Dvorak Spider ILD01 Service Manual Download Page 44

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SM-1 Ev4/100901

6.27 Exchange of the main harness

Disconnect the battery

Disconnect the jointing sleeves of all parts: control unit, throttle control, carburettor solenoid, electric motor,
STOP button, horn, charger, clutch, driving servomotor, steering motor, starter relay and control panel

Unscrew the fuse box lid

Dismount the fuse box

Starter relay

Charger

Carburettor solenoid

Control panel

Connector

Driving electric motor

Battery ground

Fuse box

Summary of Contents for Spider ILD01

Page 1: ...SM 1 Ev4 100901 SERVICE MANUAL SPIDER ILD01...

Page 2: ...28 6 11 Adjustment of the tightening belt rollers of the pump and blade drives 28 6 12 Sharpening and exchange of the blade 29 6 13 Exchange of the steering chain 30 6 14 Exchange of the steering moto...

Page 3: ...16 Charging and ignition cables 62 7 17 Measuring list 63 7 18 Cable harness circuit NBB 63 8 Enclosures Service bulletins 65 8 1 Main harness ILD01 connector 65 8 2 Stabilizer pressed in 1S01K271 68...

Page 4: ...mowing blade height 0 8 m mowing width 850 mm height 1300 x 1300 mm length width value unit parameter 10 litre fuel tank capacity unleaded gasoline fuel 12 V 12Ah gel based accumulator electric start...

Page 5: ...5 98 SM 1 Ev4 100901 1 Special service tools Chunk for lifted mower 150 x 130 x 80 2 or 4 pieces Straight lath for adjustment of wheel geometry length 1300 mm Engine oil filter release jig...

Page 6: ...6 98 SM 1 Ev4 100901 Hydraulic oil filter release spanner Wheel hub puller Geometry adjustment tools No 1 No 2...

Page 7: ...7 98 SM 1 Ev4 100901 Ampere meter CEM DT 9701 Voltmeter Ben electronic DT 830 D...

Page 8: ...ned fuses Check them Wrong fuel Use BA 95 only The mower does not travel properly at all Not enough oil in the hydraulic circuit refil oil and de aerate properly Driving belts are broken Change them O...

Page 9: ...al specifications ATTENTION see section Service Bulletin 8 11 Fuses Wheel RPM min Wheel RPM min wheels off the ground blades off SPIDER turtle rabbit engine RPM hydr oil temperature ILD01 25 min 51 mi...

Page 10: ...Daily a Check the oil level in engine Picture 1 b Clean the inlet of cooling air for the engine and pump Picture 2 Picture 3 c Check the blade mounting sharpening and balance Picture 4 Test of screw t...

Page 11: ...teeth segment guide bushing of the cross XINTEX Slix Picture 5 4 2 After first 8 hours a Exchange engine oil see 6 2 Exchange of the engine oil filter 4 3 After 25 hours a Clean the rough air filter...

Page 12: ...01 4 4 After 50 hours a Clean the paper air filter Picture 8 b Lubricate the steering chain Picture 9 c Tight the steering chain Picture 10 Picture 11 Slack 20 mm paper air filter CHAIN SPRAY Chain sl...

Page 13: ...hydraulic oil level Picture 12 Picture 13 4 5 After 100 hours a Exchange engine oil b Clean the spark plugs c Clean the cooling engine ribs 4 6 After 200 hours a Exchange engine oil filter Picture 14...

Page 14: ...mpact Picture 16 d Adjust the valve clearance Picture 17 Paper air filter Arm grease nipple valve balance arm lifting bar adjustment screw valve clearance intake 0 10 0 15 mm exhaust 0 10 0 15 mm adju...

Page 15: ...4 7 Seasonal period a Change the spark plugs Champion RCJ8Y b Change the hydraulic oil 6 3 Exchange the hydraulic oil filter c Change the engine oil 6 2 Exchange of the engine oil filter d Change the...

Page 16: ...ours Check and add engine oil X Check for loose or lost nuts and screws X Check for fuel and oil leakage X Check or clear air intake screen X Clean air cleaner foam element X Clean air cleaner paper e...

