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Dennis E-SERIES ES-36 Instruction Manual

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ES-36
ELECTRIC MOWER
INSTRUCTION MANUAL
SP20059_REV0.3

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  • Page 1 ES-36 ELECTRIC MOWER INSTRUCTION MANUAL SP20059_REV0.3...

  • Page 2: Table Of Contents

    CYLINDER CYLINDER DRIVE SHEAR BLADE FRONT ROLLER HANDLE MOUNTS HANDLE CONSOLE GRASS BOX CRADLE SCRAPPER BAR GUARDS DECALS NOTICE OF COPYRIGHTS AND PROPERTY RIGHTS ● K eep this operating manual confidential. ● O nly make this operating manual accessible to authorized persons. ● O nly pass this operating manual to third parties after obtaining written permission from DENNIS. ● All documents are protected under the Copyright Act. Passing on and reproducing documents, including excerpts, and exploiting and sharing the contents of documents is prohibited unless expressly approved in writing. ● Violations are punishable and subject to compensation of damages. DENNIS reserves the right to exercise any and all industrial property rights. SP20059_REV0.3...

  • Page 3: Certificate Of Conformity

    MAKE A NOTE OF THE SERIAL NUMBER OF YOUR MACHINE AND ALWAYS Ashbourne Road, Kirk Langley, Derbyshire, DE6 4NJ, England QUOTE IT IN ANY COMMUNICATION WITH PERSONNEL AT DENNIS. Tel: +44 (0) 1332 824 777 A division of Howardson Ltd – a proudly British company www.dennisuk.com www.sisis.com...

  • Page 4: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS TITLE CAUTION:- READ THE INSTRUCTIONS. We want you to obtain the best performance from this machine. If you have any difficulty in carrying out the following instructions please contact your local DENNIS dealer. TRAINING ● Be familiar with the controls and the proper use of the equipment. ● Never allow children or people unfamiliar with these instructions to use the mower. Local regulations or insurance may restrict the age of the operator. ● Never mow while people, especially children, or pets are near by. ● Keep in mind that the operator or user is responsible for accidents or hazards occurring to the other people or their property. PREPARATION ● Thoroughly inspect where the equipment is to be used and remove all stones, sticks, wire, bones and other foreign objects. ● Before using the machine always inspect the safety devices, including the emergency cut-off switch, as well as checking the blades for excessive wear or damage. Replace if necessary. ● While mowing always wear substantial footwear and long trousers. Do not operate the mower barefoot or in open sandals. ● In dry, dusty or windy conditions it may be necessary to wear eye protection to protect your eyes from flying debris. OPERATION ● Do not operate the machine when tired, ill, under the influence of drugs or alcohol. ● Mow only in daylight or good artificial light.

  • Page 5: Introduction

    INTRODUCTION TITLE This operating manual is an essential tool to ensure the proper and safe operation of the ES-36 Electric Cylinder Mower. This user manual contains important information regarding the safe, proper and efficient operation of the ES-36. Adherence to this manual will help to avoid risk, lower repair costs and reduce downtimes while simultaneously increasing the service life of the ES-36 itself. The operating manual must always be available, and every person tasked with working on or with the ES-36 must read and follow the instructions. In the case of any difficulty, or if further information or advice is required, our Service Department is always at your call. In the interests of speed and accuracy of information please quote the serial numbers of the machine when making enquiries. For the machine, this is to be found on a plate attached to the side of the chassis. We suggest you write the numbers on the front page of this book. MACHINE DESCRIPTION A rotary cutting machine manufactured with 36” (91.4cm) cutting width this machine is run by a pair of 48V high efficiency brushless permanent magnet AC motors powered from an 111 Ah lithium ion battery. The rear roller and cutter are controlled independently via belt drives operated from the display screen on the upper handle bar. A mechanical parking brake is fitted for added safety when working around uneven ground, when applied this disengages drive to both motors for added safety. In the design of the machine, special attention has been given to the importance of easy service and maintenance with the construction based on a sectional assembly system. These are the Electrical Drive system, the Rear Roller Unit and the Front Roller Unit, each of which can be readily removed individually from the main Frame Chassis Unit.
  • Page 6 TECHNICAL DATA TITLE ES-36 DIMENSIONS - WIDTH (mm) 1147 - LENGTH with Grass Box (mm) 2031 - LENGTH without Grass Box (mm) 1512 1086 - HEIGHT (mm) WEIGHT (Kg) Cutting Width 914.4mm / 36” DRIVE SYSTEM Roller Motor (W) 1200 Roller Drive System Timing Belt Cylinder Motor (W) 1200 Cylinder Drive System Multi V belt ELECTRICAL SYSTEM Battery Type Lithium Ion System Voltage Battery Capacity (Ah) Self Discharge @ 25 °C < 2% per month *BELT GUARD REMOVED SP20059_REV0.3...
  • Page 7 TITLE *BELT GUARD REMOVED NUMBER PART NUMBER PART Electrical Box Bottom Blade Angle Adjustment Battery Cover Belt Guards Roller Motor Mechanical Hand Brake Cylinder Motor Cutting Height Adjuster Cylinder Grass Box Bottom Blade Adjustment Knob Handle Bar Adjusters NUMBER PART NUMBER PART Key Switch Deadman’s Handle Display Screen Start Button Emergency Stop SP20059_REV0.3...

