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McConnel ROBOCUT2 RC40 Operator's Manual

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Publication 992
January 2021
Part No. 24214.92
Revision: 24.06.22
REMOTE CONTROLLED TRACTOR UNIT
Operator Manual

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Summary of Contents for McConnel ROBOCUT2 RC40

  • Page 1 Publication 992 January 2021 Part No. 24214.92 Revision: 24.06.22 REMOTE CONTROLLED TRACTOR UNIT Operator Manual...
  • Page 2 VERIFICATION OF WARRANTY REGISTRATION Dealer Warranty Information & Registration Verification It is imperative that the selling dealer registers this machine with McConnel Limited before delivery to the end user – failure to do so may affect the validity of the machine warranty.
  • Page 4 1500 hours. Engine warranty will be specific to the Manufacturer of that unit. 1.02. All spare parts supplied by McConnel Ltd and purchased by the end user are warranted to be free from defects in material and workmanship from the date of sale to the original purchaser for a period of 6 months.
  • Page 5 2.02. Any fault must be reported to an authorised McConnel Ltd dealer as soon as it occurs. Continued use of a machine, after a fault has occurred, can result in further component failure for which McConnel Ltd cannot be held liable.
  • Page 6 MISCELLANEOUS 4.01. McConnel Ltd may waive compliance with any of the terms of this limited warranty, but no waiver of any terms shall be deemed to be a waiver of any other term. 4.02. If any provision of this limited warranty shall violate any applicable law and is held to be unenforceable, then the invalidity of such provision shall not invalidate any other provisions herein.
  • Page 8 England Telephone: +44 (0)1584 873131 www.mcconnel.com In line with our policy of constant improvement, this publication will be periodically updated; to ensure you have access to the latest version of this manual please visit the manuals library on our website where an ‘up-to-date’...

  • Page 10: Table Of Contents

    McCON NEL TABLE OF CONTENTS 1 - GENERAL DESCRIPTION 1.1 - PRELIMINARY INFORMATION 1.2 - TRAINING REQUIRED FROM THE OPERATOR 1.3 - WARNINGS ON USE AND STORAGE 1.4 - INTRODUCTION 1.4.1 - UPDATING THE MANUAL 1.4.2 - COPYRIGHT 1.5 - WARRANTIES 1.6 - RESPONSIBILITIES 1.7 - PERMITTED USES 1.8 - IMPROPER OR PROHIBITED USES...
  • Page 11 McCON NEL 4 - TECHNICAL DATA 4.1 - TECHNICAL SPECIFICATIONS 4.2 - MACHINE NAME 5 - TERMINOLOGY 5.1 - DEFINITION OF THE TERMS USED 6 - USE OF THE MACHINE 6.1 - PRELIMINARY CHECKS 6.2 - CHECKS TO BE PERFORMED AT THE START OF EACH WORKING DAY 6.2.1 - CHECKING THE CHROME-PLATED PARTS 6.2.2 - DESCRIPTION OF RECEIVER UNIT 6.2.3 - TRANSMITTER DESCRIPTION...
  • Page 12 McCON NEL 6.5.5 - FORCED STATIONARY REGENERATION 7.1 - FAULTS 7.1.1 - DIESEL ENGINE 7.1.2 - TROUBLESHOOTING CONTROL UNIT LE70 7.1.3 - ELECTRICAL CIRCUIT 7.1.4 - HYDRAULIC SYSTEM 7.1.5 – DRIVE MOTORS 7.2 - WORKING WITH THE MACHINE 7.3 - CONTROL STATION – OPERATOR WORK AREA 7 - TRANSPORTATION AND HANDLING 7.1 - LOADING AND UNLOADING OPERATIONS FOR ROAD TRAVEL 7.1.1 - IF THE MACHINE BREAKS DOWN...
  • Page 13 McCON NEL 9.10 - WHEEL DRIVE MAINTENANCE 9.10.1 - CHECKING THE TIGHTNESS OF THE SCREWS 9.11 - TRACK MAINTENANCE 9.11.1 - CHECKING THE TRACK TENSION PRESSURE 9.11.2 - REPLACING THE TRACK 9.11.3 - ROLLER WEAR 9.12 - GREASING THE LIFTING DEVICE 9.12.1 - CHECKING THE CHROME-PLATED PARTS 9.13 - MAINTENANCE OPERATIONS 9.13.1 - MAINTENANCE FREQUENCY...

  • Page 14: General Description

    Model: RC40 The manual is valid from serial number: M2165985 McConnel Limited, Temeside Works, Ludlow, Shropshire, SY8 1JL, UK Tel: +44 (0)1584 873131 Email: sales@mcconnel.com Website: www.mcconnel.com AS SUPPLIED (Hood Ram Spacer) The flail head is fitted with a hydraulic ram to allow movement of the hinged hood. The movement of this ram is restricted with an internal spacer.

  • Page 15: Training Required From The Operator

    1.3 - WARNINGS ON USE AND STORAGE The operating instructions contained in this manual are valid exclusively for the McConnel RC40. This instruction manual must be read and used as follows: •...