Page 17: ...ection to which you will be tilting the mower Always tilt the mower exhaust up in order to prevent the oil from leaking to the air filter and carburetter Only tilt the mower for the time necessary for...

Page 18: ...lter put some oil on the filter sealing during assembly Fill up engine oil approximately 1 5 l 1 7 l when exchanging oil filter Picture 23 Picture 24 Check the oil level with the gauge up to the upper...

Page 19: ...ure 28 Fill up the hydraulic oil HV68 approximately 6 5 l Start the motor a move forward and backward to get rid of air in the hydraulic system the wheels must move smoothly Fill up the oil so that th...

Page 20: ...3 screws of the pump head Picture 31 Tight the screws back in the pump head Hydraulic tube A short nuts 2 and 3 simultaneously then 4 Picture 32 35 Hydraulic tube B long release nut 5 then simultaneo...

Page 21: ...s Glue the screw on the pump shaft LOCTITE 243 Seal the contact surface of the pump and screw heads with silicone sealing Note After exchanging the pump you need to fill up about 0 5 l of hydraulic oi...

Page 22: ...A 1650 LW Dismount the pulley and hydraulic motor from the cross Picture 36 Picture 36 Picture 37 Mounting Take reverse steps Seal the hydraulic motor and screws with silicone sealing Glue the screw o...

Page 23: ...23 98 SM 1 Ev4 100901 Picture 40 Picture 41 Picture 42 Tightening moment Feather Lock the pulley screw with glue 95Nm 95Nm...

Page 24: ...belt slack adjuster Picture 46 Remove the belt Picture 43 Picture 44 Picture 45 Mounting Take reverse steps Belt B 750 GOODYEAR Clearance between the spring and securing nut Glue the screws of the clu...

Page 25: ...ue the bearings LOCTITE 638 Press in the blade hub Clean the roller pins lubricate them with grease and glue the thread LOCTITE 243 Check the belt position in middle of the tightening roller Picture 4...

Page 26: ...each other brake is activated promptly but the brake disc must not warm up Eventually loosen the nut 1 Picture 52 Mount the console of the blade hub belt of the blade and slack adjuster Test the clutc...

Page 27: ...tight the main screw of the clutch Clutch adjustment Set the distance x with the adjustment nut 1 tight slightly the nut 1 both sides are closely each other brake is activated promptly but the brake...

Page 28: ...ng belt rollers of the pump and blade drives Glue Central screw of the blade hub console Screws of the tightening roller pins Pulley bearings Screws in the roller of the tightening lever Lubricate the...

Page 29: ...aightened use a new one Cutting sections of the blade must be in one level Picture 62 Distance between the blade seating and cutting section level should be 13 14 mm Picture 63 Picture 62 Picture 63 S...

Page 30: ...71 Disconnect the chain and connect the free chain section the left one to the new chain with a connecting link roller chain 084 1 MOFA 1 2 x 3 16 Picture 67 Picture 68 Turn the driving wheels to rep...

Page 31: ...upply cables of the electric motor Picture Release the driving chain Disconnect the chain and remove it from the motor teeth wheel Release the screws of steering motor and exchange the motor Picture 7...

Page 32: ...ght direction or adjust the steering geometry after mounting MIND a position of the needle bearing securing ring in the arm groove Lubricate the needle bearings pulley shaft and the steering teeth tra...

Page 33: ...nscrewing the screws 1 2 and 3 Picture 74 Remove the belts from the pulley Disconnect the following STOP button plug of the electric motor control unit horn choke pull rod hydraulic oil overflow hose...

Page 34: ...l rod horn control unit plug of the electric motor and STOP button Mount the belts on the pulleys follow the order 1 2 3 4 Picture 80 Push the console on the shaft by hands Tight the screws follow the...

Page 35: ...warm up the stabilizer journal in hot water for about 5 minutes and press on the ball journal Mount the clamp bushings on the steering shaft and tight smoothly see 6 22 Adjustment of the wheel geometr...

Page 36: ...with a screw longer than 30 mm after tightening replace the screw for the original screw Secure it with glue LOCTITE 243 and tight it ATTENTION Do not knock the wheel transmission clearance Mount the...

