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Niko Rapid RoboFlail One D Operating Instructions Manual

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Operating instructions
RoboFlail One D
Read through the operating
instructions before commissioning!!
Operating Instructions Version 2.31
(Sept. 2021)
Device no.: __________
Engine no.: __________
Pump no.:
___________

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Summary of Contents for Niko Rapid RoboFlail One D

  • Page 1 Operating instructions RoboFlail One D Device no.: __________ Read through the operating instructions before commissioning!! Engine no.: __________ Operating Instructions Version 2.31 Pump no.: ___________ (Sept. 2021)
  • Page 2 Table of contents Chapter 1 Basic information Foreword General warranty conditions Liability Information about the device Operational hour counter (MOTO TIMER) Chapter 2 Information on the device application/operation Areas of application of the machine Prohibited uses Operation Chapter 3 Safety information Safety information General safety information Warning and information signs...
  • Page 3 Table of contents Chapter 4 Maintenance and upkeep Coolant Hydraulic circuit Electrical maintenance - Electromagnetic clutch 4.10 Air filter cartridge & primary filter 4.11 Cleaning the radiator 4.12 CleanFix reversing fan control 4.13 Replacing rubber tracks Chapter 5 Instructions for maintenance and care work General tests before each working day Coolant level Fuel level...
  • Page 4 Table of contents Chapter 6 Technical data + Characteristics Technical data Structure of the machine Working with the machine Chapter 7 Key fob description Description of the radio remote control Starting the engine Forward and reverse movement Changing direction R/L Potentiometer Steering potentiometer Lifting and lowering the mowing unit...

  • Page 5: Table Of Contents

    Table of contents Chapter 10 Mulching 10.0 Mounting the attachment (Mulcher) 10.1 Commissioning Chapter 11 11.0 Guiding and manoeuvring the machine 11.1 Driving on a slope 11.2 Working zone and danger zone Chapter 12 Other 12.0 Transport 12.1 Storage 12.2 Use of an additional battery 12.3 Disposal...
  • Page 6 1. Foreword Dear Customer, We thank you for your trust, which you have shown us by purchasing a NIKO product. Together with our cooperation partner Rapid Technic GmbH, we have made every effort to provide you with a powerful and reliable product.

  • Page 7: General Warranty Terms

    12 months after delivery of the device to the original purchaser. Therefore, NIKO provides a 12-month warranty if the devices are not used for more than 300 working hours a year and if the following conditions are met: The warranty begins on the date of purchase.
  • Page 8 The warranty protection expires as soon as non-genuine components are installed or used. Non-genuine parts can seriously affect both the safety of the machine and the operator. Niko GmbH accepts no liability for any resulting machine failures or personal injury caused by non-genuine parts.
  • Page 9 1.2 Liability: Niko GmbH and Rapid do not accept any liability in the event of accidents in which persons or material damage have occurred, which have been caused by the following circumstances: - failure to comply with the standards described in the operating and maintenance instructions.

  • Page 10: Information About The Device

    1.3 Information about the device: The type plate of the machine is located on the cover of the drive motor (battery side). Important: When ordering spare parts or if there are any questions about the unit, please note the unit type + manufacturer number as well as the operational hours.
  • Page 11 1.4 Operational hour counter (MOTO TIMER) The operational hour counter installed on the RoboFlail One D gives you information about the machine's running time. The operational hour counter helps you to observe the maintenance intervals and can give you information about operating times for rental equipment.
  • Page 12 2nd Area of application of the machine: The RoboFlail is an equipment designed for professional personnel and intended primarily for tillage, cutting natural materials such as branches, undergrowth and grass. Any other use is improper and the manufacturer excludes any liability for possible damage to persons, property or the machine that may result from it.

  • Page 13: Hazard Warning

    2.1 Categorically avoid the following Types of use: In any case, the following applications must be avoided under all circumstances: Use of the machine by unauthorised or untrained personnel or by persons under 18 years of age. Use of the machine to lift and move various objects. - The machine should not be used on loose stones, glass, metal pieces or other surfaces contaminated with foreign bodies that could be thrown into the air by the blades/knives of the mowing units or damage the mowing units.