  • Page 16: Introduction

    1.5 - WARRANTIES The parts supplied by McConnel are covered by a 12-month warranty, that becomes valid upon commissioning, proven by the documentation delivered to the customer. In any case, refer to the machine order confirmation or to any specific agreements entered into during the sale.

  • Page 17: Responsibilities

    For all cases not included and for every type of assistance, contact McConnel directly by registered letter or fax, even in the case of agreements made by telephone. McConnel shall not be held responsible for any delays or missed interventions. McConnel shall not be held responsible for any damage or malfunctions due to technical operations carried out on the machine by unauthorised personnel.

  • Page 18: Improper Or Prohibited Uses

    This paragraph indicates some of the improper or unauthorised uses; as it is impossible to foresee all possible improper uses, if there are particular occasions of use of the machine not contemplated among those permitted, consult McConnel before carrying out the work.

  • Page 19: Running-In And Testing The Machine

    McCON NEL 1.9 - RUNNING-IN AND TESTING THE MACHINE Each machine is carefully adjusted and tested before delivery. A new machine must however be used with caution for the first 100 hours for the purpose of the efficient running-in of the various components. If the machine is subjected to an excessive work load during the initial phase of operation, its potential performance will be prematurely compromised, and its functionality reduced in a short period of time.

  • Page 20: Machine Specifications

    McConnel to be connected. PERMITTED EQUIPMENT All the equipment validated by McConnel and listed here, does not alter the stability of the vehicle, including the equipment, up to the permitted gradient (both for equipment with and without ballast).

  • Page 21: Rules Applied

    McCON NEL 2.2 - RULES APPLIED This machine has been designed and built in compliance with EC directives on safety and the approximation of the laws of the Member States; Specifically, the Machinery Directive 2006/42/EC, where applicable and S.I. 2008 No. 1597. The following standards were also taken into account during the design phase: •...

  • Page 22: Machine Identification

    McCON NEL 2.3 - MACHINE IDENTIFICATION The machine's identification plate is fixed to the left or right-hand side of the chassis, on the outside of the side member. WARNING The serial number and year of manufacture must always be indicated in assistance requests and spare parts orders.

  • Page 23: Noise Level

    McCON NEL 2.4 - NOISE LEVEL LpA = This value indicates the maximum sound level perceived by the operator calculated by making a worst case assessment at the 4 points around the machine being tested. = This value indicates the sound level outside the machine and refers to the noise perceived by those who are in the vicinity of the work area.

  • Page 24: Safety Requirements

    McCON NEL 3 - SAFETY REQUIREMENTS 3.1 - GENERAL SAFETY RULES ATTENTION • Stickers are applied to the machine to ensure safer use. They must be replaced if they are no longer legible. • The operator must never be an occasional worker but must have some experience with this type of machine.

  • Page 25: Wear Protective Clothing

    McCON NEL 3.1.2 - WEAR PROTECTIVE CLOTHING Wear tight fitting clothing and use personal protective equipment in accordance with current regulations. In particular, they are required to wear: • Noise protection headphones; • Safety footwear; • Overalls; • Work gloves. During use, the machine may produce dust emissions.

  • Page 26: Warnings For Checks And Maintenance

    McCON NEL 3.1.4 - WARNINGS FOR CHECKS AND MAINTENANCE DO NOT SWITCH ON THE ENGINE Apply a “DO NOT START THE ENGINE” sign to the machine. Remove the keys from the ignition before carrying out checks or maintenance work and delimit the area (for example with road cones). 3.1.5 - CHECKING THE MACHINE •...

  • Page 27: General Precautions

    McCON NEL 3.2 - GENERAL PRECAUTIONS • It is mandatory to read and follow the instructions indicated in the use and maintenance manual before performing any operation or manoeuvre with the machine. It is too late to do so while working.

  • Page 28: Operational Safety

    McCON NEL 3.2.2 - OPERATIONAL SAFETY The manufacturer shall not be held responsible in case of malfunction and damage if the machine: • is used for purposes other than those for which it was intended; • is not manoeuvred, started and maintained according to the service instructions specified in the following manual;...

  • Page 29: Safety Requirements For The Hydraulic System

    Stop immediately if you notice oil leaks. • Periodically check the hoses. If they are worn, contact McConnel. Before working on the system, lay the head on the floor (or any other mounted equipment) and turn off the engine. •...

  • Page 30: Location Of The Safety Signs

    McCON NEL 3.2.5 - LOCATION OF THE SAFETY SIGNS...

  • Page 31: Description Of The Safety Signs

    Ensure the good condition of the safety pictograms. If the plates are damaged, they must be replaced with original plates that can be requested from McConnel and placed in the position indicated in the manual. Make sure that all safety decals are legible.
  • Page 32 McCON NEL Emergency stop button Moving parts danger warning signs Indicates the presence of moving mechanical parts. Do not lubricate Indicates that it is strictly forbidden to lubricate moving parts and that the engine must be switched off. Hot parts warning sign Indicates the presence of hot parts such as exhaust pipes or bonnets.

  • Page 33: Precautions Regarding The Equipment

    ○ If for some reason, the rotor of the equipment begins to shake, stop the equipment immediately and try to understand the reason and / or restore correct operation. McConnel declines all liability for injury to people or damage to property if the operator fails to comply with these instructions.

