McCONNEL

Publication 679
August 2011
Part No. 22674.79
Revision 18.04.12

ROBOCUT
REMOTE CONTROLLED MOWER
Operator & Parts Manual
 IMPORTANT
VERIFICATION OF WARRANTY REGISTRATION

DEALER WARRANTY INFORMATION & REGISTRATION VERIFICATION

It is imperative that the selli ng dealer registers this machine with McConnel Limited bef ore
delivery to the end user – failure to do so may affect the validity of the machine warranty.
To register machines go to t he McConnel Limited web site at www.mcconnel.com, log
onto ‘Dealer Inside’ and select the ‘ Machine Registration button’ which can be found in
the Service Section of the si te. Confirm to the customer that the machine has bee n
registered in the section below.
Should you experience any problems registering a machine in this manner p lease contact
the McConnel Service Department on 01584 875848.
Registration Verification
Dealer Name: ……………………..…………………………………………………………….
Dealer Address: …….………………………………………………………………………….
Customer Name: ……………………..…………………………………………………………
Date of Warranty Registration: ……/……/...…… Dealer Signature: ………………..……

NOTE TO CUSTOMER / OWNER

Please ensure that the above section above has been completed and signed by the selling
dealer 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, bolts and hose connections for tightness and re-tighten if required. New
hydraulic connections occasionally weep small amounts of oil as the seals and joints settle in – where
this occurs it can be cured by re-tightening the connection – refer to torque settings chart below. The
tasks stated above should be performed on an hourly basis during the first day of work and at least
daily thereafter as part of the machines general maintenance procedure.
TORQUE SETTINGS FOR HYDRAULIC FITTINGS
HYDRAULIC HOSE ENDS PORT ADAPTORS WITH BONDED SEALS
BSP Setting Metric BSP Setting Metric
1/4” 18 Nm 19 mm 1/4” 34 Nm 19 mm
3/8” 31 Nm 22 mm 3/8” 47 Nm 22 mm
1/2” 49 Nm 27 mm 1/2” 102 Nm 27 mm
5/8” 60 Nm 30 mm 5/8” 122 Nm 30 mm
3/4” 80 Nm 32 mm 3/4” 149 Nm 32 mm
1” 125 Nm 41 mm 1” 203 Nm 41 mm
1.1/4” 190 Nm 50 mm 1.1/4” 305 Nm 50 mm
1.1/2” 250 Nm 55 mm 1.1/2” 305 Nm 55 mm
2” 420 Nm 70 mm 2” 400 Nm 70 mm
 WARRANTY POLICY
WARRANTY REGISTRATION

All machines must be registered, by the selling dealer with McConnel Ltd, before delivery to the end
user. On receipt of the goods it is the buyer’s re sponsibility to check that the Verification of Warranty
Registration in the Operator’s Manual has been completed by the selling dealer.

1. LIMITED WARRANTIES
1.01. All machines supplied by McConnel Limited are warranted to be free from defects in mate rial
and workmanship from the date of sal e to the original purchaser for a period of 1 2 months,
unless a different period is specified.

1.02. All spare parts supplied by McConnel Limited 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.

1.03. The manufacturer will replace or rep air for the p urchaser any part or pa rts found, upon
examination at its factory, to be defective under normal use a nd service due to defects in
material or workmanship. Returned parts must be complete and unexamined.

1.04. This warranty does not apply to any part of the goods, which has been subjected to improper or
abnormal use, negligence, alteration, modification, fitment of non-genuine parts, accid ent
damage, or damage resulting from contact with overhead power lines, dam age caused by
foreign objects (e.g. stones, iron, ma terial other than vegetati on), failure due to lack of
maintenance, use of incorrect oil or lub ricants, contamination of the oil, or which has served its
normal 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 consequential loss - i.e. oil, do wntime and associated parts are
specifically excluded from the warranty.

1.06. Warranty on hoses is limit ed to 12 months and does not include hoses w hich have suffere d
external damage. Only complete hoses may be returned under warranty, any which have been
cut or repaired will be rejected.

1.07. Machines must be repaired immediately a problem arises. Continued use of the machine after a
problem has occurred can result in furt her component failures, for which McConnel Ltd ca nnot
be held liable, and may have safety implications.

1.08. Except as provided herein, no employee, agent, dealer or other person is authorised to give any
warranties of any nature on behalf of McConnel Ltd.

1.09. For machine warranty periods in excess of 12 months the follo wing additional exclusions shall
apply:
1) Hoses, external seals, exposed pipes and hydraulic tank breathers.
2) Filters.
3) Rubber mountings.
4) External electric wiring.

1.10. All service work, particularly filter c hanges, must be carried out in accordance with the
manufacturer’s service schedule. Failure to comply will invalidate the warranty. In the event of a
claim, proof of the service work being carried out may be required.
NB Warranty cover will be invalid if any non-genuine parts have been fitted or used. Use of
non-genuine parts may seriously affect the machine’s performance and safety. McConnel Ltd
cannot be held responsible for any failures or safety implications that arise due to the use of
non-genuine parts.
2. REMEDIES AND PROCEDURES
2.01. The warranty is not effective unless the Selling Dealer registers the machine, via the McConnel
web site and confirms the registration to the purchaser by completing the confirmation form in
the operator’s manual.

2.02. Any fault must be reported to an authorised McConnel dealer as soon as it o ccurs. Continued
use of a m achine, after a f ault has occurred, can result in further component failure for which
McConnel Ltd cannot be held liable.

2.03. Repairs should be undertaken within two days of the failure. Claims submitted for re pairs
undertaken more than 2 weeks after a failure ha s occurred, or 2 days after the pa rts were
supplied will be rejected, unless the delay has been authorised by McConnel Ltd.

2.04. All claims must be submitted, by an aut horised McConnel Service Dealer, within 30 days of the
date of repair.

2.05. Following examination of the claim an d parts t he manufacture will pay, at their discretio n, for
any valid claim the cost of any parts and an appropriate labour allowance if applicable.

2.06. The submission of a claim is not a guarantee of payment.

2.07. Any decision reached by McConnel Ltd. is final.

3. LIMITATION OF LIABILITY
3.01. The manufacturer disclaims any express (exc ept as set forth herein) an d implied warranties
with respect 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 the goods.

3.03. Except as provi ded herein, the m anufacturer shall have no liability or responsibility to the
purchaser or any other person or entity w ith respect to any liability, loss, or damage caused o r
alleged to be caused directly or indirectly by the goods including, but not limited to, any indirect,
special, consequential, or incidental damages resulting from the use or operation of the goods
or any breach of this warranty. Notwithstanding the above limitations and warranties, the
manufacturer’s liability hereund er for d amages incurred by the purchase r or others shall not
exceed the price of the goods.

3.04. No action arising out of any claimed breach of this warranty or transactions under this warranty
may be brought more than one (1) year after the cause of the action has occurred.

4. MISCELLANEOUS
4.01. The manufacturer 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 applic able law and is held to be
unenforceable, then the invalidity of such provision shall not invalidate any other provisions
herein.

4.03. Applicable law may provide rights an d benefits to the purch aser in addition to those provided
herein.
 DECLARATION OF CONFORMITY
Conforming to EU Machinery Directive 2006/42/EC

We,

McCONNEL LIMITED, Temeside Works, Ludlow, Shropshire SY8 1JL, UK

Hereby declare that:

The Product; Radio Controlled Tracked Mower

Product Code; RMOW

Serial No. & Date ………………………………… Type …………………………

Manufactured in; Italy

Complies with the required provisions of the Machinery Directive 2006/42/EC

The machinery directive is supported by the following harmonized standards;
 BS EN ISO 14121-1 (2007) Safety of machinery - Risk assessment, Part 1:
Principles Part 2: practical guide and examples of methods.
 BS EN ISO 12100-1 (2010) Safety of mach inery - Part 1: Basic terminology and
methodology Part 2: Technical principles.
 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 construction of fixed and movable guards.
 BS EN 982(1996)+ A1 (2008) Safety requirements for fluid power systems and their
components. Hydraulics

McCONNEL LIMITED operates an IS O 9001:2008 quality management system,

certificate number: FM25970.
This system is continually assessed by the;
British Standards Institution (BSI), Beech House, Milton Keynes, MK14 6ES, UK
BSI is accredited by UK Accreditation Service, accreditation number: UKAS 003.
The EC declaration only applies if the machine stated above is used in
accordance with the operating instructions.

