BigDog® Mowers A Series General Service Manual
Contents
1. Tension idler Bottom View Figure 4 8 Hydraulic system This mower is equipped with two integrated hydrostatic trans missions Figure 4 9 IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system The hydraulic expansion tank is located in front of the engine and under the operator s platform Figure 4 9 Check oil level in hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if system appears to be leaking or otherwise malfunctioning Fluid level should be at the Full Cold line on the expansion tank Use only SAE 20W50 SL SM service motor oil Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transmission every 2 years or 200 hours whichever comes first NOTE The filter guard must be removed to access filter Each transmission s filter is located per Figure 4 10 A stan dard oil filter wrench is used to change filter threads are right handed Use a BigDog Mowers approved filter element 115623 1111 only WARNING When washing the mower direc2. Figure 8 1 15 KE Figure 8 2 nk sch mh mk sch mk sch ch mk gt Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Deck Lift Pivot Zerks 4 Park Brake Switch 2 Drive Tire Pump Belt Engine Air Intake Screen Front Gauge Wheel Tires Front Gauge Wheel Zerks 2 Deck Belt Blades Hydraulic Oil Expansion Tank Hydraulic Oil Filter Fuel Evaporation System Filter Figure 8 3 10 8 2 115623 1111 SYMPTOMS PROBABLE CAUSES TROUBLESHOOTING SUGGESTED REMEDIES Starting motor does not crank The engine will not start starts hard or fails to keep running Steering control levers not in park brake position or switch not adjusted Place steering control levers in park brake posi tion or re adjust switch Deck clutch switch engaged Weak or dead battery Electrical connections are corroded or loose Disengage clutch switch Recharge or replace Check the electrical con nections 15
3. Uneven cutting height The blade s are not sharp A cutting blade s is are bent The deck is not level An anti scalp wheel is not set correctly The underside of the deck is dirty Tires improperly inflated Sharpen the blades Install new cutting blade s Level the deck per the Deck leveling and height adjustment section of the General Service Manual Adjust the height of the anti scalp wheel Clean the underside of the deck Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your dealer High oil consumption Mower jerky when starting or operates in one direc tion only 115623 1111 Numerous Steering control linkage needs adjustment Loose steering linkage Contact your dealer Adjust linkage Tighten linkage Transaxle component faulty Contact your dealer 9 1 9 2 115623 1111 PAGE ir orita 4 4 6 4 SIE iii a ed 6 3 Deck 6 4 Deck Routing 8 Tensioning 6 5 Deck leveling ayn R a n Keda kiyan 6 1 Electrical Schematic 7 1 Engine air MeF Aj lae el nax keke kiika 5 1 Engine oil and filter sses teares k l l l nan dn 5 1 Engine RPM settings 5 3 Fluid changing procedure 4 5 Fuel evaporative system line routin
4. 115623 1111 NOTE The following notes are the same for the three different decks shown 1 Spring length after tensioning new belt is measured from outside of hook to outside of hook with deck set at the D setting cut height 2 Route belt as shown 36 42 46 Deck Belt Routing amp Tensioning 2 4 5 5 5 Figure 6 12 115623 1141 6 5 6 6 115623 1111 Qui zo 5 4 Ou ELECTRICAL Electrical Schematic 81 SZ er 1115 old YIN _ EL TN 4 81 EZ 2 81 mim 81 0 128008 JD YO 21 Jos n 81 NY 81 9 oia 1 and 91 81 WIS 12 A L 940 11 oo xSS34d 110 91 118 62 gt ae 91 1716 01 E 010N 3708 o 187018 9 81 02 _ 9 gt Ke en 81 gt 5 81 o DS 019 ip NESTON 81 MT TIT 51 2 81 IVILN3N E dad rege gt AV 139 91 LUWLS LZ 0397080 1 12 EY 21 940 yl y J 3803 HILSYW 81 Y418 038 6
5. 4 4 Hydraulic system 4 4 AED Sse ce se es Se woe O 4 6 Engine Maintenance 5 1 General Engine 5 1 Engin ista xwa wan ee Al E 5 1 Engine Ali Fille gt z3 Bak ale O 5 1 Fuel evaporation system filter 5 1 Fuel evaporative system line routings 5 1 Engine RPM 5 lt 5 3 Deck AQUSIMENES std eee etal dr 6 1 Deck Levelng EE 6 1 Blades nada E oe Rae aa EES 6 3 O teeter sed an ee 6 4 Deck Belt 6 4 36 42 46 Deck Belt Routing Tensioning 6 5 e A re e ee er A O 7 1 Electrical 5 7 1 BigDog Mowers A Series 8 1 c 1 Maintenance 5 8 1 BigDog Mowers A Series Maintenance Locator Chart 8 2 Troubleshooting 9 1 c 2 114660_ 1111 GENERAL INFORMATION BigDog Mowers A Series Service Program This manual 15 part of a service package for the BigDog A Series mowers Use of this manual in conjunction with other BigDog A Series mower and component manuals will provide the information necessary to service an
6. Wash hands after handling A Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools A Avoid skin and clothing contact with battery acid Always wear eye protection when checking the battery acid can cause serious injury to skin and eyes If con tact occurs flush area with clean water and call physi cian immediately Acid will also damage clothing Do not drink the battery electrolyte Do not allow open flame near the battery when charg ing Hydrogen gas forms inside the battery This gas is both toxic and flammable and may cause an explosion if exposed to flame Always disconnect the negative black battery cable s before disconnecting the posi tive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Do not overfill battery Electrolyte may overflow and damage paint wiring or structure When cleaning the battery use soap and water Be careful not to get soap and water into the bat tery Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded A Shorts caused by battery terminals or metal tools touch ing metal mower components can cause sparks Sparks can cause a battery gas explosion which will result in per sonal injury Prevent the battery terminals from to