  • Page 34: Safety During Refuelling And Topping Up

    McCON NEL ATTENTION • Do not clean electrical parts (for example the fuse box, actuator and control units) with high pressure water. • Cover electrical parts with a plastic bag to protect them during washing. 3.3.2 - SAFETY DURING REFUELLING AND TOPPING UP •...

  • Page 35: Personnel

    The routine maintenance indicated in the manual must be carried out exclusively by authorised and trained personnel. To perform maintenance on or service components not specified in this manual, please contact McConnel. 3.4.4 - WORKING UNDER THE MACHINE If it is necessary to carry out maintenance under the machine, make sure that you have all the suitable tools to do so.

  • Page 36: Periodical Replacement Of The Main Safety Components

    McCON NEL 3.4.6 - PERIODICAL REPLACEMENT OF THE MAIN SAFETY COMPONENTS Periodically check the following components, important for fire prevention: • Supply system: fuel delivery and return pipes; • Hydraulic system: main delivery pipes of the hydraulic motors; • Hydraulic system: pipes for utilities from the control valve to the hydraulic cylinders.

  • Page 37: Technical Data

    McCON NEL 4 - TECHNICAL DATA 4.1 - TECHNICAL SPECIFICATIONS DIMENSIONS 1280 / 1310 1960 with track 250 mm; with track 280 mm;...
  • Page 38 McCON NEL WEIGHT The total weight of the RC40 machine, without equipment, is 1150 kg. DRIVES 3TNV88C Supplier YANMAR Type DYI2D No. of cylinders Engine displacement 1642 cc Power @ 3000 rpm 29 kW / 40 CV Peak torque @ 1950 rpm 105 Nm Cooling Liquid...
  • Page 39 McCON NEL TRACKS Type Width (mm) Weight: Pair / single track (kg) Rubber 250 x 72 x 47 94 / 47 Rubber 280 x 72 x 47 158 / 79 Rubber with iron cleats and studs 250 x 72 x 47 200 / 100 CAPACITIES TABLE Quantity...

  • Page 40: Machine Name

    McCON NEL 4.2 - MACHINE NAME Pos. Description Pos. Description Front bonnet Right engine bonnet Left engine bonnet Right drive wheel Left Track Lifting device Hydraulic oil tank Right track Fuel tank...
  • Page 41 McCON NEL Pos. Description Pos. Description Ignition key Radiator casing Display Air filter Left drive wheel Radiator...

  • Page 42: Terminology

    Personnel trained to carry out extraordinary maintenance operations, assembly, disassembly, and reassembly of machine components. Must be authorised in writing by the company McConnel to intervene on the machine. Must not have disabilities of any kind or health problems. OPERATOR ASSISTANT Personnel trained to help the operator in any manoeuvre of the machine (manoeuvre at the construction site with reduced visibility, loading and unloading from the means of transport, use of the manual pump, etc.) and...

  • Page 43: Use Of The Machine

    McCON NEL 6 - USE OF THE MACHINE 6.1 - PRELIMINARY CHECKS The operator must verify that the machine is supplied with: • Machine and equipment user manual; • Check/service booklet; • Engine manual; • Technical annexes; If the machine is resold as a “second hand” machine, the customer / user must provide the purchaser with the complete use and maintenance manual as well as the inspection log book.

  • Page 44: Description Of Receiver Unit

    McCON NEL 6.2.2 - DESCRIPTION OF RECEIVER UNIT The radio receiver unit is located in the front where all the control units are positioned. It can only be accessed via the front bonnet. WARNING If you wish to clean the machine with a pressure washer, do not direct the jet towards the radio receiver unit.

  • Page 45: Transmitter Description

    McCON NEL 6.2.3 - TRANSMITTER DESCRIPTION TRANSMITTER FUNCTIONS Joystick: • Forward/reverse gear • AUX 1 auxiliary function Joystick: • Steering • Raise/lower tool Status LED: radio/battery connection Fan activation switch: manual/timed auto-pilot Travel change switch: slow/fast LCD Display Tool motor rev/activation switch Emergency button Engine on/off switch Transmitter/receiver connection button / horn...

  • Page 46: Transmitter Use

    McCON NEL 6.3 - TRANSMITTER USE ATTENTION • Before starting up the machine, the information and safety instructions contained in the user manual must be read and understood. • Professional operators must be instructed and trained. • Familiarise yourself with the controls before starting operation. DANGER •...

  • Page 47: Connection Between Machine And Transmitter

    McCON NEL 6.3.1 - CONNECTION BETWEEN MACHINE AND TRANSMITTER To make a connection between the machine and transmitter, proceed as follows: Arm the emergency stop button (A) on the machine, by turning it clockwise. Turn the ignition key to the “I” position (B), by turning it one turn clockwise. Arm the emergency stop button (6) on the remote control, by turning it clockwise.

