Excel BigDog R Series General Service Manual

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Page 1

BigDog® Mowers

R Series

General Service Manual

108935BD REV E

••••• 200 South Ridge Road

••• Hesston, Kansas

• 67062-2097

Page 2

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 remov ed or rendered inoperative by any person.

WARNING

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 Requ irement s. 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.

REV E 108935BD

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Table of Contents

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

BigDog® Mower Service Program . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Steering Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Park Brake Spring Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Fuel & Evaporative System Line Routings. . . . . . . . . . . . . . . . . 5-2

Engine RPM Settings 5-3

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Deck Belt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

48" Deck Belt Routing & Tensioning . . . . . . . . . . . . . . . . . . . . . 6-5

54" Deck Belt Routing & Tensioning . . . . . . . . . . . . . . . . . . . . . 6-5

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Electrical Schematic – Kawasaki, Briggs & Stratton & Kohler . . 7-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

108935BD c-1 REV E

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REV E c-2 108935BD

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GENERAL INFORMATION

BigDog® Mower Service Program

This manual is part of a service package for the BigDog® R Series mowers. Use of this manual in conjunction with other BigDog the information necessary to service and maintain BigDog

R Series mower and component manuals will provide

Series mowers.

This General Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units.

The Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts.

The Operator's Manual provides fundamental operational information and operational safety that is needed when 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.

108935BD 1-1 REV E

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REV E 1-2 108935BD

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SAFETY

DANGER

WARNING

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.

– 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 operator’s manual and all manuals fur-

nished 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 impairme nt or loss of hearing.

108935BD 2-1 REV E

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• 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 operator’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 su re hoses

are tightly secured and bolts are tightened.

 Always keep engine and machine clean, removing accu-

mulated 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 an odorless and deadly poison.

 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 st op 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

ensure that original standards are maintained.

Mower replacement parts to

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 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.

REV E 2-2 108935BD

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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 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 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 term inals with a solution of four parts water and one part baking soda when they become corroded.

 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 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 veget able oil.

• Get medical attention immediately.

108935BD 2-3 REV E

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REV E 2-4 108935BD

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TORQUE

WARNING

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 FT-LBS N-M SIZE FT-LBS N-M

#10 32.4 IN.-LBS. 3.6 M3 12 IN.-LBS. 1.3 .250 98.4 IN.-LBS. 11.1 M4 26.4 IN.-LBS. 3 .312 204 IN.-LBS. 23 M5 54 IN.-LBS. 6.1 .375 30 40 M6 92.4 IN.-LBS. 10.4 .438 48 65 M8 222 IN.-LBS. 25 .500 73 99 M10 37 50 .562 105 143 M12 64 87 .625 145 200 M14 103 140 .750 260 350 M16 160 215 .875 420 565 M20 320 435

Special Torques

Description FT-LBS N-M

Wheel (lug) nuts

Blade spindle bolt top 118 160

Blade spindle bolt bottom 118 160

Electric Clutch mounting bolt

Front wheel axle bolt 73 99

Transaxle hub nut

Transaxle pump pulley nut 45 – 55 61 – 74

NOTE:

1. Lug nuts only – It is recommended that these be checked

after the first 2 hours of operation and every 50 hours and following removal for repair or replacement.

2. Engine torque values – Refer to the respective engine

owner’s manual.

3. If clutch mounting bolt is loosened or removed, do not re-use. Replace with a new bolt. Use only hand tools to

install this fastener.

4. If using pin locknut, 250 ft.-lbs.

70 95

45 – 48 61 – 65

275 339

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.

108935BD 3-1 REV E

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POWER UNIT MAINTENANCE

WARNING

Mower

harness

Seat

switch

Female spades

Shown with steering control levers in park brake position

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:

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 4-1

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 wi th the floor or any object that would permit the unit to propel it self. 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.

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

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.

Figure 4-1

4. Loosen the jam nuts on each end of the steering control

rod assemblies. Figure 4-5

5. Set both steering control levers in the park brake position.

Figure 4-2 NOTE: Both steering control levers need to be in the park brake position when starting the engine but need to be moved rapidly out of the park brake position once engine is started so that the brakes do not fight the transmissions since they have not yet been adjusted.

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.