Signed …………………................ Responsible Person

CHRISTIAN DAVIES on behalf of McCONNEL LIMITED

Status: General Manager Date: May 2011

LIST OF CONTENTS
Page No.
Operator Section
General Information 1
Features & Specifications 2
Safety Information 3
Safety Decals & Warnings 6
Safety Devices & Emergency Stop 7
Machine Delivery 8
Machine Overview 9
Starting the Engine 14
Driving & Manoeuvring 15
Emergency Manual Control Unit 20
Pre-Operation Checks 22
Operation 23
Maintenance 25
Undercarriage Specifications 37
Electrical System Fuses & Relays 38
Troubleshooting 39

Parts Section
Track Drive Assembly 42
Engine Unit Assembly 44
Frames & Tanks Assembly 48
Protection Guards & Covers 52
Flailhead Assembly 54
Rotors & Flails 58
Machine Decals 60
Service Parts – Filters and Filter Cartridges 61
GENERAL INFORMATION
Always read this manual before attempting to operate the machine – whenever any doubt exists
contact your dealer or the McConnel Service Department for advice and assistance.

Use only McConnel Genuine Service Parts on McConnel Equipment and Machines

DEFINITIONS – The following definitions apply throughout this manual:

WARNING
An operating procedure, technique etc., which –
can result in personal injury or loss of life if not observed carefully.

CAUTION
An operating procedure, technique etc., which –
can result in damage to either machine or equipment if not observed carefully.

NOTE
An operating procedure, technique etc., which 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 instructional purposes only and may on occasion not show
some components in their entirety. In some instances an illustration may appear slightly different to that of
your particular model but the general procedure will be the same. E&OA.

MACHINE & DEALER INFORMATION

Record the Serial Number of your machine on this page and always quote this number when
ordering parts. Whenever information concerning the machine is requested remember also
to state the make and model of tractor to which the machine is fitted.
Machine Serial Number: Installation Date:
Machine Model details:
Dealer Name:
Dealer Address:
Dealer Telephone No:
Dealer Email Address:

1
FEATURES & SPECIFICATIONS

RoboCut
○ 40HP (29kW) 3 Cylinder ISUZU Diesel Engine
○ Tracked Carriage Hydraulically Driven via Piston Pumps
○ Self-Tightening Tracks
○ Remote Controlled Operation (up to 150m range)
○ Rubber Tracks with Removable Riveted Stirrups
○ 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, Hydraulically Powered Flail Head
○ Proportional Joystick Speed Control – Forwards & Backwards 0 to 7km/h
○ 21 Litre Fuel Tank Capacity
○ 1280mm Carriage Width
○ 1.3m Flail Head capable of cutting materials up to 30mm diameter
○ Machine Weight 1000kg

2
SAFETY INFORMATION

This machine has the potential to be extremely dangerous - in the wrong hands it can kill or
maim; It is therefore imperative that both owner and operator of the machine reads and
understands the following section to ensure they are fully aware of the dangers that do, or may
exist, and their responsibilities surrounding the use and operation of the machine.
The operator of this machine is responsible not only for their own safety but equally for the
safety of others who may come into the close proximity of the machine, as the owner you are
responsible for both.
When the machine is not in use it should be parked on a firm level site with the cutting head
resting on the ground and the 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 technician.

 Before starting the machine the operator must read and understand all aspects of use and
maintenance of the machine as stated in this manual.

 The machine must only be used by a responsible adult who is familiar with all aspects
relating to safe operation.

 The machine must not be operated by children or non-authorised persons.

 Operators must know the meaning of all operation and safety decals on both the machine
and the remote control unit.

 Operators must know the procedure for switching the machine off normally and by using the
Emergency Stop.

 Do not attempt to use the machine if the Emergency Stop switch is damaged or
malfunctioning.

 Never use the machine with safety guarding removed or defective.

3
 Operators should practice operation on flat open ground to familiarise themselves with
driving and manoeuvring the machine before attempting to use it on sloping ground.

 Operators should practice manoeuvring the machine around obstacles without the flail head
running before using the machine for work purposes.

 Never operate the machine when your vision is blocked by obstacles such as vehicles,
buildings, hedges etc.; move to a position where you have an un-interrupted view of the
machine.

 Never operate the machine standing directly in the line of travel.

 Do not use the machine on sand piles, gravel, or similar materials.

 Only operate the machine in good light conditions.

 Never run the machine in an enclosed area or building.

 Keep the machine clean to avoid build ups of dry materials that could ignite on hot
components.

 Never stand directly below a machine that is operating or parked on a slope.

 Always operate the joystick control slowly; rapid or jerky movements 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 head off before approaching it.

 When using the machine the operator should place themselves in a position that provides
optimum visibility over the work area.

 Never leave a running machine unattended; always switch the engine off and remove the
ignition key.

 Always stop and switch the machine off if persons or animals enter the work area, do not
restart the machine until they are at a safe distance.

 Never use the machine to perform tasks it was not designed for.

 Never ride, or allow others to ride on the machine.

 Always inspect the work area prior to operation and remove stones, glass, metal, wire or any
other foreign objects that are hazardous. Immovable hazards should be ‘marked’ so they
can be avoided.

 Take extra care when operating the machine on slopes or uneven ground, there is increased
risk of objects being thrown from the flail head when working in these conditions.

 The machine can be used on slopes of up to 50° (maximum) providing the surface is dry and
firm.

4
 Should a machine overturn, a suitable crane or winch should be used to recover it, keep all
persons at a safe distance before and during recovery.

 Do not operate the machine in foggy or frosty conditions as there is increased risk of
accidents.

 Take extra care when working in close proximity to electrical cables; in some circumstances,
operating the machine under overhead power lines can result in loss of radio signal causing
the engine to deactivate.

 Do not operate the machine close to vehicles or properties where there is risk of damage by
objects accidentally thrown from the flail head.

 It is the user’s responsibility to protect persons in or near the work zone.

 When servicing or maintaining the machine no one should be allowed beneath it when it is
raised unless it is securely supported on suitable ramps or stands.

 Never attempt to service or maintain the machine whilst it is running; always switch off the
engine and remove the starting key.

 When transporting the machine on another vehicle or trailer the engine must be switched off
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.

 Always clean the machine after use; care must be taken if the machine is hot. Never use
solvent based chemicals for cleaning.

 When operating in excessively dusty conditions work may need to be interrupted on a

regular basis to remove any build ups of dust on components that could cause overheating.

 Always press the Emergency Stop switch before refuelling.

 Wherever possible refuel the machine before work when the engine is cold. If refuelling
during work, switch off the engine and allow it to cool before adding fuel.

 Test the Emergency Stop switch before each period of work to ensure it functions correctly.

 Never leave the machine, ignition key and control unit unattended where it could be started
and used by un-authorised persons.

 Any inspection, service or maintenance of the flail head must only be performed with
machine switched off and the starting key removed.

 Always wear safety gloves and glasses when performing service or maintenance on the flail
head.

 Flail head must always be switched off when manoeuvring outside of the work zone.

5
SAFETY & WARNING DECALS

1.

WARNING: Read the manual first.

2. DANGER: Risk of thrown objects, keep your distance.
3. DANGER: Electrical voltage and harmful substances.
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 machine first.
8. ADVISORY: Always wear ear defenders and safety glasses when using the machine.
9. ADVISORY: Always wear safety footwear when using the machine.

6
SAFETY DEVICES & EMERGENCY STOP

Automatic Emergency Safety Features

As the RoboCut is operated by remote control and the user is not directly operating the driving
elements of the machine specific safety features have been built in to protect the user, third
party persons and the machine itself; these are as follows

Danger / Risk Situation Automatic Safety Feature

Machine beyond signal reception area or radio signal blocked. EMERGENCY STOP will activate.
Radio signal failure. EMERGENCY STOP will activate.
Another machine on same frequency operating in the area. EMERGENCY STOP will activate.