7. To check move the steering control lever to the reverse position and release The steering control lever should return to the neutral position If not repeat steps 1 through 7 Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 1 115623_1111 Shut engine off place steering control levers in the park 4 3 WARNING Never operate the mower with the seat latch un installed and secured properly The seat platform must be securely latched to prevent seat from moving tilting in the event of mower tipping or rollover Figure 4 6 brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 On one side measure the park brake spring It should be compressed to 85 95 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 7 3 Repeat for other side 4 Reconnect the negative battery cable Brake arm spring Figure 4 7 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight rav eling of belt covering does not indicate failure trim ravelings with a sharp knife If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while op
8. 4 2 A E 4 6 Understand Machine Operation 2 1 Warranty 1 1 Wear Protective Clothing 2 1
9. amp fuse is blown Replace the 15 amp fuse For additional causes No fuel or line plugged Fuel valve is turned off See engine manual Fill tank or replace line See Fuel System section for more details Open the fuel valve There is incorrect fuel in the fuel system Drain the tank and replace the fuel with the proper type There is dirt in the fuel filter Dirt water or stale fuel in the fuel system The choke is not on Numerous Replace the fuel filter Contact your dealer Move the choke lever to ON See engine manual Engine Runs with continuous mis firing or engine runs unevenly or erratically Numerous See engine manual Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Poor compression Steering linkage needs adjustment Tow valve open Contact your dealer Adjust linkage Close tow valve The traction drive belt is worn loose or broken Install a new traction drive belt Air in system For additional causes Check filter and fittings See engine manual Air cooled engine over heating Low engine oil pressure Air intake screen or clean ing fins clogged Clean screen and fin For additional causes Low oil level Oil diluted or too light See engine manual Add oil Change oil and check for source of contamination Failed oil pump Contact your dealer SY
10. flame or spark or pilot light such as on a water heater or appliances Use extreme care when handling gasoline and other fuels They are extremely flammable and vapors are explosive A fire or explosion from fuel can burn you and others and can damage property 115623 1141 2 1 Refuel outdoors Never refuel drain the fuel from the machine indoors Never attempt to start engine when there is a strong odor of gasoline or diesel fuel fumes present Locate and correct cause Store fuel in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of fuel Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners Always place fuel containers on the ground away from your vehicle before filling When practical remove gas or diesel fuel powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser nozzle If a fuel dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is com plete Do not use a nozzle lock open device Never use gasoline or diesel fuel for cleaning parts Read and observe safety precautions elsewhere in this manual A Gasoline and diesel fuel is harmf
11. freely and clear of all obstructions 2 Chock the front tires 115623 1111 4 1 4 5 Raise the seat platform and disconnect the mower harness from the seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 4 1 Mower harness Figure 4 1 Loosen the jam nuts on each end of the steering control rod assemblies Figure 4 5 Set both steering control levers in the park brake position Figure 4 2 NOTE Both steering control levers need to be in the park brake position when starting the engine but need to be moved rapidly out of the park brake position once engine is started so that the brakes do not fight the transmissions since they have not yet been adjusted Shown with steering control levers in park brake position Figure 4 2 Loosen the nuts on the rear steering damper ball studs The dampers must be allowed to slide in the slots in the mower frame Figure 4 5 Start the engine Move the steering control lever to barely engage the brake neutral slot and hold it in that position Do not engage the steering control lever far enough to engage the brakes in the brake slot Figure 4 3 lever should return to the neutral position Figure 4 5 13 Check to make sure you have all fasteners tightened to the correct torque specifications A WARNI NG A 14 Repeat steps 4 thru 12 for the left side 15 Once both sides are properly adjusted check them together to make sure eve
12. fuel spillage Allow machine to cool before storing A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attachment while the engine is running or deck clutch is engaged A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine 1s secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appro priate jack stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands A Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good working condition A Never tamper with safety devices Check their proper operation regularly A Exercise caution when working under the deck as the mower blades are extremely sharp Wrap the blade s or wear gloves and use extra caution when servicing them A Use only genuine BigDog Mower replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A Be prepared if an accident or fire should occur Know where the first aid kit and the fire extin