Page 37: ...the bearings If the bearings need to be exchanged dismount the securing ring of the bearings and press the bearings out Mounting take reverse steps Lubricate the shaft with grease Degrease the cone s...

Page 38: ...re them with LOCTITE 243 glue and middle one by self securing nut Picture 89 90 Secure the wheel housing spring pin no 2 Picture 89 Mount the big chain wheel and wheel hub see 6 19 Exchange of the whe...

Page 39: ...geometry adjustment tool no 2 for distance adjustment between the rest of arms Picture 94 Tight the right side of the stabilizer Check the clearance between the wheels and case Following adjustment o...

Page 40: ...ble collision of the screw and driving pulley Picture 99 Put a straight lath along the wheel portals on the left side and to the tyre discs on the right side Adjust the wheels to be parallel Picture 1...

Page 41: ...e it MIND the correct polarity of the electric motor Mounting PAY ATTENTION to the colours of supply cables and their position in the connector Wrong wiring may result in destruction of the electric m...

Page 42: ...ry Tight the lever nut 30 Nm Adjustment of neutral position Support the mower the wheels must get over the ground Release the securing nuts of servomotor pull bars left and right thread Start the mowe...

Page 43: ...the ground cable under the relay fixing screw during mounting Check When the relay switches on the voltage must be on both heavy current relay connectors If not check the relay control voltage of the...

Page 44: ...control unit throttle control carburettor solenoid electric motor STOP button horn charger clutch driving servomotor steering motor starter relay and control panel Unscrew the fuse box lid Dismount th...

Page 45: ...ture 111 you can increase maximum revolutions if you move the throttle console up Kawasaki maximum revolutions 2700 rpm Carburettor discharge screw seasonal maintenance discharge of sludge from the fl...

Page 46: ...ter Model 9 Throttle Valve 10 Screws 11 Pilot Jet 12 Screw 13 Choke Valve 14 Choke Shaft 15 Spring 16 Coller 17 Main jet 18 Float 19 Main Nozzle 20 Valve Seat 21 Float Chamber 22 Gasket 23 Bolt 24 Gas...

Page 47: ...47 98 SM 1 Ev4 100901 6 29 Hydraulic diagram Hydraulic oil pressure nominal 90 bar maximal 120 bar...

Page 48: ...ase Chain lubrication spray Mobilux EP023 Picture 112 Picture 113 Bolt material 5D 6S 8G 10K 12K Material strength MPa 480 680 580 780 780 980 980 1180 1180 1380 Torque M U max N m M 6 4 3 7 3 9 7 13...

Page 49: ...l component placement fuses control panel accumulator Linak connector Linak main switch Emergency STOP horn engine rpm servo selenoid starter starter relay connectors clutch charging and ignition Lina...

Page 50: ...r supply ATTENTION dismount only with disconnect accumulator Check If you press main switch contact 1 2 switch off and 3 4 switch on Main switch 7 3 Horn Characteristics supply voltage 12 V red Horn B...

Page 51: ...ain both Linak 1 A down 7 A up by Spider loading Check By connectors we connect power supply 12 V We changing power polarity and check if it switching off in end positions For light moving is possible...

Page 52: ...supply 6 V control f 50 Hz solenoid of the carburator 12V ground black power supply 6V red control yellow Engine rpm servomotor 7 7 Carburettor solenoid electromagnetic valve for fuel closing Charact...

Page 53: ...uld cause large damage or even fire to the mower ATTENTION see section Service Bulletin 8 11 Fuses 7 9 Control panel signaling hour meter 1 Power indicator shines green if power is on 2 Signal recepti...

Page 54: ...arge for gel accumulator INHACO ACL 1 danger supply long time lower 12 16 V quick accumulator destruction Accu current 7 11 Steering servomotor APS Characteristic 12 V APS 8132186 power supply 12V whe...

Page 55: ...12 Servomotor of the drive control Characteristic 12 V PAL both directions max 2 A Motor power supply 12 V controlling power supply 12 V Driving servomotor NBB Current measuring neutral position sens...

Page 56: ...uency range 400 477 MHz With release and reconnecting cabel harness connector to the control unit be careful to the contacts in the connector Attention FOR SPIDER ILD01 USE ONLY NBB 01 control unit AT...