  • Page 48: Starting The Engine

    McCON NEL 6.3.2 - STARTING THE ENGINE ATTENTION • Observe the safety instructions; • Only start the machine outside, not in closed environments to avoid the danger of carbon monoxide poisoning; a toxic gas which can kill in a matter of minutes.
  • Page 49 McCON NEL • To start the engine using the remote control, proceed as follows: Make the connection between the machine and transmitter (see section 6.3.1). Wait a few seconds for the active functions check. Press the starter switch (7) up on the remote control; once the engine has started, release the switch.

  • Page 50: Stopping The Engine

    McCON NEL 6.3.3 - STOPPING THE ENGINE To stop the engine using the remote control, proceed as follows: decrease the engine rpm. Wait about thirty seconds. Press the switch (7) down until the engine switches off. Turn the remote control off by turning the ignition key (10) anti-clockwise. Press the emergency stop button (6) to disable the remote control;...

  • Page 51: Stopping The Engine In An Emergency

    Additionally, if it is left like this for a long time, it uses a large amount of power and damages the battery. • McCONNEL RESERVES THE RIGHT TO REPLACE THE DAMAGED PART ONLY AFTER ANALYSING IT.

  • Page 52: Engine Rpm Check

    McCON NEL 6.3.5 - ENGINE RPM CHECK The buttons (14) on the left-hand side of the remote control are used to increase (A) and decrease (B) the engine revs. Press the buttons repeatedly or hold them down (A) (B) to adjust the revs. 6.3.6 - SLOW/FAST TRAVEL SWITCH Press the switch (3) up to engage fast gear or down to engage slow gear.

  • Page 53: Travel Speed Potentiometer

    McCON NEL 6.3.7 - TRAVEL SPEED POTENTIOMETER The potentiometer (12) regulates the maximum speed of the machine from 0 to 100%. The potentiometer setting chosen will depend on the various work conditions that the operator will come across and should always ensure maximum control over the machine. 6.3.8 - MOVING THE MACHINE FORWARDS AND BACKWARDS The forward travel of the machine is controlled by the left-hand proportional joystick (A).

  • Page 54: Steering The Machine

    McCON NEL 6.3.9 - STEERING THE MACHINE The steering is controlled by the right-hand proportional joystick (B). • The machine steers to the left when you move the joystick (B3) to the left. • The machine steers to the right when you move the joystick (B4) to the right. The right-hand joystick (B) used in combination with the left-hand joystick (A) allows the machine to be turned 180°, thus turning the machine in the opposite direction.

  • Page 55: Lifting Device

    McCON NEL 6.3.11 - LIFTING DEVICE The lifting device is controlled by the right-hand proportional joystick (B). • The lifting device is lowered by moving the right-hand proportional joystick (B) forwards. • The lifting device is raised by moving the joystick (B2) backwards. WARNING FLOATING FUNCTION Lower the lifting device so that the tool is resting on the ground.

  • Page 56: How To Hitch Up A Tool

    ATTENTION In some cases, the tool change causes the overall centre of gravity to shift which could make the machine unstable. Contact McConnel about adding ballast to correct the machine’s centre of gravity. The machine is fitted with a lifting device on which the various approved tools can be attached.
  • Page 57 McCON NEL Slowly move the RC40 until it is close to the mounting plate of the tool that was previously placed in front of the machine; Using the right-hand joystick (B), raise the lifting device to attach the equipment; Secure the tool with six M12 x 40 bolts to the machine support using an 18-mm spanner; Turn off the engine;...

  • Page 58: Operating The Tool

    McCON NEL Connect the hydraulic service pipes (of the tool) to the machine’s quick couplings on the right-hand side, taking care to clean them before making the connection. • The outermost couplings are used for the auxiliary function (AUX 1). •...

  • Page 59: Stopping The Tool

    McCON NEL 6.3.14 - STOPPING THE TOOL To stop the tool, proceed as follows: • Decrease the engine rpm by pressing the button (14B) until you reach the minimum speed. • Turn the potentiometer anti-clockwise (11) to the minimum setting. The tool’s hydraulic motor then stops.

  • Page 60: Auxiliary Function (Aux 2)

    McCON NEL 6.3.16 - AUXILIARY FUNCTION (AUX 2) The auxiliary function (AUX 2) is controlled by the switch (15). • The auxiliary function is enabled by pressing the switch up. • The auxiliary function with the opposite effect is enabled by pressing the switch down. •...

  • Page 61: Transmitter/Receiver Connection Button / Horn

    McCON NEL 6.3.18 - TRANSMITTER/RECEIVER CONNECTION BUTTON / HORN This button has two functions: • The first function is used when the machine is switched off to connect the transmitter to the receiver. • The second function is only used when the machine is switched on and allows the button to be used as a horn.

  • Page 62: Reversible Fan

    McCON NEL 6.3.19 - REVERSIBLE FAN Th reversible fan is controlled by the button (9). • The fan blades are inverted when the switch is press up. The blades remain inverted until the switch is released. • If the switch is pressed down, the fan blades are automatically inverted for a set time. •...

  • Page 63: Remote Control Display

    McCON NEL 6.3.20 - REMOTE CONTROL DISPLAY The remote control has an LCD display on which some parameters can be viewed which indicate the machine status during operation. The parameters displayed are: rpm of the engine Coolant temperature °C Fuel tank level 6.3.21 - STATUS LED The status LED indicates the charge and battery status.

