Bigdog SERIES X General Service Manual

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Bigdog SERIES X General Service Manual | Manualzz

BigDog

®

Mowers

Series X

General Service Manual

108936BD_0812

•••••

P.O. Box 7000

•••

Hesston, Kansas

67062-2097

REV E

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

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 regarding 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 E 108936BD_0812

Table of Contents

108936BD_0812

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . 3-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Park brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Fuel evaporation system filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Fuel & evaporative system line routings. . . . . . . . . . . . . . . . . . . 6-2

Engine RPM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Deck Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Electrical Schematic – Briggs & Stratton . . . . . . . . . . . . . . . . . 8-1

Electrical Schematic – Kawasaki . . . . . . . . . . . . . . . . . . . . . . . 8-2

Electrical Schematic – Kohler . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

c-1

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

c-2 108936BD_ 0812

GENERAL INFORMATION

Service Program

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 operating the mower.

The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicing of their products.

Maintenance Introduction

Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain 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 performing 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 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 poorer quality of cutting. 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

Customer 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 Authorized Dealer will invalidate the warranty claim and warranty credit will not be approved.

108936BD_0812 2-1 REV E

REV E 2-2 108936BD_0812

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.

DANGER

– denotes immediate hazards which WILL result in severe personal injury or death.

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

 Be sure you understand a service procedure before you work on the machine.

 Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

 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

 To avoid personal injury or property damage, use extreme care in handling fuel. Fuel is extremely flammable and the vapors are explosive.

 Observe usual fuel handling precautions:

• Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

• Do not remove fuel cap or fill tank with engine running 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.

• 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 dispenser 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 complete. 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.

 Gasoline and diesel fuel is harmful or fatal if swallowed.

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 container opening.

Keep fuel away from eyes and skin.

If fuel is spilled on clothing, change clothing immediately.

Understand Machine Operation

 Only qualified and trained personnel should operate the equipment.

 Carefully read the owner’s manual and all manuals furnished with the attachments. Learn the location and purpose of all controls, instruments, indicators and labels.

Wear Protective Clothing

 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 jewelry may get tangled in moving parts. Always wear long pants, safety glasses, ear protection and safety shoes when operating or servicing this machine.

 Always wear adequate eye protection when servicing the hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

 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.

108936BD_0812 3-1 REV E

• Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention.

Operation Precautions

Avoid Fire Hazards

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

 Avoid possible injury or death from machine runaway.

 Do not start engine by shorting across starter terminals.

 Before you start the engine:

• Sit on the operator’s seat.

• Move control levers to the neutral/brake position.

Operate Machine Safely

 Refer to the unit’s owner’s manual for complete safety information on safe machine operation.

 Always maintain a safe distance from people and pets when mowing

 Always be aware of what is behind the machine before backing up.

 Never leave machine unattended with ignition key in switch, especially with children present.

 Follow daily and weekly checklists, making sure hoses are tightly secured and bolts are tightened.

 Always keep engine and machine clean, removing accumulated dirt, trash and other material from machine.

 Never put hands or feet under any part of the machine while it is running.

 Never attempt to start engine when there is a strong odor of gasoline fumes present. Locate and correct cause.

 Keep all safety shields and covers in place, except for servicing.

 Do not touch hot parts of machine.

General Maintenance Precautions

Repairs or maintenance requiring engine power

should be performed by trained maintenance personnel only.

 Never run the engine in an enclosed area unless exhaust is vented to the outside. Exhaust gases contain carbon monoxide which is odorless and deadly poison.

 Unless specifically required, DO NOT have engine running 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.

 Before working on or under the deck, make certain engine cannot be accidentally started. Shut engine off, remove ignition switch key and disconnect negative battery cable for maximum safety.

 Except when changing or checking belt, always keep belt covers on mower deck for safety as well as cleanliness.

 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.

 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.

 Always wear adequate eye protection when servicing the hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

 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.

 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 minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

 Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good working condition.

 Never tamper with safety devices. Check their proper operation regularly.

 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.

 Use only genuine BigDog

®

Mower replacement parts to ensure that original standards are maintained

Maintenance Precautions

Avoid Fire Hazards

 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.

 Provide adequate ventilation when charging batteries.

 Do not smoke near battery.

 Never check fuel level with an open flame.

 Never use an open flame to look for leaks anywhere on the equipment.

 Never use an open flame as light anywhere on or around the equipment.

 When preparing engine for storage, remember that fuel stabilizer is volatile and therefore dangerous. Seal and

REV E 3-2 108936BD_0812

tape openings after adding the inhibitor. Keep container tightly closed when not in use.

 Inspect electrical wiring for worn or frayed insulation.

Install new wiring if wires are damaged.

Prepare For Emergencies

 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

 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 after handling.

 Charge batteries in an open well ventilated area, away from sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

 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 contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing.

• Do not drink the battery electrolyte.

• Do not allow open flame near the battery when charging.

• 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 positive (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 battery. Clean the battery terminals with a solution of four parts water and one part baking soda when they become corroded.

 Shorts caused by battery terminals or metal tools touching metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in personal injury.

• Prevent the battery terminals 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.

