R O T A R Y S L O P E M O W E R
SERVICE MANUAL
SPIDERPůvodní návod MINI k použití II
SM-8 Ev3/08072015
Dvořák – svahové sekačky, s.r.o. Tel: +420 569 425 767 Dvorce 62 Fax: +420 569 429 239 Havlíčkův Brod 580 01 Mail: [email protected] Czech Republic Web: www.spider-cz.com
SPIDER MINI
TECHNICAL SPECIFICATIONS ...... 3 1 SPECIAL SERVICE TOOLS ...... 4 2 TROUBLESHOOTING ...... 6 3 BASIC TECHNICAL SPECIFICATIONS ...... 9 4 REGULAR MAINTENANCE OF SPIDER MINI ...... 10 4.1 DAILY OR EACH 8 mth ...... 10 4.2 AFTER FIRST 5 HOURS ...... 13 4.3 AFTER 50 HOURS...... 13 4.4 AFTER 200 hours ...... 14 4.5 SEASONAL PERIOD ...... 16 5 ENGINE MAINTENANCE CHART ...... 19 6 INSTRUCTION MANUAL SPIDER MINI ...... 20 6.1 Tilting of the mower for maintenance-service position...... 20 6.2 Replacement of engine oil and filter ...... 21 6.3 Replacement of hydraulic oil and filter ...... 22 6.4 Replacement of hydraulic pump ...... 24 6.5 Replacement of hydraulic motor ...... 28 6.6 Replacement of the clutch, drive V-belt and engine pulley ...... 33 6.7 Replacement of the blade hub and bearing ...... 37 6.8 Sharpening of the blade ...... 39 6.9 Replacement of the steering chain ...... 40 6.10 Replacement of the steering servomotor ...... 41 6.11 Replacement of the main drive chain ...... 43 6.12 Replacement of the wheel chain ...... 46 6.13 Replacement of the wheel shaft, bearings and chain tensioners ...... 53 6.14 Replacement of the wheel suspension ...... 58 6.15 Wheel geometry alignment ...... 62 6.16 Replacement of the alternator ...... 66 6.17 Replacement of the drive servomotor ...... 68 6.18 Replacement of the brake solenoid ...... 73 6.19 Replacement of the main harness ...... 75 6.20 Carburetor of the engine Briggs &Stratton Professional 950 ...... 80 6.21 Modification of the engine brake Briggs & Stratton ...... 81 6.22 Replacement of the engine Briggs & Stratton Professional 950 ...... 82 6.23 Hydraulic circuit ...... 87 6.24 Torque chart ...... 88 6.25 Lubricators ...... 88 7 ELECTRICAL SYSTEM ...... 89 7.1 Electrical component location ...... 89 7.2 Electric circuit diagram ...... 90 7.3 Fuse box ...... 91 7.4 Current measurement table...... 92 7.5 Main switch – Emergency STOP ...... 92 7.6 Horn ...... 93 7.7 Brake solenoid ...... 93 7.8 Light for neutral position ...... 94 7.9 Battery ...... 94 7.10 Steering servomotor PAL ...... 95 7.11 Drive servomotor NBB ...... 95 7.12 Alternator - charging ...... 96 7.13 Control unit NBB ...... 97 Programming of the control unit ...... 98
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TECHNICAL SPECIFICATIONS Parameter Unit Value Length/Width mm (inch) 910 x 1040 (36 x 41) Height mm (inch) 600 (23,6) Mowing width mm (inch) 560 (22) Mowing blade height mm (inch) 40 – 90 (1,5 – 3,5) - 6 levels Weight kg (pound) 125 kg (275) Driving speed km/h (mph) 0 – 4 (2,5) Mower deck - Single blade with a firm blade attached to a clutch flange Blade clutch - Mechanical with a friction brake Hydraulic pump Hydro Gear PC Hydraulic motor - Sauer Danfoss OMM20 Drive system - 4 x 4 Wheels inch 13 x 5,00 – 6 with V-pattern Battery 12 V, 18 Ah, gel Fuel - Unleaded petrol / gasoline Fuel tank capacity litre (gallon) 4 (1) Engine Briggs&Stratton 950 Professional Series Cylinder volume cm3 223 Power output HP/min-1 4,1 /3060 Torque N.m/min-1 12,59 / 3060 Ignition Electronic Starting Electric Frequency range of the Remote MHz 433.100 - 434.750 controller NBB for EU and USA for Japan 429.250-429.7375 MHz
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1 SPECIAL SERVICE TOOLS
Wooden blocks for lifting the mower ( 150x130x80) – 4 pieces
Stright lath for wheel geometry adjustment (length 1100 mm)
Oil filter release jig
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Wheel hub puller
Ampere meter CEM DT – 9701
Voltmeter Ben electronic DT - 830 D+
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2 TROUBLESHOOTING Problem Possible cause Correction No green light illuminates after RC No or empty batteries in the RC Insert fully charged batteries into is turned on the RC. RC failure Turn off the RC and turn it on again. If restart does not help, contact an authorized service. Red light flashes after RC is turned Empty RC batteries Insert fully charged batteries into on the RC. After pressing the confirmation / The RC does not belong to this Check the RC number and Control horn button a connection between mower. Unit number. They must be the RC and the mower is not identical. Use the correct RC. established. The mower is Signal is interfered with by another Turn off the interfering device, get otherwise fully functional. device working on the same closer to the mower. frequency. Press and holed the antenna button on the RC and at the same time press the horn button to change the RC channel. Then press the horn button again.
The mower does not activate after turning on the main switch on the mower Beacon does not flash (failure of Battery is not connected properly or Properly connect a fully charged main electric power supply) is empty battery. Disconnected cables of the mower Check cables and connectors. electric harness Main fuse failure Change the fuse for a new one with the same value Beacon flashes (electric power is Mower battery is not fully charged Charge or replace mower battery supplied) Connection between the RC and the Repeatedly press the RC Control Unit was not confirmed confirmation button. Check the RC functions. See the beginning of this chapter. Control Unit is not properly Check the LED light on the Control connected Unit. It must flash. Control unit is properly connected, Control unit failure. Contact an but the light on the Control Unit is authorized service centre. not flashing.