13. load on the spring Figure 6 6 Tighten the rear nut against the block on the deck lift indicator until the front chain is taut Figure 6 6 Make sure the stop handle is pushing firmly against the height adjusting stop so that there is no free play forward 13 14 15 16 17 18 Figure 6 5 or rearward when you shake the deck lift indicator Figure 6 3 Finger tighten the front nut against the block on the deck lift indicator Figure 6 3 Tighten the 5 16 bolt on the front left deck leveler yoke until the chain is taut Tighten the jam nut against the deck leveler yoke Tighten the two flange nuts Verify that the front right chain remains taut while tightening the nuts Figure 6 5 Adjust the rear nut on the right rear lift block until the right rear chain 15 taut and the deck 15 firmly on the installation block Figure 6 6 Screw the front nut finger tight against the rear block on the deck lift spring Tighten these two nuts Figure 6 6 Check the right front deck chain to be sure it is taut If there is slack in the chain adjust the rear nut forward against the square block on the deck lift indicator to gain tension Figure 6 6 Tighten the 5 16 bolt on the left rear deck leveler yoke until the chain is taut Tighten the jam nut against the deck leveler yoke Tighten the two flange nuts Figure 6 5 6 2 19 Right rear deck chain 20 21 Tighten both the front and rear nut
14. 7 1 115623 1141 115623 1111 BigDog Mowers A Series Maintenance Schedule Refer to Figure 8 1 Figure 8 2 8 Figure 8 3 SERVICE AT EE Yak INTERVALS INDICATED HOURS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 4 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen 8 securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Replace air cleaner paper element 4 As needed Clean engine and transaxle compartment Daily Change transaxle oil and filter 7 Every 200 hours or 2 years Grease deck height pivots x Grease gauge wheel bearings x Change engine oil and filter 1 3 x Clean cylinder and head fins a x Check battery connections X Check tire pressure with a gauge X Check hydraulic oil level x Clean engine exterior a x Clean amp regap spark plugs a x Check pump and deck belt tension and condition 5 x Check fuel system 6 x Check hydraulic lines x Tighten lug nuts on wheels 2 X Change fuel filter x Replace spark plugs X Replace fuel evaporation system filter 8 X Check ROPS mounting hardware 9 X NOTES 1 Initial oil change is af
15. BigDog Mowers A Series General Service Manual KE nr P O Box 7000 Hesston Kansas 67062 2097 115623_1111 WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER This equipment may create sparks that can start fires around dry vegetation California Public Resources Code Sec tion 4442 6 provides that it is unlawful to use or operate an internal combustion engine on any forest covered brush covered or grass covered land unless the engine is equipped with a spark arrester maintained in effective working order A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammable particles over 0 0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States For est Service Other states or federal areas may have similar laws The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER inspect spark arrester daily replace every 500 hours or as needed The Engine Owner s Manual provides information regarding the U S Environ
16. MPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Loose steering linkage Tires improperly inflated Transaxle component faulty Tighten linkage Adjust air pressure to 8 12 psi 55 83 KPa Contact your dealer Mower creeps when park ing brake engaged There is abnormal vibra tion Blades do not rotate Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment The engine mounting bolts are loose The engine pulley idler pul ley or blade pulley is loose The engine pulley is dam aged Adjust parking brakes Tighten the engine mount ing bolts Tighten the appropriate pul ley Contact your dealer The cutting blade s is are bent or unbalanced Install new cutting blade s A blade mounting bolt is loose Tighten the blade mounting bolt Spindle bearing is worn or loose A blade spindle is bent The deck drive belt is worn loose or broken Replace or tighten spindle bearing Contact your dealer Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason m ectric clutch is not engag ing Check and or replace 10 amp fuse Contact your dealer
17. PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment A DANGER denotes immediate hazards which WILL result in severe personal injury or death A A denotes a hazard or unsafe practice which COULD result in severe personal injury or death WARNING Safe Servicing Practices This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death Understand Correct Service A Be sure you understand a service procedure before you work on the machine A Unauthorized modifications to the machine may impair the function and or safety and affect machine life A If it is necessary to make checks with the engine running always use two people with the operator at the controls able to see the person doing the checking Pre Operation Precautions Fuel Handling A To avoid personal injury or property damage use extreme care in handling fuel Fuel is extremely flamma ble and the vapors are explosive A Observe usual fuel handling precautions Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine run ning or while engine is hot Clean up any fuel spills Allow engine to cool before storing machine inside a building Keep fuel away from open flame or spark and store machine away from open
