Swine Robotics Boar Bot User manual

Table of Contents
Overview............................................................................................................................................ 1
Options and accessories.................................................................................................................. 1
Specications .................................................................................................................................... 1
Operating the Boar Bot ................................................................................................................... 2
Remote control........................................................................................................................................2
Power switch............................................................................................................................................2
Battery charger........................................................................................................................................2
Boar harness.............................................................................................................................................3
Boar attached to Boar Bot ...................................................................................................................3
Warranty............................................................................................................................................. 4
Service and Parts .............................................................................................................................. 4
Maintenance...................................................................................................................................... 4
Grease the wheels—MONTHLY.........................................................................................................5
Clean the battery connections—MONTHLY.................................................................................5
Check the chain tension—MONTHLY .............................................................................................5
Oil the drive chains—MONTHLY.......................................................................................................5
Check gear box oil level—YEARLY....................................................................................................6
Trouble shooting .............................................................................................................................. 6
Machine does not move ......................................................................................................................6
Wheels on one side of the Boar Bot do not turn.........................................................................7
Motor runs but wheels do not turn .................................................................................................8
Drive chains do not stay on sprockets............................................................................................8
Batteries do not charge or maintain a charge .............................................................................9
Erratic operation .....................................................................................................................................9
Clicking noise coming from the machine................................................................................... 10
Circuit breaker blows ......................................................................................................................... 11
Mechanical Service.........................................................................................................................12
Removing the top cover ................................................................................................................... 12
Removing the wheels ........................................................................................................................ 12
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Removing the drive motor............................................................................................................... 13
Removing a gear box......................................................................................................................... 13
Removing an axle................................................................................................................................ 13
Replacing the gearbox seal.............................................................................................................. 14
Replacing gearbox broken shaft.................................................................................................... 14
Replacing the remote control batteries ...................................................................................... 15
Electrical Service............................................................................................................................. 15
Checking the power switch............................................................................................................. 15
Checking the remote control.......................................................................................................... 15
Checking the receiver unit inside the single speed, old 2-speed, Boar Bot ................... 16
Checking the single speed, old 2-speed, solenoids................................................................ 16
2.0 Electrical System Trouble Shooting ....................................................................................... 17
Checking a drive motor..................................................................................................................... 20
Checking the battery charger......................................................................................................... 21
Checking for low voltage symptoms ........................................................................................... 21
Testing the individual batteries ........................................................................................... 21
Testing the combined battery voltage.............................................................................. 22
Testing internal voltage.......................................................................................................... 22
Testing receiver unit for voltage.......................................................................................... 22
Checking the old two speed Boar Bot ........................................................................................ 23
Mode of operation.............................................................................................................................. 23
Checking voltages on a two speed Boar Bot............................................................................. 23
Trouble shooting a two speed Boar Bot...................................................................................... 24
Electrical Block Diagram ...............................................................................................................26
Single speed Boar Bot........................................................................................................................ 27
Two speed Boar Bot............................................................................................................................ 28
2.0 Electrical Diagram ........................................................................................................................ 30
Parts Diagram Main Assembly..................................................................................................... 31
Parts Diagram Cover Assembly.................................................................................................... 32
Boar Bot Parts List................................................................................................................................ 32
APPENDIX.........................................................................................................................................36
Hearse winch parts – Version II....................................................................................................... 38
Hearse winch parts – Version I........................................................................................................ 41
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1
OWNER’S MANUAL
Overview
The Boar Bot is a remote controlled steerable vehicle powered by 2 rechargeable
12 volt deep cycle batteries connected to operate as a 24 volt system. A set of wheels
on each side of the vehicle are separately powered to permit steering of the vehicle.
The power source, drive motors, and receiver are encased within the housing assembly.
An opaque protection screen is used to permit safe release of the boar from the vehicle.
Options and accessories
The Boar Bot is available in several options--
Single speed Boar
Two speed Boar Bot for faster transport between places
Single speed Boar Bot narrow version for narrower alleys.
The Boar Bot can be fitted with several accessories—
Hearse with power winch for ease in removing dead carcasses
Side shields to limit the boars visibility
Lead boar harness to add the capability of attaching two boars
Specifications
Mode of operation- remote controlled
Weight—over 500 lbs
Power Source—2 –12 volt deep cycle batteries
--24volts single speed Boar Bot or 12/24volts two speed Boar Bot
Operating time—over 8 hours continuous use

