BigDog® Mowers Alpha General Service Manual
Contents
1. AVI JU 11 nyd g ma Ee j Y e 81118 92 A 8 81 038 NVL 91 9 f o ONE 81 NYg 61 Jani ona Cy w amp 10N3108 pi MONIO pel aaa NITE 82 Me ES TUTU 02 lt DN J BOINI ST ABDI ri AA BDNI ET por sys HJLIMS LYTS S oO a z HILNT 3 A HOLIMS TVELNIN HOLIMS WWYLNIN 2 v emeze ZA 0 8 Z Av ad 2 LUVLS 2 BA S 911940 L gt 913418 22 ene 91 038 980 Z 9 14311 V8 HIND 810118 a HOLIMS 2 14 62 QO 9 van EOF yaaa 2 NOI LINO 3SN4 YILSVN WS 1 wove ze 81 418 038 v yl und E REV B 7 1 119293 REV B 7 2 119293 MAINTENANCE Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 amp Figure 8 5 SERVICE AT ee jA av j ya INTERVALS INDICATED 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 amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Check tire pressure with a gauge Prior to each u2. 5 1 General maintenance precautione 2 2 Maintenance introduction 1 1 Maintenance locator Chart l l 8 2 119293 i 1 PAGE Maintenance precautions nuseeersnnenenennnnnneneennn 2 2 Maintenance Schedule nssennennnennn 8 1 Mower blade replacement nn 6 5 Operate machine Safely UUU U U 2 2 Operation Precautions urssenreeennnnnennnnnnnn 2 2 Park brake spring adjustment 4 3 Pre operation precautions nneeeernnnenen nennen 2 1 Safe servicing practices w wwwwmmmamemaama 2 1 Service Program K E EEiu keke 1 1 Special torques urssnsennnennnnnnennnnnnnnnnnnnnnnn 3 1 Standard torques EEEii Ek kek 3 1 Steering adjustments eseese 4 1 Steering control lever neutral adjustment 4 1 PROS Se E dd AA sts 4 6 Transaxle Belt Adjustment 4 3 Warranty enisee ea 1 1 REVB
3. Tighten the cam hardware IMPORTANT When tightening the cam hardware you must tighten the inner nut while holding the bolt and outer nut to keep the cam from rotating and changing the adjustment The inner nut must be tight to prevent cam movement Figure 6 7 amp Figure 6 8 Figure 6 4 Hold the bolt and outer nut so cam does not move while tightening the inner nut Figure 6 7 11 Go to the front of the deck and measure the center of the deck from the ground to the top of the deck This distance should be 1 8 to 3 8 less than the rear corner Figure 6 5 i y dimensions If it is not then it will be necessary to adjust 8 Pivot the cam by using a 3 8 rachet and extension Pivot the deck front to back Figure 6 9 the cam until the top of the deck is the same distance 12 Level the front of the deck by turning the lock nut at the from the ground as the right side Figure 6 6 front of the mower until the correct distance from the ground to the top of the deck is attained Figure 6 10 REVB 6 2 119293 Figure 6 10 Front center of deck j e Figure 6 9 119293 6 3 REV B Blades Mower blade maintenance Refer to the Mower blade replacement section for blade removal and installation Check the mower blades daily as they are the key to power efficiency and well groomed turf Keep the blades sharp A dull blade will tear rather than cut the grass leaving a brown ragged top on the grass
4. or one in good condition should never run against the bot tom of the groove Replace the pulley when this is the case oth REV B erwise the 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 Belt adjustment The transaxle drive belt tension remains constant by means of a tension idler and spring There is no tension adjustment of this belt Figure 4 10 NOTE Inspect the belt every month and replace as needed Replace the belt every two 2 years A If the transaxle belt fails loss of control will occur espe cially when operating on a slope If you lose steering con trol 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 Transaxle drive belt Figure 4 10 REV B 4 4 Belt replacement A WARNING A This procedure will require that the mower to be raised and blocked up off of the ground 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 supplied with the vehicle stands A WARNING Allow the engine and muffler to cool before proceeding w
5. The deck drive belt is off the pulley Install the deck drive belt and check for a reason Electric clutch is not engag ing Check and or replace 15 amp fuse Contact your Dealer 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 Sharpen the blades Install new cutting blade s Level the deck per the Deck leveling section of the General Service Manual Adjust the height of the anti scalp wheel Clean the underside of the deck Tires improperly inflated Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your Dealer REV B REV B 9 2 119293 INDEX PAGE Belt adjustment ennnnnnennnnnnnnnnnnnnnnnnnnn 4 4 Belt replacement ersnnssersnnnnnnnennnnnnnnnnn nn 4 4 Blades 2 ne he 6 4 Control lever stops adjustmen 4 2 Deck belt ciel eee einai dt 6 5 Deck belt adjustment 4sser nennen nennen 6 6 Deck belt replacement u 4444 nn 6 6 Deck Belt Routing L ke 6 8 Deck leveling r Prr oaoo2o0 0j59 6 1 Electrical Schematic nnnnennnnnnnnnnn 7 1 Engine air fille i iaia 5 1 Engine oil and MEN s susy yanan kebk k katan W 5 1 Engine RPM settings ll ez 5 2 General engine maintenanece