Mower cannot be started. Communication between RC and Control Unit is OK. Mower power supply is OK. Beacon is flashing. Neutral light is not illuminated Communication between RC and Press confirmation / horn button on Control Unit was not confirmed. the RC Drive servomotor is not in the Move drive joystick slightly neutral position. forward and backward until neutral light illuminates. Check if the drive servomotor lever Release the drive servo lever so is not mechanically blocked (by that it can freely move. debris, sticks etc.) Light is damaged (does not affect Change the LED neutral light starting of the mower) Servo lever does not respond to Restart the mower and try again. joystick movement Otherwise contact authorized service Neutral light is illuminated No relay clicking sound is audible Change the starter relay in the fuse from the fuse box when start button box. on the RC is pressed Neutral light is illuminated. Engine brake is activated Release the engine brake by Starter relay works correctly. pressing the lever, which activates 6 / 102 SM-8 Ev3/08072015
starter and ignition. Neutral light is illuminated. Disconnected cable between fuse Check cables and connectors Starter relay works correctly. box and starter Engine brake is released Defective switch of the engine Check voltage before and behind brake (under engine cover) the engine brake switch. You should read 12 V when start button is pressed. Defective engine starter Replace the engine starter Mower cannot be started. Closed fuel cock or lack of fuel in Check the fuel cock and refuel Starter freely turns the engine. the fuel tank Clogged fuel filter Change the fuel filter. Low quality fuel Change fuel Disconnected or defective spark Check the spark plug and replace if plug necessary Broken ignition cable Check the cable Defective switch of the engine Change the switch. brake Dirty air filter Clean or change the air filter and rough air filter Clogged and dirty carburettor Clean the carburettor Blocked or non-functional Check the choke line, replace if automatic engine choke. necessary. Clogged engine exhaust. Clean Mower cannot be started. Blocked mowing blade Disengage blade clutch and select Starter turns the engine with maximum height of cut difficulty. Empty battery Check battery voltage and recharge or replace battery if necessary. Lack of engine oil Check and add engine oil Worn starter pinion Replace Defective started Replace Blocked drive belt Clean the belt space and make sure it turns freely Blocked hydraulic pump. After releasing drive belt check if (possible repair should only be the pump pulley freely turns. performed by authorized service) Blocked alternator After releasing drive belt check if the alternator freely turns. Clean the space around the alternator. Drive servo lever does not react. Loose lever between the Check the tightness of nuts and Connection between RC and CU is servomotor and the hydraulic pump bolts of the lever mechanism OK. Mower can be started. Mower drive does not work or is Open pump By-pass Close the pump By-pass insufficient Worn, broken or loose drive belt Check the drive belt Lack of oil in hydraulic system Add oil in authorized service Worn mechanical elements of the Change in authorized service hydraulic circuit Overheated hydraulic oil Let the mower cool down and clean the space around the hydraulic pump for better cooling Mowing blade clutch slips Dirty functional surfaces of clutch Clean Clutch worn out excessively Replace worn components Clutch damaged by hitting a firm Check the blade hub and replace if obstacle necessary. Clutch does not stop the blade Dirty functional surfaces of clutch. Clean Block clutch disengagement Check and clean. mechanism Clutch worn out excessively Replace worn components Clutch makes noise Dirty functional surfaces of clutch. Clean Clutch loose on the crankshaft or Tighten and glue fastening bolts of loose blade. clutch and blade 7 / 102 SM-8 Ev3/08072015
Worn clutch bearings Check free turning of functional components of the clutch. Replace if necessary. Mower vibrates when clutch Unbalanced or bent blade Balance and sharpen blade, replace engaged. if necessary Damaged blade hub Replace Bent crankshaft Contact authorized service Insufficiently tightened blade Glue and tighten blade bolts Mower pivots around vertical axis Unevenly inflated tyres Check tyre pressure while driving Wrong wheel geometry Check and adjust geometry Bad mowing quality Overgrown, wet or tall grass Mow grass max. 3x higher than the selected height of cut. Let the grass dry before mowing. Blunt or worn mowing blade Sharpen or replace the blade Low engine RPM Check engine RPM in an authorized service centre High driving speed Slow down Clogged mower deck Clean Engine brake does not work when Dirty surfaces of the lever Clean and lubricate EMERGENCY STOP button is mechanism pressed Mechanically damaged brake Check in an authorized service mechanism. centre. Engine brake excessively worn Replace in an authorized service centre.