  • Page 14: Operation

    Only secure the devices with the prescribed devices. Do not operate the track unless all guards are in place and in the protective position. Only Rapid/NIKO attachments may be used, NIKO does not assume any liability for third-party installations.

  • Page 15: Safety Information

    3.0. Safety information 3.1. General safety information The following information applies for your safety. Follow all the instructions and always keep these documents in direct access for all operators! If you do not understand any information contained in this safety data sheet or the product-specific assembly or operating instructions, please contact your seller or contact Rapid directly! 3.2 Warning and information signs The warning and information signs attached to the device provide important information...
  • Page 16 Do not touch machine parts unless they have come to a complete standstill. Danger from moving parts when engine is running keep a safe distance. Never open or remove protective devices while the engine is running. Before parking, secure the machine with a chock to prevent unintentional rolling away.
  • Page 17 Measures to avoid danger Passenger transport prohibited Wear head protection Wear ear protection Wear safety shoes. Wear protective gloves Wear tight-fitting clothing Wear face protection...
  • Page 18 Parking brake Gearbox On/Start Rotating blades Spring tension of Off/Stop V-Belt tension roller Risk of falling Danger due to Fast flying objects Slow Infinitely adjustable Mower blades Pinch point Mower blades Switching on Hours counter Mower blades Switching off Discharge side Danger to people present Objects thrown Around.
  • Page 19 4.0 General information on maintenance and care: To avoid machine damage or life-threatening injury when servicing the machine, the following points must be observed: − All work steps for the maintenance of the machine must be carried out in the specific order.
  • Page 20 - Before starting work, check that all movements, the stop and the protective elements work and are not impaired in their function. - Keep hands, feet, clothes, jewellery and long hair away from all moving parts to prevent them from being seized. - Never leave a running machine unattended.
  • Page 21 4.1 Running-in and maintenance of the machine in the first 50 hours Every machine that leaves the Niko GmbH plant is checked again in a categorical manner before it is delivered. Similar to other motorised vehicles, the RoboFlail must be used carefully during the first 50 hours to ensure a good running-in of the various components.

  • Page 22: Maintenance Intervals

    4.2 Maintenance intervals Attention: When replacing the oil filters, the oil should be checked for wear. If you notice any abrasion in the oil, you must first find the cause and then correct the damage before you can put the machine back into service.

  • Page 23: Maintenance

    The choice of the right engine oil is a decisive factor in the service life of your device. Therefore, only use the lubricants approved by Niko GmbH or by the manufacturer of the affected component. (refer to the engine oil selection according to the attached table in section 4.5)
  • Page 24 4.5 Recommended oils and lubricants Lubricant Engine Agrifarm Stou SAE10W30MC Hydraulic oil Agrifarm Stou SAE10W30MC Coolant Ethylene glycol -35°C Lubrication points Multi-purpose grease Attention: The warranty will be invalidated if incorrect oil types are filled in or used!!
  • Page 25 4.6 Fuel Use only fuels according to the specification EN590. Make sure the machine is always refuelled with the appropriate fuel. Other fuels with different specifications can damage the engine or reduce performance. Attention: Fuel and its fuel vapours are extremely flammable/and explosive. Fire or explosion can cause serious burns or death.

  • Page 26: Hydraulic Circuit

    4.8 Hydraulic circuit The following maintenance procedures should be carried out regularly. Please also observe the regular maintenance intervals to be performed according to the table in section 4.2 - Daily checking of the oil level in the tank at operating temperature. - Regular replacement of the oil filter cartridge (see maintenance table in section 4.2, if the filter is clogged)

  • Page 27: Electrical Maintenance

    4.9 Electrical maintenance Check the gap dimension of the electromagnetic clutch, adjust if necessary The electromagnetic clutch should be adjusted every 250 hours or, if necessary. Setting the brake Tools required: Feeler gauge Adjusting the brake (Electromagnetic clutch) Feeler gauge Settings: 0.4 mm (For 25-31 HP engines)
  • Page 28 Explanation of the setting: Push the feeler gauge between the two jaws (metal+black). Gradually tighten the screws until the feeler gauge slightly jammed at all 3 adjustment slots. This can take some time, as the adjustment on all adjustment slots has to be adjusted and checked again and again with the 3 nuts!! Set point –...
  • Page 29 4.10 Air filter cartridge The air filter consists of a main high capacity cartridge and a safety cartridge. The main element can be blown out for cleaning with air, the safety cartridge must be replaced after contamination. Replace the cartridge after 6-8 cleanings of the main cartridge or after 12 months.When replacing the safety cartridge the main cartridge must also be replaced.