6. lock tool Hustler part number 381442 over the two blades to prevent them from rotating DANGER Never work with blades while engine is running or deck clutch is engaged Always place deck clutch in the disen gaged position engage control levers in the park brake position and turn engine off Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes a rock branch or other foreign object during mowing DANGER Exercise caution when working under the deck as the mower blades are extremely sharp Wearing gloves is advisable when working around or with the blades e Blade lock tool Figure 6 14 4 Use a 5 8 wrench to remove the 7 16 cap screw holding the blade to the spindle shaft NOTE Only remove and install one blade at a time 119293 6 5 when using the blade lock tool 381442 as it requires two blades to work properly 5 Inspect the blade for damage If the blade is damaged replace it If the blade is not damaged either sharpen it or replace it with a new blade or another sharpened used blade A WARNING 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 6 If sharpening the blade refer to the Mower blade maintenance section for proper sharpening procedures 7 The spindles have a 5 8 diameter boss that centers the blades o
7. this equipment as prolonged exposure to uncomfortable or loud noises can cause impairment or loss of hearing REV B Do not wear radios or music headphones while operat ing the machinery Safe operation requires your full attention Operation Precautions Avoid Fire Hazards amp 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 Sit on the operator s seat e 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
8. Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved REV B REV B 1 2 119293 SAFETY This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment denotes immediate hazards which WILL result in severe personal injury or death A DANGER WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death 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 no
9. BigDog Mowers Alpha General Service Manual ED BIGDOG MOWER CO 200 South Ridge Road Hesston Kansas 67062 119293 REV B A 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 eguipment may create sparks that can start fires around dry vegetation California Public Resources Code Section 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 Forest 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 regar
10. FORMATION BigDog Mowers Service Program This manual is part of a service package for the BigDog Alpha mowers Use of this manual in conjunction with other BigDog mower and component manuals will provide the infor mation necessary to service and maintain the BigDog Alpha mower 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 components Maintenance Introduction Regular maintenance is the best prevention for downtime or premature failure The following pages contain suggested main tenance 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 co
11. al connections are corroded or loose Disengage clutch switch Recharge or replace Check the electrical con nections 15 amp fuse is blown Replace the 15 amp fuse For additional causes No fuel or line plugged There is incorrect fuel in the fuel system There is dirt in the fuel filter See engine manual Fill tank or replace line See Fuel System section for more details Drain the tank and replace the fuel with the proper type Replace the fuel filter Dirt water or stale fuel in the fuel system Contact your Dealer The choke is not on Numerous Numerous Restrictions in air cleaner Move the choke lever to ON See engine manual See engine manual Service air cleaner Poor compression Contact your Dealer Steering linkage needs adjustment Tow valve open The traction drive belt is worn loose or broken Adjust linkage Close tow valve Install a new traction drive belt For additional causes See engine manual Air cooled engine over heating Low engine oil pressure High oil consumption Air intake screen or cooling fins clogged For additional causes Low oil level Clean screen and fins See engine manual Add oil Oil diluted or too light Change oil and check for source of contamination Failed oil pump Numerous Contact your Dealer Contact your Dealer Mower jerky when starting or operates in one direc tion