 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 personal injury. Always disconnect the negative (black) battery 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

 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:

• Filling batteries in a well-ventilated area.

• Wearing eye protection and rubber gloves.

• Avoiding breathing fumes when electrolyte is added.

• Avoiding spilling or dripped electrolyte.

If you spill acid on yourself:

• Flush your skin with water.

• Apply baking soda or lime to help neutralize the acid.

• Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

If acid is swallowed:

• Drink large amounts of water or milk.

• Then drink milk of magnesia, beaten eggs or vegetable oil.

• Get medical attention immediately.

108936BD_0812 3-3 REV E

REV E 3-4 108936BD_0812

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.

SIZE

.438

.500

.562

.625

#10

.250

.312

.375

.750

.875

Special Torques

FT-LBS

32.4 IN.-LBS.

98.4 IN.-LBS.

204 IN.-LBS.

30

48

73

105

145

260

420

N-

M

65

99

143

200

3.6

11.1

23

40

350

565

SIZE

M8

M10

M12

M14

M3

M4

M5

M6

M16

M20

FT-LBS

12 IN.-LBS.

26.4 IN.-LBS.

54 IN.-LBS.

92.4 IN.-LBS.

222 IN.-LBS.

37

64

103

160

320

N-

M

25

50

87

140

1.3

3

6.1

10.4

215

435

DESCRIPTION

Wheel (lug) nuts

1

Blade spindle bolt top

Blade spindle bolt bottom

Electric clutch mounting bolt

3

Front wheel axle bolt

Wheel motor hub nut (prior to s/n 10110311)

Wheel motor hub nut (s/n 10110311 and later)

Hydraulic pump pulley bolt

Engine torques

2

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.

108936BD_0812 4-1

FT-LBS

65 – 75

65 – 75

118

45 – 48

100

200 – 210

220 – 240

45 – 55

N/A

N

M

88.14 – 101.7

88.14 – 101.7

160.01

61 – 65

136

271.2– 284.7

298 – 325

61 – 74.6

N/A

WARNING

Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts. Failure to correctly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury.

REV E

REV E 4-2 108936BD_0812

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 position. 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 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 transmission’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:

WARNING

This procedure will require that the unit 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 supplied with the vehicle stands.

3. 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 5-1

Female spades

Seat switch

Mower harness

Figure 5-1

4. Start the engine.

5. Position the steering control lever in the neutral position and observe which way the wheels are rotating. Figure 5-

2

WARNING

Keep hands, hair, clothing, etc., clear of the cooling fans on top of the transmissions. Exercise extreme caution.

Park brake slot

Steering control lever

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. Raise the rear of the mower and block with certified jack stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

2. Chock the front tires.

108936BD_0812 5-1

Steering control lever in neutral position

Figure 5-2

6. If wheel(s) are rotating forward, loosen the jam nuts on the pump linkage rods and rotate the rod to lengthen the steering control linkage until the wheel(s) come to a stop.

Figure 5-3

7. Repeat for the opposite side if necessary.

REV E

Jam nut

Pump

Pump linkage rod

Figure 5-3

8.

If wheel(s) are rotating in reverse then loosen the jam nuts on the pump linkage rods and rotate the rod to shorten the steering control linkage until the wheel(s)

come to a stop. Figure 5-3

Repeat for the opposite side if necessary

9. When both wheels remain in neutral, tighten the jam nuts to lock the turnbuckle in place.

10. Test again by moving the steering control levers forward and backward before returning them to the neutral position. If the tires are in neutral, the unit is now ready for operation.

11. After adjusting for neutral it may be necessary to readjust the control lever stop and/or damper.

12.

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

properly. Figure 5-1

WARNING

Do not operate the mower without plugging the mower’s wiring harness into the seat switch. 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.

Control lever stops

The steering control lever stops (see Figure 5-4) are designed

to do two things: First, and most important, they must keep the pumps from bottoming out internally. Secondly, the stops may be adjusted to help drive straight when the steering control levers are pushed forward against the stops.

To keep the pumps from bottoming out internally use the following procedure:

This adjustment is only required if the hydraulic pump(s) have been replaced.

WARNING

Pump damage will occur if these stops are set incorrectly.

1. To make the first adjustment the mower engine must not be running.

2.

Check to make sure the steering control levers are against the stops before the pumps are bottomed out internally.

3. To do this, gently and slowly move the steering control levers forward and feel if there is some resistance on the pump lever before the control levers hit the stops. Check one side at a time. If you sense that the pump arms are stopping the forward motion of the control arms, loosen the jam nut on the adjustable stop of the corresponding side, turn the stop (set screw) inward to stop the steering control levers slightly before the pump bottoms out. Lock in place when the adjustment is correct by re-tightening the jam nut. Do this for each side.

Steering lever support

Stop screw

WARNING

Never operate the mower with a non-functioning seat switch. Always reconnect the seat switch to the mower harness.

13. Check to make sure all tools or obstructions are removed from under the mower.

14.

Raise the rear of the mower and remove the jack stands.

Lower the mower.

15.

Lower and secure the seat platform.