18. a free of any objects or bystanders 1 Raise and block the mower up so the drive wheels are off of the floor A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine is secure when it is raised and placed on the jack stands The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating Use only certified jack stands Use only appropriate jack stands with a mini mum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands WARNING 2 Position the control lever in neutral position Disengage the deck clutch switch Figure 4 13 3 With the bypass valve open and the engine running slowly move the directional control in both forward and reverse directions 5 or 6 times Figure 4 14 4 With the bypass valve closed and the engine running slowly move the control lever in both forward and reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine 5 It may be necessary to repeat Steps 3 and 4 until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged 4 6 Steering control lever 3 Shown with steering control levers in neutral posi
19. after the first 5 hours of oper ation and per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty conditions then it is recommended oil be changed more frequently IMPORTANT When removing the oil filter take precautions to minimize oil spillage on the exhaust system Draining the engine oil 1 Locate the oil drain valve on the engine Figure 5 1 2 Position a suitable oil drain container under the machine below the oil drain valve 3 Twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drain 4 After oil is drained close the valve by twisting it clockwise 5 Once the valve is closed clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine Engine Air Filter Perform engine air filter maintenance per the engine s owner s manual Fuel evaporation system filter All BigDog A Series mowers have a fuel evaporation system filter This filter must be checked and replaced every 300 hours or annually whichever comes first Figure 5 2 Fuel amp evaporative system line routings There are two rubber hoses that are connected to each fuel tank One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose is connected to the port on the side wall of the 115623 1111 5 1 Fuel eva
20. amper is spring loaded to return the steering control levers to the neutral position from the reverse position This gives the operator a sense of neutral during operation If the mower does not return to neutral from reverse then 4 2 115623 1111 Steering control lever Steering damper Slot O 1 10 4 damper Steering ES stud DSS 5 sa a O O Jam e O 9 nut Steering Jam S contro t rod G Figure 4 5 adjust as follows To set the steering dampers in the correct operating position follow these steps 1 2 10 Shut engine off place steering control levers in the park brake position disengage deck clutch and remove ignition switch key Raise seat platform and disconnect negative battery cable before doing any adjustments Place the steering control lever in the neutral position Figure 4 3 Loosen the steering damper s rear ball stud Figure 4 6 Pull the damper spring housing to the rear past the point that the internal spring is engaged Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position Tighten the nut on the steering damper s rear ball stud Figure 4 6 Reconnect the negative battery cable Lower the seat platform making sure that it is secured properly with the latch
21. d maintain BigDog A Series mowers This General Service Manual is a service guide for use by Service Technicians It provides the necessary information needed to perform normal maintenance requirements on these units The Parts Manual provides a complete parts listing for the unit Use this manual when ordering parts The Operator s Manual provides fundamental operational information and operational safety that is needed when operat ing the mower The component manuals are furnished by the various manu facturers to be used for the troubleshooting and servicing of their products Maintenance Introduction Regular maintenance is the best prevention for costly down time or expensive premature repair The following pages con tain suggested maintenance information and schedules which the operator mechanic should follow on a routine basis Remain alert for unusual noises they could be signaling a problem Visually inspect the machine for any abnormal wear or damage A good time to detect potential problems is while per forming scheduled maintenance service Correcting the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine and under the seat platform areas minute dust par 115623 1141 1 1 ticle are abrasive to close tolerance engine and hydraulic assem blies Daily inspect mower for grass clippings and wire and string tangles The underside of the mow
22. er deck will collect a build up of grass clippings and dirt especially when grass is wet or has high moisture content This build up will harden restricting blade and air movement and will probably show a poorer quality of cutting Therefore 1t should be removed routinely To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position and scrape the build up from underneath Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel Consult your BigDog Mowers service center when assistance is needed Information included in this manual was current at the time of printing but subsequent production changes may cause your machine to vary slightly in detail BigDog Mowers reserves the right to redesign and change the machine as deemed neces sary without notification If a change has been made to your machine which is not reflected in this service manual contact the Customer Service Department at BigDog Mowers for addi tional information Warranty Warranty repair must be performed by a BigDog Mowers Authorized Dealer before warranty credit can be allowed Work performed by anyone other than an Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved 1 2 115623 1111 SAFETY This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of