Manual Emergency Safety Feature

In addition to the automatic safety features stated above the operator can immediately stop the
machine either by pressing the Emergency Stop button located on the remote control unit or by
pressing the Emergency Stop button located on the top panel of the 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
occur;
 Engine will be switched off
 Ignition will be turned off.
 Machine movement will be halted.
 Electrical voltage will be deactivated.
 Entire electrical system will be disabled.

In the unlikely event of movement malfunction

If machine movements perform in an unexpected or incorrect manner follow the instructions
below;
1) Release the forwards/backwards movement joystick – the control is equipped with automatic
zero position; on release it will automatically return to the central (stop) position, this action
activates the track brakes.

2) Press the Emergency Stop button on the control unit.

DANGER! Do not approach the machine if it is moving.

3) Press the machine’s Emergency Stop button.

4) Turn the ignition key into the off position (anti-clockwise) and remove the key.

Contact your Authorised Dealer or McConnel Service – do not attempt to operate the
machine until advice has been sought.

7
MACHINE DELIVERY

The machine will be delivered ready for use having been pre-filled with all necessary lubricants
and fluids other than fuel.
Before use all packaging must be removed and the transport fasteners loosened.
The reception antenna will be supplied as a loose item and must be screwed onto the machines
receiver prior to use.
The standard items supplied will be as follows:

Standard Equipment
 Machine with Mounted Receiver
 Transmitter and Battery Pack
 Reserve Battery 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 Engine

Machine Lifting Points

The photos below shown the machine’s lifting points; the lifting eyes are located at each end of
the track plates on both sides of the machine. The positions of the lifting points enable the
machine to be safely raised using suitable overhead lifting equipment.

Note: All equipment used to raise the machine must have a SWL in excess of the total weight of the
machine – keep all persons at a safe distance from the machine during the lifting procedure.

8
MACHINE OVERVIEW – Component Identification

◄ Right Side View

1. Oil Tank
2. Diesel Fuel Tank
3. Track Tensioner Access
4. Track Roller
5. Drive Wheel
6. Alternator (12V)

Left Side 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. Hydraulic Ram (Front Hood)

◄ Engine Top View

1. Air Filter Clogging Sensor
2. Radio Control Antenna
3. Warning Beacon Mount
4. Engine Oil Filler Plug
5. Air Filter
6. Air Filter Breather

9
Engine Right Side View ►
1. Radiator Filler
2. Radio Control Antenna
3. Warning Beacon Mount
4. Emergency Stop Switch
5. Electric Plug for Services (12V)
6. Horn
7. Electric Compressor
(Self-Cleaning 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. Radiator Filler
6. Oil Cooler Input
7. Oil Cooler Output
8. Engine Oil Filler Plug
9. Secondary Fuel Filter
10. Electric Actuator
11. Electric Pump
12. Temperature Gauge
(Engine Coolant)
13. Ignition Key

10
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

11
Ignition Panel Warnings

WARNING LED LIGHT AUDIBLE

CAUSE REMEDY
SYMBOL REFERENCE WARNING

1. Yellow LED Light Yes Fuel tank running on reserve. Top up fuel.

Check brake release valve

2. Red LED Light No Parking brake on.
pressure.

Check for leaks and repair.

3. LED Light Yes Hydraulic oil level too low.
Replenish hydraulic oil.

4. Red LED Light No Alternator not charging battery. Contact local dealer.

Disassemble the filter

5. Yellow LED Light No Air filter blocked. cartridge and clean with
compressed air line.

6. Red LED Light Yes Oil filter blocked Replace oil filter cartridge.

Wait for light to go out

7. Yellow LED Light No Pre-heat plugs are on. before attempting to start
engine.
Replenish oil if required.
8. Red LED Light & Yes Insufficient engine oil pressure. If oil level correct seek
9. Red LED Light advice from local dealer.

9. Red LED Light No Engine stop Reset Emergency Switch.

Check coolant level.

10. Red LED Light Yes Coolant temperature too high. Clean radiator matrix and
protection guard.

12
Radio Control Unit – Control Locations & Functions

1. Display
2. Potentiometer – Speed Regulator
3. Right Joystick 
 Steering (Left / Right) ◄O►
 Flail Head (Up / Down) 
4. Auxiliary #1
5. Auxiliary #2
6. Front 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 (Forward) O Default O Drive Swap Mode
 Drive (Reverse)   switch 11 activated
14. Steering Bios
15. Engine Start
16. Horn
17. Codified Key
18. Engine Stop
19. Engine Revs (-)
20. Battery
21. Engine Revs (+)

13
STARTING THE ENGINE

Before attempting to start the engine ensure you have read and understood the
manual and observe all safety instructions surrounding use of the engine and
machine.

WARNING!
Engine must only be started in open air, never in an enclosed environment.

Diesel Engine Starting

 Observe all Safety Instructions.

 Ensure machine is in the open air and not in an enclosed environment.

 Check fuel level and replenish if required.

 Turn ignition key on the machine clockwise to the first position; pre-heat plug light on the
ignition panel will illuminate – wait until light goes out before continuing.
NOTE: When the ignition key is turned to the first position the machine will perform a
sequence of system checks during which time lights on the control panel will be lit or
flashing, when the check is complete these lights will stay lit.

 Start engine by a further turn of the ignition key.

Linking Remote Control Unit to Machine

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 either be turned to the pre-starting position or the engine running to
allow the remote control to link to the machine.

 Turn on the control unit by rotating the Emergency Stop Switch clockwise – the button
will ‘spring out’ to the ON position.

 Press and hold the horn button down – the unit will search for the machine’s transmitter
and lock onto the signal, the horn will sound to confirm that the units are linked. Release
the horn button as soon as the confirmation sound is received.

 If not already running, the machine can now be started by operation of the start button on
the remote controls (refer to controls section) – release button as soon as the engine
starts.
NOTE: If the engine fails to start within 5 seconds release the button and wait for a
minute or so before trying again.

GENERAL CAUTION!
Never operate a starter for excessive uninterrupted periods attempting to start an engine as this
can damage or burn out the starter motor.

14
DRIVING & MANOUEVERING THE MACHINE

Operation of the machine must only be performed by a responsible person who

has read the manual and is familiar with the machine controls and all aspects
relating to its safe use.

It is advisable that all new operators practice using the machine, without the
cutting head running, in a safe open area in order to familiarise themselves
with the controls and movements of the machine.

Forwards & Backwards Travel (Default Mode)

Operation of the machine’s forward and backwards movements are controlled by using the left-
hand 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 the lever is moved the faster the machine travels. The maximum speed
available will be determined by gear and potentiometer settings, switch ‘K’ and dial switch ‘C’,
details of which are in the following pages.

Forwards & Backwards Travel (Direction Swap Mode)

Direction Swap Mode is selected by activation of switch ‘L’; this swaps the machines direction of
travel on operation of joystick ‘A’. The primary function of this feature is for ease of operation
when the machine’s particular work tool is ‘rear mounted’ type and requires the machine to be
operated in reverse.

15
Steering Direction Control
The steering direction of the machine is controlled by sideways operation of the right-hand
joystick (B); moving the lever to the right will steer the machine to the right and moving the lever
to the left will steer the machine left.
Steering is achieved by adjusting the speed or the turning direction of the tracks in relation to
each other; depending on the intensity of the turn one or other track will decelerate, stop or
even reverse causing the machine to change direction, the sharpness of the turn is relative to
how far the operation lever is moved.

Steering Bios
The steering bios feature allows a
degree of ‘steer’ to be pre-set 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 the greater the bios. Although
steering will still need to be monitored
and operated as normal it will be to a
much lesser degree.

NOTE: When the machine is operating in ‘direction swapped mode’ (refer to previous page),
steering direction control will be swapped so the steering direction lever continues to operate in
the same left and right manner to match the selected drive direction, the same will also apply to
the steering bios feature.

Flail Head (Tool) Height Control

The tool height is controlled by forward and backwards operation of the right-hand joystick (B);
pushing the lever forwards will lower the tool and pulling the lever backwards will raise the tool.

16
Flail Head Rotor Controls
Operation of the rotor is controlled by using
switches ‘I’ & ‘J’. Each of the switches
performs a dual function; switch ‘I’ is for pre-
setting the rotor cutting direction and for
switching the rotor off, and switch ‘J’ is for
starting the rotor and adjusting its speed.
Refer below for specific details of each
function.