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3 BASIC TECHNICAL SPECIFICATIONS
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4 REGULAR MAINTENANCE OF SPIDER MINI
4.1 DAILY OR EACH 8 mth a) Check leakage of engine and hydraulic oil
Dipstick
b) Check and add engine oil level, fill up to the maximum mark on the dipstick - see 6.2 Replacement of engine oil and filter
min max
c) Check tires pressure 200 kPa / 2 bar / 30 PSI
10 / 102 SM-8 Ev3/08072015 d) Check tightening of steering and driving chains - see 6.9 Replacement of the steering chain - see 6.11 Replacement of the main drive chain
e) Check out electric and safety equipment f) Check geometry and sharpening of the blade - see 6.8 Sharpening of the blade g) Check tightening of blade bolts
Blade bolts
Sharpening of the blade
h) Retighten all bolts and nuts ch) Clean the engine cooling system, exhaust cover, alternator, starter, hydraulic pump and controls
11 / 102 SM-8 Ev3/08072015 d) Lubricate the sliding of the machine shown in the figure below
- Use a spray lubricant: Berner grease for chains
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4.2 AFTER FIRST 5 HOURS a) Change engine oil - see 6.2 Replacement of engine oil and filter
4.3 AFTER 50 HOURS a) Check tightening of V-belt - see 6.6 Replacement of the clutch, drive V-belt and engine pulley
b) Check or recharge main gel battery c) Retighten all bolts and nuts d) Check and clean mechanical blade clutch - Remove the cover of the mowing device and blow it with compressed air - Check the wear on the clutch plates and brake, the brake must not touch the clutch plate with engaged blades - see 6.6 Replacement of the clutch, drive V-belt and engine pulley
e) Change engine oil - see 6.2 Replacement of engine oil and filter f) Change engine oil filter - see 6.2 Replacement of engine oil and filter
13 / 102 SM-8 Ev3/08072015 g) Check and add engine oil level, fill up to the maximum mark on the dipstick h) Clean paper and rough air filters
4.4 AFTER 200 hours a) Check or adjust wheel geometry - see 6.15 Wheel geometry alignment
b) Adjust neutral position of driving system – SW SpiderMiniConfig - see Programming of the control unit or use a special procedure (adjustment of the neutral position by steering joystick) - see 6.17 Replacement of the drive servomotor
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c) Change hydraulic oil and filter - see 6.3 Replacement of hydraulic oil and filter
d) Check oil level of wheel suspension - see 6.12 Replacement of the wheel chain
e) Check or replace drive V-belt - see 6.6 Replacement of the clutch, drive V-belt and engine pulley
f) Check bearings of the clutch and blade hub - see 6.6 Replacement of the clutch, drive V-belt and engine pulley
15 / 102 SM-8 Ev3/08072015 g) Replace paper and rough air filters
4.5 SEASONAL PERIOD a) Visually check hydraulic hoses, fuel leading, wiring or eventually exchange b) Adjust neutral position of driving system – SW SpiderMiniConfig- see Programming of the control unit or use a special procedure (adjustment of the neutral position by steering joystick) - see 6.17 Replacement of the drive servomotor c) ) Change hydraulic oil and filter - see 6.3 Replacement of hydraulic oil and filter
16 / 102 SM-8 Ev3/08072015 d) Check oil level inside the wheel suspension - see 6.12 Replacement of the wheel chain
e) Check after-running limit of the blade
f) Check bearings of the clutch - see 6.6 Replacement of the clutch, drive V-belt and engine pulley
g) Replace spark plugs
h) Replace fuel filter, breath filter and clean fuel tank
17 / 102 SM-8 Ev3/08072015 ch) Check and adjust valve clearance
Valve clearance:
Intake - 0,10 – 0,20 mm Exhaust - 0,10 – 0,20 mm
Adjustment:
-Using a feeler gauge (A), adjust rocker nut to obtain the clearance -Hold rocker nut and tighten the rockerball setscrew (B).
Piston must be in T.D.C. This prevents the compression release from holding the valves open
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5 ENGINE MAINTENANCE CHART
First 5 Hours
Change oil
Every 8 Hours or Daily
Check engine oil level
Clean are around muffler and controls
Clean finger guard
Every 50 Hours or Annually
Clean air filter*
Clean pre-cleaner*
Change oil
Change oil filter
Check muffler and spark arrester
Every 200 Hours or Anually
Replace air filter*
Replace pre-cleaner*
Annually
Replace spark plug
Clean air cooling system*
Replace fuel filter
Check or adjust valve clearance
*In dusty conditions or when airborne debris is present, clean more often
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6 INSTRUCTION MANUAL SPIDER MINI
6.1 Tilting of the mower for maintenance-service position - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Turn the wheels across the direction of the tilt-wheel housings must be turned down - Always tilt the mower exhaust up to prevent ingress of oil into the engine air intake and air filter - Before starting work, make sure the mower is stable in this position, and that there is no possible rollover - Secure it against a possible fall - Leave the mower in this position only for the time required for maintenance - Do not use cutting height adjustment in this position , it could cause an injury
Exhaust
Hydraulic tank
Wheel housing
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6.2 Replacement of engine oil and filter - Clean thoroughly the area around oil filter and filling neck - Suck out the oil from the crankcase through the filling neck (or discharge the oil with a discharge screw when the mower is tilted) CAUTION! The oil must not get under the engine in the clutch space – the belts might slip.
Suction pump
Oil filter Filler neck
- Remove and replace oil filter (put some oil on the filter sealing during assembly) - Fill up engine oil, approximately 0,5 l (0,7l– when exchanging oil filter)
min max
- Check the oil level with the dipstick (up to the upper gauge line to increase slope accessibility) - Recommended engine oil: SAE 30
The manufacturer recommends the following oil brands:
- Per API classification: SF, SG, SH, SJ - Per viscosity, see table above - Oil consumption increases in case of multistage kind of oil (5W-20, 10W-30, 10W-40). In such a case, check the oil level more frequently.
