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Dvorak SPIDER MINI II, Service Manual

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Dvorak SPIDER MINI II Service Manual Download Page 24

 

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102

 

SM-8 Ev3/08072015 

 

6.4 Replacement of hydraulic pump 

 
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Disconnect the battery and spark plug to prevent accidental starting of the machine and possible injury 

 
Disassembly: 
 
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Set the mower to the lowest cutting position, you will get more space for easier removal of the pump 

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Disconnect fuel line from the carburetor and remove the fuel tank 

  

 

  
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Tilt the mower to the service position  

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Remove the cover of the mowing device 

  

 

 

 
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Remove securing bolt M4 of the pump pulley 

  

 

 
 

 

Summary of Contents for SPIDER MINI II

Page 1: ...R P vodn n vod k pou it SM 8 Ev3 08072015 Dvo k svahov seka ky s r o Dvorce 62 Havl k v Brod 580 01 Czech Republic Tel 420 569 425 767 Fax 420 569 429 239 Mail info spider cz com Web www spider cz com...

Page 2: ...ent 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 geomet...

Page 3: ...e 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 U...

Page 4: ...4 102 SM 8 Ev3 08072015 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...

Page 5: ...5 102 SM 8 Ev3 08072015 Wheel hub puller Ampere meter CEM DT 9701 Voltmeter Ben electronic DT 830 D...

Page 6: ...electric power is supplied Mower battery is not fully charged Charge or replace mower battery Connection between the RC and the Control Unit was not confirmed Repeatedly press the RC confirmation butt...

Page 7: ...nion Replace Defective started Replace Blocked drive belt Clean the belt space and make sure it turns freely Blocked hydraulic pump possible repair should only be performed by authorized service After...

Page 8: ...tyre pressure 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 Blun...

Page 9: ...9 102 SM 8 Ev3 08072015 3 BASIC TECHNICAL SPECIFICATIONS...

Page 10: ...MINI 4 1 DAILY OR EACH 8 mth a Check leakage of engine and hydraulic oil 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 c Ch...

Page 11: ...f 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 h Retighten all bolts an...

Page 12: ...12 102 SM 8 Ev3 08072015 d Lubricate the sliding of the machine shown in the figure below Use a spray lubricant Berner grease for chains...

Page 13: ...ttery 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 b...

Page 14: ...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 o...

Page 15: ...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 bearin...

Page 16: ...g 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 j...

Page 17: ...pension 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...

Page 18: ...earance 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...

Page 19: ...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 Ann...

Page 20: ...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 posit...

Page 21: ...lace 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 Check the oil level with the dipstick up to the upper gauge li...

Page 22: ...sertion 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 a...

Page 23: ...s 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...

Page 24: ...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...

Page 25: ...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 ke...

Page 26: ...rom 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...

Page 27: ...he 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 hydrau...

Page 28: ...f 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 batt...

Page 29: ...29 102 SM 8 Ev3 08072015 Lock the drive system with mechanical brake Remove the bolt Imbus M6x55 from the motor shaft Release the drive brake...

Page 30: ...osen 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 le...

Page 31: ...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...

Page 32: ...on 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...

Page 33: ...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...

Page 34: ...4 102 SM 8 Ev3 08072015 Remove the V belt from pulleys of the alternator and hydraulic pump Remove control lever of the clutch 2xbolt M5x10 Remove bolt UNF 30 from engine crankshaft use pulse tightene...

Page 35: ...072015 Remove blade hub from the crank shaft For removing use the original bolt UNF 30 and bearing puller Remove clutch plate Remove static part of the clutch brake In case of need replace bearing 600...

Page 36: ...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 e...

Page 37: ...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 Rem...

Page 38: ...05 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 eng...

Page 39: ...cing should be in the range of 11 12 mm Sharpening Along the blade Blade angle should be about 40 Allowable blade wear Do not exeed 12 mm total metal removed at end of the blade Sharpen evenly on both...

Page 40: ...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 th...

Page 41: ...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 cha...

Page 42: ...vomotor 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...

Page 43: ...park 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...

Page 44: ...ng 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 s...

Page 45: ...hain 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...

Page 46: ...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...