108935BD 4-1 REV E

Figure 4-2

Page 14

6. Loosen the nuts on the rear steering damper ball studs.

WARNING

Steering control lever

Shown with steering control

levers in neutral position

WARNING

Align handles

± .125”

The dampers must be allowed to slide in the slots in the mower frame. Figure 4-5

7. Start the engine. Move the steering control lever to barely

engage the brake (neutral) slot and hold it in that position (Do not engage the steering control lever far enough to engage the brakes in the brake slot) (Figure 4-3).

This operation is extremely dangerous. Pay close attention when adjusting the transmission control rod so you do not get your fingers, tools, or anything else close to the transmission’s cooling fans.

8. Beginning with the right side of the mower, adjust the

steering control rod so that the right side wheel starts rotating forward while holding the steering control lev er in the neutral position. Now, adjust the steering rod back the opposite direction to the point when the wheel stops rotating. From that point, turn the steering rod back again ½ turn. This ensures that the steering rod is adjusted so that the transmission control arm is centered in the neutral band of the transmission. Figure 4-5

nut is tightened, when the steering control lever is in the reverse position and then released, the steering control lever should return to the neutral position. Figure 4-5

12. Check to make sure you have all fasteners tightened to

the correct torque specifications.

13. Repeat steps 4 thru 12 for the left side.

14. Once both sides are properly adjusted, check them

together to make sure everything is working properly.

15. 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 4-1

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.

Figure 4-3

9. Move the steering control lever forward and backward

making sure that the wheel rotates forward and backward correctly. Return the steering control lever to ne utral and re-check to make sure the wheel has stopped in the neutral position. Place the steering control lever in the park brake position. NOTE: If neutral is set properly, you should not hear the transmission whine.

10. Turn the engine off.

11. With the engine off, move the right side steering control

lever into the neutral position and pull the lever to the full reverse position. Now, slowly bring the steering control lever back to the neutral position and then place it in the park brake position. This sets the steering damper in the correct neutral position. Tighten the nut on the damper’s rear ball stud. Once this

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

16. The steering control levers should be adjusted so that

they align vertically with each other when in the neutral position (Figure 4-3). Space between ends of steering control handles to be .50” ±.25”. Figure 4-4

17. Check to make sure all tools or obstructions are removed

from under the mower.

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

Lower the mower.

Figure 4-4

REV E 4-2 108935BD

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Steering damper

Steering

damper

Steering

damper

stud

Nut

Slot

Jam

nut

Jam

nut

Steering

control

rod

Steering

control

lever

Seat

latch

Bolt

Torque to

17 ft.-lbs.

Slot

Seat

platform

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

If the mower does not return to neutral from reverse then adjust as follows:

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, and remove ignition switch key.

2. Raise seat platform and disconnect negative battery cable

before doing any adjustments.

3. Place the steering control lever in the neutral position.

Figure 4-3

4. Loosen the steering damper’s rear ball stud. Figure 4-7

5. Pull the damper spring housing, to the rear, past the point

that the internal spring is engaged.

6. Release the damper spring housing and allow the internal

spring to bring the housing back to the neutral position.

7. Tighten the nut on the steering damper’s rear ball stud.

Figure 4-7

8. Reconnect the negative battery cable.

9. Lower the seat platform making sure that it is secured

properly with the latch. NOTE: If you have the seat latch shown in Figure 4-6, lower the seat platform and re-install latch. Make sure the

108935BD 4-3 REV E

seat latch is properly seated in the slot in the mower’s crossmember. Torque seat latch bolt to 17 ft .-lbs. .

Figure 4-5

10. To check, move the steering control lever to the reverse

Figure 4-6

position and release. The steering control lever should return to the neutral position. If not, repeat steps 1

Page 16

through 7.

WARNING

Steering

damper

WARNING

Nylock nut

Brake arm

spring

”

Bottom View

Hydraulic pump belt

Tension idler

Spring

Never operate the mower with the seat latch un-installed or not properly secured. The seat platform must be securely latched to prevent seat from moving/tilting in the event of mower tipping or rollover.

Figure 4-7

Figure 4-8

Hydraulic Pump Belt Adjustment

The transmission drive belt tension remains constant by means of a tension idler and spring. There is no tension adju stment of this belt. Figure 4-9

NOTE: Inspect the belt every 100 hours and replace as

needed. Replace the belt every 200 hours or every two (2) years whichever comes first.

