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Timan RC-1000 Workshop Manual

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WORKSHOP MANUAL
RC-1000
"A safe investment"
www.timan.dk

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Summary of Contents for Timan RC-1000

  • Page 1 WORKSHOP MANUAL RC-1000 ”A safe investment” www.timan.dk...
  • Page 3 12 34 5 6 2 7 84 92  2  ...

  • Page 5: Workshop Manual

    WORKSHOP MANUAL RC-1000 ”A safe investment” www.timan.dk...

  • Page 6: Table Of Contents

    ........................31 AIN SWITCH ..........................31 USES ..........................32 ELAYS ........................32 LTENATOR ..........................32 ROUND ....................33 HANGING THE FREQUENCY ........................34 ONTROL LOGIC LUBRICATION PLAN ......................42 EQUIPMENT FOR RC-1000 ....................50 ..........................50 PIKES TOOLS ............................51...
  • Page 7 CONTENTS ........................51 LAIL MOWER 10 TECNICAL DATA ........................57 11 TROUBLESHOOTING ......................58 12 HYDRAULIC SYSTEM CHART ..................... 59 13 ELECTRICAL SYSTEM CHART .................... 60...

  • Page 8: Structure Of The Machine Rc 1000

    1 STRUCTURE OF THE MACHINE RC 1000 Hydraulic pumps Hydraulic tank Air filter Antenna Oil outlet Tilt sensor Manoeuvring valve Engine oil cooler Oil cooler Oil filter Fuel tank...

  • Page 9: Component Placement

    Component placement 1: Main switch. 9: Oil temperature warning 2: Battery 12 V 18 Ah 10: Oil filter 3: Safety sensor 11: Emergency stop 4: NBB control unit 12: Operating hours counter 5: Fuel pump 13: Tilt sensor 6: Fuel filter 14: Engine oil cooler 7: Tank cap/tank gauge 15: Oil pressure sensor...
  • Page 10 1: Horn for tilt sensor 7: Starter 2: Throttle 8: Oil filling cap (engine) 3: Air filter 9: Oil dipstick (engine oil) 4: Choke 10: Oli filling cap/oil dipstick (hydr.) 5: Charger 11: Hydraulic return filter 6: Starter relay...
  • Page 11 1: Valve block (hydraulic manoeuvring system) 3: Hydrostatic pump 2: Gear pump (PTO) 4: Test fitting (pressure in the supply line)

  • Page 12: Saftey

    2 SAFTEY The machine RC-1000 is controlled via remote control which means that the operator is away from the machine from time to time. In order to ensure the optimal safety of the operator and other people, the machine is equipped with a safety system which can either be activated manually or automatically.

  • Page 13: Tilt Sensor

    Tilt sensor. A tilt sensor is fixed to the rear of the machine. This sensor has two purposes. 1. Protection of the engine. The engine is tested and approved for driving on slopes with a max inclination of 50 degrees. When driving on a slope higher than 50 degrees, the engine loses its ability to lubricate and there is a risk of being damaged 2.

  • Page 14: Towing The Machine

    Towing the machine The machine can be towed in the event that the hydraulic system of the machine fails or if you cannot start the engine. Start by loosening the two screws that hold the brakes. Remove the top screw and turn the fitting so that the screw can be put into the bottom hole.

  • Page 15: Starting With An Auxiliary Batteri And Recharging The Battery

    Starting with an auxiliary batteri and recharging the battery. RC-1000 is equipped with a rechargeable battery 12 V 18 The battery can be damaged if it is poorly handled. In order to reach its full effect, the battery must be handled properly.

  • Page 16: Oil Pressure

    Oil pressure Oil pressure is measured in the opening in which the oil pressure sensor is mounted. 1: Remove the oil pressure sensor, and put in the gauge with a numeric indicator (barometer) (0-5 bar). 2: Start the motor. Once the engine warms up, measure the oil pressure both at idle and at higher speeds.