  • Page 8: Technical Data

    CONTROLS FOR THE LOCATION OF CONTROLS AND COMPONENTS REF “MACHINE DESCRIPTION” & ‘TECHNICAL DATA’ PAGES. BE FAMILIAR WITH THE CONTROLS AND THE PROPER USE OF THE EQUIPMENT BEFORE STARTING. KEY SWITCH & START BUTTON (ITEM 13 & 17) This switch cuts power to the electrical components and can be used to do so at any time during the operation of the machine. See basic operations page for more information DEADMANS CONTROLS (ITEM 16) This is an operator presence control. This must be depressed before the drive and cylinder motors will engage. Releasing the handle during operation will cut power to both motors.

  • Page 9: Basic Screen Controls

    When in DRIVE or REVERSE TRIP DISTANCE TRIP TIME SELECTED CLIP RATE or RPM 09:33 23 SEPT 2020 5.5 KM KM/H 135 MIN DENNIS NO.1 KM/H MENU Enter MENU BATTERY LEVEL KM/H KM/H DRIVE - To operate mower Turning Speed Turn ON / OFF...

  • Page 10: Screen Menu

    SCREEN MENU TITLE SP20059_REV0.3...
  • Page 11 23 SEPT 2020 DRIVE SELECT ROLLER SPEED 5.5 KM DRIVE / NEUTRAL / PARK / REVERSE KM/H 135 MIN SPEED DOWN (0.1) SELECTION DOWN DENNIS NO.1 KM/H MENU ACTIVATE TURNING SPEED MAIN MENU TRIP STATISTICS BATTERY CHARGE (DISTANCE COVERED / TIME RUN) &...
  • Page 12 EDIT CLIPS PER METRE / VIEW AND RESET LOGS NAME / ADD NOTES DISTANCE / TIME / CHARGE ES-34 Serial No. - ES340001 RESETABLE TRIP & LIFETIME DENNIS NO.1 READOUTS BATTERY & MACHINE TYPE CHARGE INFO MACHINE SERIAL NUMBER LAST FULL CHARGE /...
  • Page 13 TITLE BUTTON SELECTION MAINTENANCE SCREEN SCREEN INFO MAINTENANCE SCREEN. SELECT AND SIGN OFF DAILY / WEEKLY & YEARLY CHECKS. BACKLAPPING (REVERSE CYLINDER) IN MONTHLY CHECKS. RETURN TO HOME RETURN TO MAIN SCREEN MENU SCREEN DAILY CHECKS Last Completed GIVES LIST OF CHECKS. 24/10/2019 LOG AS COMPLETE ONCE DONE...
  • Page 14 TITLE BUTTON SELECTION INFORMATION SCREEN SCREEN INFO INFORMATION SCREEN. VIEW SELECT MANUAL PAGES, FREQUENTLY ASKED QUESTIONS AND DENNIS CONTACT DETAILS. RETURN TO HOME RETURN TO MAIN SCREEN MENU SCREEN MANUAL INFO KEY MANUAL PAGES / INFO Mower Type - ES-34 Program No.