12. ding the U S Environmental 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 or illegible replace immediately Replacements may be ordered per the information found in the Product Information section of the owner s manual Federal law and California State law prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair replacement of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use or 2 The use of the equipment after such device or element of design has been removed or rendered inoperative by any person REV B 119293 119293 TABLE OF CONTENTS General Information 1 1 BigDog Mowers Service Program 1 1 Maintenance Introduction 1 1 A mania een DD BDB 1 1 OR 2 1 Safe Servicing Practices 2 1 Pre Operation Precautions 2 1 Operation Precautions 2 2 Operate Machine Safely 2 2 General Maintenance Precautions 2 2 Maint
13. e fibers of the belt covering Keep oil and grease away from belts and never use belt dress REV B Boss Spindle shaft face Figure 6 15 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 There is no tension adjustment of this belt Figure 6 16 amp Figure 6 17 Spring mount Tensioning Idler spring Z Figure 6 17 REV B 6 6 Spring mount Tensioning Idler spring Figure 6 16 Deck belt replacement A WARNING A Allow the engine and muffler to cool before proceeding with the following procedure A WARNING A Exercise caution when releasing spring tension from the belt idler 1 Park the mower on a flat surface and stop the engine Make sure deck clutch switch is in the down OFF position Remove ignition key Place the steering control levers in the park brake position Make sure the blades are stopped before leaving seat Disconnect the negative battery cable 2 Lower the deck to the lowest setting 3 Remove the deck covers Figure 6 18 amp Figure 6 19 4 Using a tension spring hook Hustler part number 604462 disconnect the tension idler spring from the spring mount to release tension from the deck drive belt Figure 6 16 Figure 6 17 amp Figure 6 18 NOTE The spring and spring mount will b
14. eat cycle 119293 8 1 REV B Maintenance Locator Chart REV B Figure 8 1 13 Z o u u u u u B Figure 8 2 Figure 8 3 36 42 Deck Figure 8 5 12 Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Park Brake Switch 2 Drive Tire Pump Belt Engine Air Intake Screen Front Wheel Tires Front Wheel Zerks 2 Deck Belt Blades Fuel Evaporation System Filter Figure 8 4 52 Deck 8 2 119293 SYMPTOMS PROBABLE CAUSES TROUBLESHOOTING SUGGESTED REMEDIES Starting motor does not crank The engine will not start starts hard or fails to keep running Engine Runs with continuous mis firing or engine runs unevenly or erratically Loss of power or system will not operate in either direction 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 Electric
15. ecome loose and can become misplaced Set these aside after removal for easier access upon re assembly 5 Remove the deck drive belt from the deck spindle pulleys and idler pulley 6 Remove the deck drive belt from the electric clutch pulley located on the engine shaft 7 Route the new deck drive belt around the clutch pulley spindle pulleys and stationary idler pulley Make certain the belt is routed properly Figure 6 21 Figure 6 22 amp Figure 6 23 119293 ension idler Tension spring hook 604462 Figure 6 18 Never operate the mower without the deck covers in place cover cover COW ZAM Electric __ NI NN a clutch y an un N pulley Figure 6 19 8 Using the tension spring hook 604462 re tension the deck drive belt by pulling on the deck belt idler spring Figure 6 21 and hooking it in the spring mount on the deck 9 Re install the deck covers Figure 6 18 amp Figure 6 19 119293 6 7 REV B NOTE The following notes are the same for the different decks shown 1 There is no tension adjustment of this belt 2 Route belt as shown 36 42 Deck Belt Routing Figure 6 22 52 Deck Belt Routing NI Figure 6 23 REV B 6 8 119293 ELECTRICAL Electrical Schematic Kawasaki
16. einstalling REVB 6 4 Lay the blade on a flat surface and check for distortion Fig ure 6 12 amp Figure 6 13 Replace any distorted blade 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 11 Warped Blade Replace uN Cutting plane n Straight Blade Comparison of Warped and Straight Blades Figure 6 12 Cutting edge Twisted Blade Edge replace Cutting Plane Cutting edge Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 13 119293 Mower blade replacement A WARNING This procedure will require that the mower to be raised and blocked up off of the ground 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 supplied with the vehicle stands 1 Park the mower on a flat surface and stop the engine Make sure deck clutch switch is in the down OFF position Remove ignition key Place the steering control levers in the park brake position Make sure the blades are stopped before leaving seat Disconnect the negative battery cable 2 Raise the front of the unit and block with certified jack stands This allows easier access to the blades under the deck 3 Install a blade
