McConnel RoboCut Programming manual

Publication 679
August 2011
Part No. 22674.79
Revision: 09.10.13
McCONNEL
ROBOCUT
REMOTE CONTROLLED MOWER
Operator & Parts Manual

IMPORTANT
VERIFICATION OF WARRANTY REGISTRATION
DEALER WARRANTY INFORMATION & REGISTRATION VERIFICATION
It is imperative that the selling dealer registers this machine with McConnel Limited before
delivery to the end user – failure to do so may affect the validity of the machine warranty.
To register machines go to the 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 site. Confirm to the customer that the machine has been
registered in the section below.
Should you experience any problems registering a machine in this manner please 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.
CAUTION: DO NOT OVER TORQUE HYDRAULIC FITTINGS AND HOSES
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 material
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 lubricants, 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 purchaser 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
Chassis Assembly 42
Rubber Tracks 44
Equipment Mounting Assembly 46
Engine Cover Assembly 48
Machine Cover Assembly 50
Diesel Engine Assembly 52
Diesel Engine Components 56
Pumps Assembly 58
Actuator Assembly 60
Reversible Fan System 62
Diesel Fuel Circuit 64
Oil Tank Assembly 66
Electrical Components 68
Electrical Wiring 72
Control Transmitting / Receiving Units – Robocut Models 74
Control Transmitting / Receiving Units – Robocut ‘PURE’ Models 76
Intake & Drain Pumps 78
Change Over Valve Circuit 82
Tracks Hydraulic Circuit 84
Hydraulic Rams Circuit 88
Hydraulic Equipment Circuit 90
Flailhead Assembly 92
Rotors & Flails 96
Decal Kit 98
Service Parts 99

1
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:

2
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

3
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.

4
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.

5
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.

6
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.

7
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.

8
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.

9
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

10
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

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

12
Ignition Panel Warnings
WARNING
SYMBOL LED LIGHT REFERENCE AUDIBLE WARNING CAUSE
REMEDY
1. Yellow LED Light Yes Fuel tank running on reserve. Top up fuel.
2. Red LED Light No Parking brake on. Check brake release valve
pressure.
3. LED Light Yes Hydraulic oil level too low. Check for leaks and repair.
Replenish hydraulic oil.
4. Red LED Light No Alternator not charging battery. Contact local dealer.
5. Yellow LED Light No Air filter blocked.
Disassemble the filter
cartridge and clean with
compressed air line.
6. Red LED Light Yes Oil filter blocked Replace oil filter cartridge.
7. Yellow LED Light No Pre-heat plugs are on. Wait for light to go out before attempting to start
engine.
8. Red LED Light &
9. Red LED Light
Yes Insufficient engine oil pressure. Replenish oil if required. If oil level correct seek
advice from local dealer.
9. Red LED Light No Engine stop Reset Emergency Switch.
10. Red LED Light Yes Coolant temperature too high. Check coolant level. Clean radiator matrix and
protection guard.

13
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 ODrive 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 (+)