  • Page 15: Wiring

    E-SERIES MACHINE WIRING 10. WIRING TITLE HYPERDRIVE - HYP-00-2890 CONNECTED TO - HANDLE CONTROLLER HANDLE WIRING HARNESS HARNESS (SP12108) (SP12107) PARKING BRAKE MICROSWITCH ELECTRICAL BOX TOP 800253A 106 MOTOR - GEARBOXED CYLINDER 103 MOTOR - DRIVE ROLLER DRIVE (SP15104) (SP15102) NODE 1 BATTERY (SP12126) SP19031_REV1 - 04/02/2021...
  • Page 16 E-SERIES MACHINE WIRING TITLE HYPERDRIVE - HYP-00-2890 ELECTRICAL BOX TOP 800253A ATTENTION: Refer to Manual ATTENZIONE: Riferirsi al Manuale ATTENTION: Se référer au Manuel VORSICHT: Siehe Handbuch ATENCIÓN: Referirse al Manual OPGELET: Naar het Handboek PARKING BRAKE MICROSWITCH HANDLE WIRING HARNESS E-STOP (SP12107) DISPLAY PV450...

  • Page 17: Charging

    11. CHARGING E-SERIES CHARGING INFO Follow charging instruction shown below - PLUG CHARGER (D153) INTO WALL/POWER SUPPLY. MAKE SURE DISPLAY/LIGHTS ARE ILLUMINATED TO BE SURE OPEN CHARGING COVER ON ELECTRICAL BOX AND POWER IS LIVE TO CHARGER CONNECT CHARGER INTO MOWER Hyperdrive Cell START BUTTON CHARGER SOLID LARGE RED LIGHT TO INDICATE CHARGING.

  • Page 18: Frequently Asked Questions

    Contact Dennis or your dealer if you have changed and forgotten your password. They can talk you through resetting your password. FAQ section also available within the ‘Information’ section ->...

  • Page 19: Cut Height Adjustment

    13. CUT HEIGHT ADJUSTMENT SETTING FOR HEIGHT OF CUT Always turn the machine off before adjusting the height of cut. Failure to do this may result in serious injury. The length of grass after cutting depends on the setting of the front roller in relation to the main frame of the machine. To set: ● Slacken the clamp nuts on the front roller quadrants (see image opposite) [19mm spanner] - Item 1 ● Rotate the quadrants using the toothed gear [19mm ITEM 1 spanner], raising and lowering the machine. As a ITEM 2 guide, there are notches in the quadrant and holes in the side plate. Align these on both sides to level the machine. - Item 2 To check the height of cut and that the machine is level, the setting bar can be used (228090). Place the bar between the front and rear rollers, resting the underside of the bolt head on the lip of the shear blade.

  • Page 20: Shear Blade Carrier Adjustment

    ES-36 SHEAR BLADE POSITIONING ES-36 SHEAR BLADE POSITIONING 14. SHEAR BLADE CARRIER ADJUSTMENT DETAIL B DETAIL B DETAIL A DETAIL A CLEVIS FORK CLEVIS FORK CLEVIS PIN CLEVIS PIN Remove side cover from left hand side of Remove side cover from left hand side of machine, as facing the machine from the front.
  • Page 21 ES-36 SHEAR BLADE SETTING Shear Blade position is adjusted using Micro Adjuster System. To adjust: 1: Rotate Brass Hex Bolt using a 15mm Spanner. Clockwise moves the sheer blade closer. - Each click of the adjuster moves the sheer blade 0.003mm (3microns). - 30 clicks (One full revolution) will move the sheer blade 0.09mm.

  • Page 22: Routine Maintenance

    Check cables are not split or damaged and plug connections are all fitted correctly. Damaged cables should be replaced before the machine is next operated. NEVER USE A MOWER WITH A DAMAGED BATTERY OR ELECTRICAL BOX. IF IN ANY DOUBT CONTACT YOUR DEALER OR DENNIS DIRECT. NEVER ATTEMPT ANY ELECTRICAL WORK. ANY ATTEMPT WILL VOID THE WARRANTY! BLADES Worn or damaged blades can be dangerous resulting in serious injury or death of the operator or bystanders. Replace worn or damaged blades.