  • Page 30: Cleaning The Primary Filter

    also pull out the safety cartridge by a slight twist and replace it each time, when the main cartridge is replaced. Reinstall the filter elements by reversing the procedures described. Attention: Do not wash out air elements with water. Do not use solvents for cleaning. The compressed air could damage the elements.

  • Page 31: Cleaning The Radiator

    4.11 Cleaning the radiator It is quite normal that by mowing shredded material is attracted to radiator and thus the protective grilles are clogged. The CleanFix fan control is pre-programmed so that it cycles every 15 minutes through a reverse function. A manual reverse can be applied if necessary.
  • Page 32 4.12 CleanFix reversing fan control The blades of the CLEANFIX fans can be turned around their own axis – via the transverse position! A brilliantly simple idea, but the only one that guarantees that the blade profiles are always in the optimal position to create maximum airflow and pressure for efficient cooling and thorough cleaning.
  • Page 33 4.12 Manual operation - CleanFix Depending on the degree of contamination of the radiator, the CleanFix reversing ventilation can also be operated manually via the switch (1) (at the touch of a button) on the bonnet if necessary (outside the set interval of 15 min.).
  • Page 34 4.12 CleanFix reversing fan control...
  • Page 35 4.12 CleanFix reversing fan control...
  • Page 36 4.12 CleanFix reversing fan control...
  • Page 37 4.13 Replacing rubber tracks A track change must be carried out if only a profile depth of > 10mm is available, the track has cuts, breaks or other damage. To change the tracks, the machine must be raised and parked on a stable platform. Use a 27 mm ring spanner to loosen the nut on the grease nipple.

  • Page 38: Checking The Coolant Level

    5.0 General tests before each working day Before each working day with the RoboFlail One D, a detailed visual inspection of the following described parts should be carried out to carry out repairs if any abnormalities occur. - Check the operation of the acoustic/visual warning devices and their safety-related parts such as: Emergency STOP button, sticker, brake, etc.

  • Page 39: Fuel Level

    5.2 Fuel level The fuel level in the tank is visually checked when the engine is switched off and on a flat surface. To refuel, loosen the fuel tank cap and refuel. Do not fill the tank to the top edge, but allow some space for the fuel to expand.

  • Page 40: Engine Oil

    5.4 Engine oil To check the engine oil level, open the hood. The fill level of the engine oil is checked via the dipstick (1) and must be on the MAX. sign (marks). The engine fill level must be checked while the machine is parked on a horizontal surface with the engine cold.
  • Page 41 5.5 Test – Pressure – Track tension For optimum maintenance of the track and to avoid pressure loss or the like, the test must be carried out regularly. As before, check the track tension after ten hours, then every 50 hours or as needed.

  • Page 42: Changing Engine Oil + Filter

    5.6 Changing engine oil + filter To change the oil, proceed as follows: - Place the RoboFlail One D on a solid and level surface. - Remove the drain plug on the engine (1) (underbody) and drain the oil into a suitable container.
  • Page 43 5.7 Changing hydraulic filter To change the hydraulic filter, proceed as follows: - Unscrew the black cap on the hydraulic filter using a 32 mm open-ended spanner. - Remove the inner filter element by pulling out the handle. - The filter should be replaced before it is completely clogged.

  • Page 44: Changing Hydraulic Oil

    Warning notices: The use of an oil other than the one approved by Niko GmbH can lead to significant damage to the hydraulic system. The use of another oil or mixing of the manufacturer's approved oil (see table section 4.5) with other oils can also cause damage to the hydraulic system.