  • Page 64: Control Panel

    McCON NEL 6.4 - CONTROL PANEL 6.4.1 - LCD DISPLAY 1000 °C Engine rpm Coolant temperature Fuel liquid level Warning light/fault area PAGE UP button PAGE DOWN button ENTER button HOME button...
  • Page 65 McCON NEL HOW TO MOVE AROUND IN THE MENU...

  • Page 66: Warning Lights

    McCON NEL HANGE MAPPING PAGE (OPTIONAL) 6.4.2 - WARNING LIGHTS The following indicator lights/warnings may appear on the display according to the faults that may arise. STOPS HORN CAUSE SOLUTION ENGINE Fuel tank less than 1/4 full Top up Move the left-hand side joystick for- The parking brake is on wards/backwards Hydraulic oil level less than 2/3...

  • Page 67: Machine Hours Counter / Maintenance Screen

    When the servicing has been completed, enter the four-digit numeric code (four digits) supplied at the time of purchase or contract McConnel’s support service. The code in this case is 6094. To view the page, press the ENTER button for 3 seconds.

  • Page 68: Alarms Screen

    If the machine breaks down and/or malfunctions, “Alarm” codes will appear on the display followed by a number that identifies the type of error. ATTENTION Contact McConnel’s support service for further information. 6.4.5 - INCLINOMETER SCREEN (OPTIONAL) Y 0.0 X 0.0...

  • Page 69: Change Operation Mode Screen (Optional)

    • Scrolling in the menu with the UP and DOWN arrows to the screen (A); • Enter the numeric code (1234) supplied at the time of purchase or contact McConnel’s support service, then press ENTER; • This accesses the screen (B) in which it will be possible to select modes (1), (2) or (3) using the UP and DOWN buttons;...

  • Page 70: Fuses And Relays

    • Flashes when stationary regeneration is required; • Flashes when the DPF (level 1) has to be cleaned of ash. Contact McConnel’s support service; STOP ENGINE: • Appears when serious engine faults are detected. Stop the engine immediately and contact McConnel’s support service;...
  • Page 71 FUSES Position Amp Function Position Amp Function Radio control 12V socket Ignition panel Engine control unit Alternator Automatic idler roller Work lights LE70 Fuel pump Horn Sensors Services LE70 Start-up Telematics XF26 XF27 RELAYS Position Function Position Function Interlock Low engine oil pressure Work lights Start controller Radio / manual control...

  • Page 72: Exhaust Gas Post Treatment System

    A means to regenerate the SF is therefore required. The engines used by McConnel use a continuous regeneration method i.e. they regenerate the filter at the same time as they collect the particulates.

  • Page 73: Maintenance And Assistance For The Particulate Filter

    In this case, the DPF has to be cleaned. McConnel recommends performing maintenance every 6000 working hours. Make sure that you use specific fuel and lubricating oil so that the DPF can function correctly.

  • Page 74: Reset Regeneration

    Exhaust filter replacements, including the particulate filter, can be ordered from McConnel. 6.5.3 - RESET REGENERATION Reset regeneration is carried out automatically by the RC40 every 100 hours.

  • Page 75: Forced Stationary Regeneration

    McCON NEL ATTENTION Follow these rules when carrying out stationary regeneration: • Do not carry out the regeneration in enclosed places; the accumulation of gases can cause carbon monoxide poisoning; • Regeneration involves bringing the exhaust gases to a high temperature so make sure that there are no flammable materials around the machine;...
  • Page 76 McCON NEL From the menu shown in Figure 1, press the DOWN key twice (see section 6.9.1) to access the forced regeneration menu Figure 2, then press the ENTER key for a few seconds (see Figure 2); Figure 2: Regeneration menu Figure 3 Figure 4 At this point, an indicator (A) (Figure 3) appears, prompting you to confirm the activation of the...

  • Page 77: Faults

    Compressed air leaking from the intake / discharge valves Engine stop solenoid faulty If the fault or the reason for it is not indicated in the list of faults shown, contact McConnel in order for repairs to be carried out.

  • Page 78: Troubleshooting Control Unit Le70

    Fuel injection timing delay Engine oil If the fault or the reason for it is not indicated in the list of faults shown, contact McConnel in order for repairs to be carried out. 7.1.2 - TROUBLESHOOTING CONTROL UNIT LE70 Error...
  • Page 79 ECU activates a system response If the fault or the reason for it is not indicated in the list of faults shown, contact McConnel in order for repairs to be carried out.
  • Page 80 Problems with output pin B35 of control unit LE70 Check the cable; Controller output error; If the fault or the reason for it is not indicated in the list of faults shown, contact McConnel in order for repairs to be carried out.

  • Page 81: Electrical Circuit

    (ignition Faulty cables Check and repair.(*) key on "I"). (*) If the fault or the cause that caused it is not indicated in the tables below, contact McConnel for the necessary repair. 7.1.4 - HYDRAULIC SYSTEM Malfunction Cause Solution The pump makes a strange noise.

