HEAD SCREW 4 1 4000086 ACTUATOR 5 3 4000381 AUTOGRIP NUT 6 4 9100104 WASHER 7 1 9313064 HEX HEAD SCREW 8 4 9313033 FLANGED HEAD SCREW 9 1 4000058 THROTTLE BRACKET 10 1 4000059 ACTUATOR ARM 11 1 40...

Page 69: ...62 REVERSIBLE FAN SYSTEM ROBOCUT McCON NEL...

Page 70: ...4000450 COMPRESSOR CLAMP 11 2 9100103 WASHER 12 2 4000452 CYLINDRIC HEAD SCREW 13 2 4000453 HOSE CLAMP 14 1 4000451 FAN COMPRESSOR c w FITTINGS 15 1 4000454 FAN COMPRESSOR FILTER 16 1 4000455 AIR HOSE...

Page 71: ...64 DIESEL FUEL CIRCUIT ROBOCUT McCON NEL...

Page 72: ...90mm 7A 1 4000469 DIESEL HOSE 870mm 7B 1 4000470 DIESEL HOSE 260mm 7C 1 4000471 DIESEL HOSE 1350mm 8 1 4000126 FUEL PUMP 9 2 4000472 FLANGED HEAD SCREW 10 2 9100103 WASHER 11 2 4000443 AUTOGRIP NUT 12...

Page 73: ...66 OIL TANK ASSEMBLY ROBOCUT McCON NEL...

Page 74: ...2 6 7315750 FLANGED HEAD SCREW 3 2 4000127 PLUG 4 2 4000148 LEVEL SENSOR 5 1 4000124 OIL CAP LEVEL 6 1 4000475 OIL FILTER SENSOR BRACKET 7 1 4000476 FILTER CLOGGING SWITCH 8 1 4000122 OIL FILTER HOUSI...

Page 75: ...68 ELECTRICAL COMPONENTS ROBOCUT Machine Serial No 00088 McCON NEL...

Page 76: ...312 IGNITION SWITCH 15 1 4000143 WATER TEMPERATURE INDICATOR 16 1 4000149 HOURS COUNTER 17 2 4000309 HEX SKT BUTTON HEAD SCREW 18 2 9163001 LOCK NUT 19 1 4000484 FEMALE CONNECTOR 20 1 4000316 FLANGED...

Page 77: ...70 ELECTRICAL COMPONENTS ROBOCUT Machine Serial No 00089 McCON NEL...

Page 78: ...RICAL BOX ASSEMBLY 18 4 4000309 FLANGED HEAD SCREW 19 4 4000321 WASHER 20 4 9163003 AUTOGRIP NUT 21 1 4000317 ELECTRICAL SYSTEM COMPLETE 22 1 4000318 CONNECTOR PLUG FEMALE 23 1 9100101 WASHER 24 1 916...

Page 79: ...72 ELECTRICAL WIRING ROBOCUT McCON NEL...

Page 80: ...CONNECTOR 10 5 4000486 CONNECTOR 11 7 4000487 RUBBER CABLE SLEEVE 12 7 4000337 2 WAY CONNECTOR 13 1 4000328 WIRING LOOM DISTRIBUTOR 14 2 4000488 24 WAY CONNECTOR 15 1 4000489 3 WAY FEMALE CONNECTOR 1...

Page 81: ...74 TRANSMITTING RECEIVING UNITS ROBOCUT McCON NEL...

Page 82: ...17 4 4000510 PUSH BUTTON BLACK 18 1 4000511 STOP PUSH BUTTON 19 1 4000512 PUSH BUTTON GREEN 20 2 4000513 POTENTIOMETRIC SELECTOR 21 1 4000514 RADIO MODULE EUR 22 1 4000515 RADIO MODULE USA 23 1 400051...

Page 83: ...76 TRANSMITTING RECEIVING UNITS Pure Models ROBOCUT McCON NEL...

Page 84: ...ON BLACK 18 1 4000511 STOP PUSH BUTTON 19 1 4000512 PUSH BUTTON GREEN 20 2 4000513 POTENTIOMETRIC SELECTOR 21 1 4000514 RADIO MODULE EUR 22 1 4000515 RADIO MODULE USA 23 1 4000726 UPPER CONTROL UNIT R...

Page 85: ...78 INTAKE DRAIN PUMPS ROBOCUT Machine Serial No 00028 00088 McCON NEL...

Page 86: ...TOR 11 2 7315777 CONNECTOR 12 1 7315775 CONNECTOR 13 4 7315774 CONNECTOR 14 1 4000542 CONNECTOR 15 6 4000543 CYLINDRIC HEAD SCREW 16 6 4000544 SPRING WASHER 17 2 4000545 PUMP CONNECTION 18 1 4000546 C...

Page 87: ...80 INTAKE DRAIN PUMPS ROBOCUT Machine Serial No 00089 McCON NEL...

Page 88: ...15777 CONNECTOR 12 1 7315775 CONNECTOR 13 4 7315774 CONNECTOR 14 1 4000542 CONNECTOR 15 6 4000543 CYLINDRIC HEAD SCREW 16 6 4000544 SPRING WASHER 17 2 4000545 PUMP CONNECTION 18 1 4000546 CHECK COUPLI...