17. enance Precautions 2 2 lere AA Ne KK aa oe tarts 3 1 Standard Torgues 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Park Brake Spring Adjustment 4 3 Transaxle Drive Belt 4 3 MEES anna re a ee er ee enges 4 6 Engine Maintenance 5 1 General Engine Maintenance 5 1 Engine Oil and Filter 5 1 Engine Air Filter 5 1 Fuel evaporation system filter 5 1 Engine RPM Sellings os 153 4 2aka as ns Ea k k ala k d 5 2 Deck Adjustments 6 1 Deck Leveling 6 1 Blades ka 2 222 205 Qa ae Bea eee yey oN See 6 4 BIA SI i a ah X ed Mu et we Aa Meek KA y 6 5 36 42 Deck Belt Routing 6 8 52 Deck Belt Routing 6 8 t 1 REV B REV B Electrical 0 o WA ee H HHH HHHH ee 7 1 Electrical Schematic Kawasaki 7 1 Maintenance 8 1 Maintenance Locator Chart 8 2 Troubleshooting a xa kenau Pacer ott a cers tere ai 9 1 119293 GENERAL IN
18. f the safety start interlock system Serious injury can result if the seat switch is not plugged Z into the mower s wiring harness Align handles A 125 5 Start the engine and move both steering control levers forward against the stops in the steering cover 6 Determine if the drive wheels are rotating equally or if one is faster than the other If the wheels are not the same speed proceed to the next step 7 Shut engine off and place the steering control levers in the park brake position 8 Loosen the cap screw under the seat platform on the side which is rotating too fast Tighten the cap screw on the top of the steering cover to adjust the drive straight Figure 4 5 bracket up to stop the steering control lever sooner Repeat this procedure until both drive wheels rotate at the same speed Figure 4 8 REVB 4 2 119293 10 11 Figure 4 7 Tighten the cap screws under the seat platform on both sides to lock the drive straight brackets in place Snug the cap screws on the top of the steering cover so they don t move during operation IMPORTANT With the engine off disconnect the two female spade connectors from each other from step 4 and reconnect them to the seat switch This must be completed so that the safety circuit is functioning properly Figure 4 7 Lower the seat platform and secure in place A WARNING A Do not operate the mower without plugging the mower s wiring harness into the seat s
19. fter handling 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 119293 e 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 2 3 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 termina
20. g 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 Tire section for detailed information NOTE Proper park brake adjustment must 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 WARNING 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 w
21. h will not be duplicated here Engine Oil and Filter amp 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 Mower must be on a level surface when checking oil Refer to engine manual and maintenance schedule for oil recommenda tion and capacities Change the engine oil and filter after the first 5 hours of oper ation and then per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty condi tions then it is recommended oil be changed more frequently IMPORTANT After the new oil filter has been installed clean up any oil which may have spilled onto the engine plate muffler and heat shield Draining the engine oil 1 Locate the oil drain valve on the lower right side of the engine 2 Locate the oil drain hose that was supplied with the machine Be sure to clean and clear it of debris that might block the flow of the engine oil Figure 5 1 3 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the valve 4 Position the loose end of the hose forward and down in front of the right side transmission so that it can drain in
22. 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 General 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 is 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 REV B 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 s
23. ith the following procedure 1 Park the mower on a flat surface and stop the engine Make sure deck clutch switch is in the down OFF position Remove ignition key Place the steering control levers in the park brake position Make sure the blades are stopped before leaving seat Disconnect the negative battery cable 2 Lower the deck to the lowest setting 3 Raise the rear of the mower and block with certified jack stands 4 Remove the deck covers Figure 4 11 amp Figure 4 12 Spring mount Tensioning Idler spring Figure 4 11 5 Using a tension spring hook Hustler part number 604462 disconnect the tension idler spring from the spring mount to release tension from the deck drive belt Figure 4 13 NOTE The spring and spring mount will become loose and can become misplaced Set these aside after removal 119293 Spring mount Tensioning Idler spring Deck Deck cover cover NN Figure 4 12 for easier access upon re assembly A WARNING Exercise caution when releasing spring tension from the belt idler 10 119293 Spring mount Tension spring hook 604462 Figure 4 13 Remove the deck drive belt from the electric clutch pulley located on the engine shaft Figure 4 14 NOTE Do not remove the deck drive belt from the deck spindle pulleys It will only need to be removed from the electric cl