  • Page 17: Changing Oil And Filter

    Changing oil and filter Engine oil: SAE 30 The required amount of oil when changing the oil and oil filter: approx. 1,7L 1. Drain the engine oil through the drain plug (A). The drain plug can be loosend from the bottom through the hole in the chassis 2.

  • Page 18: Fuel Pump

    Fuel pump When replacing the fuel pump, it is necessary to make sure that the pump is exactly identical. The pump is chosen exactly according to its pressure and flow. If you install a pump with a higher pressure, there is a risk that the engine will run unevenly when driving on a slope.

  • Page 19: Air Filter

    Air filter A dirty air filter reduces the air flow to the combustion chamber of the engine and thus reduces engine performance. When running the engine without an air filter or with a dirty air filter, dirt gets into the engine which leads to severe wear and damage to the engine.

  • Page 20: Valves

    Valves Inspect the valves after every 200 hours. 1: Remove the protective frame, side covers and rear end. 2: Remove the valve covers Do not forget the seals on the screws and the valve cover! 3: Remove the spark plugs 4: Adjust the valves in the combustion stroke approx.

  • Page 21: Carburettor

    Carburettor Cleaning the carburettor. In the event that the machine starts to move unevenly in idle, it is often due to the presence of oil in the carburettor. When the inclination of the engine is greater than 50 degrees, engine oil starts to leak into the vent pipe and then into the carburettor.
  • Page 22 Clean the nozzles on the floater with compressed air! Do not forget about the float valve! Clean all channels and nozzles in the carburettor. Mount the floater, bowl and terminals onto the carburettor. Mount the carburettor back in the reverse order of the given steps.

  • Page 23: Ajustment Of The Regulator

    Ajustment of the regulator Basic adjustment of the regulator Press on the arm of the regulator, and hold it in the direction of the engine. Turn the regulator up against the limit switch, and tighten the arm firmly. Idle control...

  • Page 24: Replacing The Engine

    Replacing the engine Before the Vanguard engine is installed in the machine, some changes are necessary for operation of the machine on slopes up to 50°. The suction strainer in the oil pan is replaced os that it can suck in oil regardless of the angle the engine is in.
  • Page 25 Replacing the altenator Due to the large consumption of electricity in the oil cooler, a 20 A alternator is fixed to the engine. Along with the replacement of the alternator, a screen will be mounted above the flywheel to protect against falling foreign objects and damage to the flywheel/alternator.

  • Page 26: Engine Specifications

    Engine specifications Model 38x400 Engine displacement (ccm2) Idle speed (rpm) 1750 Amount of oil (L) 1,4/1,7 (1.7l incl. filter) Spark plug Champion XC92YC Electrode gap (mm) 0.7-0,8 Valve clearance : (mm) Intake 0,10-0,15 Exhaust 0,10-0,15 Cylinder bore 75.500-75,520 Tightening torque (Nm) Flywheel Cylinder head Connecting rod...

  • Page 27: Hydraulic System

    4 HYDRAULIC SYSTEM Hydraulic oil: Shell Tellus TX 46 Tank capasity: Approx. 17L Hydraulic filter. Boost filter Spare part nr: VHY-00114 Oil filling cap With relief valve Oil level...

  • Page 28: Replacing The Hydraulic Filter

    Replacing the hydraulic filter Method of replacing the hydraulic filter. Important: Before you start working, it is important to clean the area around the filter to prevent dirt from getting into the oil. 1. Lift the top hood, and set the cooler into the service position. With a single open ended wrench (26 mm), loosen the stopper of the hydraulic tank.

  • Page 29: Hydrostatic Pump

    Hydrostatic pump Hydrostatic pump: Hansa TPV 6-7 Piston pump 7ccm Feed pressure: 22 bar Pressure relief valve: 300bar (Not adjustable) PTO-pump: Rexroth Gear pump 11 ccm 1: Amount limiter 2: Neutral adjusting 3: Feed pressure adjusting 4: By-pass valve (towing) A2 og B2 ½”...
  • Page 30 IMPORTANT! If the pump is removed or has just been replaced, it is necessary to fill it with oil before starting the machine. If the machine is started without oil in the hydrostat, the supply pump of the hydrostat will be damaged! Once the hydrostat is attached to the machine, you mount the hose to the hydrostatic pump.