  • Page 23: Storage

    16. STORAGE The machine should always be kept in a clean dry place, free from condensation. After use ensure that the machine is thoroughly clean, dry and free from grass and mud. Before off season storage smear a thin layer of grease on to the cutter blades and the shear blade. Under no circumstances must the machine be steam cleaned as this may remove grease from the pre packed bearings and damage electrical components. If stored for more than a month disconnect battery connector located under the battery cover. SP20059_REV0.3...

  • Page 24: Battery Care Information

    E-SERIES BATTERY CARE 17. BATTERY CARE INFORMATION No hazards occur during the normal opera�on of a Ba�ery as it is described in the instruc�ons for use that are provided with the Ba�ery. Ba�ery modules are electrical devices that must be handled and used with care.
  • Page 25 E-SERIES BATTERY CARE LIMITED WARRANTY >85% capacity for minimum 2000 cycles when cycled to 100% DoD at50A at a cell temperature of 25°C. Devia�on from these condi�ons will be assessed on a case by case basis. See Hyperdrive website for further details. www.hyperdriveinnovation.com/ RETURN OF BATTERIES AT END OF LIFE Hyperdrive Innova�on as a producer of Industrial ba�eries can take back ba�eries free of charge at...

  • Page 26: Trouble Shooting

    Check the ba�ery has not been fully drained. Plug the mower into the charger and power the machine on to see if the display starts up with the ‘On Charge Screen’ If the problem persists please contact your dealer or Dennis directly My screen powers on briefly then switches off...
  • Page 27 E-SERIES ELECTRICAL TROUBLE SHOOTING Check the mechanical brake has been disengaged (handle on the lower le�-hand side of the machine) Check the parking brake microswitch is being disengaged from the brake hammer under the le�-hand side guard My mower won’t operate and displays a ‘PLEASE HOLD DEADMAN HANDLE’ message My mower doesn’t disengage when I release the bail bar Check the bail bar is being held or fully released when a�emp�ng to operate Listen if you can hear the quiet ‘click’...
  • Page 28 Check all three power cables to each motor are connected and the le�ers on the wires match those on the motor (U, V and U) If your problem isn’t referenced on this document or you are still having problems please contact your dealer or Dennis Mowers directly.
  • Page 29 NOTES SP20059_REV0.3...

  • Page 30: Parts Book

    19. ES-36 - PARTS BOOK SP20059_REV0.3...

  • Page 31: Chassis

    HINGE PIVOT PREM E1-1065_REV0 WASHER M12 SPRING LOCK E1-1161_REV0 HEX SET SCREW M12 X 60 J20297_REV2 SERIAL NO PLATE (DENNIS) SP01034_REV0 HEX SET SCREW M10 X 20 SP02044_REV0 RIVNUT HEX M8 (0.5-3.0) [NO HEAD] SP02045_REV0 RIVNUT HEX M8 (4.0-6.0) [NO HEAD]...

  • Page 32: Electrical System

    21. ELECTRICAL SYSTEM REAR DRIVE SYSTEM ITEM NO. PART NUMBER DESCRIPTION QTY. 380043_REV0 BATTERY BRACE R.H. 380044_REV0 BATTERY BRACE L.H. 800253_REV5 HYPERDRIVE ELECTRIC CONTROL ASSY F20384_REV1 CAP HEAD M8 X 25 SP01009_REV0 HEX SET SCREW M8 X 20 SP02006_REV0 NUT M8 NYLOC (T) SP03008_REV0 WASHER M8 FORM A SP03029_REV0...

  • Page 33: Rear Roller

    REAR ROLLER ASSY REAR ROLLER ASSEMBLY 22. REAR ROLLER SPARE PARTS ITEM NO. PART NUMBER DESCRIPTION QTY. 800100_REV1 PREM CENTRE ROLLER ASSY 800156_REV1 PREM 36" REAR ROLLER OUTER 089575_REV0 KEY 3/16" X 3/16" X 2 1/4" RD END 380035_REV0 36" ROLLER SHAFT ELECTRIC 185660_REV1 LOCKING COLLAR (SMALL) 065824_REV0...