Selection of Rotor Cutting Direction ►

Switch ‘I’ is for pre-selection of the rotor cutting direction;
move the switch to the up position for uphill cutting or to the
down position for downhill cutting - an led light will be
illuminated to indicate the direction selected. Starting the
rotor is performed by operation of switch ‘J’ – see below.

◄ Rotor Start
Starting the rotor is by operation of switch ‘J’; set engine
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; release the switch as soon as the
rotor starts to run. Engine revs can now be increased
according to requirements.

Rotor Speed (RPM) ►

Once the rotor is running its speed can
be increased or decreased as required
by subsequent operations of switch ‘J’;
each upward or downward operation of
the switch will respectively speed up or
slow down the rotor by a determined
amount.

◄ Rotor Stop
To stop the rotor, first reduce the rotor speed to its
minimum using switch ‘J’ as described above, then
move Switch ‘I’ into the central ‘off’ position.
Note; in an emergency situation the rotor can be
stopped by use of the Emergency Stop button – this
will immediately switch off and deactivate all
machine functions completely, including the engine.

Flail Hood Control

17
The flail head is equipped with hydraulically operated front hood allowing the operator to
remotely adjust its opening position to suit differing materials and conditions. The hood, which is
powered by a hydraulic ram, is controlled by up and down operation of switch ‘H’; the switch is
self-centering so operation of the hood in either direction only occurs when the switch is held in
the up or down ‘on’ positions, on release of the switch hood operation stops.

Engine Speed Control (RPM)

The speed of the engine is adjusted using control buttons ‘P’ and ‘Q’; pressing button ‘P’ will
increase engine revs and pressing button ‘Q’ will decrease the revs.

Gear Control
The machine has 2 gears to provide a choice of travel speeds; in addition to the gear selected
the travel speed will be managed by operation of the travel joystick which itself is directly
proportional to the speed setting of the potentiometer – see below.
When in work it is recommended that the machine is operated in gear 1 and speed limited
especially when working on steep slopes. Gear 2 is primarily 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
travel speed capability of the machine, from 0 – 100%, when operating the
travel joystick - it is in effect an adjustable speed governor.
Adjustment is by rotating the switch to the required speed (%) position; the
setting chosen will depend on numerous factors but should always be at a
setting that allows the operator optimum control of the machine in work.

Engine Shutdown
Before shutting down the engine all machine movements must be halted, engine revs reduced
to minimum and the rotor switched off. Allow the machine to run at this level for about 1 minute
to stabilize pressures and temperatures - shutting down the engine is then performed by
pressing button ‘N’ which will stall the engine. When the engine has stopped the procedure is
completed by switching off the ignition key on the machine.
If the machine is to be left unattended the key should be removed and control unit and key
placed in a secure safe location.

Engine Start
Engine start from the remote control unit is by use of button ‘O’ – refer to ‘Starting Engine’
section for details of this procedure.

18
Clean Fix Control
Clean Fix is a built in ‘self-clean’ feature
designed to reduce the build up of dirt and
dust in the radiator matrix; on activation of
the its control switch (‘M’) the blades of the
fan change angle 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 function to perform
additional cleaning cycles when working in
dirty or dustier conditions.

Normal fan operation ▲ Clean Fix activated ▲

– air drawn through radiator for cooling – air blown through radiator for cleaning

19
Manual Control Unit (Emergency Track Operation only)
A manual control device for track operation is provided with the machine to allow the operator to
bypass the Radio Controller in the event of a controller malfunction.
When connected to the machine, this devise will allow the operator to raise and lower the
flailhead and manoeuvre the mower in any direction.
This feature is primarily for use in an emergency situation to allow transport of the machine in
the event of a sudden breakdown or for diagnosing an issue with the controller.
When operated in this mode the machine will only travel at minimum speed and all other control
features are deactivated.
To use this control the unit must first 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 this feature for normal work operations.

Manual Controller

A) Forwards left track

B) Backwards left track
C) Flailhead (tool) lift
D) Flailhead (tool) lower
E) Forwards right track
F) Backwards right track

Manual Controls Operation

To manoeuvre the machine;
Forward travel is by simultaneous operation of buttons ‘A’ & ‘E’.
Right turn is by operation of button ‘A’ only.
Left turn is by operation of button ‘E’ only.
Reverse travel is by simultaneous operation of buttons ‘B’ & ‘F’.
Counter-rotation to the right is by simultaneous operation of buttons ‘A’ & ‘F’.
Counter-rotation to the left is by simultaneous operation of buttons ‘B’ & ‘E’.
Flailhead (tool) lift is by operation of button ‘C’.
Flailhead (tool) lower is by operation of button ‘D’.

20
Converting the Machine for use with the Manual Control Unit
The method of adapting the machine for use with the manual control unit requires attachment of
the Control Unit and deactivation of the Brake Control Module; the procedures are as follows;
Control Unit Attachment
Connect the manual control unit to its connection point on the electronic ignition box, this point
is located on the right hand side of the machine as shown in the photos below.

Location of connection point for the Manual Control Unit Remove dust cover and plug unit into the connection point

Deactivating the Brake Control Module

Under normal operating conditions when
using the remote control, movement of the
joystick sends 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
disconnecting the wiring loom from the
brake control module.
The brake control module is located under
the bonnet on the right hand side of the
machine – indicated ‘T’ in the photographs
Location of Brake Control Module (T)
opposite and below.

Brake Control Module identification (indicated ‘T’) Disconnect the wiring loom plug from the Brake Control
Module to allow machine operation with Manual Control

Note: Failure to disconnect the Brake Control Module will result in the engine
stalling when attempting to transport the machine in Manual Control Mode.

21
PRE-OPERATION CHECKS

WARNING! All checks or inspections of the machine should be performed with

the machine parked on firm level ground with the engine switched off and the
starting key removed.

The following checks should be made daily before using the machine;
 Check all safety guarding is in good condition and fitted correctly.
 Check nuts and bolts for tightness, retighten if required.
 Check flail head for damaged or missing flails – replace if required before use.
 Check oil, coolant and fuel levels, replenish if required.
 Check filters – clean or replace if required.
 Check radiator matrix is clean – clear blockages if required using compressed air.
 Lubricate 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, metal component, wire and glass etc. which could damage
machine component or be ejected by the flail head. Any immoveable object should be
visually marked or avoided.
 Ensure the area is clear of animals and persons. Never manoeuvre the machine into an
area where you can no longer see it working.
 Only work the machine in grass or brushwood that is within its cutting capability;
attempting to cut materials beyond the machines capability will damage components.
 When working on slopes always start at the bottom and work up.
 Never run the machine down a slope in excess of 50°
 Never operate the machine on slopes or ground where there is a risk of overturn.

22
OPERATION

Always wear safety shoes, ear defenders and safety glasses when
operating the machine.

Always work in good lighting conditions. If necessary, use artificial lighting in

compliance with local rules in force.

Do not smoke near the machine; oils, fuels and lubricants are flammable.

Before moving the machine, ensure that there are no persons, animals, or obstacles in the work
zone.

Do not change direction whilst moving on kerbs, rocks or

surfaces with considerable differences in height (more than
20cm); in these instances always move perpendicular to the
obstacles.

When reversing 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

one track in the horizontal position and the other inclined or
partially raised (when machine is inclined in excess of 10°).
To avoid risk of track damage, always proceed with both tracks
travelling on the same horizontal plane.

When the machine manoeuvres over an obstacle, a space is

created between the bearing rollers and the track - this can
cause the track to come off its seat. The same situation can
occur in reverse when a space is created between bearing roller,
idler roller, and track. To eliminate this risk, track guides are
provided on the front part of the undercarriage.

23
 If the machines changes direction, and the track cannot move
sideways due to the presence of an obstacle, there is a risk that
the track can be damaged 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 reverse in these conditions, there is risk

of the track coming off its seat.

◄ If the machine is steered in these conditions, the track will come

off its seat.

24
MAINTENANCE SECTION

Diesel Engine Maintenance

For specific service and maintenance information regarding the diesel engine, refer to the
engine manufacturer’s handbook provided with the machine. Ensure all service and
maintenance work on the engine is carried out at the intervals stated in that manual.