  • Page 82: Drive Motors

    McCON NEL 7.1.5 – DRIVE MOTORS Malfunction Cause Solution Oil leakage from the seals Strengthening for prolonged storage Clean the area and check after a few days Seals damaged or worn Contact an authorised service centre Excessive quantity of lubricant Check the oil level Excessive vibrations and/or noise Wheel reduction unit not installed correctly...

  • Page 83: Working With The Machine

    McCON NEL 7.2 - WORKING WITH THE MACHINE DANGER Before moving the machine, ensure full knowledge of the function of the controls and safety standards associated with them. The operator must be in the vicinity of the machine. Before moving the machine, ensure that nobody is within the operating range of the machine and that the action range is free from obstacles.
  • Page 84 McCON NEL Avoid moving along the edge of a slope or on uneven ground with one track in a horizontal position and the other inclined or partially raised (with the machine inclined more than approximately 10°). In order not to damage the tracks, always proceed with the sliding blocks resting on the same horizontal plane. When the machine manoeuvres over an obstacle it creates an empty space between the bearing rollers and the tracks and there is a risk that the track may come out of its seat.

  • Page 85: Control Station - Operator Work Area

    McCON NEL 7.3 - CONTROL STATION – OPERATOR WORK AREA • The operator must always be at a minimum distance of at least 5 m from the machine. • The operator should be provided with PPE (shoes, overalls, and goggles). If working in very dusty conditions, a protective face mask should be worn.

  • Page 86: Transportation And Handling

    McCON NEL 7 - TRANSPORTATION AND HANDLING 7.1 - LOADING AND UNLOADING OPERATIONS FOR ROAD TRAVEL Use suitable vehicles with a carrying capacity of greater than 1600 kg to transport the machine. Use loading ramps, both of which are suitable for supporting a load of not less than 800 kg and which are hooked to the bed of the vehicle.

  • Page 87: If The Machine Breaks Down

    McCON NEL Note that when using ropes, slings, or chains to lift the machine, it is necessary to comply with the diagram below, indicating the minimum pulling angles. Angle at Load increase the top factor Rope Load Rope angle 0° opening increase with horizon...

  • Page 88: Using The Manual Control

    McCON NEL 7.2 - USING THE MANUAL CONTROL If the machine has to be moved without using the remote control (e.g. remote-control batteries discharged), this can be done by connecting the manual control unit supplied with the machine. To do this, follow the instructions below: Remove the cap with the bayonet fitting (B) from the socket (A).

  • Page 89: Starting The Engine Using An Auxiliary Battery

    McCON NEL 7.3 - STARTING THE ENGINE USING AN AUXILIARY BATTERY If the engine has to be started using an external battery, proceed as follows: Open the cover of the junction box (A) located close to the diesel pre-filter. Connect one terminal of the red cable to the screw of the node and the other to the positive terminal (+) of the auxiliary battery.

  • Page 90: Storage

    McCON NEL 8 - STORAGE If the machine is stopped for long periods, it must be stored in a place protected from the elements to prevent damage. Before storing the machine, it is advisable to clean it thoroughly and to lubricate all the mechanical components to protect them from rust.

  • Page 91: Maintenance

    For further information, please contact our service centre: Contact McConnel’s technical support service centre: Telephone +44 (0)1584 873131 Email sales@mcconnel.com...

  • Page 92: Extraordinary Interventions

    McCON NEL 9.3 - EXTRAORDINARY INTERVENTIONS These are repairs or replacements of one or more components of the machine, which usually become necessary after a few years of efficient operation and which do not alter the characteristics of the machine. In the case of considerable changes, the manufacturer shall not be held responsible for possible hazards which might arise.

  • Page 93: Coolant

    ASTM D 3306; ASTM D 4656; ASTM D 4985, ASTM D 6210; JIS K 2234; SAE J 1034. 9.4.3 - FUEL DANGER • Do not use diesel filling systems that use auxiliary electric pumps without the written consent of McConnel. • It is forbidden to tamper with or modify the fuel supply system and/or electrical system. DANGER •...

  • Page 94: Engine Maintenance

    McCON NEL • Other fuels with different specifications can damage the engine or reduce its power. For further details and/or explanations, consult the annexed engine manual. • When refuelling, check there is no condensate on the fuel tank cover. Do not remove the condensate water on the bottom.

  • Page 95: Filter And Engine Oil Change

    McCON NEL 9.5.2 - FILTER AND ENGINE OIL CHANGE ATTENTION • After the first 50 hours of running in, the filter and thermal motor oil must be replaced. • Replace the filter and thermal motor oil every 250 working hours. •...
  • Page 96 McCON NEL Unscrew the oil filler cap (D); Retighten the oil sump drain cap (C) once all the oil has drained out; Remove the side guard (E); Unscrew the filter cartridge (F) anticlockwise and remove it; Apply a film of clean oil to the new filter in the external and internal seals, and the filter thread; Dry the sealing head of the filter thoroughly with a clean rag and reinstall the filter, tightening it with the wrench (max.