REV E 5-2

Figure 5-4

To adjust the stops for driving straight when steering control levers are against the stops during operation:

1.

Determine which drive tire is rotating too fast when both steering control levers are against the stops in the control

panel (see Figure 5-5).

2. Then, stop the mower and loosen the lock nut on the side which is rotating too fast and turn the stop (set screw) inward to stop the steering control lever sooner. Tighten the lock nut on the stop and test again.

3.

Repeat this procedure until unit drives straight.

108936BD_0812

NOTE: Since this is a hydrostatic drive, variables such as temperature of oil, efficiency of pumps and motors, tire pressure etc. may effect the consistency of the ability to rely on the stops to drive straight without the operator making minor steering adjustments with the control arms.

Steering control lever

Jam nut

Steering control lever shown in park brake position

Figure 5-6

Stop

Steering damper spring housing

Figure 5-5

Steering damper

The steering dampers are spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation.

To set the steering dampers in the correct operating position follow these steps:

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.

Place the steering control lever in the neutral position.

Figure 5-6

3.

Loosen the steering damper’s front ball stud. Figure 5-7

4.

Pull the damper spring housing past the point that the

internal spring is engaged. Figure 5-7

5.

Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position.

6. Tighten the nut on the steering damper’s front ball stud.

NOTE: The damper must not bottom out when the pump lever is fully stroked in either direction.

7.

Reconnect the negative battery cable.

8.

Lower and secure the seat platform.

9. 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 6.

Steering control lever adjustment

The steering control levers can be adjusted for operator comfort.

1.

By loosening the cap screws that attach the upper control lever to the lower lever the upper control lever can be pivoted to fit the operator’s personal preference (see

Cap screws

Front ball stud

Figure 5-7

Figure 5-8)

2. The steering control levers should be adjusted so that they align vertically with each other when in the neutral

position. Figure 5-9

Figure 5-8

108936BD_0812 5-3 REV E

Align steering control lever

±.125” (3.175mm)

Brake link

Figure 5-10

Figure 5-9

Park brake adjustment

Bypass valve

WARNING

This procedure will require that the unit 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 supplied with the vehicle stands.

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.

Raise the rear of the mower and block with certified jack stands. The rear wheels need to be able to rotate freely and clear of all obstructions.

3.

Chock the front tires.

4.

Position the steering control levers in the neutral position.

NOTE: The front brake link is not to be adjusted. Figure

5-10

5.

Open the hydraulic pump’s bypass valve, on the side that is being adjusted, by turning the bypass valve counter clockwise one-half to one revolution. Figure 5-11

6. Try and rotate the tire by hand. The tire should rotate.

Remember hydraulic oil resistance will prevent the tire from rotating freely even with the bypass valves open.

There should be no resistance from the brakes at this point.

7.

Move the steering control lever to where it is just inside

(1/8” [3.175mm]) the park brake slot. Figure 5-12

REV E 5-4

Figure 5-11

NOTE: When the steering control lever is against the outside edge of the slot, the brakes should not be engaged.

8.

Rotate the tire. If the brake is adjusted properly the tire will still rotate but friction will start to become noticeable here. However, if no brake resistance is noticed, the brake needs adjusted as follows:

a. Loosen the brake linkage jam nuts. (Figure 5-13)

Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure. When you feel the brake begin to engage, stop adjusting the turnbuckle.

Re-tighten the jam nuts on the turnbuckle.

b. Place the control lever in the park brake slot. The tire should not rotate when the control lever is in the park

brake position. Figure 5-12

c. Place the control lever in the neutral position. The tire should rotate freely.

9. Close the hydraulic pump’s bypass valve. Figure 5-11

10. Repeat steps 4 through 9 for the other side.

11.

Check to make sure all tools or obstructions are removed from under the mower.

12. Raise the rear of the mower and remove the jack stands.

108936BD_0812

Control lever

Park brake slot

Outside edge

1/8”

(3.175mm)

Figure 5-12

Lower the mower.

13.

Reconnect the negative battery cable.

14.

Lower and secure the seat platform. short time.

Hydraulic Pump Belt Adjustment

The transmission drive belt tension remains constant by means of a tension idler and spring. There is no tension

adjustment of this belt. Figure 5-14

Inspect the belt every 100 hours and replace as needed.

Replace the belt every 400 hours or every two (2) years whichever comes first.

WARNING

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.

Hydraulic pump belt

Bottom View

Tension idler

Spring

Jam nuts

Figure 5-13

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 raveling 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 bottom of the groove. Replace the pulley when this is the case, otherwise 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 dressings. Any of these will destroy the belt composition in a very

Hydraulic system

Figure 5-14

IMPORTANT: Never use hydraulic or automatic transmission fluid in this system; use only motor oil as specified.

Remember, dirt is the primary enemy of any hydraulic system.

WARNING

Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor, familiar with this form of injury, or gangrene may result.

108936BD_0812 5-5 REV E

Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. To find a leak under pressure, use a piece of cardboard or wood — never use your hands. Relieve all pressure in the system before disconnecting or working on hydraulic lines. To relieve pressure, lower all attachments and shut off engine.