24. ith the vehicle stands A WARNING Keep hands hair clothing etc clear of the pulleys on top of the transmissions Exercise extreme caution A WARNING 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 1 Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 119293 4 1 Raise the rear of the mower and block with certified jack stands Remove the rear wheels Chock the front tires Make sure both steering control levers are in the park brake position Figure 4 1 Steering control levers in park brake position NEIGDOS Figure 4 1 5 Loosen the nuts adjacent to the steering bushing Figure 4 2 Bushing Figure 4 2 Place a clamp on the transmission pump arm as shown in Figure 4 3 Tighten the nuts against steering bushing Figure 4 4 Verify that the pump arms are still in the neutral position Move the steering control levers out of the park brake position and push fully forward verify that the pump arm does not bottom out against the stop on the transmission Move the levers to the full reverse position and release Verify that the levers return near to the neutral position The s
25. l 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 amp Gasoline and diesel fuel is harmful 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 operator 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
26. ls from touching 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 Avoiding spilling or dripped electrolyte If you spill acid on yourself e Flush your skin with water Apply baking soda or lime to help neutralize the acid 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 Get medical attention immediately REV B REV B 2 4 119293 TORQUE Standard Torques The following chart lists the standard torque values for the threaded fasteners f
27. mpartment and under the seat platform areas 119293 1 1 minute dust particles are abrasive to close tolerance engine and hydraulic assemblies Daily inspect mower for grass clippings and wire and string tangles The underside of the mower 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 lesser quality of cut Therefore it 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 necessary without notification If a change has been made to your machine which is not reflected in this service manual contact the Cus tomer Service Department at BigDog Mowers for additional 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
28. n the spindles When re installing blades ensure that the blade is centered on the boss and seated flat against the spindle shaft face 8 When attaching the blade to the spindle shaft do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 48 foot pounds 65 14 Nm when reinstalling blades IMPORTANT The blade sail curved part must be pointing upward toward the inside of the deck to ensure proper cutting Rotate the blades after installation to ensure blade tips do not touch each other or sides of the mower Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury A WARNING WARNING 9 Remove the blade lock 10 Raise the front of the mower and remove the jack stands 11 Lower the mower 12 Re attach the negative battery cable Deck Belt 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 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 the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage th
29. only 119293 Steering control linkage needs adjustment Adjust linkage Loose steering linkage Transaxle component faulty Tighten linkage Contact your Dealer 9 1 SYMPTOMS 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
30. ound 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 FT LBS FT LBS 32 4 IN LBS 12 IN LBS 98 4 IN LBS 204 IN LBS 26 4 IN LBS 54 IN LBS 92 4 IN LBS 222 IN LBS 750 260 350 M16 160 215 875 420 565 M20 320 435 Special Torques DESCRIPTION FT LBS N M Wheel lug nuts 70 95 Blade spindle bolt top 60 81 3 Blade spindle bolt bottom 48 65 Electric clutch mounting bolt 3 47 63 7 Front wheel axle bolt Tighten the nut then back it off until the wheel spins freely Transaxle hub nut 200 271 2 Transaxle pump pulley nut 50 67 8 Engine torques 2 N A N A 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 WARNING A A Particular attention must be given to tightening the drive 2 Engine torque values Refer to the respective engine owner s manual wheel lug nuts and blade spindle bolts Failure to cor 3 If clutch mounting bolt is loosened or removed do not rectly torque these items may result in the loss of a wheel 119293 re use Replace with a new bolt Use only hand tools to install this fastener 3 1 or blade which can cause serious damage or personal injury REV B REV B 3 2 119293 POWER UNIT MAINTENANCE Steerin