  • Page 97: Coolant Level Check

    McCON NEL 9.5.3 - COOLANT LEVEL CHECK ATTENTION • Check the coolant level daily or before each use. • The coolant must be chosen very carefully; refer to the table in section 9.4.2. DANGER • Danger of burns due to very hot coolant! •...

  • Page 98: Coolant Replacement

    For disposal or correct recycling of waste, contact the relevant agencies. • The protective agents of the cooling system must be ordered from McConnel partners. • Never use the engine without coolant, not even for a short time!
  • Page 99 McCON NEL Proceed as follows to check the coolant level: Position the machine on a flat surface and switch off the engine; Allow the coolant and engine to cool down; Detach the two rubber stay rods (B) securing the bonnet (A). Pull the locking pin (C), raise the bonnet and block it by releasing the pin.
  • Page 100 McCON NEL Drain the coolant from the monobloc removing the hose clip (H) and detaching the hose pipe (I) from the oil filter; After having drained the coolant, wash the radiator and monobloc in order to remove any rust, scale and contaminants;...

  • Page 101: Fuel Level Check

    McCON NEL 9.5.5 - FUEL LEVEL CHECK ATTENTION • Check the fuel level daily or before each use. • The fuel must be chosen very carefully; refer to the table in section 9.4.3. DANGER • When more fuel is added, avoid spilling it as this may cause a risk of fire. •...

  • Page 102: Draining And Bleeding The Fuel Separator

    McCON NEL 9.5.6 - DRAINING AND BLEEDING THE FUEL SEPARATOR ATTENTION • Check the fuel separator every 50 working hours or weekly. • When contaminants appear, remove them immediately, DO NOT wait for scheduled maintenance to be carried out. DANGER •...

  • Page 103: Primary Fuel Filter Replacement

    McCON NEL 9.5.7 – PRIMARY FUEL FILTER REPLACEMENT ATTENTION • The cartridge must be replaced every 500 working hours. • When contaminants appear, remove them immediately, DO NOT wait for scheduled maintenance to be carried out. DANGER • In certain specific conditions, diesel is flammable and explosive. •...
  • Page 104 McCON NEL Place an approved container under the bowl (F) of the fuel separator to collect the contaminants. Close the fuel separator valve by turning it to OFF, (A2). Loosen the drain valve (G) and drain the diesel and contaminants. If the water doesn’t drain, loosen the vent screw (B).

  • Page 105: Replacing The Fuel Filter

    McCON NEL 9.5.8 - REPLACING THE FUEL FILTER ATTENTION The fuel filter must be replace every 500 working hours. DANGER • In certain specific conditions, diesel is flammable and explosive. • Never use diesel as a cleaning agent. • When a component is removed from the fuel supply system to carry out maintenance (e.g.
  • Page 106 McCON NEL Close the fuel separator valve by turning it to OFF, (A2). Remove the fuel filter (B) by turning it to the left. Hold the filter firmly to prevent fuel from spilling out. In the event of spillages, clean the area affect thoroughly.

  • Page 107: Cleaning Or Replacing Air Filters

    McCON NEL 9.5.9 - CLEANING OR REPLACING AIR FILTERS ATTENTION • The filters should be cleaned daily. • The cartridges of the air filter unit should be replaced every 500 working hours DANGER • Dismantle the air filter only when the engine is stopped and do not start the engine with the air filter open.
  • Page 108 McCON NEL To clean/replace the air filter unit cartridge: Detach the two rubber stay rods (B) securing the bonnet (A). Pull the locking pin (C), raise the bonnet, then block it by releasing the pin. Release the two catches and remove the cover (D). Pull the primary cartridge (E) out.

  • Page 109: Cleaning The Radiator Casing And The Radiator

    McCON NEL 9.5.10 - CLEANING THE RADIATOR CASING AND THE RADIATOR ATTENTION Cleaning of the radiator casing and the radiator should be done daily or every 8 working hours. The radiator casing (A) should be cleaned both internally and externally. Clean with a jet of compressed air or with special products following the instructions on the containers of the products.

  • Page 110: Hydraulic System Maintenance

    McCON NEL 9.6 - HYDRAULIC SYSTEM MAINTENANCE 9.6.1 - HYDRAULIC OIL LEVEL CHECK ATTENTION Check the hydraulic oil level every 8 working hours or daily. WARNING • Do not top up oil beyond the MAX level, this could cause oil to leak from the tank.

  • Page 111: Changing The Hydraulic Oil Filter

    McCON NEL 9.6.2 - CHANGING THE HYDRAULIC OIL FILTER ATTENTION • The hydraulic oil should be replaced as follows: Type Supplier Replacement within Mineral Q8 HELLER 46 1000 hours Biodegradable PANOLIN HLP SYNTH E 46 15000 hours • Quantity required for filling: 20 litres (approx.) DANGER •...

  • Page 112: Changing The Hydraulic Oil Filter

    McCON NEL Tighten the cap (B) at the end of the operation and replace the copper washer, if necessary. Add new hydraulic oil; refer the table above for the choice of oil. Check the level on the dipstick attached to the filler cap (C). As soon as the correct oil level has been reached (see section 9.6.1), start the engine and let it run for ten seconds, repeat this operation until the supercharging pressure is reached on the pumps (20÷22 bar).