  • Page 31: Servo

    -Start the machine again, and check whether the problem has been solved and all funktions are working. If you want to decrease the speed of the RC-1000 machine, you can reduce the oscillation in the servomechanism. The adjustment is performed on the set screws on both ends of the servomechanism.

  • Page 32: Manoeuvring Valve - Front

    Manoeuvring valve - front The manoeuvring valve controls: - Mower (tool) on/off - Tool frame up/down/floating position - Front terminal Relief pressure: Electrical adjusted. 1:Holding valve/floating position 2:Lifting and lowering tool frame 3:valve for front terminal 4:On/off valve for tool (mower) 5: Termostat for cooling fan 6: Pressure control valve 7:Oil temperature sensor...
  • Page 33 4.4.1 Temperature sensor Two sensors are located on the valve block 1: Oil temperature sensor. If the temperature of the hydraulic oil exceeds 82 °, [horn no. 1] will activate and the warning light on the control box will light up. It is necessary to immediately stop the machine and clean the cooler.

  • Page 34: Wheel Engine

    Wheel engine Danfoss OMPW160 Orbitrol engine 160ccm Before mounting the traction wheels, lubricate the axles with thin oil. 5 BELTS It is essential that the belts of the machine are properly tensioned. When driving with belts that are too loose, there is a risk that the belts will come off when driving on a slope. If the belts are too tight, it increases the wear of the oil engine and bearings.

  • Page 35: Brakes

    Brakes RC-1000 is equipped with a parking brake which automatically clasps on when the machine is turned off. The brake is deactivated when the machine is started and the engine creates oil pressure - approx. 3 seconds after the machine is started. The parking brake prevents the machine from rolling away when it stops on a slope.

  • Page 36: Electrical System

    6 ELECTRICAL SYSTEM IMPORTANT! If welding must be performed on the machine, you MUST turn the main switch off and disconnect the multi-connector of the control box! IMPORTANT! During any work on the electrical system, turn the main switch off to prevent a short circuit. Main switch The power switch is located under the top protective cover on the left in the engine compartment.

  • Page 37: Relays

    Relays K1: Relay for starting the engine K2: Relay for spark plug (run signal) K3: Relay for fuel coil (afterfire) K4: Relay for hours counter and charge indicator K5: Cooling fan blow K6: Cooling fan suck K7: Saftey sensor for tool frame K8: Emergency stop double relay Altenator The alternator of RC 1000 is replaced with an...

  • Page 38: Changing The Frequency

    Changing the frequency If the remote control signal of the machine is interrupted, the machine will stop automatically. In order to continue operation, it is necessary to change the channel on the remote control. You can do this by holding down button [1] while activating button [2].
  • Page 44 Basic 12V power supply 12 V after activating the emergency stop on the machine GND power supply 12 V after activating the emergency stop on the machine Input IN 2 Oil sensor motor Feedback to comtroller, whether the engine is running IN 3 V Oil sensor motor.
  • Page 45 Out 23 On/off for the oil cooler fan. The fan sucks for 2.5 min after which it stops for 4 sec. After 4 seconds, the direction of the fan flow changes for 15 seconds. Then it stops for 4 seconds and sucks for 2.5 minutes etc.