Page 57: ...nly during fault free operation Irregular flashing means that the HF channel is probably at fault please set another channel LED 4 red If this led flashes the HF channel is at fault not in the scanner...

Page 58: ...F or O depends on the cable version Switch on the power on the Spider Operating with Spider Parameter Program Select the tab Com Port settings and select the com port you are using on your computer Wh...

Page 59: ...o 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 incr...

Page 60: ...oad Save parameter to read all data from the NBB receiver and save them in a file You can also load a parameter file and write that to the NBB receiver When you have completed all parameter settings s...

Page 61: ...Starter starter relay Characteristic relay 12 V LG35 IN LBS control cable switch on 12 V and main cable voltage 12 V coil resistant 4 1 ohm Starter relay ground blue control cable brown starter cable...

Page 62: ...control cable of the moving servomotor clutch connector Clutch connector 7 16 Charging and ignition cables Charging voltage 13 8 V max current 13 A FH 531 18 A FH 500 Ignition cable grounding ignitio...

Page 63: ...s Current Voltage Resistance A V ohm Solenoid carb 0 4 12 40 Clutch switch on 3 5 12 2 9 Charging max 13 18 12 Steering max 30 12 Linak 1 down 3 7 up 12 starter relay coil 3 12 4 1 moving servo max 2...

Page 64: ...64 98 SM 1 Ev4 100901 Key diagram NBB ATTENTION see section Service Bulletin 8 1 Main harness ILD01 connector Connector diagram NBB...

Page 65: ...er ILD01 sn 1 281 Control unit NBB Obligation Preventive or at the earliest exchange of the Control unit NBB Background New models of Spider ILD01NBB and every models of Spider ILD02 are fitted by the...

Page 66: ...on Qty Picture Screwdriver cross 1 Wrench flat 10 1 Preparation Dismount the Bonnet engine 02 Technique Op Description Tools Picture 1 Disconnect the battery Dismount the main connector from Control u...

Page 67: ...under the earthing screw of main connector Screwdriver cross 6 Assemble the main connector Screwdriver cross 7 Connect the Main connector to the Control unit 8 Connect the battery Wrench flat 10 Chec...

Page 68: ...nical modification by reason of danger possibility Service is obligatory Summary Subject Exchange of Stabilizer pressed in 1S01K271 Valid for Spider ILD02 Spider ILD01 Obligation When Stabilizer press...

Page 69: ...izer pressed in 1S01K271 1 Price and Availability Price unchanged see latest Price list Availability September 2007 available immediately upon PO Retrofit table New Stabilizer pressed in 1S01K271 is p...

Page 70: ...unt the original Stabilizer pressed in 6 Mount new Stabilizer pressed in to the rod of the Stabilizer 7 Screw in the screws M8 Imbus 8 Warm up the first Stabilizer pressed in hot air 9 Mount the stabi...

Page 71: ...otor spanner Spider ILD02 only Wrench flat 13 14 Tight the screws of the hydromotor Spider ILD02 only Wrench flat15 Check out Check the tension of the every screw Imbus M8 Check the geometry Check the...

Page 72: ...the Wheel suspension and the Gear Technical description The producer is recommending the periodical checking of the Gear oil capacity by reason of the high working life and the smooth running periodi...

Page 73: ...Check the Chain tensioner condition friction surface when the abrasion is higher than 5 mm change the Chain tensioner 3 Check the Chain and chain wheels conditions Chain slack max 8 mm otherwise to ch...

Page 74: ...an and degrease the sealing surface of the lid and wheel suspension 7 Fit the sealing surface with the silicone sealant 8 Mount the lid of the wheel suspension and tight all bolts 10 Nm Wrench Imbus 5...

Page 75: ...teeth Hard abrasion change the gear 4 Fill the grease to the Gear Mobilux EP023 Approx 100 ml 5 mm above the gear wheel 5 Clean the sealing surface of the Gear 6 Mount the lid with sealing ring and t...

Page 76: ...er ILD01 and ILD02 may have occasional troubles with the Accelerator servo by reason of the wrong assembly of the servomotor gas control bracket and servomotor rod The producer is recommending to chec...