Park Brake Spring Adjustment

Occasionally check the park brake spring adjustment using

the following method:

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. On one side measure the park brake spring. It should be

compressed to 1.437”. If it is not, adjust the nylock nut until the proper spring compression is achieved. Figure 48

3. Repeat for other side.

4. Reconnect the negative battery cable.

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. Slig ht 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.

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.

Figure 4-9

Hydraulic System

The BigDog® R Series mowers are equipped with two trans-

REV E 4-4 108935BD

Page 17

axles. Figure 4-10

WARNING

Transaxles

Expansion

tank

Transaxle filter

Screw

Filter

guard

IMPORTANT: Never use hydraulic or automatic transmis-

sion fluid in this system; use only motor oil as specified.

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

The hydraulic expansion tank is located in front of the engine

and under the operator’s platform. Figure 4-10

Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning.

Fluid level should be at the “Full Cold” line on the expansion tank. Use only SAE 20W50 SL/SM service motor oil.

Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first. Thereafter, replace filter and oil in each transaxle every 2 years or 200 hours, whichever comes first. NOTE: The filter guard must be removed to access filter.

Each transaxle’s filter is located per Figure 4-11. A standard oil filter wrench is used to change filter, threads are right handed. Use a BigDog

Mowers approved filter element only.

Purging procedures must be followed after changing the oil and filter. Refer to Purging Procedure section for detailed information.

Figure 4-11

When washing the mower, direct the spray away (especially if using a power washer) from the transaxle’s seals to prevent water intrusion and to ensure component performance.

Figure 4-10

Fluid changing procedure

1. Park the unit on a level surface. Place control levers in

the park brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable.

2. Remove the three 1/4” filter guard screws and filter

guard. Clean any loose debris from around the filter Figure 4-12

3. Place an oil drain pan beneath the oil filter and remove

the oil filter from the transaxle.

108935BD 4-5 REV E

Figure 4-12

4. After the oil has been drained, wipe the filter base surface

off and apply a film of new oil to the gasket of the new replacement filter.

5. Install the new filter by hand, turn 3/4 to one full turn

after the filter gasket contacts the filter base surface.

6. Re-install the filter guard with three 1/4” screws. Torque

the screws to 65 in.-lbs. each. Figure 4-12

7. Repeat steps 2 - 6 for the opposite side transaxle.

8. Drain oil filters of all free flowing oil prior to disposal.

Place used oil in appropriate containers.

9. IMPORTANT: Remove the top port plug from both

transaxles prior to filling with oil. This will allow the transaxles to vent during oil fill. Figure 4-13

10. Remove the cap from the transaxle's expansion tank.

11. Fill with 20W50 motor oil until oil just appears at the

bottom of each transaxles top port (approximately 2 qts. per transaxle). Install the top port plug into each transaxle as the oil level reaches this port. Torque plugs to 180 in. lbs. Clean up any oil that leaked from the ports. Figure 413

12. Continue to fill the transaxles through the expansion tank

until the “Full Cold” line is reached on the expansion

Page 18

tank.

Top port plug

WARNING

Steering control lever

Shown with steering control

levers in neutral position

13. Re-install the expansion tank cap by hand. Be careful not

to overtighten.

14. Proceed to the purge procedure.

Figure 4-13

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.

Purging procedure

Due to the affects air has on efficiency in hydrostatic drive

applications, it is critical that it is purged from the system.

Air creates inefficiency because its compression and expan-

sion rate is higher than that of the oil approved for use in hydrostatic drive systems.

These purge procedures should be implemented any time a

hydrostatic system has been opened to facilitate maintenance or the oil has been changed.

The resulting symptoms in hydrostatic systems may be:

1. Noisy operation.

2. Lack of power or drive after short term operation.

3. High operation temperature and excessive expansion of

oil.

Before starting, make sure the transaxle is at the proper oil

level. If it is not, fill to the specifications outlined in this manual.

The following procedures are best performed with th e vehi cle

drive wheels off the ground. Then repeated under normal operating conditions. If this is not possible, then the procedure should be performed in an open area free of any objects or bystanders.

1. Raise and block the mower up so the drive wheels are off

of the floor.

2. Position the control lever in the neutral position.

Disengage the deck clutch switch. Figure 4-14

3. With the bypass valve open and the engine running,

slowly move the directional control in both forward and reverse directions (5 or 6 times). Figure 4-15

4. With the bypass valve closed and the engine running,

Figure 4-14

slowly move the control lever in both forward and reverse directions (5 or 6 times). Check the oil level, and add oil as required after stopping the engine.

