Tajfun RCA 400 joy User manual

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Ver.: 2.5 07/2010-ENG
RCA 400 joy
Please read operating instructions carefully before installing and using the machine!
OPERATING INSTRUCTIONS
FIREWOOD PROCESSOR

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TABLE OF CONTENTS
Chapter: Page:
1 GENERAL 3
1.1 MANUFACTURER’S ADDRESS 3
1.2 APPLICATION 4
1.3 SCOPE OF DELIVERY 4
1.4 OPTIONAL EQUIPMENT 4
1.5 TECHNICAL DATA 6
1.5.1 SPECIFICATION PLATE 6
2 SAFETY INSTRUCTIONS 7
3 MACHINE SETUP AND OPERATION 7
3.1 DISCHARGE CONVEYOR ASSEMBLY 8
3.1.1 RETRACTION OF DISCHARGE CONVEYOR 9
3.2 TRACTOR P.T.O. SHAFT DRIVE 9
3.3 CONNECTING THE LOG LOADER (OPTIONAL) 10
3.4 STARTING UP 10
3.5 TRANSPORT POSITION OF THE MACHINE 11
4 OPERATING THE FIREWOOD PROCESSOR 11
4.1 BASIC FUNCTIONS 11
4.2 NOISE 12
4.3 LOG FEEDING 12
4.4 SAWING 13
4.4.1 ADJUSTING THE WOOD LENGTH 13
4.5 SPLITTING 14
4.5.1 ADJUSTING THE HEIGHT OF THE SPLITTING WEDGE 14
4.5.3 MACHINE COVER WITH SAFETY SWITCH 16
4.6 DISCHARGE CONVEYOR 17
4.7 CLEANING DURING THE OPERATION 17
5 MAINTENANCE AND REPAIR 18
5.1 MAINTENANCE PLAN 18
5.2 TROUBLESHOOTING 19
5.3 CHAIN REPLACEMENT 21
5.4 CHAIN TENSIONING 22
5.5 CUTTING CHAIN SHARPENING ANGLES 22
5.6 SPLITTING WEDGE REPLACEMENT 22
5.7 HYDRAULIC SYSTEM OIL CHANGE 22
5.8 CHANGE OF FILTER INSERT 23
5.9 LUBRICATION OF THE ANGLE REDUCTION GEAR 23
5.10 CHAIN LUBRICATION 23
5.11 CUTTING CHAIN BELT REPLACEMENT 24
5.11.1 BELT TENSIONING 25
5.12 INDICATIONS OF IMPROPER USE 27
5.13 SUPPLIES 27
5.14 SPARE PARTS ORDERING 27
WARRANTY SHEET 32
5.11.2 CLEANING AND REPLACING THE AIR FILTER 26
4.5.2 PROPER USE OF SPLITTING WEDGE 15

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Dear Customer,
By purchasing our firewood processor you obtained the equipment which will provide you with great help in
your work. To make operating the machine as safe and pleasant as possible, please carefully read this operat-
ing instructions and follow the safety and maintenance directives.
We would like to thank you for your trust and wish you great satisfaction in your work.
1 GENERAL
1.1 MANUFACTURER’S ADDRESS
Tajfun Planina, d.o.o., Planina 41a, 3225 Planina pri Sevnici, Slovenia
Tel.: [phone], Fax.: [phone], E-mail: [email protected], www.tajfun.com
A In – feed Conveyor H Safety STOP Switch
B Machine Cover with Safety Switch I Low pressure Gauge
C Chainsaw cover J High pressure Gauge - Splitting
D Telescopic discharge Conveyor K Sawbar movement Gauge
E Control Handle
F Discharge Conveyor’s speed Regulator
G Log Loader Control Handle
A
B C
D
E F G H
K J I
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1.2 APPLICATION
Firewood processor (RCA 400 joy) is a machine used for preparation of firewood. For open air use only! The
processor can handle logs from 10 to 40 cm (4" - 15,7") in diameter, which can be cut to 20 – 50 cm (7,9" -
20") length and thereafter split.
The work process is as follows:
1. Lifting and transportation of the log on the conveyor belt using the log loader (optional).
2. Transportation of the log with the conveyor belt to the limiter which sets the length of cut log. (Ch. 4.3).
3. Sawing with the chainsaw (Chapter 4.4).
4. Splitting (Chapter 4.5).
5. Transportation off the exit conveyor belt (Chapter 4.6).
1.3 SCOPE OF DELIVERY
 RCA 400 joy  Discharge conveyor  Operating instructions
 Log Loader Control Valve –
integrated in the machine con-
trol panel
 Chain 3/8" Oregon MULTI-
CUT ; Number of driving teeth
= 64, b=0.058” (1.5 mm)
 Discharge Conveyor’s speed
regulator – integrated in Dis-
charge Conveyor
 Manual Winch Operating In-
structions
 Sawbar: Oregon 178SLHD009
or compatible
1.4 OPTIONAL EQUIPMENT
 LOG LOADER DM 1511 - Tajfun (Figure 2)
 LOG LOADER DM 2000 - Tajfun (Figure 2)
 ELECTRIC POWER UNIT EP 11 with built-in 12V power supply - Tajfun
Chain lubrication oil is not included in the scope of delivery.
LOG LOADER DM 1511 - Tajfun
Retractable, with drive cylinders
Log loader length: 1840 mm
Lifting power: 4500 N
Weight: 160 kg
LOG LOADER DM 2000 - Tajfun
Retractable, with drive cylinders
Log loader length: 1650 mm
Lifting power: 7000 N
Weight: 330 kg
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DM 1511 DM 2000