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6.3 Replacement of hydraulic oil and filter
- Remove hydraulic hose from the tank throat - Remove the throat from hydraulic tank together with hydraulic filter - CAUTION! throat is glued with silicone sealant
- Exchanged hydraulic oil must be discarded in the prescribed manner
- Remove and replace hydraulic filter, lubricate o-ring gasket with oil for easier insertion - In case of damage of expansion bellows, remove securing tie tapes and replace it with a new one - CAUTION! during installation of a new bellows, both ends must be thoroughly plugged on the bottom and upper throat for a perfect tightness of the system. Both ends of the bellows secure with two tie tapes
Hdraulic filter
- Add HV68 hydraulic oil (about 2.5 l) - After addition of the oil, level should be 20 mm below the edge of the opening of the hydraulic tank - Clean the remains of the original silicone sealant around the opening, and from both sides of the throat and degrease it
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- Apply required amount of silicone sealant (universal sealant for sealing gearboxes) to the hydraulic tank
- Install the tank throat and tighten all 4 screws - Reinstall hydraulic suction hose 30Nm
- Start the engine and with using the drive system , backward and forward direction, vent hydraulic system (wheel must rotate smoothly) - After the oil is heated to the operating temperature, check the tightness of the throat of the tank - In the event of leakage inside oil breather hole in the throat tank, check the tightness of expansion bellows
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6.4 Replacement of hydraulic pump
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Disassembly:
- Set the mower to the lowest cutting position, you will get more space for easier removal of the pump - Disconnect fuel line from the carburetor and remove the fuel tank
- Tilt the mower to the service position - Remove the cover of the mowing device
- Remove securing bolt M4 of the pump pulley
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- Loosen the lower alternator bolt and shift the alternator bracket to the right, it will loosen the V-belt
- Remove the V-belt from engine and pump pulley
- With two tire levers pull the pulley off the shaft, careful to the feather key
- Now turn the mower back to the operating position
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- Disconnect terminals of the brake solenoid
- Remove solenoid from the bracket by loosing of the clip and bracket from the pump
- Now thoroughly clean the connecting places of the hydraulic hoses to the pump
CAUTION! The oil must not get under the engine in the clutch space – the belts might slip
- Before you disconnect the hydraulic hose mark them for subsequent reassembly
- Loosen the pump 2xM8 nuts, for release use a small ratchet with a jointed extender
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- Turn the wheel to the forward direction, thereby you will get enough space to remove the pump from the machine - (space for removal - between right wheel and right corner of the hydraulic tank)
- Disconnect the rod of the hydraulic pump from the servomotor
- Remove the pump
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Mounting: (Take the above steps in reverse order)
- Loctite the bolt of the pump shaf and of the sliding bar (LOCTITE 243) - When tightening the V-belt do not overload tension of the belt
±10mm
Note: - When replacing the pump it is needed to add about 0.1 l of hydraulic oil HV68 - Adjust neutral position of the drive system - see 6.17 Replacement of the drive servomotor - see Programming of the control unit
6.5 Replacement of hydraulic motor
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Disassembly:
- Before you disconnect the hydraulic hose mark them for subsequent reassembly - CAUTION! The oil must not get under the engine in the clutch space – the belts might slip
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- Lock the drive system with mechanical brake
- Remove the bolt Imbus M6x55 from the motor shaft
- Release the drive brake
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- Loosen the chain by upper tightenning pulley - Release securing bolt M8x20 of the upper pulley - Release tensioning bolt M6x45 and loosen the chain
- Loosen the steering chain by lower tightening pulley - Release securing bolt M8x20 of the lower pulley - Release tensioning bolt M6x45 and loosen the chain
- Remove one chain pulley on the left side from the hydraulic motor, bolt M8x110 with self securing nut M8 CAUTION! check assembly position of both pulleys – longer recessing against each other
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- Pull out the chain from the pinion of the hydraulic motor
- Remove two self securing nuts M6 from the bearing bracket
- Use a bolt no. M8x70 or longer for removal of the pinon together with flange bearing - Remove the gear slowly together with the bearing by screwing the bolt into the thread inside the pinion - CAUTION! chain must not come into the a collision with the pinion gear
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- Now you can remove the hydraulic motor by removing of three screws Imbus M6x20 - CAUTION! careful to the spring washers
Mounting (Take the above steps in reverse order)
- Loctite Imbus bolts M6x20 of the hydraulic motor (LOCTITE 243) - For easier instalation of the pinion lubricate the shaft of the hydraulic motor - Install by hand or by using the bolt M6 the pinion on the shaft - CAUTION! check correct position of the chain inside all pulleys before installation
- Install hydraulic hoses in the correct order and tighten them 30 Nm - After starting the engine add carefully speed of the wheels (air inside the hydraulic system - about 1 minute, increased noise of hydraulics) - Tighten the chain, do not overload tension of the chain, deflection approximately 10 mm
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6.6 Replacement of the clutch, drive V-belt and engine pulley - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Tilt the mower to the service position
Disassembly:
- Blade and mowing device cover
- Release lower bolt of alternator and by movement of the alternator to the right release the V-belt
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- Remove the V-belt from pulleys of the alternator and hydraulic pump
- Remove control lever of the clutch, 2xbolt M5x10
- Remove bolt UNF ¼-30 from engine crankshaft (use pulse tightener)
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- Remove blade hub from the crank shaft - For removing use the original bolt UNF ¼-30 and bearing puller
- Remove clutch plate
- Remove static part of the clutch - brake - In case of need replace bearing 6007 2RS (press it out)
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- In some cases the brake can pull off the pulley of the engine. Therefore press the brake out from the pulley to remove the V-belt
Mounting: (Take the above steps in reverse order)
- CAUTION! when changing the engine pulley do not forget install the feather key - Loctite all bolts with LOCTITE 243 - No need to adjust the clutch, check only the distance between the clutch and the blade hub. When the blade is engaged there should be about 1 mm gap. If the gap is insufficient, and both pieces are touching each other, replace worn parts of the clutch (clutch plate)
1mm
- When tightening the V-belt do not overload tension of the belt
±10mm
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6.7 Replacement of the blade hub and bearing
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Tilt the mower to the service position
Disassembly:
- Blade and mowing device cover
- Remove bolt UNF ¼-30 from engine crankshaft (use pulse tightener)
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- Remove blade hub from the crank shaft - For removing use the original bolt UNF ¼-30 and bearing puller
- Press out the bearing 6305 2RS
Mounting: (Take the above steps in reverse order)
- Loctite all bolts with LOCTITE 243 - No need to adjust the clutch, check only the distance between the clutch and the blade hub. When the blade is engaged there should be about 1 mm gap. If the gap is insufficient, and both pieces are touching each other, replace worn parts of the clutch (clutch plate)
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6.8 Sharpening of the blade
Check the blade geometry: - The blade must not be twisted, bent or deformed - CAUTION! twisted blade must not be straightened, USE A NEW ONE - Cutting sections of the blade must be in one level - The blade must not have any cracks - For high quality of cut - Ensuring the quality cut, the distance between the plane of cutting sections and the plane of blade placing should be in the range of 11-12 mm
Blade placing
Cutting sections
12
Sharpening:
- Along the blade - Blade angle should be about 40°
125
12
Sharpen here
Allowable blade wear
- Do not exeed 12 mm total metal removed at end of the blade - Sharpen evenly on both sides of the blade. Make sure that each cutting edge receives an equal amount of grinding to prevent having an unbalanced bar, which will cause excessive vibration at high speeds and may damage the mower - Ensure blades are balanced after sharpening - If the blade is out of balance, remove metal on the heavy and by grinding, until blade is balanced
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Replacement of the blade:
- Switch off the machine and disengage the blade - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Tilt the mower to the service position - Use a gloves for removing and sharpening - Remove 2 securing bolts M10x20 and washers povolte - CAUTION! the blade can fall down and injure - When installing take the above steps in reverse order - Install the blade using LOCTITE 243 and torque to 60 Nm - Check again proper mounting and tightening of the both securing bolts - Pay caution to the first start after replacing the blade. Make sure it does not produce any unknow sounds, vibrations, etc.