31. own i e EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US HIGH IDLE 3200 50 RPM REVB 5 2 119293 DECK ADJUSTMENTS Deck Leveling 1 Park the mower on a hard flat surface 2 Check tire pressures 8 12 psi to make certain the tires are properly inflated before starting to level deck A WARNING A Stop engine Make sure deck clutch switch is in the down OFF position Remove ignition key Place steering con trol levers in the park brake position Make sure blades are stopped before leaving seat 3 Raise and place deck cutting height adjusting lever in the E position Figure 6 1 Make sure this hardware is tight Height adjusting lever YI Measure to top of deck Figure 6 1 4 Make sure all deck hardware is tight on the right rear of the deck Figure 6 2 5 Measure the right rear of the deck from the ground to the top of the deck Figure 6 3 6 Now go to the left rear of the deck and measure from the ground to the top of the deck If it is different than the right hand side then the deck will need to be re leveled Figure 6 4 7 Loosen the hardware that secures the cam just enough to allow the cam to pivot Do not over loosen the cam as it will allow the deck to move on its own Figure 6 5 Figure 6 3 119293 6 1 REV B 9 To allow for easier access when tightening the adjusting hardware lower the deck to its lowest position Figure 6 6 10
32. pulley Make certain the belt is routed properly around the spindle pulleys and stationary idler pulley s Using the tension spring hook 604462 re tension the deck drive belt by pulling on the deck belt idler spring and hooking it in the spring mount on the deck Figure 4 11 Figure 4 12 Figure 4 13 amp Figure 4 14 13 Re install the deck covers WARNING amp amp Never operate the mower without the deck covers in place REV B 14 Raise the rear of the mower and remove the jack stands 15 Lower the mower 16 Re attach the negative battery cable Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive wheels REVB 8 12 psi 55 83 KPa 4 6 Front 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 119293 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 Special attention should be paid to applicable data whic
33. se Clean engine and transaxle compartment After each use Grease gauge wheel bearings Change engine oil amp filter 1 3 Check battery connections x Xx X gt lt Clean engine exterior a Replace air cleaner paper element 4 Check pump amp deck belt tension and condition 5 Check fuel system 6 Check fuel tank grommet 6 Tighten lug nuts on wheels 2 Change fuel filter 6 Replace fuel evaporation system filter 7 NOTES 1 Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and dur ing hot weather periods Torque initially and after first 2 hours of operation Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items Service more often under dusty or dirty conditions Pump drive belt only Inspect every month and replace if worn or cracking is noticed Otherwise replace every 2 years Check fuel system for any crack or leaks including but not limit to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets Replace as needed More often under dusty or dirty conditions and during hot weather PARON N REFERENCES A Refer to engine owner s manual for engine service information NOTE After completing maintenance cycle 100 hours rep
34. t 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 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 119293 2 1 Refuel outdoors Never refuel or 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 al
35. teering control levers should be adjusted so that they align vertically with each other when in the neutral position Figure 4 5 Space between ends of steering control handles to be 50 25 Figure 4 5 Check to make sure all tools or obstructions are removed from under the mower REVB Control lever stops adjustment WARNING A Keep hands hair clothing etc clear of the rotating drive wheels hubs during this process Exercise extreme cau tion The steering control lever stops may be adjusted to help drive straight when the steering control levers are pushed forward against the stops 1 Raise the rear of the mower and block with certified jack stands 2 Chock the front tires 3 Make sure both steering control levers are in the park brake position Figure 4 6 Figure 4 3 Steering control levers in park brake position EIGDos Bushing Figure 4 6 4 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 Figure 4 4 together Figure 4 7 11 Re install the rear wheels Torque lug nuts to 70 ft Ibs 95 NM 12 Raise the rear of the mower and remove the jack stands WARNING A Lower the mower 13 Re attach the negative battery cable Do not operate drive the mower without plugging the 14 Close the seat platform mower s wiring harness into the seat switch This switch is an important part o