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Warranty
Swine Robotics, Inc. will replace any part found to be defective in workmanship
within the first year of purchase. The warranty covers the cost of the replacement part,
but does not cover the shipping or labor costs associated with the removal and
installation of the defective part.
The factory installed batteries carry a two (2) year warranty. Batteries found to
be defective within one year from the original purchase date will be replaced. Batteries
found to be defective within the second year from original purchase date will be
replaced at a pro-rated cost. Do not return batteries under warranty to Swine Robotics:
contact the nearest Delco battery dealer with battery warranty issues.
Service and Parts
For parts and technical support, contact your local distributor or
Swine Robotics, Inc. at [phone].
Please return parts under warranty to the following address
Swine Robotics, Inc.
748 Sherman St
Leola, SD 57456
USA
Maintenance
The Boar Bot has been designed to give you many hours of trouble free service
with a minimum of maintenance. To help extend the life of your machine and to keep it
operating smoothly the following maintenance should be performed.

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1. Grease the wheels--MONTHLY
The wheels can be greased with a standard grease gun. The grease zerks are
located on the outside of the wheels near the hub. Under extreme conditions it may
be necessary to grease the wheels more often
2. Clean the battery connections--MONTHLY
To reduce battery terminal corrosion, the battery terminals need to be cleaned.
Turn the power switch to the ―OFF‖ position. Remove the terminal connections from the
batteries. Remove the corrosion from the battery terminals using emery paper or a wire
brush. Reconnect the wire terminals and apply anticorrosion grease or spray. Under
extreme conditions it may be necessary to clean the battery terminals more often.
.
3. Check the chain tension--MONTHLY
Support the machine with a hoist or blocks to suspend the wheels off the floor. If
supporting with a chain hoist, lift from the U-bolt on the top of the machine. With the
wheels suspended, run the machine so the chain slack is on the bottom portion of the
chain. Turn the power switch to the ―OFF‖ position and disconnect the negative battery
terminal on the rear battery. Loosen the idler sprocket with a ¾ inch wrench and slide
the sprocket up to snug the chain. If the idler sprocket can not be moved to tighten the
chain, it maybe necessary to remove the offset link or a link from the chain. Proper
chain tension will allow you to move the slack side of the chain about ½ inch
The chain should be snug but not extremely tight. Over tightening the chain will
shorten the life of the drive components.
4. Oil the drive chains--MONTHLY
Turn the power switch to the ―OFF‖ position. Open both the front and rear doors.
Lubricate the drive chains using a spray type chain lubricant. Under extreme
conditions it may be necessary to lubricate the chains more often.

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5. Check gear box oil level--YEARLY
Turn the power switch to the ―OFF‖ position. Open the rear door and remove the
rear battery. Remove the gearbox oil plug through the access hole in the gearbox
mounting bracket. The oil level of each gearbox should be at the bottom of the plug
hole. If the oil level is low, fill the gearbox with 80W90 gear oil to the oil plug l Tighten
the plugs and reinstall the rear battery. Do not remove the low oil plug. Filling the
gearbox only to the low oil plug level will result in severe gearbox damage
Trouble shooting
1. Machine does not move
Possible Cause Check/Repair
Receiver fuse is blown Check fuse and replace with a 3 amp fuse if
necessary
Corrosion on battery
connections
Clean battery connections as outlined in the
Maintenance section
Discharged or faulty batteries Charge or replace batteries as necessary.
Loose wire in electrical box Check connections in electrical box
Battery charger not properly
attached
Check if the charger receptacle wires are connected
to batteries.
Faulty power switch Check power switch. Refer to Electrical service-
Checking the power switch.