Maintenance Scheme (General Machine)

Every Hour
Clean radiator air suction filter.
Clean radiator matrix using ‘Clean Fix’ system or if required using a compressed air line.
Clean air intake area around the oil radiator.
Clean oil radiator.

After Initial 8 Hours - New Machine

Check nuts, bolts, pipes and hoses for tightness – tighten if required.
Check track tension and adjust if required – refer to specific 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 – replenish if required.
Check engine oil level – replenish if required.
Check coolant level – replenish if required.

Every 50 Working Hours

Grease carrying rollers and sliding rollers.
Check track tension and adjust if required.

After Initial 100 Hours - New Machine

Drain and replace hydraulic oil.
Replace hydraulic oil filter.
Drain and replace engine oil.
Replace engine oil filter.
Check track tension and adjust if required.

Every 100 Working Hours

Check alternator belt tension and tighten if required.
Replace engine oil.

Every 250 Working Hours

Drain and replace hydraulic oil.
Replace hydraulic oil filter.
Drain and replace engine oil.
Replace engine oil filter.
Replace engine air filter

25
Maintenance Scheme (Track Components)

Daily Checks
Check track tension.
Check condition of gear motors.
Check track condition; replace tracks when there is less than 10mm of tread remaining or
sooner if there are visible signs of deep cuts or cracks.
Check there are no stones or foreign bodies within the tracks, rollers, gears or sprockets.

Monthly Checks
Check oil level in gear unit.
Check rollers are correctly fastened.
Check there is no slack in the bearings.

Six Monthly Checks

Check wear and tear and overall condition of connections, pinions and lower rollers – these
must 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 warning decals are in good condition.
Make sure the machine is thoroughly cleaned on a regular basis.
Check all fastenings, supports, steel structural parts, welds and pins etc. are in good condition.
Ensure paintwork is kept in good condition.
Lubricate the tracked undercarriage every 20 working hours.

Hydraulic Hoses
Hoses and hydraulic connections should be inspected for signs of wear or damage on a regular
basis, damaged or worn components must be replaced immediately. The working life of
undamaged hoses is approximately six years, they should be replaced after this period.

26
Cleaning the Air Filters Grills & Radiator
If the machine is running, reduce to minimum revs and allow engine to run for a further minute
before switching off – remove and pocket the ignition key.
Clean outsides of air suction grills before releasing the three rubber hooks and opening the
cover. Clean the radiator matrix, inside of the air intake grill and 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 grills of the machines front cover to ensure maximum airflow to the engine.

Ensure covers are closed and secured correctly to stop dirt getting in.

WARNING!
If the engine temperature becomes too high a red temperature warning light on the ignition panel
will be illuminated to notify the operator – where this occurs refer to the engine manufacturer’s
manual.

27
Checking Hydraulic Oil Level
The procedure for checking and replenishing the machines hydraulic oil is as follows;
 Park the machine on a firm level site.
 Ensure engine is switch off and the key removed and pocketed.
 Release rubber hooks and raise the front engine cover.
 Unscrew the dipstick (located under the filler cap), remove and wipe with a clean rag.
 Replace dipstick without screwing in, then remove again and check the level – oil level is
correct if the oil reaches the marker on the dipstick.
 If oil level is too low, top up using ‘PANOLIN HLP SYNTH 46’ oil (E2019HLPSE46).
 When oil level is correct, screw the dipstick back in, close and secure the engine cover.
Note: Only use ‘PANOLIN HLP SYNTH 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 machines engine oil is as follows;
 Park the machine on a firm level site.
 Ensure engine is switch off and the key removed and pocketed.
 Undo the 4 knurled head screws and lower the cover.
 Remove dipstick and wipe with a clean rag.
 Replace dipstick then remove again and check the level – oil level is correct if the oil reaches
the upper marker on the dipstick.
 If oil level is too low, top up using ‘MOBIL SUPER 3000 X1 5W40’ oil (E2022MB05W40).
When topping up oil always clean the surrounding area of the filler cap before removal of the
cap to avoid the risk of dirt contaminating the oil.
 When oil level is correct, replace dipstick before raising and securing the cover.

Location of engine oil dipstick

28
Engine Oil Replacement and Filter Change
Oil Capacity: 6.1L without filter
6.6L with filter
Oil Type: MOBIL SUPER 3000 X1 5W40 (E2022MB05W40)

The procedure for changing the engine oil and filter is as follows;

 Park the machine on a firm level site.

 Remove drain plug and release the oil into a suitable container – ensure the container used
has sufficient capacity for the amount of oil.

Engine oil drain plug location

 Once all the oil has been released, replace drain plug and torque to 34.5Nm.
 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 ¾ of a turn.
 Remove filler cap and slowly refill with 6.6L of MOBIL SUPER 3000 X1 5W40 engine oil.
 Replace filler cap and start the engine.
 Run engine for 5 minutes or so and stop for a further 3 minutes before checking the oil level
is correct.

NOTE: Used engine oil is both a dangerous waste and a precious raw material; collect it in a
suitable container and recycle it. Never pour waste oil into drains or waterways – it is harmful
and illegal.

29
Hydraulic Oil Replacement and Filter Change
Hydraulic Oil Tank Capacity: 18 Litres
Complete System Capacity: 28 Litres
The procedure for changing the hydraulic oil and filter is as follows;
 Remove the protection plate from the underside of the hydraulic oil tank.
Note: Removal of the plate allows access to both the hydraulic tank drain plug and the fuel
tank drain plug – identify the correct plug before continuing to the next step.

Tank protection plate Hydraulic oil tank drain plug

 Remove drain plug and release the oil into a suitable container.
 When the oil has drained completely, replace drain plug and refit protection plate.
 Unscrew and remove the hydraulic 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.

Filter Wrench ►

◄ Hydraulic oil filter location

 Fit new hydraulic oil filter and tighten securely – take care not to over tighten.
Note: Always replace filters at the intervals stated in the maintenance schedule using quality
original filters as specified and supplied by the manufacturer.
 Refill the hydraulic oil tank with ‘PANOLIN HLP SYNTH 46’
hydraulic oil – check using the dipstick until the level is
correct.
 Start engine and allow it to run for 2 minutes.
 Stop engine and re-check oil level on the dipstick, top up if
the level has dropped.
 Check all components and covers are tightly secured
before using the machine. Hydraulic oil tank filler location
30
Hydraulic Distributor Valve
The distributor valve that controls the hydraulic functions of the machine is located under the
vehicle and is only accessible from beneath the machine. When working on this, or any other
item located under the machine, great care must 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 using suitable equipment specifically designed for the task and capable of
supporting its weight.

Access to the valve is gained by removal of the protection plate which is held in position by six
bolts.

Hydraulic valve protection plate Hydraulic distributor valve

31
Fuel Filter Cleaning / Replacement
The procedure for cleaning or renewing the fuel filter is as follows;
Park the machine on a firm level site, switch the engine off and open the engine cover.

Fuel Filter Fuel Supply Tap

 Close the fuel supply tap located on the filter housing.

 Place a suitable container under the filter assembly and unscrew the filter bowl securing ring
using a filter key.
 Carefully remove filter bowl using the container underneath to catch spilled fuel - retain
sealing ring for subsequent re-attachment.
 Remove and clean (or renew) the filter element.
 Clean out the inside of the filter bowl using a clean rag.
 Re-install the 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 tap to restore the fuel supply to the filter.
 Unscrew the breather screw on the fuel filter by approximately one turn.
 Place a collecting bowl under the fuel filter.
 Turn ignition key to position 1, this will switch on the electric fuel pump.
 Allow the pump to run until fuel (free of bubbles) begins to flow from the breather screw.
 Screw the breather screw back in.
 Start the engine.
 Check components to ensure there is no fuel leakage.
WARNING: Do not allow the starter motor to run for more than 30 seconds at a time if the engine
fails to start – allow at least 2 minutes before re-starting.

32
Fuel Filter Water Drain
Water will accumulate in the filter bowl that will from time to times need to be purged; the
frequency of this task will primarily depend on the quality of the diesel being used. The filter
bowl should be regularly inspected, and water drained off as and when required.
The procedure for draining the water is as follows;

 With the engine switched off, place a suitable container under the fuel filter.
 Open the water drain valve located on the base of the filter bowl.
 Allow water to run into the container until it is gradually replaced by a flow of fuel.
 Close the drain valve.