  • Page 45: Changing Coolant

    5.9 Changing coolant When changing the coolant fluid proceed as follows: - Place the machine on a firm, level surface. The machine should be in cold condition. - Slowly loosen the lid of the expansion tank (1) to allow any residual pressure to escape. - Remove the lower radiator hose (2) with a 36 open-ended spanner and collect the cooling fluid that is leaking with...
  • Page 46 5.9 Changing coolant Bleeding the cooling system! - To bleed the system, first remove the hose (3) on the expansion tank. - Then open the fitting on the breather hose (4) with a size 19 spanner. - After opening the breather hose (4) it must be positioned below the radiator by holding it.
  • Page 47 5.10 Lubrication points (grease gun) All specified lubrication points must be lubricated regularly, see specification, with the enclosed grease gun: 1. Track suspension weekly 2. R/L hitch weekly 3. Mulcher daily 4. Mulcher daily (use extension)
  • Page 48 5.10 Lubrication points (grease gun) For the difficult to access lubrication points, we recommend using the extension provided 2. Mulcher daily (use extension) To move the specified lubrication point of the mulcher (1) under the cover into position, place a 17 mm open-ended spanner on the shaft (2) and turn it clockwise until the grease nipple (oval opening) is visible under the cover.
  • Page 49 5.11 Fan - Checking and adjusting V-belt...
  • Page 51 5.12 Checking and adjusting pump drive belt Instruction: V-Belt tension: 1. Undo screw (1) 2. Turn the square element (2) on the clamp clockwise with a 36- open-ended spanner until a value of 15° appears on the scale fitted!! 3. Then lock screw (1) again. 4.
  • Page 52 6.0 Technical data - Characteristics Weight: Total weight (with tracks) = 730 kg Total weight (with tracks + mulching deck) = 920 kg Engine: Brand: = Yanmar diesel engine Model: = 3TNV76 Number of cylinders: Max. power (KW/HP) = 19 KW/25 HP Cooling = water-cooled Displacement...

  • Page 53: Remote Control

    Transmit power = 10 mW Range = max. 300 m Gain = approx. 1 dB EIRP = < 10 mW Usable attachments: NIKO mowing system Type = KM110 System = flail mower Mowing width = 1.10 m Knife type = Y-knife...
  • Page 54 6.1 Structure of the machine 1. Air filter 2. Battery 3. Exhaust system 4. Coolant expansion tank 5. Fuel pump 6. Fuel primary- filter 7. 30 litres fuel tank 8. Track tensioner grease nipple 9. Rubber track 10. Track drive gear cover 11.

  • Page 55: Hydraulic Filter

    6.1 Structure of the machine 1. Mowing unit adjustment cylinder 2. Board box 3. Hydraulic filter 4. Hydraulic oil filler neck 5. Horn 6. Radiator 7. Electrical box (softstart board) 8. CleanFix control unit 9. Radio remote control receiver 10. Drive engine...

  • Page 56: Working With The Machine

    6.2 Working with the machine 1. Be sure to wear the right work clothes. Wear approved safety shoes, no sandals or tennis shoes. 2. Check the blades of the mowing units. Bent blades, blades with cracks or other damage must be replaced with spare parts from the manufacturer.

  • Page 57: Commissioning

    7.0 Description of the radio remote control Forward, neutral, back 1.1 Tank swivel right/left 2. turn right, turn left 3. Signal configuration 4. Mowing deck UP/DOWN 5. Engine speed +/- 6. Emergency stop switch on/off remote control 7. Engine start/Engine stop 8.

  • Page 58: Starting The Engine

    Attention: Before starting the engine, read the instructions thoroughly again and check your knowledge of the commands. From the time the engine is started, the operator is immediately responsible for any damage that may occur as a result of improper manoeuvres and non-compliance with safety and traffic laws.
  • Page 59 7.2 Forward and reverse movement To operate the forward and reverse movement of the machine, use the left joystick on the remote control; push the lever forward to move the machine forward and pull the lever back to move the machine backwards. The joystick works proportionally, so the more the lever moves, the faster the machine moves.