6.9 Replacement of the steering chain - Replacement is required if the deflection due to wear is too big with no chance to tension it - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Replacement:
- Lift or support the machine so that the wheelsare off the ground and can turn freely - Turn the wheels until the chain connecting link is between chain rollers and above the hydraulic pump
- Release the chain tension as much as possible - bolt M8x20 and tensioning bolt M6x45
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- Open the chain link and split the chain, then connect the free chain section (the left one) to the new chain with a connecting link (MOFA 084-304links)
- Turn the driving wheel mechanism to replace the old chain with a new one (this way the wheel geometry is not impaired to much) - Disconnect the chains and connect the new one (!!!Spring clip upwards!!!) - Check the position of the chain in the pulleys - Tension the chain but do not over load it, the chain slack should be approx 10mm - Lubricate the chain with a chain lubrication spray - Check the wheel geometry – see 6.15 Wheel geometry alignment
6.10 Replacement of the steering servomotor
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Disassembly:
- Release the securing clip and disconnect the connector
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- Release the wiring from the servomotor
- Remove 3 bolts Imbus M6x20
- Remove the chain from the servomotor sprocket - Remove the servomotor from the girder
- Remove the sprocket from the servomotor shaft
Mounting: (Take the above steps in reverse order)
- Loctite securing Imbus bolts M6x20 with LOCTITE 243 - Tighten the sprocket nut torque to 35Nm - Tension the chain but do not over load it, the chain slack should be approx 10mm
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6.11 Replacement of the main drive chain - Replacement is required if the deflection due to wear is too big with no chance to tension it - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Replacement:
- Lift or support the machine so that the wheelsare off the ground and can turn freely - Release the bypass valve on the hydraulic pump 2 turns
- Turn the wheels until the chain connecting link is between chain rollers and above the hydraulic pump - Release the upper chain
- Remove one countersunk screw M6x40
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- Now using the remote control turn the wheels, align the hole in the steering wheel with the hole in the top drive wheel
- Screw both chain wheels together, do not tighten the screw
- Remove tensioning pulley for sufficient slackness of the chain
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- Move the chain out from the girder - Open the chain link and split the chain
- Connect the free chain section (the left one) to the new chain with a connecting link (MOFA 084-286links) - Turn the driving wheel mechanism to replace the old chain with a new one
- Disconnect the chains and connect the new one (!!!Spring clip upwards!!!)
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- Remove the countersunk screw from the wheels and screw it back to the steering wheel taperlock
- Check the position of the chain in the pulleys - Tension the chain but do not over load it, the chain slack should be approx 10mm - Lubricate the chain with a chain lubrication spray
6.12 Replacement of the wheel chain
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Lift or support the machine so that the wheelsare off the ground and can turn freely - Release the bypass valve on the hydraulic pump 2 turns
- Remove the wheel 3x self-securing nut M10 + spring washers
- Dismantle the whole wheel suspension for an easier chain exchange - see 6.14 Replacement of the wheel suspension
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Disassembly:
- Remove metal cover of the green chain tensioners 6x Imbus M6x12 - CAUTION! two lower bolts are with spring washers
- Release two green tensioning segments – remove springs
- Remove bearing rollers 6x bolt Imbus M6x12
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- Remove wheel hub 8x bolt Imbus M6x12
- Remove flange of wheel suspension 5x bolt Imbus M8x20
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- Remove chain from the wheel housing
- In case of need replace bearing in the wheel flange, remove securing ring pos.3.4. and press out the bearing 6004 2RS
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Mounting:
- Install the chain in to the wheel housing
- Clean and degrease sealing surfaces and apply silicone sealant
- Install the chain onto the sprocket - Mount the wheel hub to the wheel housing - Clean and degrease sealing surfaces of the bearing rollers - Applay silicone sealant and screw it on the wheel housing 8x bolt Imbus M6x12 (15Nm) - CAUTION! the chain must not twist - By turning of the wheel hub adjust tension of the chain ( tensioning - clockwise direction)
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- Clean and degrease sealing surfaces of the wheel suspension flange - Apply silicone sealant - Instal the chain onto the sprocket - CAUTION! the chain must not twist
- Mount the flange to the wheel housing 5x bolt Imbus M8x20 (30Nm) - Turn by hand carefully with the wheel shaft forward and back, for proper seating of the chain inside the sprockets and chain guides. It must turn freely
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- Install the springs of tensioning segments - first on the pin in the housing and then into the hole on the segment. Use a small sharp pliers
- Before installing the cover of the tensioners be sure that the chain is not twisted and can turn freely - In case of need fill up the oil into the wheel housing, total quantity is 100ml of MOBILUX EP004 - Clean and degrease sealing surfaces - Apply silicone sealant
- Install the wheel – see 6.13 Replacement of the wheel shaft, bearings and the chain tensioners - Tighten the Bypass of the hydraulic pump
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6.13 Replacement of the wheel shaft, bearings and chain tensioners
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Lift or support the machine so that the wheels are off the ground and can turn freely - Release the bypass valve on the hydraulic pump 2 turns
- Remove the wheel – 3x self securing nuts M10 + spring washers
- Release the main nut M12 and the flat washer
- Leave the nut on the thread to protect the shaft against any damage during disassembly
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- Use a 3-arm puller for removing. In case of need heat up the hub for an easier disassembly
Disassembly of the wheel shaft:
- Remove metal cover of the green chain tensioners 6x Imbus M6x12 - CAUTION! two lower bolts are with spring washers
- Release tensioners – remove both springs
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- Remove bearing rollers 6x bolt Imbus M6x12
- Remove wheel hub 8x bolt Imbus M6x12
- Pull out the hub with sprocket from the wheel housing and then from the chain - Remove bearing seal pos.1.7 and shaft securing ring of the shaft pos.1.6 - Press out the shaft of the wheel hub
