Tajfun RCA 480 JOY User manual

FIREWOOD PROCESSOR
OPERATING INSTRUCTIONS
RCA 480 JOY
Ver.: 2.2 09/2015-ENG
Please, read these Operating Instructions carefully before
installing and using this machine!
RCA 480 JOY PLUS

MANUFACTURER’S ADDRESS
Tajfun Planina d.o.o.
Planina pri Sevnici 41a,
3225 Planina pri Sevnici,
Slovenia
T: [phone], F: [phone]
E-mail: expor[email protected]
W: www.tajfun.com
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TABLE OF CONTENTS
1. INTRODUCTION 5
1.1. Copyrights 5
1.2. Manufacturer’s liability 5
1.3. Reservations 5
2. SAFETY INSTRUCTIONS 6
2.1. General safety instructions 6
2.2. Additional safety instructions for the rewood processor 6
2.3. Safety instructions for the conveyor 7
2.4. Safety instructions for the rope pulleys 7
2.5. Noise 7
2.6. Other dangers 7
2.7. Application 7
2.8. Improper use of the machine 7
3. GENERAL 8
3.1. Scope of the operating instructions 8
3.2. Description of the machine’s functions 8
3.3. Machine’s main components 8
3.4. Specications 9
3.4.1. Type plate 9
3.5. Machine labels and their meaning 10
4. MACHINE SETUP 13
4.1. Connecting to the mains circuit 14
4.2. Additional equipment setup 14
4.2.1. Attaching the loading deck to the machine’s hydraulic control system 14
5. MACHINE STARTUP 15
5.1. In-feed conveyor setup 15
5.2. Operating the RCA 480 JOY 16
5.2.1. Turning on the RCA 480 JOY control 16
5.2.2. Description of the RCA 480 JOY control functions 16
6. MACHINE OPERATION 18
6.1. Conveyor 18
6.2. Log feeding 19
6.3. Sawing 20
6.3.1. Adjusting the log cutting length 21
6.3.2. Removing sawdust 21
6.4. Splitting 22
6.4.1. Adjusting the height of the splitting wedge and replacing the splitting wedge (RCA 480 JOY)
22
6.4.2. Proper use of splitting wedge 23
6.4.3. Machine cover with a safety switch 25
6.5. Cleaning during operation 26

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7. MAINTENANCE AND SERVICE 27
7.1. Maintenance plan 27
7.2. Troubleshooting 28
7.3. Cutting chain replacement 30
7.4. Tensioning a cutting chain 31
7.5. Angles used for sharpening the cutting chain 31
7.6. POWER MATE Sprocket 31
7.7. Changing the hydraulic system oil 32
7.8. Replacing the oil lter cartridge 32
7.9. Lubrication of the multiplication gear 32
7.10. Lubrication of the cutting chain 33
7.11. Replacing the cutting chain belt 34
7.11.1. Belt tensioning 35
7.11.2. Cleaning and replacing the air lter 36
7.12. Indications of improper use 37
7.13. Wear and tear parts 37
7.14. Spare parts ordering 37
8. LOADING AND TRANSPORTING 38
8.1. Loading with a forklift 38
8.2. Loading with the help of lifting straps 39
8.3. Transporting with a tractor 40

Dear Customer,
By purchasing our firewood processor you obtained a piece of equipment that will provide you with
great assistance at your work. To make machine operation as safe and as pleasant as possible, please
carefully read these operating instructions and follow the safety and maintenance directives.
We would like to thank you for your trust and we wish you to be satisfied with your work.
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UVOD
1. INTRODUCTION
1.1. COPYRIGHTS
All documents are protected by the copyright laws.
No part of this document may be distributed or reproduced.
1.2. MANUFACTURER’S LIABILITY
Before using this machine carefully read these operating instructions.
Report any faults immediately upon identification.
The manufacturer’s liability for faults becomes void in the following events:
• Improper use;
• The use of unsuitable implements and drives, which are not supplied together with the machine;
• The use of other spare parts and tools;
• Rework and modification carried out without manufacturer’s prior written agreement.
The manufacturer cannot be held liable for defects of the wear and tear parts.
1.3. RESERVATIONS
The manufacturer reserves the right to change specifications, graphical material and safety standards
listed in the supplied operating instructions.
The manufacturer does not assume any liability for damages or faults if the
machine was not used in accordance with the operating instructions.