23. erating the machine place the steering con trol levers in the park brake position immediately WARNING Inspect the machine and involve your BigDog Mow ers dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bot tom of the groove Replace the pulley when this is the case oth erwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dress ings Any of these will destroy the belt composition in a very short time Hydraulic Pump Belt Adjustment The transmission drive belt tension remains constant by 4 4 means of a tension idler and spring There is no tension adjust ment of this belt Figure 4 8 NOTE Inspect the belt every 100 hours and replace as needed Replace the belt every 200 hours or every two 2 years whichever comes first If the transmission belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering control levers in the park brake position immediately Inspect the machine and involve your dealer to resolve the problem WARNING A Hydraulic pump belt
24. gs 5 1 Fuel evaporation system filter 5 1 Fuel FAM Ge 2 1 General engine maintenance 5 1 General Maintenance Precautions 2 2 Hydraulic pump belt adjustmeni 4 4 Hydraulic system 4 4 Maintenance introduction 1 1 Maintenance locator chart 8 2 Maintenance Precautions 2 2 114660_1111 1 1 Maintenance Schedule 8 1 Mower blade maintenance 6 3 Mower blade removal 6 3 Operate Machine Safely 2 2 Operation Precautions 2 2 Park brake spring 4 3 Pre Operation Precautions 2 1 Purging Drocechure yek 4 5 Safe servicing practices 2 1 Service Program 1 1 Special torques 3 1 Standard torques 3 1 Steering adjustments 4 1 Steering control lever neutral adjustment 4 1 Steering damper
25. guishers are located and how to use them A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A When preparing engine for storage remember that fuel stabilizer is volatile and therefore dangerous Seal and tape openings after adding the inhibitor Keep container tightly closed when not in use A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged 115623 1111 Prepare For Emergencies Avoiding spilling or dripped electrolyte A Be prepared if a fire starts If you spill acid on yourself A Keep a first aid kit and fire extinguishers available e Flush your skin with water A Keep emergency numbers for doctor ambulance service Apply baking soda or lime to help neutralize the acid hospital and fire department near the telephone e Flush your eyes with water for 10 15 minutes Get medical attention immediately If acid is swallowed e Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil A Get medical attention immediately Prevent Battery Explosions A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm
26. hen operating on a slope If you lose steering control while operating the machine place the steering con trol levers in the park brake position immediately WARNING Inspect the machine and involve your BigDog Mow ers dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bot tom of the groove Replace the pulley when this is the case oth erwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage 6 4 the fibers of the belt covering Keep oil and grease away from belts and never use belt dress ings Any of these will destroy the belt composition in a very short time Deck Belt Adjustment The spindle belt tension remains constant by means of a ten sion idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 11 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Spring chain anchor point Spring chain Figure 6 11
27. mental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep Engine Owner s Manual with your unit Should the Engine Owner s Manual become damaged illegible replace immediately Replacements may be ordered per the information found in the Product Information section of the owner s manual 115623_1111 114660_1111 General _ 1 1 BigDog Mowers A Series Service Program 1 1 Maintenance 1 1 ee nn has 1 1 GE AN Ee E a e 2 1 Sale Servicing Practices 2 1 Pre Operation 2 1 Operation Precautions 2 2 Operate Machine Safely 2 2 General Maintenance 2 2 Maintenance Precautions 2 2 Bete ete 3 1 Standard Torqlesssr er ts KK KK KS 3 1 TOUS eee wig ect ae de a 3 1 Power Unit Maintenance 4 1 SlSerinG AGiUSUNENIS 23 45 24 22 ones Cheats a 4 1 Park Brake Spring 4 3 a ee 4 4 Hydraulic Pump Belt Adjustment
28. ndling blades Always check for blade damage if mower strikes rock branch or other foreign object during mow ing A WARNING Always wear adequate eye protection when grinding mower blades Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath NOTE A blade holding tool part number 381442 is available from BigDog Mowers It is designed to prevent the blades from rotating when they are being removed or installed on the spindle Contact your BigDog Mowers dealer for more information Sharpen the blades on a grinder following pattern as shown Figure 6 8 Touch up sharpening can be done with a file Check the blades for balance following grinding A commer cial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Fig ure 6 9 amp Figure 6 10 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 0 Nm when reinstalling blades Properly compressed cup washers maintain the correct com WARNING 115623 1141 6 3 pression load the blades Re
29. place the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be point ing upward toward the inside of the deck to ensure proper cut ting IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower WARNING A Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury A Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING Resharpening pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above Original edge Figure 6 8 Warped Blade Replace Cutting plane ng A Straight Blade Comparison of Warped and Straight Blades Figure 6 9 Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge vr Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 10 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight rav eling of belt covering does not indicate failure trim ravelings with a sharp knife If the pump belt fails loss of control will occur especially w