7
Faulty remote control Check remote control. Refer to Electrical service-
Checking the remote control.
Faulty receiver Check receiver. Refer to Electrical service- Checking
the receiver unit inside the Boar Bot.
2. Wheels on one side of the Boar Bot do not turn
Possible Cause Check/Repair
30 Amp circuit breaker blown Check and reset circuit breaker.
Corrosion on battery
connections
Clean battery connection as outlined in the
maintenance section.
Discharged or faulty batteries Charge or replace batteries.
Loose wire in junction box Check connections in electrical box.
Battery charger not properly
attached
Check if the charger receptacle wires are connected
to batteries.
Loose or broken drive chain Tighten or replace chain.
Faulty remote control Check remote control. Refer to Electrical service-
Checking the Remote Control
Faulty receiver Check receiver. Refer to Electrical service-Checking
the receiver unit inside the Boar Bot.
Faulty solenoid Check solenoids. Refer to Electrical service-Checking
the solenoids.

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Faulty motor Check motor. Refer to Electrical service-Checking the
drive motor.
3. Motor runs but wheels do not turn.
Possible Cause Check/Repair
Loose or broken drive chain Tighten or replace chain.
Worn sprockets Replace sprockets if sprockets have excessive wear.
Sheared key on gearbox
sprocket
Replace key, if key is sheared.
Sheared key on motor
driveshaft.
Remove motor and replace key if key is sheared.
Faulty gearbox Check that the gearbox output shaft is not turning
when motor is running. Replace gearbox.
4. Drive chains do not stay on sprockets.
Possible Cause Check/Repair
Improper chain tension Adjust chain tension with idler sprocket.
Worn wheel bushings Replace bushings if bushings have excessive wear.
Worn axle shaft Replace axle shaft if axle has excessive wear.
Bent axle shaft Replace axle if bent.

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5. Batteries do not charge or maintain a charge
Possible Cause Check/Repair
Corroded battery connections Clean battery connections.
Charger not plugged in
correctly
Properly attach charger plug.
Charger receptacle not
attached to battery
Inspect wires from battery charger receptacle to the
batteries.
Faulty battery charger Check for faulty battery charger. Refer to Electrical
service-Checking the battery charger.
Faulty batteries Check batteries with digital voltmeter or battery tester.
Refer to Electrical service-Testing the individual
batteries.
6. Erratic operation.
Possible Cause Check/Repair
Low remote control batteries If voltage is less than 1.3 volts per battery, replace
remote control batteries.
Low main battery voltage Check for low voltage. Refer to Checking for low
voltage symptoms.
Faulty 12-volt main battery Replace battery.
Faulty antenna lead Inspect antenna lead. Replace if faulty.

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Faulty remote control Verify if remote control is functioning. Replace if
faulty.
Faulty receiver Replace if faulty. Refer to Electrical service-Checking
the receiver unit inside Boar Bot.
7. Clicking noise coming from the machine
Possible Cause Check/Repair
Improper chain tension Adjust chain tension with idler sprocket.
Worn wheel bushing Replace bushings if bushings have excessive wear.
Worn sprockets Replace sprockets if sprockets have excessive wear
Sheared key on gearbox
sprocket
Replace key if key is sheared.
Sheared key on motor
driveshaft.
Remove motor and replace key, if key is sheared.
Faulty gearbox Check that the gearbox output shaft is not turning
when motor is running. Replace gearbox.
Low battery voltage Check if solenoids are clicking. Recharge or replace
12-volt main batteries.