2.2. ADDITIONAL SAFETY INSTRUCTIONS FOR THE
FIREWOOD PROCESSOR
2.1. GENERAL SAFETY INSTRUCTIONS
• Machine operation and maintenance may be carried out only by individuals who have the
knowledge about machine’s operation, work-related dangers and operating instructions.
• Machine operation and maintenance may not be carried out by people under the influence of
alcohol, drugs or medicinal products that affect people’s psychophysical abilities.
• The machine can be operated by one person only. Please, make ensure that nobody is standing
in the near vicinity (in the 3 m radius) of the machine’s operating area!
• Machine operation and maintenance may be carried out only by qualified personnel over 18
years of age!
• Before starting the operation place the machine in a stable position in accordance with the
machine’s installation instructions!
• Use only PTO shafts of appropriate strength (min. 25 kW) with undamaged exterior plastic
protective cover!
• Never use damaged, cracked or deformed cutting chains, chain sprockets and saw bars!
• All protective parts of the machine (safety nets, saw shield, covers, etc.) must be fixed in place
during the machine’s operation. Any modification of these protective parts is prohibited!
• Always wear personal protective equipment (safety glasses, hearing protectors, gloves and
forestry boots)!
• When troubleshooting, replacing the chain, cleaning or any other service procedure always
disengage the PTO shaft and shut down the power unit (tractor) or unplug the power cord from
the mains (EP 12)!
• Do not wear loose clothing!
• Keep the operating area clean and tidy!
• Always use caution when operating the machine! Moving parts can cause serious injuries in case
of improper use of the machine!
• During the running of the machine never leave the machine unsupervised!
• Do not reach into the working area during the operation of the machine!
• Before removing any wedged pieces of wood shut down the machine’s drive or turn off the
machine.
• For transportation of the machine via public roads install lights on the rear end of the machine!
• For personal safety use only original spare parts and accessories approved by the manufacturer!
• The damaged power cord or plug must immediately be replaced.
UVOD
2. SAFETY INSTRUCTIONS
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• The manufacturer,Tajfun Planina d.o.o., provides the declaration of conformity and risk estimation
only for the machines operated by a single person that has sufficient overview over the entire
surrounding area, and applies to the machine’s entire operating area.
• Personal protective equipment and protective parts, which must always be used when operating
the machine, are included in the scope of delivery.
• Never reach within the chain saw or splitting cylinder working area during the machine’s
operation. Never remove cut pieces and other wood residues from the sawing and splitting area
during the machine’s operation.
• For outdoor use only. When operating the machine indoors it is necessary to install a suction
device on the machine, which is supplied as part of the accessories.
• Ensure regular machine maintenance and cleaning. Regularly remove the sawdust and wood
residues.
• The operating pressure of the hydraulic system must not exceed 230 bars.

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2.3. SAFETY INSTRUCTIONS FOR THE CONVEYOR
• Observe the working area of the machine located in the near vicinity of the moving parts, as well
as under the entire construction along the conveyor belt, and not only on the discharge conveyor.
• The transported material can fall off the conveyor in this area.
• Never reach inside the chute and never touch the conveyor belt during the machine’s operation.
• Shut down the machine prior to removing any wedged parts of wood.
2.4. SAFETY INSTRUCTIONS FOR THE ROPE PULLEYS
• Prevent the pulling of the wire rope over the sharp edges!
• Never hold the wire rope during winding and unwinding!
2.5. NOISE
During the machine’s operation the operator is exposed to the following noise levels (measured near
the operator’s ear):
RCA 480 JOY
Idling 85 dB (A)
Operation 92 dB (A)
The total noise level depends on the noise generated by the power machines (tractor, diesel unit).
Therefore, it is mandatory to wear hearing protectors while operating the machine.
2.6. OTHER DANGERS
Provided that all safety measures are followed and the machine is being used in accordance with the
operating instructions other risks still persist:
• Contact with the machine’s moving parts;
• Injuries due to the flying particles of wood;
• Burns due to contact with hot machine parts (multiplication gear);
• Hearing impairment in case of hearing protector’s improper use or lack of use;
• Human errors (overstraining, mental stress, etc.).
2.7. APPLICATION
RCA 480 JOY Firewood Processor is a machine used for processing firewood.The processor is intended
for cutting wood logs with a diameter from 5 to 48 cm, which are thereafter split into 4, 6, 8, 12 or 16
firewood logs (with an adjustable length of 25 to 50 cm) using a splitting force of 250 kN.
The machine is intended for outdoor use only.
2.8. IMPROPER USE OF THE MACHINE
Any use of the machine, which does not comply with the use described under the previous section,
is considered to be improper and is prohibited.