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 1” (2.54cm) from top of reservoir. Use only SAE 20W50 SL/SM service motor oil. Figure 5-15

Change hydraulic system filter element and oil after first 50 hours of machine operation, then replace filter and oil in reservoir every 500 hours thereafter. Figure 5-15

The system filter is located in front of the hydraulic reservoir.

A standard oil filter wrench is used to change filter, threads are right handed. Use a BigDog

®

Mowers approved filter element

only. Prefill the filter element with clean oil, before installing, to prevent drawing air into the system pump.

WARNING

Do not attempt any adjustments with the engine running. Use extreme caution while working in or around all vehicle linkage! High temperatures can be generated. Follow all safety procedures outlined in the vehicle owner’s manual!

Installation & Testing Procedures

Disconnect the system hoses at the wheel motor, or system hoses from the pump and connect the Bi-Directional Flow Test

Kit. (Special care should be taken to prevent contamination debris from entering pump or wheel motor system ports).

NOTE: Using the Bi-Directional Flow Test Kit, determination of directional flow is not necessary. The flow meter may be connected in either direction into the forward and reverse high pressure system lines.

NOTE: The following adapter fittings will be required when connecting the Bi-Directional Test Kit (Excel P/N 783886 or

Hydro-Gear P/N 70661):

PK (12) Series Pumps require two 771311 adapter fittings.

CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the vehicle’s high pressure system lines. Failure to perform this properly could result in bodily injury.

Testing Procedures

1. Use approved jack stands to raise the drive wheels off the floor.

WARNING

Hydraulic reservoir

WARNING

Hydraulic filter

Figure 5-15

Hydraulic Pump Flow Test

The design purpose of the Bi-Directional Flow Test Kit is to allow the customer to isolate the pump from the wheel motor and determine if the pump is acceptable. The following information can be used to install and test the pump by simulating a wheel motor load.

Certain procedures require the vehicle engine to be operated and the vehicle to be raised off of the ground.

To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured.

REV E 5-6

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 minimum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

2. Open the restriction valve all the way.

3. Bring the engine to maximum operating speed.

Pumps Engine full throttle rpm setting

PK (12) 3600

CAUTION: Damage to the flow meter and/or re-calibration may result from testing at input speeds that exceed the above recommendations.

4. For the pump being tested, move the steering control levers in full forward motion. (It will be necessary to lock the steering control levers into full forward position to prevent false readings).

5. Operate without any load for approximately 30 seconds to 1 minute. This allows the system oil temperature to

108936BD_0812

rise.

NOTE: Raising the system oil temperature will make a difference in the readings you receive. It has been determined that to complete this test accurately, the oil temperature must be near system operating temperatures.

Suggested temperature range 160° - 210° F (71.1° - 98.9°

C)

6. Tighten the flow meter restriction valve until the gauge reads 300 psi (21 bar).

Record the flow reading on the Bi-Directional Flow

Meter.

Test Example: PK (12) Pump

RESTRICTION VALVE

BI-DIRECTIONAL

FLOW METER

300 psi (21 bar) reading

7.

Increase the pressure to 1100 PSI (76 bar).

Record the flow reading on the Bi-Directional Flow

Meter.

8. The acceptable gpm “flow droop” or (difference) is:

PK (12) 2.0 gpm (7.6 l/min)

If the difference exceeds these values the pump would not be operating efficiently and should be replaced or repaired. See the following example.

9 gpm (34 l/min) (1st reading)

CONNECTIONS TO

THE FWD/RVS LINES

DISCONNECTED

FROM WHEEL MOTOR

RESTRICTION VALVE

BI-DIRECTIONAL

FLOW METER

CONNECTIONS TO

THE FWD/RVS LINES

DISCONNECTED

FROM WHEEL MOTOR

1100 psi (76 bar) reading

PK (12)

300 psi (21 bar) reading

1100 psi (76 bar) reading

5 gpm (19 l/min)

9 gpm (34 l/min)

-5 gpm (19 l/min)

4 gpm (15 l/min)

(2nd reading)

(1st reading)

(2nd reading)

(the difference)

Subtract the 1st reading from the 2nd.

(In this example, 4 gpm difference would indicate further pump examination).

Purging Procedures

Due to the affects air has on efficiency in hydrostatic drive applications, it is critical that air is purged from the system.

These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or additional oil has been added to the system.

Air creates inefficiency because its compression and expansion rates that are higher than that of oil.

108936BD_0812 5-7

Entrained air in the oil may cause the following symptoms:

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 reservoir is at the proper oil level. If it is not, fill to the vehicle manufacturer’s specifications.

REV E

The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under normal operating conditions.

WARNING

Potential for serious injury! Certain procedures require the vehicle be operated and the vehicle to be raised off of the ground. To prevent possible injury to the servicing technician and/or bystanders, insure the vehicle is properly secured. Use only appropriate vehicle stands, with a maximum weight rating of 2000 pounds to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

1. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times), as air is purged from the unit, the oil level will drop.

2. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times). Check the oil level and add oil as required after stopping the engine.

It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system. When the pumps operate smoothly forward and reverse at normal speeds, purging is complete.