36. to a suitable oil drain container 5 With the hose in position use a 10 mm wrench or socket and open the valve approximately 4 turns in the counterclockwise direction Allow 10 minutes for engine oil to adequately drain 6 After oil is drained close the valve by turning it in the clockwise direction until it is fully closed 7 Once the valve is closed carefully remove the oil drain hose and clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine 8 Clean the oil drain hose and store it appropriately Figure 5 1 119293 5 1 Oil drain hose AA valve Engine Air Filter Figure 5 1 Perform engine air filter maintenance per the Maintenance Schedule shown elsewhere in this manual Fuel evaporation system filter All BigDog Alpha mowers have a fuel evaporation system filter This filter must be checked and replaced every 100 hours or annually whichever comes first Figure 5 2 Figure 5 2 REV B 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 FR651 FR691 ENGINE SPEED MODEL NO ENDING WITH MODEL NO WITHOUT EXTENSION NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be sh
37. 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 extinguishers 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 119293 A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged Prepare For Emergencies A A A Be prepared if a fire starts Keep a first aid kit and fire extinguishers available Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A 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 Wash hands a
38. ure 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 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 Exercise caution when releasing spring tension from any of the belt idlers or when working with any of the deck lift components 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 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
39. utch pulley at the rear of the mower Locate the tension idler spring Securely clamp locking pliers onto the spring at the end located next to the idler arm Figure 4 10 Release the transaxle drive belt tension using the locking pliers to remove the tension spring from the idler arm Swing the idler arm out of the way Figure 4 14 Remove the transaxle drive belt from the transaxle drive pulleys and the engine pulley Figure 4 14 Replace the transaxle drive belt and route it around the 4 5 AN Y lt j me clutch l Deck drive e Viewed from top of the mower Transaxle drive belt Transaxle drive pulley Idler arm Engine pulley Electric pulley belt Transaxle drive pulley D E UE i le Transaxle __2 M8 a drive belt 9 om al aN ly Tension idler i o E Sy Ji Transaxle drive pulley TA Figure 4 15 11 Make sure the transaxle drive belt is routed correctly around the tension idler before attaching the tension spring Using the locking pliers re attach the tension spring to the idler arm to re tension the transaxle drive belt Remove the locking pliers from the tension spring Figure 4 14 12 Reroute the deck drive belt around the electric clutch
40. witch This switch is an important part of the safety start interlock system Serious injury can result if the seat switch is not plugged into the 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 Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 119293 Cap screws Figure 4 8 1 Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 Make sure steering control levers are in the park brake position 3 Adjust the nylock nut on the end of the brake rod so that 0 625 of thread is showing Repeat for other side Figure 4 9 4 Reconnect the negative battery cable 5 Close seat platform and re install seat platform hardware C Ra O oO O 7 Figure 4 9 Transaxle Drive Belt Inspect belts freguently 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 Inspect the belt pulley grooves and flanges for wear A new belt
41. 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 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 handling blades Always check for blade damage if mower strikes a rock branch or other foreign object during mow WARNING ing A WARNING A Always wear adequate eye protection when grinding mower blades Mower blades are sharp and can cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING Sharpen the blades on a grinder following pattern as shown Figure 6 11 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 r
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