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3.1. SCOPE OF THE OPERATING INSTRUCTIONS
The (RCA 480 JOY / RCA 480 JOY PLUS) firewood processor is used for processing firewood.
The operation process includes the following stages:
Loading logs on the log deck (optional), which allows the feeding of the logs transversally and
longitudinally, as well as synchronously with the in-feed conveyor.
Transporting logs with maximum diameter of 5 to 48 cm (2” to 18.9”) with the in-feeder conveyor
to the adjustable limiter, which can be used to set the cutting length (25 to 50 cm or 7.9”to 20” (See
chapter: Log feeding)).
Sawing with the chainsaw according to the set cutting length (See chapter: Sawing).
Splitting. The use of suitable splitting wedge allows adjusting the log size (cross-section) (See
chapter:Splitting).
Transporting logs with the adjustable conveyor (adjustable speed, height and transversal offset (See
chapter:Conveyor).
The quality of the logs, as well as the machine capacity, diminishes when using pre-split wood.
3. GENERAL
3.3. MACHINE’S MAIN COMPONENTS
3.2. DESCRIPTION OF THE MACHINE’S FUNCTIONS
These operating instructions apply to the following models:
• RCA 480 JOY
• RCA 480 JOY PLUS (See: RCA 480 JOY PLUS attachment to RCA 480 JOY operating instructions)
1 In-feed conveyor 9 Conveyor
2 Log holder 10 Splitting cylinder, splitting wedge
3 Chainsaw drive 11 Splitting wedge lifting mechanism
4 Chain lubrication oil reservoir 12 Control handle
5 Trapdoors 13 Control panel
6 Cutting length limiter 14 Hydraulic oil reservoir
7 Machine cover with a safety switch 15 Three-point hitch
8 Hydraulic pulley
1
23 4 5 6 7
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9
10
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12
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RCA 480 joy
XXXXX - XXXXX
 5 -  48
250
24" x 3/8" 1300 + 180
511758
170/230
21.11.2019
2020
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3.4. SPECIFICATIONS
RCA 480 JOY / RCA 480 JOY PLUS
Cutting length 25 - 50 cm (7,9”- 20”)
Cutting diameter 5 - 48 cm (2”- 18,9”)
Saw bar 24”, b = 0,058” (1,5 mm)
Chain 3/8”, 42 cutter teeth, b = 0,058” (1,5 mm)
Splitting force 250 kN (≈ 25 T)
Machine width 1600 mm (63”)
Machine length (transport position) 2410 mm (94,9”)
Machine height (transport position) 2630 mm (103,5”)
Required tractor power 30 kW (40 KM) - drive
70 - 80 kW - transport
Required tractor outlet voltage 12 V
Electric fuse 20 A
PTO shaft speed min.: 400 min¹ (RPM)
max.: 430 min¹ (RPM)
Maximum splitting pressure 230 bars
Oil reservoir volume 100 l (25 gallons)
Chain lubrication oil reservoir volume 8 l (2 gallons)
Operating noise level (max.) 92 dB (A)
Weight 1300 kg (2866 lbs)
Transporter TT 404 / TT 404 R
Conveyor length 4000 mm (13')
Conveyor belt width 430 mm (17”)
Maximum speed 0,8 m/s (31,5”/s)
Weight 180 kg (396,8 lbs)
Transporter TT 504 / TT 504 R
Conveyor length 5000 mm (16,5')
Conveyor belt width 430 mm (17”)
Maximum speed 0,8 m/s (31,5”/s)
Weight 210 kg (463 lbs)
Transporter TT 510 S
Conveyor length 5000 mm (16,5')
Conveyor belt width 580 mm (23”)
Maximum speed 0,8 m/s (31,5”/s)
Weight 250 kg (551 lbs)
3.4.1. TYPE PLATE
Year of manufacture
Factory number