Page 77: ...rals Technique Op Description Tools Picture 1 Dismount the minimal revolution speed backstop bolt Wrench flat 7 2 By help of the screwdriver to bent the max rev speed bracket backstop right to increas...

Page 78: ...the original HM32 hydraulic oil We also recommend to use the new hydraulic oil HV68 in older Spider ILD01 and Spider ILD02 machines Oils HM32 and HV68 are fully miscible This means that hydraulic oil...

Page 79: ...ecological hydraulic oil for Spider ILD01 a ILD02 Valid for Spider ILD01 Spider ILD02 Importance Information for Spider service Background Reduced durability of ecological hydraulic oil under high th...

Page 80: ...898 999 360 4892 999 369 4794 999 367 4793 999 366 4798 999 365 4792 999 363 4791 999 362 4796 999 361 4790 999 360 4795 999 369 4697 999 368 4691 999 909 8395 999 908 8390 999 907 8394 999 906 8399...

Page 81: ...r next processing then according to NBB manufacturing possibilities you will get new remote controls with pre set serial numbers identical to the original remote controls send these new remote control...

Page 82: ...82 98 SM 1 Ev4 100901 Related documents...

Page 83: ...oporu uje se prava p i servisu Povinn Technick zm na kter reaguje na mo n nebezpe Neprodlen servisn z sah General Issue Retrofitability of the Beacon Valid for Spider ILD01 a Spider ILD02 mounted from...

Page 84: ...d Availability Price see latest pricelist Availability January 2010 Retrofitability Every older Spider ILD1 and ILD02 can be equipped with a warning beacon For retrofitting use the sets Beacon ILD01 r...

Page 85: ...t to the Stabilizer Stabilizer is placed left from the accumulator Wrench Imbus 4 4 Place the Cable in between the Sliding bar and stabilizer Between the Beacon bracket and Accu cover must be the dist...

Page 86: ...onnector faston female and mount the pin back to the connector cover see the cables orientation x x Connector pliers 9 Connect the 8pin connector of the indication panel and mount it back to the origi...

Page 87: ...stance Between the Beacon and top Cover of the machine must be distance Wrench Imbus 4 4 Disconnect Connector of the signaling panel 5 By help the small screwdriver dismount the blue and red cable fro...

Page 88: ...the control unit 9 Connect the beacon connector and new mounted connector Fix the beacon cable to the harness by means the plastic clippers 10 Connect the accumulator and a check if the beacon is wor...

Page 89: ...Technical description The original sliding tensioner is replaced by a tensioner with a sprocket wheel The new system extends the service life of the tensioner and simplifies tensioning Original tensi...

Page 90: ...90 98 SM 1 Ev4 100901...

Page 91: ...91 98 SM 1 Ev4 100901...

Page 92: ...l Stabilizer pressed in 1S01K271 has been replaced by Stabilizer pressed in 1S01K272 It is possible to fully disassembly new Stabilizer pressed in and easy replaced its entire components Original Stab...

Page 93: ...SM 1 Ev4 100901 Availability May 2010 Retrofitability Fully compatible Related documents Parts manual PM_ILD01_rev 07 01 06 2010_Parts manual ILD01 Parts manual PM_ILD02_rev 10 01 06 2010_Parts manual...

Page 94: ...94 98 SM 1 Ev4 100901...

Page 95: ...ged by the two fuse boards with two 15A fuses This reduced the heat load on the fuse sockets during intensive charging and extends the service life of the fuses Therefore the Technical plate on the mo...

Page 96: ...und A new decal was introduced in order to simplify the understanding of the maximum slope on which Spider ILD01 mower may be operated All new Spider ILD01 mowers are fitted with this decal All previo...

Page 97: ...lly compatible Warranty 0 25 hours 15 minutes Related documents Operation manual OM_ILD01_rev 08 01 04 2010_Operation manual Parts and product information PPI_036_EN_Maximum Slope Decals Parts manual...

Page 98: ...ILD01 Op Description Tools Picture 1 Degrease surfaces see picture 2 Stick 4 stickers 1P117 to each side of the mower Position see picture Sticker slope ILD01 Op Description Tools Picture 1 Degrease s...

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