30. poration system filter Figure 5 2 fuel tank It connects the fuel tank to the fuel shutoff valve Figure 5 4 The vapor line is connected to the port in the top of the fuel tank It connects the fuel tank to the engine s vapor port Figure 5 3 Figure 5 3 Fuel line Figure 5 4 5 2 115623 1111 Engine RPM Settings The engine rpm s are set at the factory for maximum mowing efficiency Occasionally it may be necessary to check and adjust the settings The idle speeds should be set as follows Kawasaki FR541 FR600 FR651 ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION MODEL NO WITH EX EXTENSION MODEL NO WITH US EXTENSION 3600 50 RPM NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown 1 e EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US 115623 1141 5 3 5 4 115623 1111 DECK ADJUSTMENTS Deck Leveling Leveling the deck must be done in the following manner and order 1 Check tire pressures to make certain they are properly inflated before starting to level deck The recommended pressures are as follows Drive wheel
31. ral Maintenance Precautions A Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A Never run the engine in an enclosed area unless exhaust 15 vented to the outside Exhaust gases contain carbon monoxide which is an odorless and deadly poison A Unless specifically required DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Place steering control levers in the park brake position disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable before doing any maintenance Wait for all movement to stop before adjusting cleaning or repairing To prevent carbon monoxide poisoning be sure proper ventilation is available when engine must be operated in an enclosed area 2 2 A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key and disconnect negative bat tery cable for maximum safety A Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness A Use a stick or similar instrument to clean under the mower making sure that no part of the body especially arms and hands are under mower A Keep your machine clean and remove any deposits of trash and clippings which can cause engine fires and hydraulic overheating as well as excessive belt wear Clean up oil or
32. ration Precautions Avoid Fire Hazards A Clean flammable material from machine Prevent fires by keeping engine compartment top of deck exhaust area battery hydraulic lines fuel line fuel tank and operator s station clean of accumulated trash grass clippings and other debris Always clean up spilled fuel and oil Start Engine Safely A Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine e Sit on the seat Move control levers to the neutral brake position Operate Machine Safely A Refer to the unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of the machine while it is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers in place except for servicing A Do not touch hot parts of machine Gene
33. ring control levers should be adjusted so that zz they align vertically with each other when in the neutral position Figure 4 3 Space between ends of steering control handles to 50 25 Figure 4 4 18 Check to make sure all tools or obstructions are removed from under the mower 19 Raise the rear of the mower and remove the jack stands Lower the mower Shown with steering control levers in neutral position Figure 4 3 9 Move the steering control lever forward and backward making sure that the wheel rotates forward and backward correctly Return the steering control lever to neutral and re check to make sure the wheel has stopped in the neutral position Place the steering control lever in the park brake position NOTE If neutral is set properly you should not hear the transmission whine 10 Turn the engine off 11 Tighten jam nuts on steering control rod Figure 4 5 12 With the engine off move the right side steering control lever into the neutral position and pull the lever to the full reverse position Now slowly bring the steering control lever back to the neutral position and then place it in the Figure 4 4 park brake position This sets the steering damper in the Steering damper correct neutral position Tighten the nut on the damper s rear ball stud Once this nut is tightened when the steering control lever is in the reverse position and then released the steering control The steering d
34. rything is working properly 16 IMPORTANT With the engine off disconnect the two female spade connectors from each other from step 3 and reconnect them to the seat switch This must be completed so that the safety circuit is functioning 8 Beginning with the right side of the mower adjust the properly Figure 4 1 steering control rod so that the right side wheel starts rotating forward while holding the steering control lever in the neutral position Now adjust the steering rod back A WARNING A the opposite direction to the point when the wheel stops rotating From that point turn the steering rod an Do not operate the mower without plugging the mower s additional 2 turn in the same direction This ensures that wiring harness into the seat switch This switch is an the steering rod 15 adjusted so that the transmission important part of the safety start interlock system Serious control 18 centered in the neutral band of the injury can result if the seat switch is not plugged into the transmission Figure 4 5 mower s wiring harness A WARNING A Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness This operation is extremely dangerous Pay close atten tion when adjusting the transmission control rod so you do not get your fingers tools or anything else close to the transmission s cooling fans SC Steering control lever 17 The stee