Water 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 procedure for this is as follows;
 Fill the tank with fuel.
 Unscrew the breather screw on the fuel filter by approximately one turn.
 Place a collecting bowl under the fuel filter.
 Turn ignition key to position 1, this will switch on the electric fuel pump.
 Allow the pump to run until fuel (free of bubbles) begins to flow from the breather screw.
 Screw the breather screw back in.
 Start the engine.
WARNING: Do not allow the starter motor to run for more than 30 seconds at a time if the engine
fails to start – allow at least 2 minutes before re-starting.

33
Support Springs
The hydraulic rams that position the front mounted flailhead are equipped with support springs,
the support pressure offered by the springs can be adjusted to suit differing needs and
applications by altering their work position tension. The procedure for adjusting the springs is as
follows;
 Raise the flailhead fully by operation of the hydraulic rams.
 Remove bolt and washer from the ram rod end and release the chain from the lug.
 Re-attach the chain selecting an alternative link to either increase or decrease tension.
 Replace washer and bolt to secure in position.
 Repeat the process on the opposite ram.

Steel Tracks
Tracks equipped with steel treads can be supplied
as an alternative to the normal all rubber type - the
steel tread version 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 using the
screws supplied and torque to 70Nm.

If a machine is fitted with spikes the operator must

avoid driving the machine on any surfaces that
would suffer damage from the spikes such roads,
car parks, recreation areas etc. unless the
machine has been fitted with rubber transport blocks specifically designed to protect surfaces.

Transport Blocks Fitment

The rubber transport blocks have
holes in them that locate on the spikes
and are fitted by pushing them onto
each set of accessible spikes before
slowly driving the machine forward so
its weight forces them tightly into
place; repeat the process until all the
spike sets are fitted with a block. After
transportation a lever or large
screwdriver will be required to prise
the blocks back off the spikes.

34
Replacing Tracks
Tracks must be changed when only 10mm of tread remains, or before if they show signs of
excessive cuts or cracks.
The components shown below are constituent parts of the track system illustrated here for
identification purposes.

Lower Roller Unit

Sprocket Assembly

Tracked Undercarriage

Backstay
Idler Roller Rubber Track

The procedure for changing the tracks is as follows;

WARNING: Never attempt to work on any machine that it not safely supported and chocked using
suitable equipment specifically designed for the task and capable of supporting its
weight. Ensure suitable safety gear is worn at all times when performing maintenance
tasks. Beware, there is ‘pinch risk’ when working on these components.
 Raise the machine off the ground to a height of approximately 30-40cm; 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 tensioner unit to release the
grease pressure.
 Once pressure has been fully released the valve
can be removed.
 Compress the idler roller; this can be done by using
your foot to press the track back.
 Draw the track down and outwards at its mid point
on the lower run to pull it off its seating, levering
between the track and the idler roller until it is free
enough to be removed. Take care to keep clear of
the track as it falls to the ground.
Installing the new track is basically a reversal of the above – tension the track by pumping
grease into the tensioner unit until the correct pressure is achieved (Max 150 Bar).

35
Track Tension Kit (Optional)
A grease tensioner system controls the track
tension on the machine. Keeping the tracks
correctly tensioned is an important duty that must
be carried out at the intervals stated in the
maintenance schedule; failure to observe the
correct tension can result in the tracks coming off
the machine during operations.
A Tension Kit, comprising of a grease pump
equipped with a manometer, is available as an
option for use in correctly checking and setting
the pressure. The maximum pressure setting is Track Tension Kit (4000271)
150 Bar.

Wear Limits
The track components
shown opposite must be
replaced when they reach
their maximum wear limit,
corresponding to 100% in
the figures stated below; Lower Rollers Front Cogs Drive Cogs
Ø when new ► 130.0mm 264.0mm 290.0mm
Ø at 25% wear ► 128.0mm 263.0mm 289.0mm
Ø at 50% wear ► 126.0mm 261.5mm 287.5mm
Ø at 75% wear ► 124.0mm 259.5mm 285.5mm
Ø at 100% wear ► 121.0mm 257.0mm 283.0mm

Lubrication of Undercarriage Components

Components of the tracked undercarriage (rollers, pins, bushings etc.), must be greased every
20 working hours.

36
UNDERCARRIAGE SPECIFICATIONS

Loading Capacity 1.2T

Length 1548mm
Axle to axle length 1192mm
Track height 479.5mm
Crossmember height (from ground) 150mm
Fixed undercarriage width 1260mm
Number of lower rollers per side (per machine) 4 + 4 (8)
Number 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 motor displacement 332cm³
Hydraulic motor pressure (Max) 190Bar
Hydraulic flow rate (Max) 39l/min
Maximum speed 7km/h
Operating temperature range -10/+40°C
Maximum operating humidity 95%
Brake release pressure range 12-16Bar
Maximum gradeability 114%

37
ELECTRICAL SYSTEM (Machines Serial No. ROBO021200089 onwards)

Fuses & Relays

F1 +12V sensors 3 Amp
F2 Actuator 3 Amp
F3 +12V Park brake 7,5 Amp
F4 Hold Solenoid + saftey stopdown 10 Amp
F5 Pull Solenoid 30 Amp
F6 Unloading Valve 7,5 Amp
F7 Alternator 5 Amp
F8 Horn 15 Amp
F9 Manual command 15 Amp
F10 Clean Fix fan / Beacon 15 Amp
F11 Light warms 5 Amp
F12 Fuel pump 7,5 Amp
F13 +30 Hp units 15 Amp
F14 +12V Plug 10 Amp
F15 Fuse Receiver 7,5 Amp
F16 Air filter sensor 3 Amp
X95 General fuse 40 Amp

X97/R1 Pull Solenoid relay X99/R2 Manual control

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 - X99/R7 Manual comand track L/H
X98/R3 Horn X100/R1 Check test before start
X98/R4 Hyd. oil filter pressure X100/R2 Low fuel level
X98/R5 Lower hyd. oil level X100/R3 Engine oil pressure sensor
X98/R6 Hold solenoid X100/R4 High water engine temp.
X98/R7 Radio-Control switch off X100/R5 Angle sensor (Opt)
X99/R1 Radio-Control stop (Link missing) X100/R6 Alternator LED
X100/R7 Parking brake relay

38
TROUBLESHOOTING

Symptom Possible Cause Solution

Track damage. Excessive tread wear; Replace track.
Loosening/breaking of internal
structural steel rope.
Track slackens frequently. Faulty tensioner valve. Replace valve.
Damaged tensioner seal. Replace seal.
Worn tensioner components. Replace worn components.
Upper track does not stay in Track slide worn. Replace slide.
position. Upper roller worn. Replace upper roller.
Lower track does not stay in Lower track guide worn. Replace lower track guide.
position. Lower roller worn. Replace lower roller.
Track ‘jams’ when the machine Material (stones, rocks, earth Remove material by turning the
is steering. etc.) trapped between rollers, track in both directions while
sprockets, idler roller and track. slackening slightly, raise machine
at same time if possible.
Oil leakage Hardened seals. Clean around component and
Gasket/seals damaged or worn. recheck after a few days.
Contact dealer.
Excessive noise. Internal malfunction. Contact dealer.
Worn seals.
Excessive vibration. Internal malfunction. Contact dealer.
Worn seals.
Overheating Lack of oil. Add oil.
Arduous conditions/hot climate. Contact dealer.
Brakes binding. Check brake release pressure.
Motor runs but gear unit not Motor wrongly assembled. Check coupling between motor
working. Internal malfunction. and gear unit.
Brake jammed. Contact dealer.
Check braking system.
Brake not releasing. Lack of brake pressure. Check brake connections.
Faulty brake seals. Contact dealer.
Brakes not locking. Residual pressure in circuit. Check hydraulic system.
Worn brake components. Contact dealer.