  • Page 46: Lubrication Plan

    7 LUBRICATION PLAN Bushings: Timan recommends the special lubricants Statoil and Greaseway CaH 92, which are designed for friction bearings. Friction bearings : Lubricate every 20 hours of operation. Under the front of the machine 2 pcs Behind the machine under the triangle...
  • Page 47 Friction bearings for undercarriage 1 pcs. in each side On both sides at the lifting arm.
  • Page 48 Timan a/s Fabriksvej 13 6980 Tim Danmark Phone +45 97 330 360 Fax + 45 97 330 350...
  • Page 49 The machine is serviced in accordance with the service inspection plan for model RC-1000. The service plans for workshops that carry out the service inspection is in the back of the service book. The workshop will put its stamp on the service plan and the below service inspection interval schedule in order to comply with the intervals.
  • Page 50 Spare parts for service after 500 hours Spare part nr. Description. Quantity. 15901064 Oil filter for Vanguard engine 22601012 Air filter Vanguard engine. 15901063 Spark plug for Vanguard engine 22201005 Petrol filter Spare parts for service after 600 hours Spare part nr. Description.
  • Page 51 20 hours service. Hour meter:___________ 100 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 200 hours service. Hour meter:___________ 300 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 400 hours service.
  • Page 52 800 hours service. Hour meter:___________ 900 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 1000 hours service. Hour meter:___________ 1100 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 1200 hours service.
  • Page 53 1800 hours service. Hour meter:___________ 1900 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 2000 hours service. Hour meter:___________ 2100 hours service. Hour meter:___________ Date:_________________ Date:_________________ Signature and company stamp Signature and company stamp 2200 hours service.

  • Page 54: Equipment For Rc-1000

    The spikes are attached between every fourth pattern on the belt. See Figure. Timan recommends the use of these spikes during every drive on slopes with an inclination greater than 35 degrees. Push the fittings onto each side of the belt and tighten the screw.

  • Page 55: Tools

    9 TOOLS Pivoting joint Flail mower The machine can be equipped with a hydraulic flail mower which is fastened to the tool frame. Before driving, check the clearance of the pivoting flail joint. Especially during the first 50 hours of operation, it is necessary to frequently tighten the joint in order to remove this clearance.
  • Page 56 Locknut Top rod 9.1.2 Mowing height With the top rod, it is possible to set the mowing height within a range from 20 to 70 mm. By extending the rod, the mowing height is reduced. Do not forget to tighten the locknut after that. The recommended mowing height varies depending on the terrain, characteristics of the surface, the type of flail and the length of the grass.
  • Page 57 Always replace the flails before they are too worn. New flails provide nicer mowing results. Adjust the mower’s height according to the conditions and never allow the flails to touch the ground. Important: All flails must be replaced at the same time because otherwise the flail bar will become imbalanced.
  • Page 58 9.1.5 Lubricating the flail mower Bearings in the mower: Lubricate every 8 hours of operation. We recommend the lubricants Statoil and Uniway LI 62, which are designed for ball bearings. Bushings: We recommend the special lubricants Statoil and Greaseway CaH 92, which are designed for friction bearings.
  • Page 59 9.1.6 Tensioning and maintenance of the belts For the proper adjustment and maintenance of the belts, a belt tension tester is attached to the machine. When driving with belts that are too loose, their service life and efficiency decreases significantly and the pulley are severely worn out. If the belts are too tight, the wear of the machine bearings is increased.
  • Page 60 9.1.7 Belt tensioning between the engine and hydraulic pump The belt tensioning is performed as follows: 1. Remove the protective belt cover, and loosen the 4 screws which are holding the engine. 2. Loosen the locknut on the adjustment screw, and adjust the nut on the adjustment screw until you achieve the correct belt tension.

  • Page 61: Tecnical Data

    10 TECNICAL DATA Model RC-1000 Engine Vanguad 23 Bhp Number of cylinders Cylinder volume 627 ccm bhp /kW 23/17 Max. rpm 3600 Cooling system Air cooled Lubrication Pressure lubrication Fuel tank 14 L Hydraulic tank 17 L Transmission Double piston pumps 2x7ccm...

  • Page 62: Troubleshooting

    11 TROUBLESHOOTING Before you start troubleshooting electrical components, it is important to check if all the fuses are intact. Defect Possible causes of the defect Possible solutions The engine starter is running, Spark plug Check the distance or replace the plug but the engine is not starting Clogged fuel filter Clean/replace the filter...