5. It may be necessary to repeat Steps 3 and 4 until all the

air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.

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 BigDog mower equipped with unapproved non-pneumatic tires.

Mowers. Warranty claims will be denied on any

REV E 4-6 108935BD

Page 19

Figure 4-15

(Right rod shown)

Bypass valve rod shown

in operating position

108935BD 4-7 REV E

Page 20

REV E 4-8 108935BD

Page 21

ENGINE MAINTENANCE

WARNING

Oil drain valve

Oil drain hose

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 manufacturer .

Engine Oil and Filter

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. Mower must be on a level surface 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 then 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 precau-

tions to minimize oil spillage on the exhaust system.

Draining the engine oil (units equipped with oil drain valve as shown in Figure 5-1):

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. Figure 5-2

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.

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

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

10. Clean the oil drain hose and store it appropriately. Figure

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.

5-2

Figure 5-1

Figure 5-2

Draining the engine oil (units equipped with oil drain

valve as shown in Figure 5-3):

1. Locate the oil drain valve on the engine. Figure 5-3

2. Position a suitable oil drain container under the machine

below the oil drain valve.

3. Twist the valve counterclockwise to open the valve.

Allow 10 minutes for engine oil to adequately drain.

4. After oil is drained, close the valve by twisting it

clockwise.

5. Once the valve is closed, clean up any spilled oil.

IMPORTANT: All oil drips or spills must be cleaned off of

the exhaust system before operating the machine. .

Engine Air Filter

Perform engine air filter maintenance per the engine’s

owner’s manual.

Fuel Evaporation System Filter

108935BD 5-1 REV E

Some mowers have a fuel evaporation system filter. This filter

Page 22

Figure 5-3

Oil drain valve

Fuel tank

Seat support

Fuel evaporation

system filter

Fuel line

Fuel

shutoff

valve

Fuel tank

Fuel line

Seat support

Fuel tank

Seat support

Vapor line

must be checked and replaced every 300 hours or annually whichever comes first. Figure 5-4

Figure 5-4

NOTE: Mowers produced after serial number 12050900 and

with an EX or AU extension after the model number do not have a fuel evaporation system filter.

Figure 5-5

Figure 5-6

NOTE: Mo wers produced after serial number 12050900 and

with an EX or AU extension after the model number do not have a fuel evaporation system.

Fuel & Evaporative System Line Routings

On mowers that have a fuel evaporative system installed there

are two rubber hoses that are connected to each fuel tank. One is the fuel hose that is part of the fuel system. The other is the vapor line that is part of the fuel evaporative system.

The fuel hose is connected to the port on the side wall of the

fuel tank. It connects the fuel tank to the fuel shutoff valve. Figure 5-5

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

REV E 5-2 108935BD

Page 23

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:

B&S 21 hp

ENGINE SPEED

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION

MODEL NO. WITH EX EXTENSION MODEL NO. WITH AU EXTENSION

3600 ± 50 RPM

B&S 26 hp

ENGINE SPEED

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION

MODEL NO. WITH EX EXTENSION MODEL NO. WITH AU EXTENSION

3600 ± 50 RPM

Kohler SV715

ENGINE SPEEDS

MODEL NO. ENDING WITH: HIGH IDLE

MODEL NO. WITHOUT EXTENSION

MODEL NO. WITH EX EXTENSION MODEL NO. WITH AU EXTENSION

3600 ± 50 RPM

Kawasaki FR651 / FR691 / FR730

Engine Speed

Model No. ending with: high idle

MODEL NO. WITHOUT EXTENSION

MODEL NO. WITH EX EXTENSION MODEL NO. WITH AU EXTENSION

3600 ± 50 RPM

NOTE: Model numbers may or may not end with an extension after the number. There are several different extensions that may be

shown; i.e. EX or AU.

Example: 922222 (no extension)

922222 EX 922222 AU

108935BD 5-3 REV E

Page 24

REV E 5-4 108935BD

Page 25

DECK ADJUSTMENTS

WARNING

Block

Nuts

Height in-

dicator bar

Lift block

Clamp here

Nuts

Deck lifting rod

1”

Deck lifting chain

Deck Leveling

Leveling the deck must be done in the following m anner 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 tire pressure . . . . . . . . .8 - 12 psi

Front wheels tire pressure . . . . . . . . .8 - 12 psi

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” high support) at the four corners of the deck as shown. NOTE: Back of deck will automatically be set 1/4” higher. Figure 6-1

4. Place the height stop in the 3” hole, with the flat side of

the height adjusting stop against the stop handle.