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ELECTRIC POWER UNIT EP 11 - Tajfun
Motor Power: 11 kW
Weight: 197 kg
EP 12
LIVE LOG DECK RN 3000 - Tajfun
Dimensions: 5550 x 2010 x 1495 mm
Weight: 700 kg
Log Length: up to 6 m
Stock Capacity : 3t or up to 4 m3
RN 3000

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1.5 TECHNICAL DATA
Length of Cut Log 20 – 50 cm (7,9"- 20")
Diameter of Log 10 – 40 cm (4 – 15.7")
Sawbar 17", b=0.058" (1.5 mm)
Chain 3/8", 64 pogonskih zob, b=0.058" (1.5 mm)
Splitting Power 150 kN (≈15T)
Machine Width 1290 mm (50.8″)
Machine Length (transport position) 2350 mm (92.5″)
Machine height (transport position) 2360 mm (92.9″)
Required Tractor Power 30 kW (40 KS)
Tractor P.T.O. Shaft Speed [400 – 430] min-1 (RPM)
Maximum splitting pressure 240 bar (3481 psi)
Oil Reservoir Volume 100 l (25 gal)
Chain Lubrication Oil Reservoir Volume 8 l (2 gal)
Operating Noise (Max.) 92 dB (A)
Weight 1080 kg (2381 lbs)
Discharge Conveyor
Conveyor Length 4000 mm (13’)
Conveyor Belt Width 430 mm (17.5″)
Maximum Speed 60 cm/s (24″)
Weight 130 kg (286 ls)
Required Tractor Outlet Voltage 12V
Minimal control fuses’ rating 16A
1.5.1 SPECIFICATION PLATE
Year of Manufacture
Serial number

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2 SAFETY INSTRUCTIONS
 The machine must be operated by one operator only. All other persons must stay away from the danger
zone (within the radius of 3 m ) Please ensure that there is nobody else in the near vicinity of the ma-
chine working area!
 Machine operation and maintenance is allowed to qualified persons older than 18 years of age, only!
 Before starting the work place the machine in a stable position, according to machine installation in-
structions!
 Use only P.T.O. shafts of appropriate strength (min. 25 kW), with undamaged outer plastic protective
cover!
 Never use damaged, cracked or deformed cutting chains, chain sprockets and sawbars!
 All protective parts of the machine (safety nets, saw shield, covers ...) must be in place during the ma-
chine operation. Any modification of these protective parts is not permitted!
 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 P.T.O. shaft and shut down the tractor or unplug the power cord from the electrical outlet (EP 11)!
 Do not wear loose clothes!
 Keep the working environment clean and tidy!
 Always use caution when operating the machine! Moving parts can cause serious injuries in case of
improper use of the machine!
 Never leave the machine running without supervision!
 Do not reach into the working area while the machine is in operation!
 Before removing a wedged piece of wood, shut down the machine drive or turn off the machine.
 When transporting the machine on public roads install lights on the read end of the machine!
 For your own safety use only original spare parts and manufacturer approved accessories!
 Damaged power cord or plug must be replaced immediately.
3 MACHINE SETUP AND OPERATION
 Mount the firewood processor to the three-point tractor system using bolts. Lower tractor connecting han-
dles must be fixed with tensioning screws, so the machine can move transversely. When transporting the
machine, consider the weight of the whole machine (Chapter 1.5).
 Connect the P.T.O. shaft to the cardan shaft and secure it using the safety chain.
 Plug the machine control cable to the 12V outlet on the tractor.
Before the first installation also check the P.T.O. shaft length.
Before the first installation also check the P.T.O. shaft length.
Check the P.T.O. shaft length by raising and lowering the machine to determine the position with the shortest
distance among connecting shafts. Tubes should be in this position, when the P.T.O. shaft is connected, app.
20 mm shorter.
In case the P.T.O. shaft is too long, it must be shortened:
 Saw of steel and plastic tubes on both ends to the same length. Afterwards file down, clean and grease the
edges.
 Do not use P.T.O. shaft with a clutch.
Tractor exit shaft and machine input shaft should be positioned as parallel as possible! P.T.O. shaft geometry
may otherwise cause uneven rotation transfer and subsequent vibrations. If this cannot be achieved you may
need to use P.T.O. shaft with wide angle linkages on both sides which is the only type of shaft that ensures
constant rotation with different angles (Figure: 3).
Model Dimensions Compatibility
PTO Shaft C Line-T 6BR + KK560 1 3/8’’ Z6 – 1 3/8’’ Z6; LKK = 560 EP 12 (RCA 380, RCA 400 JOY, RCA 480 JOY)
PTO Shaft C Line-T4 DZ BR + KK510 1 3/8’’ Z6 – 2X; LKK = 510 RCA 380, RCA 400 JOY, RCA 480 JOY
When using our machines, we recommend Tajfun PTO Shafts:

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3.1 DISCHARGE CONVEYOR ASSEMBLY (in case of separate delivery)
Hydraulically driven discharge conveyor is also a component part of the firewood processor.
 Place the discharge conveyor on the ground and move it closer to the connecting spot
 Slide the discharge conveyor on the supporting forks and secure it with two screws (1– Figure:4)
 Fasten the lifting package by fixing rope pulleys to their position (2-Figure: 5).
 Use the hand winch (3-Figure:4) to lift the discharge conveyor slightly above the desired height and attach
the carrying chain (4-Figure:4).
 Loosen the wire rope, so that the weight of discharge conveyor is distributed between the wire rope and
carrying chain (4-Figure:4)
 Connect the hydraulic connectors::
- a - hydroengine return line - c - hydroengine discharge line
- b - hydroendine pressure line
3
4
3
4
ab
c
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3.1.1 RETRACTION OF THE DISCHARGE CONVEYOR
Discharge conveyor is usually telescopically retracted in the machine transport position. By activating the ma-
chine, telescopic cylinder of the discharge conveyor automatically activates and fully extends the machine, so
the belt is tensioned.
3.2 TRACTOR P.T.O. SHAFT DRIVE
 P.T.O. shaft (grooved shaft 13/8!" Z6 – DIN 9611A) must comply with the required driving power of the
machine (technical specifications).
 The tractor P.T.O. shaft must rotate in a clockwise direction. In case you use EP11, the shaft must also ro-
tate in a clockwise direction.
 Recommended rotating speed of the P.T.O. shaft: 420 min-1; max.: 430 min-1, min.: 400 min-1
 When the machine is not coupled to its power source, place the PTO shaft into the rest hook.
To optimally tension the belt, move the control handle of the lifting table (G-Figure:1) to the lowering posi-
tion, which increases the system pressure. To position the Discharge Conveyor into the working – extended
position, the discharge conveyor valve (T-Figure:5) must be closed – fully tightened..
After you disconnect the machine drive, you can retract the discharge conveyor. Open the discharge conveyor
valve (T-Figure:5) and lift the machine cover (B-Figure:1) and leave the discharge conveyor to retract by its
own weight. Therefore put the machine in more upright position.
When the discharge conveyor is retracted, close the discharge conveyor valve (T-Figure:5). The valve should
remain closed during the operation.
Before starting the machine, make sure to loosen the conveyor belt, by moving the Discharge Conveyor from
vertical to horizontal position using the hand winch (3-Figure:4). Otherwise damages to the belt can occur
during the extension procedure!
Ensure the clearance “t” between the nut
and the hand winch handle axis.
5
T
2
t

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3.4 STARTING UP
Before each machine startup, it is necessary to check the chain tension and readjust it if necessary!
A too loose chain can induce vibrations, which unfavorably affect the drive belt’s operation. Increased vibra-
tions can also cause damages to the drive belt.
Check the oil levels of the hydraulic system and cutting chain lubrication system, before starting the machine!
 Examine the machine and equipment for faults and check the chain lubrication
 Place the tractor manual throttle handle in lowest position
 Lift the machine cover (B-Figure: 1) to activate the safety switch and disengage all major machine func-
tions
 Engage the P.T.O. shaft drive and start the machine.
 It may be necessary to turn on the headlights on some tractors to activate the 12V outlet
 Set the required rotating speed of P.T.O. shaft (420 min-1) by manually adding the throttle
 Lower the machine cover
 Push the RESET button (green) on the control panel to start the operation
 Check the function of the emergency STOP switch.
RCA 400 joy :
Remove all wood remains and other particles from the splitting chute, before starting the machine!
Before starting the machine, make sure to loosen the conveyor belt, by moving the Discharge Conveyor from
vertical to horizontal position using the hand winch (3-Figure:4). Otherwise damages to the belt can occur
during the extension procedure!
3.3 CONNECTING THE LOG LOADER (OPTIONAL)
Position the log loader in line with the machine,
as shown in the picture. The log loader can be
turned 180°, depending on the position of the
logs. Connect the hydraulic pipes for forks’ op-
eration to connectors a and pipes for cylinder
rotation to connectors b. You can reverse the
pipes on the connectors b to reverse the rotating
direction.
To retract the log loader in working position use
the fork lifting cylinder but first unscrew the nut
on the safety pin. Protect the extended log loader
using the safety supports.
In case you will not use the log loader install the
connecting pipe c. Otherwise the machine will
not operate properly!
a
b c
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Before you start to work, check all functions and safety features of the machine as described herebelow.