  • Page 34: Rear Roller - Inner

    23. REAR ROLLER - INNER BRAKE SYSTEM TITLE 14 15 ITEM NO. PART NUMBER DESCRIPTION QTY. 016386_REV0 KEY WOODRUFF 3/16" X 7/8" 052602_REV1 GEAR DIFFERENTIAL PINION 158356_REV1 THRUST WASHER SOFT 158357_REV1 WASHER THRUST HARD 158372_REV1 GEAR DIFF DOUBLE PINION 158373_REV1 SHAFT DIFFERENTIAL PINION 185664_REV1 PREMIER CENTRE ROLLER...

  • Page 35: Rear Roller - Outer

    24. REAR ROLLER - OUTER FRONT ROLLER ASSEMBLY TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 052601_REV1 GEAR DIFFERENTIAL WHEEL 158374_REV2 REAR ROLLER BUSH 171661_REV1 OUTER ROLLER (PREM) SP01036_REV0 HEX SET SCREW M8 X 35 SP03004_REV0 WASHER M8 TOOTHED SP20059_REV0.3...

  • Page 36: Roller Drive

    CYLINDER DRIVE SYSTEM 25. ROLLER DRIVE TITLE 10 14 13 11 5 13 8 15 12 6 3 17 ITEM NO. PART NUMBER DESCRIPTION QTY. 340037_REV0 PULLEY RETAINER 370096_REV0 TENSIONER BLOCK E1-1065_REV0 WASHER M12 SPRING LOCK F21884_REV0 KEY 8 X 7 X 35 SP01005_REV0 HEX SET SCREW M8 X 30 SP01021_REV0...

  • Page 37: Mechanical Parking Brake

    26. MECHANICAL PARKING BRAKE TITLE 8 32 9 12 16 26 20 26 24 29 18 13 11 ITEM NO. PART NUMBER DESCRIPTION QTY. 340135_REV0 MICROSWITCH MOUNT PLATE 340185_REV1 BRAKE DISC 340189_REV1 BRAKE SENSOR BRACKET 340195_REV2 BRAKE HAMMER W.A. 340197_REV0 BRAKE BUSH 340200_REV2 BRAKE CLAMP...

  • Page 38: Cylinder

    SHEAR BLADE ASSEMBLY 27. CYLINDER TITLE 23 19 16 16 20 SP20059_REV0.3...
  • Page 39 CYLINDER TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 228029_REV1 BEARING 2205 2RS 229701_REV1 OIL SEAL 32 X 47 X 7 340032_REV0 BEARING SPACER 340051_REV0 DEFLECTOR BRACKET 340104_REV0 BEARING HOUSING CYLINDER 380050_REV0 36" DEFLECTOR (178) 380057_REV1 CHASSIS INFILL 380100_REV0 CYLINDER 8 BLADE 36" E1-1061_REV0 WASHER M6 SPRING E1-1065_REV0...

  • Page 40: Cylinder Drive

    28. CYLINDER DRIVE TITLE 5 10 17 15 ITEM NO. PART NUMBER DESCRIPTION QTY. 370096_REV0 TENSIONER BLOCK 370099_REV0 MOTOR SPACER 370135_REV0 MOTOR PLATE 380105_REV0 PULLEY SPACER (CYL) E1-1061_REV0 WASHER M6 SPRING E1-1065_REV0 WASHER M12 SPRING LOCK F20684_REV0 KEY PARALLEL 8 X 7 X 25 J20467_REV0 GRUB SCREW M8 X 8 SP01005_REV0...

  • Page 41: Shear Blade

    29. SHEAR BLADE TITLE 13 24 ITEM NO. PART NUMBER DESCRIPTION QTY. 086792_REV2 SHEAR BLADE 36" LIPPED 185378_REV1 SCREW 3/8" X 1/2" UNF 228022_REV4 CLEVIS PIN 230699_REV0 PIVOT BOLT 230725_REV0 ADJUSTER PIVOT 230726_REV0 ADJUSTER FEMALE 230727_REV0 ADJUSTER MALE 340075_REV0 PIVOT BLOCK 340076_REV0 PIVOT CAM 340077_REV0...