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- In case of need replace bearings 6004-2RS – remove the securing ring pos.1.5 and press the bearings out from the wheel hub
Mounting: (Take the above steps in reverse order)
- Lubricate the shaft with a grease - Put it in the bearings, mind the spacing ring pos.1.3, install the securing ring pos.1.6, and new bearing seal, pos.1.7 - apply the sealant on the tensioner cover and install on the wheel housing (15Nm) - CAUTION! the chain must not twist
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- In case of need fill up the oil into the wheel housing, total quantity is 100ml of MOBILUX EP004 - Clean and degrease sealing surfaces and apply silicone sealant - Install the chain onto the sprocket - Mount the wheel hub to the wheel housing
- Install the chain onto the sprocket - Mount the wheel hub on the wheel housing - CAUTION! the chain must not twist - Install the wheel hub on the wheel housing (15Nm) - Turn by hand carefully with the wheel shaft forward and back, for proper seating of the chain inside the sprockets and chain guides. It must turn freely - Install the springs of tensioning segments - first on the pin in the housing and then into the hole on the segment. Use a small sharp pliers
- Clean and degrease sealing surfaces - Apply silicone sealant
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- Install the wheel rim hub - Clean and degrease the cone on the shaft and inside the hub - Install the feather key, hub and the washer
Degrease
- Screw the nut on the shaft ( use LOCTITE 243) and tighten it 100 Nm - Install the wheel on the hub 60Nm - Tighten the Bypass of the hydraulic pump
6.14 Replacement of the wheel suspension
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Lift or support the machine so that the wheels are off the ground and can turn freely - Release the bypass valve on the hydraulic pump 2 turns
- Remove the wheel – 3x self securing nuts M10 + spring washers
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- Release both chains
- Remove tensioning pulley for sufficient slackness of the chain
Disassembly:
- Put out the upper chain from the sprocket
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- Remove the screw Imbus M6x20
- Install two bolts Imbus M6x30 into the disassembly holes. Screw them inside and slowly remove the sprocket from the shaft
- Remove four countersunk screws M6x40 from the taperlock
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- Remove rubber handle three bolts Imbus M6x10
- Release the steering sprocket from the taperlock through two openings
- Now you can put out the housing from the placing
Mounting: (Take the above steps in reverse order)
- After reassembly align wheel geometry – see 6.15 Wheel geometry alignment - Recommendation: replace all four countersunk screws Imbus M6x40 for a new ones
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- Loctite the main bolt Imbus M6x20 of the sprocket (LOCTITE 243)
6.15 Wheel geometry alignment
- Before you will start with alignment, check the tyre pressure - each wheel should have 2 bar - Check the tension of the steering chain - CAUTION! mechanical brake must be released
- Turn the wheels forward – see picture
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- Remove plastic bonnet - four snap locks
- Release the bypass valve on the hydraulic pump 2 turns
- Push the mower (don´t start, push by hands only) adjust correct position of the upper sprocket against the cuntersunk screws for their possible exchange
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- Release taperlock - Four countersunk screws M6x40 – 1 turn
- Release the sprocket from the taperlock
- Now you can turn freely with the wheel suspension
- CAUTION! mind the countersunk screw against collision with the sprocket
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- Use a straight lath for the wheels alignment, on the right from tire side and on the left from housing side
- Tighten crosswise all four bolts 15Nm – never turn the wheel until you tighten first screw!
- Check the geometry again - Tighten the Bypass of the hydraulic pump
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6.16 Replacement of the alternator
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Tilt the mower to the service position - Remove the cover of mowing device
- Release lower bolt and move with alternator to the right
- Remove the belt form the pulleys of alternator and hydraulic pump
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- Remove the flange bolt M8x20 and Imbus M6x30 with self securing nut M6. Mind the washers
- Disconnect alternator connector from the main harness
Mounting: (Take the above steps in reverse order)
- When tightening the V-belt do not overload tension of the belt
±10mm
- Turn the mower back to the operating position
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6.17 Replacement of the drive servomotor
Disassembly: - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Disconnect connector of the drive servomotor and release supply wires
- Remove the fuel tank - Tilt the mower to the service position - Remove the bolt Imbus M12x25of the lower right sliding bar for its following release
- Turn the mower back to the operating position - Relase the rod of the engine brake nut M4
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- Release the connecting rod of the servomotor
- Remove the whole bracket with the servomotor- two bolts Imbus M6x20, mind the spring washers
- Remove the bolt Imbus M6x55 from the released sliding bar and the elevation rod
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- Boost the released sliding bar upward to make a sufficient space for the servomotor removal - CAUTION! mind the rubber stop ring under the weight
- Remove the lever and the bracket of the servomotor, self securing nut M8 and three bolts M6x20
Mounting: (Take the above steps in reverse order)
- Do not forget to install the rubber stop ring under the weight
- CAUTION! sliding bar has a flange which must properly get into the frame placing - For the bolt Imbus M12x25 use the LOCTITE 243 - Torque of the self securing nut M8 of the servomotor lever 30 Nm
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Neutral position adjusting:
- Lift or support the machine so that the wheels are off the ground and can turn freely
- Connect the main battery, first + - Start the mower – CAUTION! you can start the mower when the green neutral light is shining and the engine brake is engaged (position near the frame) - After starting increase the drive speed slowly and put it back to the neutral position - If the mower is creeping, the electronical neutral is over the neutral limit of the pump valve, you can adjust real neutral position by a special software SpiderMiniConfig – see Programming of the control unit, or use a special procedure of the remote controller (adjustment of the neutral position by steering joystick) see below
N
Adjustment of the neutral position by steering joystick
1) Activate Set all proportional controllers to zero position. programming Release the EMERGENCY STOP switch and wait till the radio mode connection ispresent. Press and hold the "1" and „1” buttons (directly left and right of theemergency stop switch) for 5 seconds. Do NOT press the „HORN/ENABLE“ button!