Figure 6-2

Figure 6-1

5. Clamp the height adjusting stop against the stop handle.

This will assure that the height will not move du ring the setting process. Otherwise, spring pressure from the deck lift springs will tend to pull the stop away from the handle. Figure 6-2

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 6-2, Figure 6-3 & Figure 6-4

7. Loosen the two nuts on the front of height indicator so

that the foot pedal is free. Figure 6-2

8. Set the amount of threads protruding on the deck li ft rod

from the lift block at approximately 1" (left & right side). Figure 6-3

108935BD 6-1 REV E

Figure 6-3

10. Start the leveling process on the left front of the deck.

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 6-2

13. Jam nuts tightly together against the deck lift block.

14. Go to the right front of the deck.

15. Loosen the hardware that clamps the adjuster to the deck

lift arm. Figure 6-4

16. 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 6-4

17. 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 6-1

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

Page 26

bolt from moving. Figure 6-4

Jam Nut

Deck lift arm

Adjuster bolt

Chain

Flange nuts

Adjuster

Jam Nut

Chain

WARNING

Jam Nut

1/2”

19. Tighten the hardware holding the chain and adjuster onto

the deck lift arm.Figure 6-4

Figure 6-4

20. Go to the right rear of the deck.

21. 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 6-5

22. 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 6-1

23. Tighten the other nut on the opposite side of the block,

and jam them tightly together against the block.

28. Compress the deck lift assist springs so that there is 1/2”

of space between the front nut on the spring and the rear nut on the deck lift block. Typical both sides. Figure 6-6

29. When completed, all chains will be tight, and deck

cutting height will be set to the deck height indicator.

Figure 6-6

Blades

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. Figure 6-7

Replace any blade which is bent, cracked or broken. Figure 68 & Figure 6-9

Figure 6-5

24. Go to the left rear of the deck

25. 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 6-5

26. 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 6-1

27. Tighten the other nut on the opposite side of the block,

REV E 6-2 108935BD

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 objects during mowing!

Page 27

WARNING

Always wear adequate eye protection when grinding

WARNING

Resharpening

pattern

Do not sharpen to original pattern (below). It is

easier to get a straight cutting edge following

the resharpening pattern shown above.

Original edge

WARNING

Warped Blade (Replace)

Straight Blade

Cutting

plane

Comparison of Warped and Straight Blades

Cutting edge

Twisted Blade Edge

(replace)

Cutting edgeCutting Plane

Straight Blade Edge

End view of blades, comparing

twisted and straightened blades

mower blades.

Mower blades are sharp and can cut. W ear gloves and use extra caution when servicing them.

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 objects during mowing!

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 6-8 & Figure 6-9). 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 point-

ing 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.

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

Figure 6-7

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

(Figure 6-7). Touch-up sharpening can be done with a file

commercial balancing tool is available through most hardware

Mowers dealer for more information.

Sharpen the blades on a grinder following pattern as shown

Check the blades for balance following grinding. A

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.

108935BD 6-3 REV E

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

Figure 6-8

Figure 6-9

Belts

Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather

Page 28

checking and cracking, or burns caused by slipping. Slig ht rav-

Spring chain

Spring chain anchor point

Idler

spring

eling of belt covering does not indicate failure, trim ravelings with a sharp knife.

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 su ch t hat 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, mov e the spring chain one (or more) link(s) at the anchor point on the deck frame. Figure 6-10, Figure 6-11, & Figure 6-12

IMPORTANT: Do not over tension the spring to compensate

for a badly worn belt or pulley.

Figure 6-10

REV E 6-4 108935BD

Page 29

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

8.3” – 9.3”

8.25” – 9.25”

1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼" cut height.