Tires

It is important for level mowing that the tires have the same amount of air pressure. The recommended pressures are:

Drive wheels . . . . . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

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.

REV E 5-8 108936BD_0812

ENGINE MAINTENANCE

General Engine Maintenance

Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner’s manual. 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 engine manufacturer.

Engine Oil and Filter

WARNING

If the engine has been running and is up to operating temperature, 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.

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 recommendation and capacities.

Change the engine oil and filter after the first 5 hours of operation 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. (units equipped with oil drain

valve as shown in Figure 6-1).

1.

Locate the oil drain valve on the lower left side of the engine.

2.

Remove the dust cap.

3.

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.

4. Attach one end of the hose onto the oil drain valve nipple.

Make sure the hose is pushed all the way onto the valve.

Figure 6-4

5.

Position the loose end of the hose out to the left side of the mower so that it can drain into a suitable oil drain container.

6. With the hose in position, twist the valve counterclockwise and pull out to open the valve. Allow

10 minutes for engine oil to adequately drain.

7. After oil is drained, close the valve by pushing in on the valve body and twisting it clockwise.

8.

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.

9.

Re-install the dust cap on the oil drain valve nipple.

10.

Clean the oil drain hose and store it appropriately.

Oil drain valve

Figure 6-1

Oil drain hose

Figure 6-2

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

Cartridge type filter

A specially designed dry filter is standard equipment on some

BigDog

®

mowers which supplies clean combustion air to the

engine. An example of the air filter is shown in Figure 6-4.

Recommended service procedure

1. Release clamps and remove element. Clean the canister with a damp cloth.

2.

Before installing a new element, inspect it by placing a bright light inside and rotate the element slowly, looking for any holes or tears in the paper. Also check gaskets for cuts or tears. Do not attempt to use a damaged element

108936BD_0812 6-1 REV E

Pre-cleaner

Oil drain valve

Canister

Figure 6-3

which will allow abrasive particles to enter the engine.

3.

Reinstall the dust cup. Make sure it seals all the way around the air cleaner body, then tighten the clamps.

4.

Check all fittings and clamps periodically for tightness and inspect hoses for holes or cracks.

5.

Periodically check the intake hose for signs of ingested dust. Locate and repair the source of ingested dirt.

6.

Never operate a machine without an air filter installed.

Overservicing

Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary. Each time the filter is removed a small amount of dirt and dust could fall in the intake system. This accumulated dirt can cause a dusted engine.

It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine.

Do not clean element, replace with a new element only.

Cleaning used air filter elements, through improper cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure.

It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on. The warranty for air filters expires upon

cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the engine manufacturer’s control. Therefore, on a dust ingested engine failure, there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner.

A partially dirty air filter element works better than a new element. Therefore, a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected. The reason is simple. The media in the filter must be porous to allow air to pass through it. When dirty air passes through the filter, the dirt plugs some of the holes in the media and actually acts as part of the filter media. When the next round of dirt enters, the first dirt helps filter out even smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration.

Of course, at some point the filter media becomes too clogged to allow air to pass.

The mowing conditions will determine the frequency of air filter element changing.

REV E 6-2

AU

Figure 6-4

Fuel evaporation system filter

All BigDog ® X Series mowers with a 9xxxxx (i.e. 922222) model number, produced after serial number 11010000, have a fuel evaporation system filter. Refer to the following table for more detailed information. Figure 6-5

BigDog ® X Series mowers with a 9xxxxxAU or 9xxxxxEX

(i.e. 922222AU or 922222EX) model number may or may not have a fuel evaporation system filter. Refer to the following table for more detailed information. Figure 6-5

This filter must be replaced every 500 hours or annually whichever comes first.Figure 6-5

MODEL

EXTENSION

NONE

EX

MODEL

EXAMPLE

922222

922222EX

SERIAL NUMBERS

ALL HAVE FILTER

PRIOR TO SERIAL NUMBER

12080000 HAVE FILTER

922222AU

AFTER SERIAL NUMBER 12080000

DO NOT HAVE FILTER

PRIOR TO SERIAL NUMBER

12080000 HAVE FILTER

AFTER SERIAL NUMBER 12080000

DO NOT HAVE FILTER

Fuel & evaporative system line routings

On mowers produced after serial number 11010000 there are two rubber hoses that are connected to the fuel tanks. 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 fuel tank. It connects the fuel tank to the fuel shutoff valve.

Figure 6-6

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

6-7

108936BD_0812

Fuel evaporation system filter

Figure 6-5

Fuel tank

Fuel line

Fuel tank

Fuel shutoff valve

Seat support

Figure 6-6

Fuel tank

Tee

Vapor line

Fuel tank

108936BD_0812

Figure 6-7

Fuel evaporation system filter

6-3 REV E

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 high idle speeds, with no load, should be set as follows:

Briggs & Stratton 26 hp

ENGINE SPEED

MODEL NO. ENDING WITH:

MODEL NO. WITHOUT EXTENSION

HIGH IDLE

3600 RPM

Kawasaki FX691, FX730, & FX850,

ENGINE SPEED

MODEL NO. ENDING WITH:

MODEL NO. WITHOUT EXTENSION

HIGH IDLE

3600 RPM

Kohler CV730, & CV740

ENGINE SPEEDS

MODEL NO. ENDING WITH:

MODEL NO. WITHOUT EXTENSION

HIGH IDLE

3600 RPM

NOTE: Model numbers may or may not end with an extension after the number. There are several different extensions that may be shown; i.e. EX or CE.