  • Page 113: Maintenance Of The Hydraulic Motors And Hydraulic Valves

    • The hydraulic fittings connected to the motor and valves are not loose. If they are, tighten them. • If the problem persists, contact the McConnel Support Service. DANGER • At operating temperature, the hydraulic oil is boiling and at times also pressurised.

  • Page 114: V-Belt Inspection/Tensioning

    McCON NEL 9.8.1 - V-BELT INSPECTION/TENSIONING To check the tension of the timing belt, proceed as follows: Switch the machine off. Open the right-hand bonnet with the relevant spanner supplied with the machine. Check the belt tension (A): press the belt with a force of 98 Nm in one of the points indicated (X) or (Y);...

  • Page 115: Replacing The V-Belt

    McCON NEL 9.8.2 - REPLACING THE V-BELT To replace the timing belt, proceed as follows: Switch the machine off. Open the right-hand bonnet with the relevant spanner supplied with the machine. Loosen the adjustment screws (B) using a 12mm spanner; PASS THE BELT THROUGH THIS SPACE Remove the old belt by passing it between the reversible fan blades and the radiator...
  • Page 116 McCON NEL Check the tension again against the specifications for a “used” belt. See the following table: Tension of USED belt Position Displacement (mm) 7-10 10-14 “Used belt” refers to a belt that has been used with the engine running for 10 minutes or more. If, during the inspection you notice that: •...

  • Page 117: Checking The Battery Charge

    McCON NEL 9.8.3 - CHECKING THE BATTERY CHARGE To check the charge of the batteries: Turn the machine off; Open the front bonnet of the RC40; On the right-hand side of the RC40, locate the junction box (A) of the positive lead which arrives directly from the battery (B);...

  • Page 118: Periodical Replacement Of The Safety Components

    McCON NEL Furthermore, make sure that: • Do not carry out any modifications to the electrical system without the prior authorisation of McConnel. • Do not eliminate or install any components without the prior authorisation of McConnel. • Prevent the electrical system from coming into contact with water.

  • Page 119: Wheel Drive Maintenance

    McCON NEL 9.10 - WHEEL DRIVE MAINTENANCE 9.10.1 - CHECKING THE TIGHTNESS OF THE SCREWS ATTENTION The screws should be tightened every 250 working hours. The check must be carried out using a torque wrench. Refer to the table below for the required tightening torques.

  • Page 120: Track Maintenance

    • NEVER WORK DIRECTLY ON THE VALVE WITH YOUR HANDS. IF THE VALVE IS BLOCKED OR DAMAGED, CONTACT AN McConnel SERVICE CENTRE. • Do not attempt to unblock the valve. Extremely dangerous pressures may have built up inside the valve.
  • Page 121 McCON NEL Track tightening pressure Track Max. pressure (bar) Rubber 250 Rubber 280 Use a lever grease gun having the following characteristics to tension the track: Filling capacity 500 cm Filling type 400 g (cartridge) Delivery / stroke volume 1.2 cm Delivery pressure (max) 400 bar System pressure (max)

  • Page 122: Replacing The Track

    McCON NEL 9.11.2 - REPLACING THE TRACK DANGER • The machine support must be capable of supporting the load and keep it in a stable and safe position. • To lift the machine, refer to chapter 7. ATTENTION It is also recommended to recheck the tensioning after 8 / 10 hours of operation and set it to the values indicated it the table above.

  • Page 123: Roller Wear

    McCON NEL 9.11.3 - ROLLER WEAR The rollers are considered wear parts. Their duration depends on the ground on which they operate (muddy, sandy or other types). An average life of 500 working hours is estimated, which obviously depends on the working conditions in which the machine is used.

  • Page 124: Maintenance Operations

    McCON NEL 9.13 - MAINTENANCE OPERATIONS 9.13.1 - MAINTENANCE FREQUENCY Check / Top up ENGINE OIL X X X X X X X X X X Replacement ENGINE OIL X X X X X X X X X X Replacement FILTER Check / Top up LIQUID...

  • Page 125: Instructions For Emergency Situations

    McCON NEL 10 - INSTRUCTIONS FOR EMERGENCY SITUATIONS 10.1 - FIRE In case of fire, use a fire extinguisher according to the standards in force. If the machine catches fire or it is close to a fire, raise the alarm and contact the fire service. 10.2 - ASSISTING THE OPERATOR IN CASE OF ILLNESS If the operator feels unwell, you need to act quickly, following the steps indicated below: •...

  • Page 126: Tightening Tables

    McCON NEL 11 - TIGHTENING TABLES 11.1 - SCREW TIGHTENING TABLE Strength class 12.9 10.9 Threading Actual Initial Initial Initial nominal section area Breaking Tightening Breaking Tightening Breaking Tightening tightening tightening tightening size as mm load torque load torque load torque force force...

  • Page 127: Notes

    McCON NEL 12 - NOTES...
  • Page 128 McConnel Limited, Temeside Works, Ludlow, Shropshire SY8 1JL. England. Telephone: 01584 873131. Facsimile: 01584 876463. www.mcconnel.com...

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