3.5. MACHINE LABELS AND THEIR MEANING
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Control panel (RCA 480 JOY):
1. STOP switch
2. Conveyor belt speed
3. Deck control
4. On / off switch
Machine working area.
The working area extends in a 3 m radius
around the machine. Read operating instructions.
Automatic stopping of the machine after
lifting the cover.
Control handle (joystick)
functions.
31 2 4

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Wear forestry boots.
Wear hearing protectors
and safety glasses.
Wear protection gloves.
Cutting length setting scheme.
Remaining log length on the in-feed conveyor scheme.
Conveyor movement controls scheme.
Hydraulic oil reservoir. Chainsaw lubrication oil reservoir.
Direction of the chainsaw drive belt
movement.

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Maximum allowed inclination
of the conveyor according to
the log length. Cutting chain lubrication
intensity setting.
Lubrication of the chainsaw’s
saw bar.
Proper belt tension
scheme.
Danger of cutting
chain contact.
Scheme of the deck’s hydraulic pipes
according to its position.
The valve handle position when operating
with or without the deck.
Proper direction of the PTO shaft rotation.
Approved rotational speed range
(only for RCA 480 JOY).
For RCA 480 JOY PLUS also see: RCA 480 JOY PLUS attachment to RCA 480 JOY operating instructions.

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• Use bolts to connect the firewood processor to the three-point tractor hitch. Fix the bottom
tractor hitch bars with the tension screws to allow the machine to move transversely. During
machine transport observe the total weight of the machine (See chapter: Specications).
• Connect the PTO shaft to the universal joint and secure it by using a safety chain.
• Plug the machine control cable into the 12 V tractor outlet.
Check the length of the PTO shaft upon rst installation.
Check the length of the PTO shaft by raising and lowering the machine to determine the position
with the minimum distance between the joints. After PTO shaft installation the length of the pipes
must be shorter for approximately 20 mm.
If the PTO shaft is too long, reduce the length as follows:
• Use a saw to cut both ends of the steel and plastic pipes to the same length. Then file down, clean
and grease the edges.
4. MACHINE SETUP
Model Dimensions Compatibility
PTO Shaft C Line-T 6BR + KK560 1 3/8’’Z6 – 1 3/8’’Z6; LKK = 560 EP 12 (RCA 330 JOY, RCA 380, RCA 400 JOY,
RCA 480 JOY)
PTO Shaft C Line-T4 DZ DZ BR + KK510 1 3/8’’Z6 – 2X; LKK = 510 RCA 330 JOY, RCA 380, RCA 400 JOY,
RCA 480 JOY
When using our machines, we recommend Tajfun PTO Shafts:
The tractor output shaft and machine
input shaft should be positioned as
parallel as possible! Otherwise, the
PTO shaft’s geometry may cause
uneven transmission of the rotation
and subsequent vibrations. If this is not
possible, a PTO shaft with two wide-
angle joints must be used, since this is
the only PTO shaft that ensures a steady
rotation under wide variety of angles.
• PTO shaft (grooved shaft 13/8” Z6 – DIN 9611A) must
comply with the required engine power of the machine
(Specifications).
• The tractor PTO shaft must rotate clockwise. In case
of EP (Electric Power Unit) the shaft must also rotate
clockwise.
• The recommended speed of the PTO shaft: 420 min¹;
maximum: 430 min¹; minimum: 400 min¹.
• When the machine is disconnected place the PTO shaft
into the PTO shaft holder.
Always use a PTO shaft without a clutch.