  • Page 42: Front Roller

    GRASSBOX ASSEMBLY 30. FRONT ROLLER TITLE 15 16 3 18 13 15 ITEM NO. PART NUMBER DESCRIPTION QTY. 185883_REV1 PREMIER FRONT ROLLER 36" 229310_REV1 QUADRANT SPACER 230741_REV0 QUADRANT GEAR 380084_REV0 ROLLER QUADRANT R.H. ASSY 380085_REV0 ROLLER QUADRANT L.H. ASSY 380087_REV0 SCRAPER FRONT ROLLER ES-36 380090_REV0 TIE BAR ASSY PREM...

  • Page 43: Handle Mounts

    31. HANDLE MOUNTS ELECTRIC ASSEMBLY TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 380114_REV0 HANDLE PLATE 800610_REV0 ES-36 HANDLE ASSY SP01065_REV0 HEX SET SCREW M12 X 30 SP02010_REV0 NUT M12 NYLOC (T) SP03012_REV0 WASHER M12 FORM A SP20059_REV0.3...

  • Page 44: Handle Console

    SCRAPER BAR ASSEMBLY 32. HANDLE CONSOLE TITLE 33 34 15 28 19 30 26 SP20059_REV0.3...
  • Page 45 HANDLE CONSOLE TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 228020_REV1 CLEVIS GM5 (5MM) 229167_REV1 CLUTCH SPRING 229585_REV1 PIVOT BLOCK 229590_REV1 SAFETY SWITCH BRACKET 229595_REV2 SAFETY LEVER PLUNGER W.A. 229620_REV2 BOLT FOR SPRING 230180_REV0 SAFETY BAR W.A. 380106_REV1 ES-36 HANDLE W.A. 380110_REV0 CONSOLE COVER W.A.

  • Page 46: Grass Box Cradle

    33. GRASS BOX CRADLE TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 228024_REV1 1" TUBE BUNG 370180_REV0 GRASSBOX ARM PIVOT 380120_REV0 E-36 CRADLE W.A. 604761_REV1 THACKERY WASHER E1-1065_REV0 WASHER M12 SPRING LOCK E1-1081_REV0 WASHER M20 FORM B SP01082_REV0 HEX SET SCREW M12 X 50 SP02010_REV0 NUT M12 NYLOC (T) SP03012_REV0...

  • Page 47: Scrapper Bar

    GRASSBOX ASSEMBLY 34. SCRAPPER BAR TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. 380095_REV0 SCRAPER BAR ES36 W.A. 380097_REV0 SCRAPER SP01034_REV0 HEX SET SCREW M10 X 20 SP01035_REV0 HEX SET SCREW M10 X 25 SP02008_REV0 NUT M10 NYLOC (T) SP03011_REV0 WASHER M10 FORM A SP03034_REV0 WASHER M10 SPRING LOCK SP20059_REV0.3...

  • Page 48: Guards

    BATTERY COVER HINGE 380150_REV0 BATTERY COVER PREM W.A. 380160_REV0 GUARD R.H. PREM 380161_REV0 GUARD L.H. PREM B32902_REV2 DECAL DENNIS 200 X 50 (LARGE) E1-1133_REV0 HEX BOLT M10 X 75 J209074_REV1 BRAKE BAND COVER SCREW SP01009_REV0 HEX SET SCREW M8 X 20 SP01025_REV0...

  • Page 49: Decals

    SCRAPER BAR ASSEMBLY 36. DECALS TITLE ITEM NO. PART NUMBER DESCRIPTION QTY. B32902_REV2 DECAL DENNIS 200 X 50 (LARGE) B32903_REV0 DECAL UNION JACK J20362_REV0 DECAL DENNIS 200 X 50 SP18026-1_REV0 BATTERY INFO DECAL SP18026-2_REV0 WARNING DECAL SP18026-3_REV0 E-SERIES DECAL SP18026-4_REV0...
  • Page 50 DENNIS, Ashbourne Road, Kirk Langley, Derbyshire, DE6 4NJ, England Tel: +44 (0) 1332 824 777 Fax: +44 (0) 1332 824 525 Email: sales@dennisuk.com Email: spares@dennisuk.com www.dennisuk.com A division of Howardson Ltd – a proudly British company Company reg No: 641526 – Vat No GB 345 9918 12 SP20059_REV0.3...

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