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8. Circuit breaker blows
Possible Cause Check/Repair
Dirty drive chain Clean drive chain if dirty.
Drive chain too tight Check chain tension and make necessary
adjustments. Refer to Maintenance-Check the chain
tension.
Loose electrical wire Open electrical box and check wires and connectors
Faulty circuit breaker Check circuit breaker and replace if necessary
Motor brushes faulty Check motor brushes and replace if necessary. Refer
to Electrical Section-Checking the drive motor.
Drive chain idler sprocket does
not turn
Check if idler sprocket turns. Replace if necessary
Drive motor faulty Check motor. Check if wire to motor is overheating.
Replace motor if necessary. Refer to Mechanical
Service-Removing a drive motor.

12
Mechanical Service
I. Removing the top cover
1. Disconnect the negative battery cables from the rear battery.
2. Disconnect the switch wires from the on/off the switch.
3. Disconnect the charger receptacle wires from the batteries.
4. Remove the top portion of the antenna with a 7/16 inch wrench.
5. Remove the antenna retaining nut to remove the antenna base from the cover.
6. Remove the four cap screws retaining the receiver to the top cover.
7. Remove the front door support chain.
8. Remove the two cap screws retaining the top cover to the rear plate.
9. Remove the four cap screws retaining the top cover to the base plate.
10.Lift the top cover straight up and off the machine.
11.To reinstall top cover reverse the above procedure.
II. Removing the wheels
1. Disconnect the negative battery cables from the rear battery.
2. Raise and support the machine with a chain hoist or blocks to suspend the
wheels off the ground.
3. Remove the plastic bottom side bumper to gain access to the chain and idler
sprocket.
4. Loosen drive chain idler sprockets and remove chains.
5. Remove cap screw from the end of the axle shaft and pull wheel/hub assembly
off the end of the axle.
6. Remove the three nuts retaining the hub assembly to the wheel (Note when
reinstalling the hub assembly to the wheel, do not tighten the three nuts until the
assembly is on the axle to ensure proper alignment.)
7. Wheels should be installed in sets of four to keep the machine driving straight.
8. When installing new bushings, coat axle with grease before reinstalling the
wheels.

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III. Removing the drive motor
1. Disconnect the negative battery cables from the rear battery.
2. Follow the procedure for removing the top cover.
3. Remove the wiring access cover at the top of the motor and disconnect the wire
nut connectors.
4. Separate the plastic conduit at the motor by loosening the plastic conduit nut and
then feeding the wires out of the motor wiring access box.
5. Remove the four cap screws holding the two drive motors together.
6. Remove the four cap screws mounting the drive motor to the gearbox..
7. Lift drive motor straight up off gearbox.
8. To reinstall drive motor reverse the above procedure.
Note: Be sure to stall shear key when reinstalling drive motor.
IV. Removing a gearbox
1. Disconnect the negative battery cable from the rear battery.
2. Follow the procedure for removing a drive motor.
3. Remove the batteries.
4. Remove the drive chain.
5. Remove the eight ¼ inch cap screws holding the gearbox to the mounting
bracket.
6. Remove the gearbox.
7. To reinstall gearbox reverse the above procedure.
V. Removing an axle
1. Disconnect the negative battery cables from the rear battery.
2. Follow the procedure for removing the wheels.
3. Loosen the set screws holding the axle to the axle housing.
4. Slide the axle out of the axle housing.
5. To reinstall axle reverse the above procedure.

