Excel BigDog R Series General Service Manual
BigDog® Mowers
R Series
General Service Manual
108935BD REV E
•••••
200 South Ridge Road
•••
Hesston, Kansas
•
67062-2097
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
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
REV E c-2 108935BD
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
®
R
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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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
• 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
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
REV E 2-4 108935BD
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.
1
3
4
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.
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