2. Route belt as shown.

48" Deck Belt Routing & Tensioning

54" Deck Belt Routing & Tensioning

Figure 6-11

108935BD 6-5 REV E

Figure 6-12

Page 30

REV E 6-6 108935BD

Page 31

ELECTRICAL

Electrical Schematic – Kawasaki, Briggs & Stratton & Kohler

108935BD 7-1 REV E

Page 32

REV E 7-2 108935BD

Page 33

MAINTENANCE SCHEDULE

BigDog® Mowers R Series

Maintenance Schedule

Refer to Figure 8-1, Figure 8-2, Figure 8-3, & Figure 8-4

SERVICE AT

INTERVALS INDICATED

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 & securely fastened Prior to each use Discharge chute - securely in place & in lowest position Prior to each use Replace air cleaner paper element (if equipped) As needed Clean engine and transaxle compartment Daily Change transaxle oil and filter (7) Every 200 hours or 2 years Grease deck height pivots X Grease front wheel bearings X Change engine oil and filter (1) (3) X Check battery connections X Check tire pressure with a gauge X Check hydraulic oil level X Clean engine exterior (a) X Check pump and deck belt tension

and condition (5) X Check fuel and hydraulic lines (6) X Check fuel valve and grommet (6) X Tighten lug nuts on wheels (2) X Change fuel filter (6) X Check ROPS mounting hardware (9) X Replace fuel evaporation system filter (8) X

WEEKLY

OR 40

HOURS

MONTHLY

OR 100

HOURS

ANNUALLY

OR 300 HOURS

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

4. Service more often under dusty or dirty conditions.

5. Pump drive belt only - Inspect every 6 months or 100 hours and replace if worn or if cracking is noticed. Othe rwise, replace every 200 hours or 2 years whichever comes first.

6. Check fuel system for any cracks or leaks including, but not limited to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon canister, and grommets. Repair as needed.

7. Initial system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first. Thereafter, replace filter and oil in each transaxle every 2 years or 200 hours, whichever comes first.

8. More often under dusty or dirty conditions and during hot weather.

9. Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first.

REFERENCES:

A. Refer to Engine Owner’s Manual

NOTE: After completing maintenance cycle (300 hours), repeat cycle.