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VI. Replacing the gearbox seal
1. Disconnect the power.
2. Remove drive chain on side of bad seal.
3. Loosen the sprocket set screw and remove sprocket and square key from gearbox
shaft.
4. Remove the 4 cap screws from the shaft end of the gearbox to remove gearbox
endplate.
5. Remove the old seal from the endplate.
6. Drive the new seal into the endplate with care that the seal is not ruined.
7. Replace end plate, key and sprocket.
8. Replace drive chain and tighten.
VII. Replacing gearbox broken shaft
NOTE: The broken shaft can be replaced without removing the cover.
1. Disconnect the power.
2. Remove the rear battery.
3. Remove the drive chain
4. Remove both end plates from the gearbox.
5. Remove the seal from shaft side of the endplate.
6. Drive the new seal into the endplate, taking care that the seal is not ruined.
NOTE: If replacing shaft only, remove old bearings and gear from old shaft and
fit them unto the new shaft. If replacing gearbox shaft assembly, continue.
7. Feed the shaft assembly into the gearbox from the inside gearbox cover.
8. Align bevel gear with worm gear by slightly turning the shaft.
9. Replace both end plates.
10. Replace sprocket and square key and tighten sprocket set screw.
11. Replace and tighten chain.
12. Replace rear battery and reconnect power.

15
V. Replacing the remote control batteries
1. Remove the remote control from the protective case.
2. Remove the four screws from the back of the remote.
3. Open the remote and replace the two AA batteries.
4. Replace the remote control cover and reinsert the four screws.
5. Tighten the four screws and put back into the protective case.
Electrical service
Refer to Electrical Block Diagram of the single speed Boar Bot on page 23.
I. Checking the power switch
1. Disconnect the wires from the circuit breaker to the main drive motors.
2. Attach the black lead of the digital voltmeter to the negative terminal of the rear
battery.
3. Turn on the power switch.
4. Test for voltage on both terminals of the power switch with the red lead of the
digital voltmeter. NOTE (If the Boar Bot is a two speed than the battery
voltage will be 12 volts not 24 volts.)
a. 24 volts only on one side of the switch –Faulty switch Replace switch.
b. 24 volts on both sides of the of the switch - Switch OK.
c. 24 volts on neither side of the switch –Dead batteries, blown 3 Amp
fuse or a bad connection between switch and batteries.
II. Checking the Remote Control
1. Check if the LED light located in the corner of the remote control flashes when
any or all the remote switches are pressed.
a. Flashing LED light usually indicates that remote control is OK.
b. No flashing LED light.—Replace remote control batteries.
c. Batteries replaced and no flashing LED light.—Replace remote control.
NOTE: When the operation of the Boar Bot is erratic, replace the remote
control’s AA batteries.

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III. Checking the receiver unit inside the Boar Bot
1. Disconnect the drive chains or place the Boar Bot on blocks allowing the
wheels to turn without the Boar Bot moving.
2. Turn on the power switch.
3. Test the power switch as outlined above.
4. Test the remote control as outlined above.
5. Check the 3 Amp receiver fuse on the cover of the electrical box.
6. Check if the light in the corner of the receiver unit is on.
NOTE: If the receiver unit light is on, you have power to the receiver.
If the receiver unit light is not on, proceed as follows.
7. Remove the cover of the electrical box.
8. Remove the two orange wire nuts.
9. Place the red lead of the digital voltmeter on the heavier red wire coming from
the switch. Place the black lead of the digital voltmeter on the black wire
coming from the terminal block.
10. If the voltmeter reads 24 volts and the receiver unit light is not on, the receiver is
faulty.(Two speed Boar Bot voltage will be 12 volts instead of 24 volts.)
11. If the voltmeter does not read 24 volts, check for a bad connection.
IV. Checking the Solenoids
1. Verify that the receiver unit is working properly by following the procedure
outlined above.
2. Place the Boar Bot on blocks allowing the wheels to turn freely without the
BoarBot moving.
3. Remove the cover of the electrical box.
4. Turn on the power switch.
5. Press the remote control switch corresponding to direction in which the Boar
Bot is not responding and listen for a click from the solenoid.
6. If the solenoid does not click, place the black lead of the digital voltmeter on
the black wire connection on the bottom of the solenoid and the red lead on
III. Checking the receiver unit inside the single speed, old 2-speed, Boar Bot
IV. Checking the single speed, old 2-speed, Solenoids