2) Adjust the ZeroPos Sta ndard value is 127 (SW SpiderMiniConfig). value To adjust the value you need the joystick on the right side (left/right).Each time you push the joystick to the left, the value will decrease the value by one. Pushing it to the right will increase the value by one. Each time you move the joystick to left or right, the horn will acknowledge the movement.
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3) Save the value To safe the value after changing it, you’ll have to push the “HORN/ENABLE"button. The values are stored now.
4) Check the values Press the EMERGENCY STOP switch. Wait 2-3 seconds. Release the EMERGENCY STOP switch again and prepare the control to operate by pressing the "HORN/ENABLE" button. If you are not content and want to change the values again, start over at point 1.
Res tore the Set all proportional channels to zero position. Release the factory settings EMERGENCY STOP switch. Wait till the radio connection is present. / default value Press and hold the buttons "5" and “5 ” for 5 seconds. The factory settings / default values are restored automatically. Release the switches. Press the EMERGENCY STOP switch. Wait 2 seconds. Release the EMERGENCY STOP switch again and prepare the control to operate by pressing the "HORN/ENABLE" button.
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6.18 Replacement of the brake solenoid
Disassembly:
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Disconnect both terminals of the solenoid
- Disconnect the control string from the brake lever
- Remove the solenoid from the bracket and the bracket itself from the pump
Mounting: (Take the above steps in reverse order)
- For the proper function of the solenoid is needed correct adjusting of the string tension - Engage down the brake lever (position near the frame), hook the string through the lever hole and secure it with the collar. The string should not be too much tensioned - Connect the main battery, first + 73 / 102 SM-8 Ev3/08072015
- Engage the engine brake
- Switch on the mower, remote controller and connect the signal - After approx 5 seconds switch off the remote controller by the Red STOP Emergency button, the brake should disengage upward automatically
- If not, release the string for approx 5mm and try the system again
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6.19 Replacement of the main harness
Disassembly:
- Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury
Disconnect:
- Main earth
- Connector of the control unit receiver
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- Connector of the horn
- Main switch – STOP button (release the latch)
- Neutral control light (release the latch)
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- connector of the beacon
- Release wiring on the girder – cut out all tie straps
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- Connector of the steering servomotor
- Brake solenoid
- Connectors of the starter, alternator and charging regulator
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- Release wiring of the drive servomotor and disconnect the connector
- Now remove the fuse box
- Remove three cross screws holding base of all relays
- Remove the fuse box 4x Imbus M5 screws
- Now you can remove complete main harness from the machine
Mounting: (Take the above steps in reverse order)
- Loctite the screws Imbus M5 with LOCTITE 243
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6.20 Carburetor of the engine Briggs &Stratton Professional 950 - Adjusting of the maximal (operation) revolutions - bend the bracket with the spring
_ +
Maximal revolutions- 3060 RPM
- If the carburetor is over floated (fuel is flowing from the exhaust), check and clean seating of the floater valve. If needed replace the valve. For cleaning never use a sharp or hard pieces like screwdriver etc.
- CAUTION! during assembly of the float chamber install first the o-ring seal to the carb body and then screw back the chamber
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6.21 Modification of the engine brake Briggs & Stratton
- When replacing the Briggs & Stratton engine brake first is necessary to modify the bracket - Cut off the part of the bracket shown in the pictures below
Bracket before the modification
Bracket after the modification
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6.22 Replacement of the engine Briggs & Stratton Professional 950 Type of the engine: Professional 950
Disassembly: - Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury - Remove the blade, cover of the mowing device, clutch, V-belt, pulley of the engine - see 6.6 Replacement of the clutch, drive V-belt and engine pulley - Turn the mower back to the operating position - Lift or support the machine so that the wheels are off the ground and can turn freely - Disconnect the fuel leading from the carburetor
- Mark position of the hydraulic hoses and disconnect them
- Disconnect following electrical components: - Brake solenoid
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- Connector of the starter, charging and engine stopping
- Main earth - self securing nut M6
- Connector of the drive servomotor
- Cut out needed tie straps
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- Remove all four bolts Imbus M6x55 on each sliding bar
- Now you can devide the mower into two parts, it means upper part with the girder and whell suspensions and lower part with the frame and the engine
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Disassembly:
- Remove the connecting rod of the engine brake nut M4- put the rod out from the bracket, arrow direction
- Release the engine by three flange nuts M8
- Remove the engine from the frame
Mounting: (Take the above steps in reverse order)
- Install brake rod on a new engine
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- Install the engine into the frame
- Tighten three flange nuts M8 of the engine, use LOCTITE 243 - Secure the brake rod in the bracket with the nut M4 - CAUTION! the rod must move freely in the bracket - CAUTION! do not tighten too much locking pins, self-locking nut M6, of the height adjustment, the lever must move freely to ensure proper function of the height adjusting
- Connected connectors and wiring fasten with tie straps - CAUTION! NEW ENGINES ARE DELIVERED WITHOUT ANY FILLING. Therefore fill the engine with oil SAE30 up to max. level approx. 0,7l - Connect the main battery in order: first positive + then negative - terminal
NOTICE For an another work on the engine Briggs & Stratton follow a special procedures and instructions included in the service manual of Briggs & Stratton Corporation
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6.23 Hydraulic circuit
Hydraulic motor OMM20
Hydrogear PC-AGJJ-MA1X-XXXX Hydraulic pump 6 cm3
Hydraulic oil pressure: - nominal 90 bar - maximal 120 bar
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6.24 Torque chart
Bolt material 5D 6S 8G 10K 12K Material strength [MPa] 480 – 680 580 – 780 780 – 980 980 – 1180 1180 - 1380
M 6 4,3 7,3 9,7 13,5 16,5 M 8 10 17,5 23 33 39,5
[N.m] M 10 20,5 35,5 47,5 67 80,5 M 8x1 10 17,5 23 32,5 39
U max max U M 10x1,25 20,5 35 47 66 79,5 M 12x1,5 35,5 61 81 114 137 M 14x1,5 56 96 128 180 216
Torque M M 16x1,5 87 149 199 281 338
6.25 Lubricators
MOBILUX EP004 (wheel suspension) Bearing grease Berner PTFE – chain spray
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7 ELECTRICAL SYSTEM
7.1 Electrical component location
Control Unit NBB
Horn
Drive Servomotor
Neutral Light Beacon
Main Switch - Brake Solenoid Emergency STOP
Fuse Box, Relays
Alternator Starter
Steering Servomotor
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7.2 Electric circuit diagram
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7.3 Fuse box
1 2
8
3 4
9
6 7 5 Relay 7x
1 2
CAUTION! When changing fuses strictlyfollow the current rating for the fuse. Do not replace damaged fusese with fuses of a higher or lower rating. These could cause severe damage to the mower or even fire!