35. s on the deck lift indicator Figure 6 3 Check to make sure that all deck linkage hardware on the right side of the machine is tight Figure 6 6 N Spring Front lift pre load block nut Deck lift spring Right front deck chain Figure 6 6 Raise the deck into the transport position before removing the mower from the leveling blocks The deck should now be level and the deck cutting height properly adjusted For quality inspections measure the deck height at the three 3 locations shown in Figure 6 7 Centerline of mower Figure 6 7 115623 1111 Blades Mower blade maintenance Check the mower blades daily they are the key to power effi ciency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine Replace any blade which is bent cracked or broken WARNING A Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Replace worn or damaged blades Never work with blades while engine is running or deck clutch switch is engaged on Always place deck clutch switch in the disengaged position place steering control levers in the park brake position and turn engine off and disconnect negative battery cable Block up mower when you must work under it Wear gloves when ha
36. s tire pressure8 12 psi Gauge wheels tire pressure8 12 psi A Stop engine Make sure deck clutch switch is in the down OFF position Place steering control levers in the park brake engaged position WARNING 2 Place the 3 08 blocks under all four lift points Figure 6 1 3 Place the height stop pin in hole D with the flat side of the height stop against the stop handle 3 08 Block Figure 6 1 4 Clamp the height stop against the stop handle Figure 6 2 5 Loosen the front and rear nuts on the deck lift indicator so that the foot pedal is free Figure 6 3 6 Loosen the two nuts at the rear of the deck lift spring Figure 6 4 7 Loosen the deck leveler yoke on the front left side of the deck by loosening the flange nuts Figure 6 5 8 Loosen the jam nut and back out the 5 16 bolt on top of the deck leveler yoke to allow the adjuster to move up and down freely Figure 6 5 9 Repeat steps 7 and 8 for the rear left deck leveler yoke Check that all deck lift chains are loose and the deck is sitting firmly on all four deck installation blocks 115623 1141 6 1 10 11 12 Deck lift indicator Figure 6 3 Set the amount of threads protruding on the deck lift spring rod from the front lift block at approximately 2 25 Jam both nuts against the front lift block Figure 6 6 Turn the spring pre load nut until it contacts the rear nut of the front lift block reducing the amount of pre
37. st be completed before the steering control lever neutral adjustment can be done Refer to the Park Brake Spring Adjustment section for detailed information Fine adjustment to the unit s steering is made with the trans mission s control rod Neutral is properly adjusted when the steering control levers are in the park brake position and the transmissions do not whine If this occurs the steering control linkage may be adjusted as follows A This procedure will require that the unit to be raised and blocked up off of the ground It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions sup plied with the vehicle stands A Keep hands hair clothing etc clear of the cooling fans on top of the transmissions Exercise extreme caution A Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only WARNING WARNING WARNING 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate
38. t the spray away espe cially if using a power washer from the transmission s seals to prevent water intrusion and to ensure component performance Filter guard Figure 4 11 6 Re install the filter guard with three 1 4 screws Torque the screws to 65 in lbs each Figure 4 11 7 Repeat steps 2 6 for the opposite side transaxle 8 Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers 9 IMPORTANT Remove the top port plug from both transaxles prior to filling with oil This will allow the transaxles to vent during oil fill Figure 4 12 10 Remove the cap from the transaxle s expansion tank 11 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 qts per transaxle Install the top port plug into each transaxle Torque plugs to 180 in lbs Clean up any oil that leaked from the ports Figure 4 12 12 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expansion tank 13 Re install the expansion tank cap by hand Be careful not to overtighten 14 Proceed to the purge procedure Top port plug Figure 4 10 Fluid changing procedure 1 Park the unit on a level surface Place control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable 2 Remove the three 1 4 filter guard scre
39. ter 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and during hot weather periods 2 Torque initially and after first 2 hours of operation 3 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 4 Service more often under dusty or dirty conditions 5 Pump drive belt only Inspect every 6 months or 100 hours and replace if worn or cracking is noticed Otherwise replace every 200 hours or 2 years which ever comes first 6 Check fuel system for any cracks or leaks including but not limited to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets 7 Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first Thereafter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first 8 More often under dusty or dirty conditions and during hot weather 9 Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REFERENCES A Refer to Engine Owner s Manual NOTE After completing maintenance cycle 300 hours repeat cycle 115623_1111 8 1 BigDog Mowers A Series Maintenance Locator Chart