4.1. CONNECTING TO THE MAINS CIRCUIT
Plug the 3 pin plug into the tractor mains or EP unit
(optional).
Check that the power source provides a constant 12 V
voltage and 16 A current; otherwise, this may lead to faulty
operation of the electrical system. Minimum cross-section
of the cables from the power source should be 2,5 mm².
4.2. ADDITIONAL EQUIPMENT SETUP
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4.2.1. ATTACHING THE LOADING DECK TO THE MACHINE’S HYDRAULIC
CONTROL SYSTEM
• Use the quick couplings to connect the loading deck’s hydraulic pipes and the machine couplings.
To ensure proper connection observe the label and the color covers of the couplings.
• If the hydraulic couplings are not installed or if the loading deck is not in operation, place the
selector valve in the appropriate position (X).
Selector valve
After operation always disconnect the supply cables; otherwise, the tractor battery may begin to
discharge.

5.1. INFEED CONVEYOR SETUP
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5. MACHINE STARTUP
Before starting up the machine always check the chain tension and re-tension the chain, if
necessary!
A loose chain can cause vibrations, which can have a negative eect on the operation of the
drive belt. The increased level of vibrations can also damage the drive belt.
Before machine start-up remove all wood residues and other particles from the splitting chute.
Check the hydraulic oil level and chain lubrication oil level before machine start-up!
Before machine operation check the machine functions, and particularly the function of the
safety devices. Follow the steps below.
• Check the faultless operation of the machine and equipment, as well as the chain lubrication.
• Set the manual tractor throttle to minimum.
• Lift the machine cover to disengage the safety switch and disable all the main functions of the
machine.
• Engage the PTO shaft drive and start the machine.
• Manually add throttle to set the required PTO shaft rotational speed (420 min¹).
• Install the machine cover.
• Check the function of the emergency STOP switch (EMERGENCY SHUTDOWN).
• Follow the RCA 480 operating instructions (See chapter: Operating the RCA 480 JOY).
Set the in-feed conveyor lifting mechanism in the operating position, open the guide plate and, if
necessary, move the side cylinders to the suitable position according to the feeding direction of the
logs on the in-feed conveyor.
When the outdoor temperature drops under 0°C leave the machine idling for 5 minutes to allow
the hydraulic system to warm-up to reach the operating temperature (the hydraulic pipes feel
warm).
The machine can be operated by only one person! Ensure that there is no
other person in the vicinity of the machine.

On / off
switch
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5.2. OPERATING THE RCA 480 JOY
Close the protective cover. Press the On / off switch, located on the control panel, and hold it for
approximately 3 seconds. Then press the green button (RESET) on the main control handle. Switch
off the safety STOP switch.
5.2.1. TURNING ON THE RCA 480 JOY CONTROL
5.2.2. DESCRIPTION OF THE RCA 480 JOY CONTROL FUNCTIONS
Main control handle (joystick)
The main control handle (joystick) has the following functions:
• Left or right -> moving the in-feed conveyor in the left or right
direction;
• Backward -> sawing (two-phase – fixing the log and starting
up the cutting chain, which is followed by the chainsaw
movement);
• Forward -> splitting (push the handle in the forward direction
briefly, do NOT hold it this position).
The control handle buttons:
• Yellow buttons -> moving the splitting wedge up/down;
• Red button -> returning the splitting cylinder home from any
position;
• Green button -> RESET function; manual opening of the
trapdoors After each machine shut down (lifting the cover,
pushing the STOP switch) push the RESET button to reactivate
the control functions.
Protective cover
For RCA 480 JOY PLUS see: RCA 480 JOY PLUS attachment to RCA 480 JOY operating instructions.

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Additional functions:
A-> safety STOP switch
B-> conveyor belt speed regulator
C-> log loader - conveyor chain
D -> on / off switch for turning el.
system on and off.
Additional functions – conveyor:
• UP/DOWN -> raising and lowering the conveyor by
means of a hydraulic winch;
• LEFT/RIGHT -> moving the conveyor left and right
(15° to each side).
Warning!
The speed of these functions depends on the conveyor
belt speed valve settings.
If the speed is set too low, the hydraulic winch brake
remains engaged and the winch does not operate.
C
AB D