39
40
 For best performance …

USE ONLY GENUINE McCONNEL SERVICE PARTS

To be assured of the latest design improvements purchase your
‘Genuine Replacements’ from the ‘Original Equipment Manufacturer’

McCONNEL LIMITED
Through your local Dealer or Stockist
Always quote:
 Machine Type
 Serial Number
 Part Number

41
TRACK DRIVE ASSEMBLY
ROBOCUT MOWER McCONNEL

42
TRACK DRIVE ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
TRACK DRIVE ASSEMBLY
1 2 4000001 INNER BARREL
2 2 4000002 OUTER BARREL
3 2 4000003 BUSH
4 2 4000004 SPROCKET FORK
5 2 4000005 SPROCKET
6 2 4000006 DRIVE SPROCKET
7 2 4000007 MOTOR COVER
8 2 4000008 SPRING
9 2 4000009 PIN
10 4 4000010 BUSH
11 2 4000011 COVER PLATE
12 2 4000012 VALVE HOUSING
13 2 4000013 VALVE
14 2 4000014 VALVE SPRING
15 10 4000015 PIN
16 10 4000016 ROLLER
17 20 4000017 NUT
18 2 4000018 NUT
19 20 4000019 WASHER
20 2 4000020 GREASE NIPPLE
21 20 4000021 BEARING
22 6 4000022 BEARING
23 20 4000023 CIRCLIP
24 4 4000024 CIRCLIP
25 2 4000025 MOTOR
26 20 4000026 BEARING
27 4 4000027 BEARING
28 2 4000028 SCRAPER RING
29 2 4000029 VALVE RETAINER
30 2 4000030 SEAL
31 2 4000031 SEAL
32 4 4000032 ROLL PIN
33 2 4000033 RUBBER TRACK (Without Steel Treads)
2 4000262 RUBBER TRACK (c/w Treads 4000035)
34 46 4000034 TRACK SPIKES
35 94 4000035 STEEL TREAD
36 46 4000036 RUBBER TRANSPORT BLOCK
37 6 4000037 BOLT
38 6 4000038 BOLT
39 1 4000039 UNDERCARRIAGE HOUSING
40 1 4000272 GRUB SCREW
41 2 4000263 RUBBER TRACK (Non Steel Tread Type)

43
ENGINE UNIT ASSEMBLY
ROBOCUT MOWER McCONNEL

44
ENGINE UNIT ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
ENGINE UNIT ASSEMBLY
1 1 4000040 WASHER
2 4000286 LIGHT BRACKET
3 1 4000277 AERIAL SUPPORT
4 1 4000041 LEFT MESH GUARD
5 1 4000042 RIGHT MESH GUARD
6 1 4000043 UPPER MESH GUARD
7 1 4000044 BRAKE VALVE
8 1 4000045 RADIATOR MOUNTING BRACKET
9 1 4000046 WATER/OIL RADIATOR
10 1 4000047 RADIATOR PROTECTION
11 1 4000048 AIR FILTER HOUSING
12 1 4000049 ENGINE MOUNTING
13 1 4000050 FLANGE
14 1 4000051 AIR FILTER COVER
15 1 4000052 AIR FILTER BRACKET
16 1 4000276 FLANGE
17 1 4000053 OIL SUMP (ENGINE)
18 1 4000054 AIR FILTER MOUNTING
19 1 4000055 RADIATOR BRACKET
20 1 4000056 HOSE JOINT
21 1 4000057 BRACKET
22 1 4000058 THROTTLE STIRRUP
23 1 4000059 ACTUATOR ARM
24 1 4000060 SPRING LINKAGE
25 1 4000061 EXHAUST MANIFOLD
26 1 4000062 EXHAUST SUPPORT
27 1 4000063 ALTERNATOR LID
28 1 4000064 ANTI-VIBRATION SPACER
29 1 4000065 EXHAUST SILENCER
30 1 4000292 PRIMARY FUEL FILTER
31 1 4000257 OIL FILTER
32 1 4000260 PRIMARY AIR FILTER
33 1 4000261 SECURITY AIR FILTER
34 1 9313074 SCREW
35 1 9313084 SCREW
36 1 4000066 SCREW
37 1 4000070 CYLINDER HEAD SCREW
38 1 4000067 COUNTERSUNK HEAD SCREW
39 1 4000068 HEADLESS SCREW
40 1 4000069 SCREW
41 8 4000071 FLANGED HEAD SCREW
42 1 4000072 FLANGED HEAD SCREW

45
ENGINE UNIT ASSEMBLY
ROBOCUT MOWER McCONNEL

46
ENGINE UNIT ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
ENGINE UNIT ASSEMBLY
43 1 4000073 FLANGED HEAD SCREW
44 1 4000074 THROTTLE SPRING
45 1 4000075 AUTOGRIP NUT
46 8 4000076 AUTOGRIP NUT
47 1 4000077 AUTOGRIP NUT
48 5 4000078 WASHER
49 2 4000079 WASHER
50 1 4000080 WASHER
51 1 4000081 WASHER
52 2 4000082 ANTI-VIBRATION MOUNTING
53 1 4000083 ANTI-VIBRATION MOUNTING
54 1 4000084 ANTI-VIBRATION RUBBER STOPPER
55 1 4000085 HYDRAULIC PUMPS
56 1 4000275 MOTOR BELT
57 1 4000274 FAN ASSEMBLY
58 1 4000086 ACTUATOR
59 2 4000087 RUBBER HOSE (CURVE)
60 1 4000278 FAN BLADE KIT (3 BLADES)
61 1 4000279 RUBBER VALVE
62 1 4000280 FILTER HOUSING CAP
63 1 4000281 CLOGGING SENSOR
64 1 4000701 ENGINE (40HP)
65 1 4000282 AERIAL
66 1 4000283 ROTATING LIGHT
67 1 4000284 LIGHT CONNECTION
68 1 4000285 WATER SENSOR

47
FRAMES & TANKS ASSEMBLY
ROBOCUT MOWER McCONNEL

48
FRAMES & TANKS ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
FRAMES & TANKS ASSEMBLY
1 1 4000088 ATTACHMENT MOUNTING FRAME
2 2 4000089 RAM PIN
3 2 4000090 RETAINING COLLAR
4 2 4000091 WASHER
5 1 4000092 LEFT BULKHEAD FIXING PLATE
6 1 4000093 RIGHT BULKHEAD FIXING PLATE
7 1 4000094 ANTI-VIBRATION MOUNTING
8 2 4000095 CHAIN
9 1 4000096 FUEL TANK
10 1 4000097 OIL TANK
11 1 4000098 ELECTRIC BOX MOUNTING FRAME
12 1 4000099 REMOTE RECEIVER MOUNTING
13 1 4000100 OIL COLLECTOR
14 2 4000101 HYDRAULIC RAM
15 1 4000102 ELECTRICAL BOX
16 1 4000103 ELECTRICAL BOX COVER
17 1 4000104 INSTRUMENT PANEL
18 1 4000105 FUEL FILTER
19 2 9217248 SCREW
20 6 4000106 SCREW
21 12 9313033 SCREW
22 2 4000107 SCREW
23 2 9313053 SCREW
24 2 4000108 SCREW
25 6 4000071 FLANGED HEAD SCREW
26 9 4000109 FLANGED SCREW
27 8 4000072 FLANGED HEAD SCREW
28 2 4000110 SPRING
29 2 9193004 NUT
30 2 9163001 LOCK NUT
31 12 9163003 LOCK NUT
32 1 9163004 LOCK NUT
33 4 9163008 LOCK NUT
34 1 4000111 RUBBER CLIP
35 2 4000112 BONNET FASTENER
36 6 9100101 WASHER
37 9 9100103 WASHER
38 1 9100104 WASHER
39 2 05.281.14 WASHER
40 6 9100108 WASHER
41 6 4000113 SPRING WASHER
42 2 9100203 SPRING WASHER