40. tion Bypass valve rod Left rod shown Figure 4 14 Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive 8 12 psi 55 83 KPa Gauge wheels 8 12 psi 55 83 KPa If you wish to use non pneumatic tires on your BigDog mower the tires must be an approved tire purchased from Big Dog Mowers Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires 115623 1111 ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break in and regular maintenance are specified in the Engine Owner s man ual Please refer to this manual for engine servicing lubricating oil levels with quality and viscosity recommendations bolt torques etc The engine warranty is backed by the manufacturer Engine Oil and Filter A A If the engine has been running and is up to operating tem perature allow the engine to cool before changing the oil Engine and engine oil will be very hot so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil WARNING Check engine oil daily and after every 4 hours of operation Machine must be setting level when checking oil Refer to engine manual and maintenance schedule for oil recommenda tion and capacities Change the engine oil and filter
41. tom 118 160 01 Electric Clutch mounting bolt 9 45 48 61 65 Front wheel axle bolt 73 99 Transaxle hub nut 275 339 Transaxle pump pulley nut 45 55 61 74 6 NOTE 1 Lug nuts only It is recommended that these be checked after the first 2 hours of operation and every 50 hours and following removal for repair or replacement 2 Engine torque values Refer to the respective engine owner s manual 3 If clutch mounting bolt is loosened or removed do not re use Replace with a new bolt Use only hand tools to install this fastener 4 If using pin locknut 250 ft Ibs 115623_1111 3 1 WARNING A Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts Failure to cor rectly torque these items may result in the loss of a wheel or blade which can cause serious damage or personal injury 3 2 115623 1111 POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustment The mower s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral posi tion However should the mower begin to creep the steering control lever linkage can be adjusted Before considering any adjustment check the tire air pressure Unequal tire pressure will cause the mower to drift to one side Refer to tire pressure information in the Tires section for detailed information NOTE Proper park brake adjustment mu
42. uching any metal mower parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts A Incorrect battery cable routing could cause damage to the mower and battery cables This can cause sparks which can cause a battery gas explosion which will result in per sonal injury Always disconnect the negative black bat tery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Avoid Acid Burns A Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes Avoid the hazard by e Filling batteries in a well ventilated area e Wearing eye protection and rubber gloves e Avoiding breathing fumes when electrolyte is added 115623 1141 2 3 2 4 115623 1111 TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners found in this manual Torque all cap screws nuts and set screws to these values unless a different torque is shown in the Special Torques section M4 26 4 IN LBS 54 IN LBS 6 4 M6 924 IN LBS 10 4 222 IN LBS M10 Special Torques Description Ft Ibs N M Wheel lug nuts 1 65 75 88 14 101 7 Blade spindle bolt top 73 99 Blade spindle bolt bot
43. ul or fatal if swallowed e Long term exposure to vapors can cause serious injury and illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank or fuel con tainer opening Keep fuel away from eyes and skin If fuel is spilled on clothing change clothing immedi ately Understand Machine Operation A Only qualified and trained personnel should operate the equipment A Carefully read the owner s manual and all manuals fur nished with the attachments Learn the location and pur pose of all controls instruments indicators and labels Wear Protective Clothing A Do not operate or service the equipment while wearing sandals tennis shoes sneakers shorts or any type of loose fitting clothing Long hair loose clothing or jew elry may get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating or servicing this machine A Always wear adequate eye protection when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A Prolonged exposure to loud noise can cause impairment or loss of hearing Always wear adequate ear protection such as earplugs when operating this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing Do not wear radios or music headphones while operat ing the machinery Safe operation requires your full attention Ope
44. ws and filter guard Clean any loose debris from around the filter Figure 4 11 3 Place an oil drain pan beneath the oil filter and remove the oil filter from the transaxle 4 After the oil has been drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter Figure 4 12 5 Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface Purging procedure Due to the affects air has on efficiency in hydrostatic drive 115623 1141 4 5 applications it is critical that it is purged from the system Air creates inefficiency because its compression and expan sion rate is higher than that of the oil approved for use in hydro static drive systems These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or the oil has been changed The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term operation 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle is at the proper oil level If it is not fill to the specifications outlined in this man ual The following procedures are best performed with the vehicle drive wheels off the ground Then repeated under normal oper ating conditions If this is not possible then the procedure should be performed in an open are
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