108935BD 8-1 REV E

Page 34

Maintenance Locator Chart

Figure 8-1

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4. Engine Oil Drain Valve

5. Battery

6. Fuel Tank

7. Engine Oil Filter

8. Deck Lift Pivot Zerks (4)

9. Park Brake Switch (2)

10. Drive Tire

11. Pump Belt

12. Engine Air Intake Screen

13. Front Wheel Tires

14. Front Wheel Zerks (2)

15. Deck Belt

16. Blades

17. Hydraulic Oil Expansion Tank

18. Hydraulic Oil Filter

19. Fuel Evaporation System Filter

Figure 8-2

REV E 8-2 108935BD

Page 35

Figure 8-4

Figure 8-3

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4. Engine Oil Drain Valve

5. Battery

6. Fuel Tank

7. Engine Oil Filter

8. Deck Lift Pivot Zerks (4)

9. Park Brake Switch (2)

10. Drive Tire

11. Pump Belt

12. Engine Air Intake Screen

13. Front Wheel Tires

14. Front Wheel Zerks (2)

15. Deck Belt

16. Blades

17. Hydraulic Oil Expansion Tank

18. Hydraulic Oil Filter

19. Fuel Evaporation System Filter

108935BD 8-3 REV E

Page 36

REV E 8-4 108935BD

Page 37

TROUBLESHOOTING

SYMPTOMS PROBABLE CAUSES

Starting motor does not crank

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

Engine: Runs with continuous misfiring or engine runs unevenly or erratically

Loss of power or system will not operate in either direction

Overheating Air intake screen or cowl-

Low engine oil pressure Low oil level Add oil

High oil consumption Numerous See your dealer

Mower jerky when starting or operates in one direction only

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

Deck clutch switch engaged

Weak or dead battery Recharge or replace

Electrical connections are corroded or loose

25 amp fuse is blown Replace the 25 amp

For additional causes See engine manual

No fuel or line plugged Fill tank or replace line

Fuel valve is turned off Open the fuel valve

There is incorrect fuel in the fuel system

There is dirt in the fuel filter

Dirt, water or stale fuel in the fuel system

The choke is not on Move the choke lever to

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

Poor compression See your dealer

Steering linkage needs adjustment

Tow valve open Close tow valve

The traction drive belt is worn, loose or broken

For additional causes See engine manual

ing fins clogged

For additional causes See engine manual

Oil diluted or too light Change oil and check for

Steering control linkage needs adjustment

Loose steering linkage Tighten linkage

Transmission component faulty

SUGGESTED

REMEDIES

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

Disengage clutch switch

Check the electrical connections

fuse

Drain the tank and replace the fuel with the proper type

Replace the fuel filter

Contact your BigDog® Mowers Dealer

Adjust linkage

Install a new traction drive belt

Clean screen and fins

source of contamination

Adjust linkage

See your dealer

SYMPTOMS PROBABLE CAUSES

Mower creeps when steering control levers are in neutral

Mower circles or veers in one direction

There is abnormal vibration

Uneven cutting height The blade(s) are not

Blades do not rotate The deck drive belt is

Steering linkage needs adjustment

Loose steering linkage Tighten linkage

Tires improperly inflated Adjust air pressure to 8 -

Transmission component faulty

The engine mounting bolts are loose

The engine pulley, idler pulley or blade pulley is loose

The engine pulley is damaged

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

A blade mounting bolt is loose

Spindle bearing is w orn or loose

A blade spindle is bent

sharp

A cutting blade(s) is/are bent

The deck is not level Level the deck per the

An anti-scalp wheel is not set correctly

The underside of the deck is dirty

Tires improperly inflated Adjust air pressure to 8 -

A blade spindle is bent

worn, loose or broken

The deck drive belt is off the pulley

Electric clutch is not engaging

SUGGESTED

REMEDIES

Adjust linkage

12 psi (55 - 83 KPa)

See your dealer

Tighten the engine mounting bolts

Tighten the appropriate pulley

Contact your BigDog® Mowers Dealer

Install new cutting blade(s)

Tighten the blade mounting bolt

Replace or tighten spindle bearing

Contact your BigDog® Mowers Dealer

Sharpen the blades

Install new cutting blade(s)

Deck leveling and height adjustment section of the parts manual

Adjust the height of the anti-scalp wheel

Clean the underside of the deck

12 psi (55 - 83 KPa)

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

108935BD 9-1 REV E

Page 38

REV E 9-2 108935BD

Page 39

INDEX

PAGE PAGE

Belts ..................................................................4-4, 6-3

Maintenance Schedule ........................................... 8-1

Blades...................................................................... 6-2

Dec k Bel t a dju s t m ent................................... ........... 6-4

Dec k Bel t R out i n g & Te n sio n i n g .......................... .. 6-5

Dec k lev e l i ng............... ............. ............. ............. ..... 6-1

Eng i n e a i r f i l t e r ......................................... ............... 5-1

Engine oil and filter................................................. 5-1

Eng i n e R P M s e t t i n g s ...... ................ ................ ........ 5-3

Fue l & ev a p o rat i v e sy s t e m li n e rou t i n gs ............... 5-2

General engine maintenance................................. 5-1

Gen e r a l M a in t e n a n c e P r e ca u t i o n s ........................ 2-2

Hyd r a u l i c p u m p b e l t a d ju s t m e n t .......................... .. 4-4

Hyd r a u l i c s y s t e m................................... ................ .. 4-4

Mai n t e n a n ce i n t r o d u c t io n ..... ................ ................ .. 1-1

Mai n t e n a n ce l o c a t o r c h ar t.... ................ ................ .. 8-2

Mai n t e n a n ce P r e c a u t i o n s.................. ................ ..... 2-2

Mow e r bl a d e m a i n t ena n c e ........................ ............. 6-2

Mow e r bl a d e r e m o v al .... ............. ............. ............. ... 6-3

Ope r ate M a chi n e Saf e l y ................ ............ ............. 2-2

Ope r ati o n Pre c a u tio n s ................................... ......... 2-2

Par k b r a ke s p r i n g a d ju s t m e n t ................................ 4-4

Pre - O p e r a t io n P r e c a u t io n s........ ................ ............. 2-1

Saf e s e r v ic i n g p r a c t i c es............. ................ ............. 2-1

Ser v i ce P r o g ram................... ............. ............. ......... 1-1

Spe c i a l to r q u e s.................. ................ ................ ...... 3-1

Standard torques..................................................... 3-1

Ste e r ing a d jus t m e nts ........................ ............. ......... 4-1

Ste e r i n g co n t r o l le v e r n e u t ra l a d j u s t m en t ............. 4-1

Ste e r ing d a mpe r............................. ............ ............. 4-3

Tires ......................................................................... 4-6

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

108935BD t-1 REV E