Example: 922222 (no extension)

922222 EX

922222 CE

922222 US

REV E 6-4 108936BD_0812

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 wheels . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

Gauge wheels . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

WARNING

Stop engine. Make sure deck clutch switch is in the down

(OFF) position. Place control levers in the brake position before leaving machine.

2.

Park the unit on a flat surface.

3.

Place 3” high deck support blocks (two stacked 2” x 4” blocks can be used to create a 3” [7.62cm] high support)

at the four corners of the deck as shown. Figure 7-1

NOTE: Back of deck will automatically be set 1/4”

(6.35mm) higher.

4.

Place the height stop in the 3” (7.62cm) hole, with the pin side of the height adjusting stop against the stop handle.

Block

Block

right side). Figure 7-4

10.

Jam both nuts against the block.

Stop handle

Nuts

Figure 7-2

Clamp here

Deck adjustment stop

Foot pedal

Block

Block

Figure 7-1

5.

Clamp the height adjusting stop against the stop handle.

This will assure that the height will not move during the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the

handle. Figure 7-2

6.

Loosen all nuts on the deck lift threaded rods, and the hardware on the height indicator bar (on the right front), until all the deck lift chains are loose, and the deck is

sitting tightly on all four blocks. Figure 7-3, Figure 7-4 &

Figure 7-7

7.

Loosen the two nuts on the front of height indicator so

that the foot pedal is free. Figure 7-3 & Figure 7-7

8.

Start the leveling process on the left front of the mower.

9.

Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1" (2.54cm) (left &

108936BD_0812 7-1

Figure 7-3

11.

Push or pull on the deck lift foot pedal until the chain on the left front just becomes tight, making sure that the deck stays tight against the block.

12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod, just enough to carry most of the deck weight on that side — the block

should be able to move with only a slight drag. Figure 7-4

13.

Jam nuts tightly together against the deck lift block.

14.

Go to the right front of the mower.

15. Loosen the 5/16” jam nut on the adjuster lift chain, and back the adjuster bolt out to allow the adjuster to move

up and down freely. Figure 7-5

16. Tighten the adjuster bolt until the chain just becomes tight. Then tighten just enough to carry the weight of the front of the deck on that side—to check, move the blocks back and forth; they should move with a slight drag.

Figure 7-5

17. Tighten the adjuster bolt jam nut to prevent the adjuster

REV E

bolt from moving. Figure 7-5

18. Tighten the hardware holding the chain and adjuster onto

the deck lift arm. Figure 7-5

Nuts

Lift block

1”

Chains

1”

Deck lift rod

Figure 7-4

19.

Go to the right rear of the mower.

20. Make sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain.

21. Tighten the appropriate nut until the chain just becomes tight, and carries most of the deck weight. Check by moving the block—it should move with a slight drag.

Figure 7-6

22. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block.

Figure 7-6

27. Compress the deck lift assist springs so that there is 1”

(2.54cm) of space between the front nut on the spring and the rear nut on the deck lift block. Typical both sides.

Figure 7-4

28. When completed, all chains will be tight, and deck cutting height will be set to the deck height indicator.

Nut

Nut

Deck lift threaded rod

5/16” bolt

Chains

Adjuster

Hardware

Jam nut

Figure 7-7

Blades

Figure 7-5

23. Go to the left rear of the mower.

24.

Make sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod

until there is slack in the deck lift chain. Figure 7-7

25. Tighten the appropriate nut until the chain just becomes tight, and carries most of the deck weight. Check by moving the block—it should move with a slight drag.

Figure 7-7

26. Tighten the other nut on the opposite side of the block, and jam them tightly together against the block.

REV E 7-2

Mower blade maintenance

Check the mower blades daily, they are the key to power efficiency 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.

108936BD_0812

Replace any blade which is bent, cracked or broken.

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. Replace worn or damaged blades.

WARNING

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 rock, branch or other foreign object during mowing!

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 7-8). Touch-up sharpening can be done with a file

Check the blades for balance following grinding. A commercial 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

(Figure 7-9 & Figure 7-10). 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 compression load on the blades. Replace the cup washers if they are cracked or flattened.

IMPORTANT: The blade sail (curved part) must be pointing upward toward the inside of the deck to ensure proper cutting.

IMPORTANT: When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower.

WARNING

Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.

WARNING

Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

Resharpening pattern

Do not sharpen to original pattern (below). It is easier to get a straight cutting edge following the resharpening pattern shown above.

Figure 7-8

Warped Blade (Replace)

Original edge

Cutting plane

Straight Blade

Comparison of Warped and Straight Blades

Figure 7-9

108936BD_0812 7-3 REV E

Cutting edge

Cutting Plane

Twisted Blade Edge

(replace)

Cutting edge

Straight Blade Edge

End view of blades, comparing twisted and straightened blades

Figure 7-10

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 raveling 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 bottom of the groove. Replace the pulley when this is the case, otherwise 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 dressings. 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 tension 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 7-11 &

Figure 7-12

IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley.