Page 89: ...82 CHANGE OVER VALVE CIRCUIT ROBOCUT Machine Serial No 00073 McCON NEL...

Page 90: ...557 HYDRAULIC HOSE 5 1 4000558 HYDRAULIC HOSE 6 1 4000559 HYDRAULIC HOSE 7 2 4000560 CONNECTOR 8 8 7315777 CONNECTOR 9 2 4000549 O RING 10 2 4000353 FLANGED HEAD SCREW 11 2 4000561 CHANGE OVER VALVE 1...

Page 91: ...84 TRACKS HYDRAULIC CIRCUIT ROBOCUT Machine Serial No 00088 McCON NEL...

Page 92: ...00571 HYDRAULIC HOSE 9 1 4000572 HYDRAULIC HOSE 10 1 4000573 HYDRAULIC HOSE 11 1 4000574 HYDRAULIC HOSE 12 1 4000575 HYDRAULIC HOSE 13 4 4000576 CONNECTOR 14 2 4000577 CONNECTOR 15 4 4000578 CONNECTOR...

Page 93: ...86 TRACKS HYDRAULIC CIRCUIT ROBOCUT Machine Serial No 00089 McCON NEL...

Page 94: ...10 1 4000573 HYDRAULIC HOSE 11 1 4000574 HYDRAULIC HOSE 12 1 4000575 HYDRAULIC HOSE 13 4 4000576 CONNECTOR 14 2 4000577 CONNECTOR 15 4 4000578 CONNECTOR 16 2 8650102 BONDED SEAL 17 4 7315775 CONNECTO...

Page 95: ...88 HYDRAULIC RAMS CIRCUIT ROBOCUT McCON NEL...

Page 96: ...AULIC RAMS CIRCUIT 1 1 4000583 HYDRAULIC HOSE 2 1 4000584 HYDRAULIC HOSE 3 1 4000585 HYDRAULIC HOSE 4 1 4000586 HYDRAULIC HOSE 5 4 4000579 CONNECTOR 6 2 4000587 CONNECTOR 7 2 4000588 TEE FITTING HYDRA...

Page 97: ...90 HYDRAULIC EQUIPMENT CIRCUIT ROBOCUT McCON NEL...

Page 98: ...4000590 HYDRAULIC HOSE 3 1 4000591 HYDRAULIC HOSE 4 1 4000592 HYDRAULIC HOSE 5 1 4000593 HYDRAULIC HOSE 6 1 4000594 HYDRAULIC HOSE 7 1 4000595 HYDRAULIC HOSE 8 3 7315797 CONNECTOR 9 4 4000587 CONNECT...

Page 99: ...92 Items 23 39 refer to notes in parts list important information on these components FLAILHEAD ASSEMBLY ROBOCUT McCON NEL...

Page 100: ...G PLATE 21 1 4000202 BELT COVER 22 1 4000203 FRONT HOOD 23 1 4000204 SPRING BRACKET Fits Spring 4000219 only 1 4000338 SPRING BRACKET Fits Springs 4000219 4000749 24 1 4000205 SPRING TENSIONER FIXING...

Page 101: ...94 Items 23 39 refer to notes in parts list important information on these components FLAILHEAD ASSEMBLY ROBOCUT McCON NEL...

Page 102: ...00254 WASHER 50 1 9100105 WASHER 51 1 4000223 GREASER 52 2 4000224 GREASER 53 2 4000225 BEARING 54 2 4000226 ROLLER BEARING 55 1 4000227 TAPERLOCK BUSH 56 2 4000023 CIRCLIP 57 1 4000228 RETAINING RING...

Page 103: ...96 ROTORS FLAILS ROBOCUT McCON NEL...

Page 104: ...ROTOR HAMMER FLAIL TYPE 6 2 4000245 BUSHING 7 1 4000703 1 3M ROTOR C W Y FLAILS 8 1 4000704 1 3M ROTOR C W HAMMER FLAILS 9 2 4000246 SCREW 10 1 4000247 SCREW 11 2 4000248 AUTOGRIP NUT 12 1 4000249 AU...

Page 105: ...Y PART No DESCRIPTION 4000700 ROBOCUT DECAL KIT 1 2 1290829 DECAL MCCONNEL ROUNDEL 2 2 1290954 DECAL ROBOCUT 3 1 1290955 DECAL ROBOCUT 1300 4 1 1290956 DECAL ROBOCUT OVERLAY ROBOCUT DECAL KIT ROBOCUT...

Page 106: ...DRAULIC OIL FILTER CARTRIDGE Part No 4000258 Fitted to Later Models HYDRAULIC OIL FILTER CARTRIDGE Part No 4000259 PRIMARY AIR FILTER CARTRIDGE Part No 4000260 SECURITY AIR FILTER CARTRIDGE Part No 40...

Page 107: ......

Page 108: ...McConnel Limited Temeside Works Ludlow Shropshire SY8 1JL England Telephone 01584 873131 Facsimile 01584 876463 www mcconnel com...

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