  • Page 60: Steering Potentiometer

    7.5 Steering potentiometer The steering potentiometer function allows a gradual pre-setting of the steering for the use of the machine on slopes or on steep slopes. The adjustment is done by means of the rotary switch marked in red. Turn the switch clockwise or counter-clockwise for right or left.

  • Page 61: Controlling The Engine Speed

    7.7 Controlling the engine Speed The engine speed can be manually adjusted by pressing the red-marked toggle switch. By pushing it upwards, the engine speed increases and by pushing it downwards it decreases. 7.8 Turning the mowing unit ON/OFF The mowing unit can be switched ON/OFF via the remote control after starting the device.

  • Page 62: Stopping The Engine

    7.10 Stopping the engine Before the engine is switched off, all machine movements must be stopped, switch (1) (mowing unit) is set to "off" and the engine speed switch (3) must be reduced to the minimum value. Allow the machine to run at this level for approximately one minute to stabilise the pressures and temperatures.

  • Page 63: Troubleshooting

    8.0 Troubleshooting A large part of the functional defects can be attributed to improper use of the machine. The following table lists malfunctions and the actions that can be taken to prevent them. Important note: If you have any problems or doubts, always contact our sales representative Rapid or your RoboFlail dealer.

  • Page 64: Hydraulic System

    8.2 Hydraulic system The pump makes a strange - no oil in the tank - Restore the oil level noise. - Defective pump - Repair or replace - The hydraulic oil is not - Replace suitable for this temperature 8.3 Electrical system - Reading error code (circuit board) To read an electronic error, press the button next to the display –...
  • Page 65 8.4 Fuses and relays (up to serial no.: 2023) The fuses and relays are located in the red electrical box under the hood. Carefully remove the protective cover by unscrewing it and replace the fuses or relays, if necessary, with fuses/relays of the same capacity.
  • Page 66 8.4 Fuses and relays (up to serial no.: 2023) Page 58...
  • Page 67 8.4 Fuses & relays Board KBL491 (from serial no.: 2024) The fuses and relays are located in the attached electrical box under the hood. Carefully remove the protective cover by unscrewing it and check the internal board (SMD/TSM) for any visual damage. Info: Circuit boards –...
  • Page 68 8.4 Board KBL491 (from serial no.: 2024) Page 58...
  • Page 69 On the strand of the cable harness, is the fuse that protects the harness from over voltage. (Fuse 40A) Fuse 40A: Main supply voltage Page 59...
  • Page 70 8.4 Softstart controller Page 60...
  • Page 71 Page 61...
  • Page 72 9.0 Additional information for program description Page 62...

  • Page 73: Terminal Assignment

    9.1 Terminal assignment Page 63...
  • Page 74 9.2 Functions Page 64...
  • Page 75 9.3 Functions/Error messages Board KBL464 Page 65...

  • Page 76: Board Versions

    9.4 Board versions - KBL486_0 - Identical to KBL464_3 (see above) Board size not identical to KBL464_X. KBL486_0 installed from serial no.: 1876 Page 66...