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6. MACHINE OPERATION
6.1. CONVEYOR
Use the conveyor control handle located near the hydraulic winch to raise or lower the conveyor.
Make sure to always use the load chain to secure it at the desired height. You may also move the
conveyor for 15° to left or right from the centre position. Before starting the works, place the conveyor
into the working position.
Placing the conveyor into the working position:
• The machine must be running (See chapter: Turning on the RCA 480 JOY control);
• Move the conveyor control handle “down” to shift the conveyor from the vertical position. If
necessary, gently push the conveyor away from the machine. The conveyor belt speed regulator
valve must not be set to minimum, as this will prevent the disengagement of the hydraulic winch
brake;
• Place the conveyor under the desired inclination angle (maximum 45°) by moving the control
handle up or down.
Conveyor TT 404 and TT 504
• Shut off the valve completely, and press and hold the yellow button on the main control handle
of the machine until the conveyor is extended to its maximum.
Conveyor TT 510 S, TT 404 R, TT 504 R
• Turn the valve into the expanding position, and press and hold the yellow button on the main
control handle of the machine until the conveyor is extended to its maximum.
Placing the conveyor into the transport position:
Conveyor TT 404 and TT 504
• Move the conveyor control handle“up”, and place the conveyor into the vertical position. Unscrew
the valve. The conveyor will fold under its own weight.
Conveyor TT 510 S, TT 404 R, TT 504 R
• Turn the valve into the stacking position, and press and hold the yellow button on the main
control handle of the machine until the conveyor is completely folded.
• Move the conveyor control handle“up”, and place the conveyor into the vertical position.
The conveyor belt speed can be regulated by means of a conveyor belt speed regulator valve).

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6.2. LOG FEEDING
Before operation place the in-feed conveyor in a horizontal operating position:
• Pull out the safety pin;
• Lower the in-feed conveyor to the horizontal position and support it using the supporting leg;
• Set the supporting leg so that the upper
rod on the conveyor belt in the middle of
the in-feed conveyor is slightly elevated
above the table (factory default setting).
Activate the feeding by pushing the control handle to the right. The feeding can be stopped at any
time (when the log reaches the cutting length limiter) by pushing the handle to home (neutral)
position. To activate the feeding in the opposite direction push the control handle to the left.
Safety pin
Conveyor TT 510 S, TT 404 R, TT 504 R Conveyor TT 404 and TT 504
• Remove the support limiter;
Attention! If the feeding is active after the log reaches the cutting length
limiter, the in-feed conveyor belt can slip and can become damaged!
Valve

During feeding both trapdoors lift and remain in place until the end of the sawing phase or until the
green RESET button is pushed.
During the feeding phase the cutting length limiter moves in the correct position.
6.3. SAWING
The chainsaw operates only during the sawing cycle, otherwise it is at standstill in the home position.
Start the sawing by pulling the main control handle backwards. Sawing is carried out in two phases.
First, fix the log with the log holder and engage the cutting chain activation clutch. This is followed by
the saw bar operation. During the sawing operation the handle must be in the “backward” position;
otherwise, the saw bar will return to the home position.
There are two inductive switches located on the saw bar operation cylinder. Switch 1 (cylinder
retracted) prevents the operation of the in-feed conveyor belt, when the saw bar is not in the home
position. Switch 2 opens the trapdoors and returns the saw bar to the home position.
The force used by the cylinder to push the saw bar is factory set and must not be modified. The saw
bar operation speed is also set to a fixed value. The sawing speed varies depending on the sharpness
of the cutting chain and type or diameter of wood.
Prior to sawing always check the sharpness and tension of the chain and the level of the chain
lubrication oil!
The wood must remain in the fixed position during sawing. Take extra care when cutting the last
piece – both clamps must be well fixed. The movement of the wood during sawing can damage the
saw bar and the cutting chain!
The trapdoors provide a smoother transfer of the cut pieces into the splitting chute and are in the
horizontal position throughout the sawing operation. The trapdoors open when the saw bar reaches
the bottom position. The trapdoors can also be opened manually at any time by pressing the green
button on the control handle. This is particularly useful when cutting warped wood, which leans on
the trapdoors during sawing and pushes the saw bar from the side thus subsequently interfering the
sawing operation.
Switch 1
(cylinder retracted)
Switch 2
(cylinder retracted)
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Log holder