49
FRAMES & TANKS ASSEMBLY
ROBOCUT MOWER McCONNEL

50
FRAMES & TANKS ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
FRAMES & TANKS ASSEMBLY
43 12 4000114 WASHER
44 12 4000115 RUBBER WASHER
45 1 4000116 BUFFER
46 2 4000117 ANTIVIBRATION
47 4 4000118 ANTIVIBRATION
48 4 4000119 ANTIVIBRATION
49 2 4000120 GREASE NIPPLE
50 1 4000121 DISTRIBUTOR
51 1 4000122 OIL FILTER
52 1 4000123 FUEL PLUG WTH KEY
53 1 4000124 OIL PLUG/LEVEL
54 1 4000125 FAN COMPRESSOR
55 1 4000126 FUEL PUMP
56 2 4000127 PLUG
57 4 4000128 BULKHEAD FITTING
58 3 4000129 BULKHEAD FITTING
59 4 4000130 NUT
60 3 4000131 NUT
61 2 4000132 CONNECTION
62 1 4000133 CONNECTION
63 1 4000134 CONNECTION
64 2 4000135 CONNECTION
65 1 4000136 CONNECTION
66 1 4000137 PLUG
67 2 4000138 PLUG
68 1 4000139 PLUG
69 2 4000140 PLUG
70 1 4000141 PRESSURE PLUG
71 2 4000142 MICROPROCESSOR
72 1 4000143 TEMPERATURE GAUGE
73 1 4000144 EMERGENCY STOP SWITCH
74 1 4000145 IGNITION SWITCH
75 1 4000146 FUEL LEVEL SENSOR
76 1 4000147 RELAYS FUSE BOX
77 2 4000148 LEVEL SENSOR
78 1 4000149 HOURS COUNTER
79 1 4000150 RADIO REMOTE CONTROL RECEIVER
80 1 4000273 REMOTE CONTROL UNIT
81 1 4000270 BATTERY FOR REMOTE CONTROL
82 1 4000269 BATTERY CHARGER (MAINS POWER)
83 2 4000288 PROPORTIONAL JOYSTICK
84 1 4000293 BATTERY CHARGER (12v)

51
PROTECTION GUARDS & COVERS
ROBOCUT MOWER McCONNEL

52
PROTECTION GUARDS & COVERS
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
PROTECTION GUARDS & COVERS
1 2 4000151 ROLL BAR SUPPORT
2 1 4000152 ROLL BAR
3 2 4000153 ROBOGREEN BATTERY COVER
4 2 4000154 SIDE GRILL
5 1 4000155 CENTRE GRILL
6 1 4000156 RADIATOR BONNET
7 1 4000157 UPPER BONNET
8 1 4000158 UPPER GRILL
9 2 4000159 SIDE GRILL
10 1 4000160 FRONT GRILL
11 1 4000161 VALVE COVER PLATE
12 1 4000162 TANK COVER PLATE
13 2 4000163 BUSHING
14 1 4000164 RIGHT SIDE BONNET
15 1 4000165 LEFT SIDE BONNET
16 1 4000166 AIR FILTER BONNET
17 1 4000167 AIR FILTER BONNET SUPPORT
18 1 4000168 OIL SUMP PROTECTION
19 1 4000169 RADIATOR LEFT SUPPORT
20 1 4000170 RADIATOR RIGHT SUPPORT
21 1 4000171 RADIATOR SUPPORT EDGE
22 1 4000172 REAR COVER
23 1 4000173 RIGHT SIDE PROTECTION SUPPORT
24 1 4000174 LEFT SIDE PROTECTION SUPPORT
25 8 4000175 SCREW
26 8 4000176 SCREW
27 9 4000177 SCREW
28 2 4000178 SCREW
29 2 4000250 SCREW
30 12 4000071 FLANGED SCREW
31 27 4000109 FLANGED SCREW
32 18 4000075 AUTOGRIP NUT
33 2 4000076 AUTOGRIP NUT
34 2 05.945.33 LOCK NUT
35 2 4000112 BONNET FASTENER
36 2 9100101 WASHER
37 18 9100103 WASHER
38 8 0100106 WASHER
39 8 4000179 WASHER
40 2 4000079 WASHER
41 2 4000251 ANTI-VIBRATION
42 2 4000180 LOCK
43 2 4000181 BATTERY

53
FLAILHEAD ASSEMBLY
ROBOCUT MOWER McCONNEL

54
FLAILHEAD ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
FLAILHEAD ASSEMBLY
1 1 4000182 CYLINDER FIXING STIRRUP
2 2 4000183 RUBBER SUPPORT
3 2 4000184 UPPER PROTECTION SUPPORT
4 1 4000185 RAM BRACKET
5 1 4000186 HYDRAULIC RAM
6 1 4000187 HEAD CASING (1.3m)
7 1 4000188 CLAMP STRIP
8 1 4000189 RUBBER FLAP
9 1 4000190 ROTOR (1.3m)
10 2 4000191 ROTOR BEARING SUPPORT
11 1 4000192 HEAD PIVOT BRACKET
12 1 4000193 PIVOT JOINT
13 1 4000194 ROLLER
14 1 4000195 ROLLER BRACKET - R/H
15 1 4000196 ROLLER BRACKET - L/H
16 1 4000197 LEFT SKID
17 2 4000198 WASHER
18 1 4000199 PLATE
19 1 4000200 RIGHT SKID
20 1 4000201 MOTOR MOUNTING PLATE
21 1 4000202 BELT COVER
22 1 4000203 FRONT HOOD
23 1 4000204 SPRING BRACKET
24 1 4000205 SPRING TENSIONER FIXING
25 1 4000206 SPRING TENSIONER
26 1 4000255 Y-FLAILS KIT (SINGLE STATION)
1 4000268 Y-FLAILS KIT (22 STATION)
27 1 4000208 SCREW
28 1 4000252 SCREW
29 2 4000209 SCREW
30 1 4000210 SCREW
31 1 4000211 SCREW
32 2 4000212 SCREW
33 1 4000213 SCREW
34 1 4000214 SCREW
35 1 4000215 SCREW
36 1 4000216 SCREW
37 1 4000217 SCREW
38 1 4000218 NUT
39 1 4000219 TENSIONING SPRING
40 1 9163003 LOCK NUT
41 1 4000220 FLANGED NUT
42 8 9163005 LOCK NUT

55
FLAILHEAD ASSEMBLY
ROBOCUT MOWER McCONNEL

56
FLAILHEAD ASSEMBLY
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
FLAILHEAD ASSEMBLY
43 2 4000221 LOCK NUT
44 11 9100105 WASHER
45 2 9100106 WASHER
46 2 4000253 WASHER
47 2 4000222 WASHER
48 1 9100206 SPRING WASHER
49 1 4000254 WASHER
50 1 9100105 WASHER
51 1 4000223 GREASER
52 2 4000224 GREASER
53 2 4000225 BEARING
54 1 4000226 ROLLER BEARING
55 1 4000227 TAPERLOCK BUSH
56 2 4000023 CIRCLIP
57 1 4000228 RETAINING RING
58 2 4000024 CIRCLIP
59 1 4000229 MOTOR
60 1 4000230 CONICAL BUSH
61 1 4000231 PULLEY
62 1 4000232 PULLEY
63 3 4000233 TRAPEZOIDAL TOOTHED BELT
64 1 4000234 OILSEAL
65 2 4000235 OIL SEAL
66 2 4000236 GUIDE FOR OIL SEAL
67 1 4000237 BUSH
68 1 4000238 WASHER

57
ROTORS & FLAILS
ROBOCUT MOWER McCONNEL

58
ROTORS & FLAILS
ROBOCUT MOWER McCONNEL
REF. QTY. PART No. DESCRIPTION
ROTORS & FLAILS ASSEMBLY
1 1 4000190 1.3M ROTOR (Y-FLAILS TYPE)
2 2 4000241 STEEL BUSHING
3 2 4000242 Y-FLAIL (6mm)
4 1 4000243 HAMMER FLAIL
5 1 4000244 1.3M 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 AUTOGRIP NUT
SINGLE STATION FLAIL KITS
1 4000255 Y-FLAILS KIT (6mm Flail)
1 4000256 HAMMER FLAIL KIT
22 STATION FLAIL KIT
1 4000268 Y-FLAILS KIT (6mm Flail)

59
ROBOCUT DECAL KIT
ROBOCUT MOWER McCONNEL

REF. QTY. 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)

60
SERVICE PARTS - Filters & Filter Cartridges
ROBOCUT MOWER McCONNEL

PRIMARY FUEL FILTER (Part No. 4000292)

OIL FILTER (Part No. 4000257)

Fitted to Early Models

HYDRAULIC 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. 4000261)

61
McConnel Limited, Temeside Works, Ludlow, Shropshire SY8 1JL. England.
Telephone: 01584 873131. Facsimile: 01584 876463. www.mcconnel.com