  • Page 77: Cable List

    9.5. Cable list Page 67...
  • Page 78 9.6 Board KBL464 Page 68...
  • Page 79 9.6 Board KBL486 Page 68...
  • Page 80 10.0 Mounting the mulcher The RoboFlail One D is equipped with a lower lifting device on which approved attachments of Niko GmbH / Rapid can be attached. Follow these steps to complete this process: Installing Niko – Mulcher RoboFlail One D...
  • Page 81 Joints/Tensioning arm Screw in the joints with the tensioning arms evenly R and L !! Hanging tab To install the hanging tab use the third hole from top (see picture) and insert the bushing. Hanging tab 1 Attach the hanging tab 1 to the top of the lift at the rear ...
  • Page 82 Hanging tab 2 Hanging tab 2  3. Mounting hole from top Attach to the coupler at the top Hanging tab 3 Hanging tab 3  3. Mounting hole from top Attach Hanging tab 4 Hanging tab 4  3. Mounting hole from top Attach Page 71...
  • Page 83 Mount the mounting tabs on the mulcher!! Please observe the sequence!! Start left Page 72...
  • Page 84 Attaching the hanging tab to the mulcher Grease Grease Attach the hanging tab using the hitching lugs on the mulcher  Start on the belt side of the mulcher Page 73...
  • Page 85 Mount the mounting tabs on the mulcher!! Please observe the sequence!! Continue right Page 74...
  • Page 86 Attaching the hanging tab to the mulcher Attach the hanging tab using the hitching lugs on the mulcher. Fasten the tabs so that they are not under tension, if necessary, compensate with washers. Grease On the side of the lifting cylinder, it may be possible to place washers on the mulcher lugs when fixing them!!! (See picture)
  • Page 87 V-belt hoisting The tension of the V-belt is increased by unscrewing the two tension screws evenly. V-Belt tension checking The V-belt should be moved by pushing/pulling about 10-15mm during the tension control. Page 76...
  • Page 88 V-Belt tension The V-Belt tension can be re-tensioned using the following tensioning element. Loosen the lock nut, when the screw is screwed in, the V-belts are tensioned, then lock the lock nut again. Additional info: When tensioning the mulcher belt, the drive belt on the magnetic clutch relaxes.
  • Page 89 10.1 Commissioning the mulcher Each time before commissioning, the working tools and their mounting must be checked for their perfect condition, and if necessary, retighten or replace the screws and nuts. Only original spare parts should be used for defective working tools. The working tools must not be extended, shortened, reoriented or welded.

  • Page 90: Guiding And Manoeuvring The Machine

    11.0 Guiding and manoeuvring the machine Attention: Before operating the machine, make sure that you are perfectly familiar with the function, commands and the associated safety standards. The operator must be in the vicinity of the machine. Before moving the RoboFlail One D, make sure that no one is within the operating radius of the machine (100m) and that the operating range is free of dangerous obstacles.

  • Page 91: Driving On A Slope

    11.1 Driving on a slope − Drive carefully − Drive slowly − Always drive up and down diagonally down the slope, if this is not possible, drive backwards up the slope, so you use the maximum climbing possibility. − When turning on a slope, the rear must always be at the top of the slope. −...
  • Page 92 Attention! The equipment is designed for a maximum gradient of 70%. Drive up a slope 70-100% in a reverse direction, drive up a slope > 100% in a diagonal reverse direction. Extreme caution should be exercised when driving over hilltops! Only drive at walking speed and never stand below the equipment on steep slopes and hilltops! Driving over hilltops...

  • Page 93: Working Zone And Danger Zone

    11.2 Working and danger zone Please keep the following safety distances: b= 20 m a= 10m (only when the mowing unit is running) Green area: When the knives are stationary, you can approach the stationary machine in this area safely. Red zone: Danger zone! Never step in this area closer when the engine is running than 20 m! 12.0 Transport (loading and unloading)

  • Page 94: Storage

    12.1 Storage When not mowing, the device must be stored in a safe place. It is recommended that the mowing unit be kept fully lowered to the ground. Proper preparation and storage of mowing unit at the end of the season is of the utmost importance in maintaining its appearance and ensuring years of reliable operation.

  • Page 95: Use Of An Additional Battery

    12.2 Use of an additional battery If it is necessary to start the engine using an additional battery, proceed as follows: Attention: Powerpack/starting aids must not be used!! Risk of overvoltage!! Avoid damage! The electrical charge of the auxiliary battery can damage the electronic components.

  • Page 96: Disposal

    12.3 Disposal In case of free delivery free of charge return of equipment by Rapid company. 12.4 Fire In the event of a fire, use a co2 fire extinguisher in accordance with the applicable standards. In the event of a fire, keep sufficient distance from the object to be extinguished. If necessary, contact the fire department to extinguish the fire.

  • Page 97: Ec Declaration Of Conformity

    13.0 EC Declaration of Conformity EC Declaration of Conformity According to the Annex II A of the EC Machinery Directive (2006/42/EC) The Manufacturer: NIKO GmbH Maschinen- & Fahrzeugbau Im Mühlgut 1a 77815 Bühl, Weitenung; Germany Hereby declares that the machine...

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