Page 47: ...15 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 rolle...

Page 48: ...48 102 SM 8 Ev3 08072015 Remove wheel hub 8x bolt Imbus M6x12 Remove flange of wheel suspension 5x bolt Imbus M8x20...

Page 49: ...49 102 SM 8 Ev3 08072015 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...

Page 50: ...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 bol...

Page 51: ...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...

Page 52: ...ing 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 degr...

Page 53: ...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 se...

Page 54: ...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 sprin...

Page 55: ...s 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 shaf...

Page 56: ...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 beari...

Page 57: ...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...

Page 58: ...all 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...

Page 59: ...59 102 SM 8 Ev3 08072015 Release both chains Remove tensioning pulley for sufficient slackness of the chain Disassembly Put out the upper chain from the sprocket...

Page 60: ...08072015 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 fro...

Page 61: ...rocket 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 geom...

Page 62: ...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 mechani...

Page 63: ...astic 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 s...

Page 64: ...2015 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 collisi...

Page 65: ...h 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 aga...

Page 66: ...ry 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...

Page 67: ...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...

Page 68: ...ting 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...

Page 69: ...2015 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 a...

Page 70: ...ver 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 s...

Page 71: ...procedure of the remote controller adjustment of the neutral position by steering joystick see below Adjustment of the neutral position by steering joystick 1 Activate programming mode Set all propor...

Page 72: ...are not content and want to change the values again start over at point 1 Restore the factory settings default value Set all proportional channels to zero position Release the EMERGENCY STOP switch W...

Page 73: ...trol 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 nee...

Page 74: ...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 re...

Page 75: ...72015 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 co...

Page 76: ...76 102 SM 8 Ev3 08072015 Connector of the horn Main switch STOP button release the latch Neutral control light release the latch...

Page 77: ...77 102 SM 8 Ev3 08072015 connector of the beacon Release wiring on the girder cut out all tie straps...

Page 78: ...78 102 SM 8 Ev3 08072015 Connector of the steering servomotor Brake solenoid Connectors of the starter alternator and charging regulator...

Page 79: ...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 Tak...

Page 80: ...ng 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 screwd...

Page 81: ...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 th...

Page 82: ...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 s...

Page 83: ...83 102 SM 8 Ev3 08072015 Connector of the starter charging and engine stopping Main earth self securing nut M6 Connector of the drive servomotor Cut out needed tie straps...

Page 84: ...v3 08072015 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 an...

Page 85: ...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...

Page 86: ...justment 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 There...

Page 87: ...87 102 SM 8 Ev3 08072015 6 23 Hydraulic circuit Hydraulic oil pressure nominal 90 bar maximal 120 bar Hydrogear PC AGJJ MA1X XXXX 6 cm3 Hydraulic pump Hydraulic motor OMM20...

Page 88: ...1180 1380 Torque M U max N m M 6 4 3 7 3 9 7 13 5 16 5 M 8 10 17 5 23 33 39 5 M 10 20 5 35 5 47 5 67 80 5 M 8x1 10 17 5 23 32 5 39 M 10x1 25 20 5 35 47 66 79 5 M 12x1 5 35 5 61 81 114 137 M 14x1 5 56...

Page 89: ...072015 7 ELECTRICAL SYSTEM 7 1 Electrical component location Fuse Box Relays Steering Servomotor Main Switch Emergency STOP Horn Neutral Light Beacon Drive Servomotor Starter Control Unit NBB Alternat...

Page 90: ...90 102 SM 8 Ev3 25062015 7 2 Electric circuit diagram...

Page 91: ...box 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 eve...

Page 92: ...trol 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 m...

Page 93: ...SM 8 Ev3 25062014 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...

Page 94: ...al 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 7 9 Battery Characteristics Gel battery Banner GiV 12...

Page 95: ...rvomotor 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 supp...

Page 96: ...regulated 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...

Page 97: ...o 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 b...

Page 98: ...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...

Page 99: ...switch on the cable in the direction SEL OFF and BSL ON 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...

Page 100: ...er 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 70...

Page 101: ...t 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 th...

Page 102: ...102 102 SM 8 Ev3 25062014 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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