Spring chain

Spring chain anchor point

Figure 7-11

Idler spring

REV E 7-4 108936BD_0812

NOTE: The following notes are the same for the different decks shown.

1.

Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (8.26cm) cut height.

2.

Route belt as shown.

52", 60” & 72” Side Discharge Deck Belt Routing & Tensioning

9.3” – 10.3”

(23.6 – 26.2cm)

Figure 7-12

108936BD_0812 7-5 REV E

REV E 7-6 108936BD_0812

ELECTRICAL

Electrical Schematic – Briggs & Stratton

108936BD_0812 8-1 REV E

Electrical Schematic – Kawasaki

REV E 8-2 108936BD_0812

Electrical Schematic – Kohler

108936BD_0812 8-3 REV E

REV E 8-4 108936BD_0812

Maintenance Schedule

Refer to Figure 9-1, Figure 9-2, Figure 9-3 & Figure 9-4

SERVICE AT

INTERVALS INDICATED

WEEKLY

OR

Every 40

HOURS

MONTHLY

OR

Every 100

HOURS

ANNUALLY

OR

EVERY 500

HOURS

Verify safety start interlock system

Visually inspect unit for loose hardware and/or damaged parts

Visually inspect tires

Check oil level, engine (1) (4)

Clean air intake screen (8)

Check fuel level

Blades - sharpen & securely fastened

Discharge chute - securely in place & in lowest position

Clean engine and pump compartment

Replace air cleaner paper element (5)

Change engine oil and filter (1) (4)

Check battery connections

Check tire pressure with a gauge

Check hydraulic oil level

Clean engine exterior (a)

Grease deck pusher arms (8)

Grease deck height pivots (8)

Grease gauge wheel bearings (8)

Check pump and deck belt tension and condition (6)

X

X

X

X

X

Prior to each use

Prior to each use

Prior to each use

Prior to each use or every 4 hours

Prior to each use or every 4 hours

Prior to each use

Prior to each use

Prior to each use

Daily

As needed

X

X

X

X

X

Check fuel system (7)

Check hydraulic lines

Check fuel valve and grommet (7)

Tighten lug nuts on wheels (2)

Change fuel filter

Clean or replace hydraulic fill cap

Change hydraulic filter & oil (3)

Grease deck spindle housings

X

X

X

X

X

X

X

Check ROPS mounting hardware (9) X

Replace fuel evaporation system filter (8) X

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 during hot weather periods.

2. Torque initially and after first 2 hours of operation.

3.

Perform initial hydraulic filter change after 50 hours (one week) of operation.

4.

Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other maintenance items.

5.

Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine.

Do not clean filter element. Replace with a new one.

6.

Pump drive belt only - Inspect every 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 400

hours or 2 years whichever comes first.

7.

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.

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 for engine service information.

NOTE: After completing maintenance cycle (500 hours), repeat cycle.

108936BD_0812 9-1 REV E

BigDog™ Mowers Series X

Maintenance Locator Chart

7

4a

2

6

12

11

9

3

4b

10

1

6

8

5

12

11

9

Figure 9-1

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4a. Engine Oil Drain Valve

(Briggs & Stratton)

4b. Engine Oil Drain Valve

(Kohler & Kawasaki)

5. Battery

6. Fuel Tanks

7. Hydraulic Oil Reservoir

8. Hydraulic Oil Filter

9. Gauge Wheel Bearing Zerks (2)

10. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tire

14. Pump Belt

13

14

REV E

13

Figure 9-2

9-2 108936BD_0812

BigDog™ Mowers Series X

Maintenance Locator Chart

2

1

1

1. Deck Pusher Arm Zerks (2)

2. Deck Belt

3. Spindle Housing Zerk (3)

4. Blades

5. Fuel evaporation system filter

4

Figure 9-3

4

3

3

4

3

108936BD_0812

Figure 9-4

5

9-3 REV E

REV E 9-4 108936BD_0812

TROUBLESHOOTING

The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventative maintenance program will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions.

SYMPTOMS PROBABLE CAUSES

SUGGESTED

REMEDIES

SYMPTOMS PROBABLE CAUSES

SUGGESTED

REMEDIES

High oil consumption

Numerous See your dealer

Starting motor does not crank

Steering control levers not in park brake position or switch not adjusted

Place steering control levers in park brake position or re-adjust switch

Disengage clutch switch Deck clutch switch engaged

Weak or dead battery Recharge or replace

The engine will not start, starts hard or fails to keep running

Electrical connections are corroded or loose

Check the electrical connections

For additional causes See engine manual

No fuel or line plugged

Fuel valve is turned off

There is incorrect fuel in the fuel system

There is dirt in the fuel filter

Fill tank or replace line

(See Fuel System section for more details)