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7.4 Current measurement table
Measured current, voltage and resistance Current Voltage Resistance Component A V ohm Control unit 2,1 12 Charging (max) 14 14,3 1,1 Steering (max) 17 12 Brake solenoid 12 2 Drive pump servo max 2 12 Neutral light 12 Horn 12 Battery capacity 18Ah 12,6
7.5 Main switch – Emergency STOP - Use like main switch of power supply - If main switch is depressed: contact 1-2 is switch off and 3-4 switch on
Black – Control Unit Blue - Earth
White - Ignition
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7.6 Horn
Characteristics: Supply voltage: 12 V (+ red)
7.7 Brake solenoid
Characteristics: Supply voltage: 12 V Coil resistance: approx 2 ohm
- Use for disengage the starter and shut down the engine
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7.8 Light for neutral position
Characteristics: Supply voltage: 12 V
- Neutral position of the drive pump servomotor (if there is neutral, the light shines green) - You can start the engine only when the signal is connected, neutral green light is shining and the foot brake is engaged
M22 LED 12-30V ~ 5-14mA
7.9 Battery
Characteristics: Gel battery Banner GiV 12-18 (12V-18Ah) Charging: Charger for gel batteries Dangerous supply: Extended time lower than 12,16 V - results in quick battery destruction
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7.10 Steering servomotor PAL
Characteristics: Supply voltage: 12V Steering load: 3,5- 4A Wheels off the ground Steering load proudu:16-17A Wheels blocked on the ground
7.11 Drive servomotor NBB
Charecteristics: Power supply: 12 V Control power: 12 V Current: max 2A
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7.12 Alternator - charging
Characteristics: Coil resistance: 1,1Ω Irregulated output voltage 28V 3000RPM Regulated output voltage 14,3V 3000 ot/min Max charging current 14A
White wire brings ignition down to earth via STOP button If the wire is disconnected or broken, it is impossible to turn the engine off!
Blue – wire of the alternator
White – ignition earth
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7.13 Control unit NBB
Characteristics: Frequency range: 400 – 477 MHz (Transmission and reception) Radio frequency output <10Mw Operating ambient temperature -20 to +65°C
!!!CAUTION!!! when removing and reconnecting the harness connector from/to the control unit be careful not to damage the contact pins in the connector. Remove the control unit only with disconnected battery!
Serial number
Service plug
!!!WARNING!!! during welding on the machine, disconnect the receiver from the power supply! There is a risk of damage to the receiver´s electronic circuit!
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Programming of the control unit
Software: SpiderMiniConfig
- Ensure the power on the Spider is off - Connect the programming cable part no.2.250.7515 between the control unit (receiver) and the USB port on your PC or notebook
USB
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- Set the switch on the cable in the direction: SEL OFF and BSL ON !!!
Programming cable
- Switch on the power on the Spider
Operating with Spider Parameter Program:
- Start the program on your PC - PC detects the cable on one specific COM port, use tab OK
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- When you select the tab “Read” you can read individual parameter from the receiver - control unit NBB. You can change them and “Write” them back to the control unit. You can match the control unit (receiver) with a new remote controller, change parameters of the hydraulic pump and read status of operating hours
Functions Default values: Recommended range of values: Zero Offset 127 115-135 Maximum Angle 80 0-80 Minimum Power Offset 700 600-800 Zero Range 4 2-5 Contra Signal 255 255
Possible adjustments:
Zero Offset - To set an offset to the middle (neutral) position of the hydraulic servomotor
Maximum Angle - To set (limit) the maximum angle of the hydraulic servomotor (speed of the mower)
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Minimum Power Offset - To set the minimum power. When the servomotor speed is too low (it reacts too slow), it can be set higher (faster). When the minimum speed is higher, it can start oscillate. This can be resolved by increasing the zero range
Zero Range - To set the tolerance of the set point of the hydraulic servomotor. When it is 0 the motor will adjust to the exact angle-range for the neutral is 0 so servo will oscillate. This can be resolved with increasing to value above 2 up to 4
Contra Signal - To set the value of the contra signal. When joystick returns to the zero position the receiver generates a short contra (reverse) signal in the backward direction. This will stop the slow drive of the hydraulic drive. Visible mainly in low speed
Match remote controller to control unit - Use the serial number of the remote controller - transmitter and “Write” it to the NBB control unit. Use this function to match the control unit with a new remote controller.
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- When you have completed all parameter settings, switch off the power on the Spider and remove the programming cable from the receiver.
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