Open the fuel valve

Drain the tank and replace the fuel with the proper type

Replace the fuel filter

Dirt, water or stale fuel in the fuel system

The choke is not on

Contact your BigDog™

Mowers Dealer

Move the choke lever to

ON

Numerous

Numerous

See engine manual

See engine manual

Engine:

Runs with continuous misfiring or engine runs unevenly or erratically

Loss of power or system will not operate in either direction

Restrictions in air cleaner Service air cleaner

Loss of power or system will not operate in either direction

Restrictions in air cleaner Service air cleaner

Hydraulic line blockage

Internal interference or leakage in wheel motor

See your dealer

See your dealer

Insufficient hydraulic oil supply

Poor compression

Steering linkage needs adjustment

Tow valve open

The traction drive belt is worn, loose or broken

Check level in reservoir

Have dealer check hydraulic pump

See your dealer

Adjust linkage

Close tow valve

Install a new traction drive belt

Air cooled engine overheating

Low engine oil pressure

Air in system

For additional causes

Check filter and fittings

See engine manual

Restrictions in air cleaner Service air cleaner

Hydraulic line blockage See your dealer

See your dealer Internal interference or leakage in wheel motor

Air intake screen or cooling fins clogged

Clean screen and fin

For additional causes

Low oil level

Oil diluted or too light

Failed oil pump

See engine manual

Add oil

Change oil and check for source of contamination

See your dealer

Hydraulic system operates hot (oil in reservoir smells rancid)

Mower creeps when steering control levers are in neutral

Low hydraulic oil level

Hydraulic pump faulty

Hydraulic oil cooler clogged

Steering linkage needs adjustment

Fill reservoir

See your dealer

Clean oil cooler core

Adjust linkage

Steering linkage needs adjustment

Wheel motors faulty

Adjust linkage

Mower circles or veers in one direction

See your dealer

Tires improperly inflated Adjust air pressure to 8 -

12 psi (55-83 KPa)

Hydraulic pump faulty See your dealer

Mower creeps when parking brake engaged

Steering linkage out of adjustment

Adjust steering linkage

Brakes need adjustment Adjust parking brakes

There is abnormal vibration

The engine mounting bolts are loose

The engine pulley, idler pulley or blade pulley is loose

Tighten the engine mounting bolts

Tighten the appropriate pulley

The engine pulley is damaged

Contact your BigDog™

Mowers Dealer

The cutting blade(s) is/are bent or unbalanced

Install new cutting blade(s)

Blades do not rotate

Uneven cutting height

A blade mounting bolt is loose

Tighten the blade mounting bolt

Spindle bearing is worn or loose

Replace or tighten spindle bearing

A blade spindle is bent

The deck drive belt is worn, loose or broken

The deck drive belt is off the pulley

Electric clutch is not engaging

The blade(s) are not sharp

A cutting blade(s) is/are bent

Contact your BigDog™

Mowers Dealer

Install a new deck drive belt

Install the deck drive belt and check for a reason

Check and/or replace 15 amp fuse.

Contact your BigDog™

Mowers dealer

Sharpen the blades

Install new cutting blade(s)

The deck is not level Level the deck per the

Deck leveling and height adjustment section of the parts manual

An anti-scalp wheel is not set correctly

Adjust the height of the anti-scalp wheel

The underside of the deck is dirty

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 BigDog™

Mowers Dealer

108936BD_0812 10-1 REV E

SYMPTOMS PROBABLE CAUSES

SUGGESTED

REMEDIES

Adjust linkage

Mower jerky when starting or operates in one direction only

Steering control linkage needs adjustment

Pump or wheel motors faulty

Tow valves not closed completely

See your dealer

Close tow valves

REV E 10-2 108936BD_0812

INDEX

PAGE

Belts.................................................................. 5-5

,

7-4

Blades.......................................................................7-2

Control lever stops ..................................................5-2

Deck Belt adjustment ..............................................7-4

Deck leveling............................................................7-1

Electrical Schematic — Briggs & Stratton .............8-1

Electrical Schematic – Kawasaki............................8-2

Electrical Schematic – Kohler.................................8-3

Engine air filter.........................................................6-1

Engine oil and filter..................................................6-1

Engine RPM settings ...............................................6-4

Fuel & evaporative system line routings ................6-2

Fuel evaporation system filter ................................6-2

General engine maintenance..................................6-1

General maintenance precautions .........................3-2

Hydraulic pump belt adjustment .............................5-5

Hydraulic system .....................................................5-5

Maintenance introduction........................................2-1

PAGE

Maintenance Locator Chart............................. 9-2

,

9-3

Maintenance precautions ........................................3-2

Maintenance Schedule ............................................9-1

Mower blade maintenance ......................................7-2

Mower blade removal ..............................................7-3

Operate machine safely ..........................................3-2

Operation precautions .............................................3-2

Pre-operation precautions.......................................3-1

Safe servicing practices ..........................................3-1

Service Program ......................................................2-1

Special torques ........................................................4-1

Standard torques .....................................................4-1

Steering adjustments...............................................5-1

Steering control lever adjustment ...........................5-3

Steering control lever neutral adjustment ..............5-1

Steering damper ......................................................5-3

Warranty ...................................................................2-1

108936BD_0812 1-1 REV E

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