BigDog X Series General Service Manual
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BigDog X Series General Service Manual

BigDog X Series General Service Manual

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108936BD_0812
BigDog
General Service Manual
®
Mowers
Series X
•••••
P.O. Box 7000
•••
Hesston, Kansas
•
67062-2097
REV E

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Summary of Contents for BigDog X Series

  • Page 1 BigDog ® Mowers Series X General Service Manual ••••• P.O. Box 7000 ••• Hesston, Kansas • 67062-2097 108936BD_0812 REV E...
  • Page 2 WARNING 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.

  • Page 3: Table Of Contents

    Table of Contents General Information ........2-1 Service Program.
  • Page 4 Troubleshooting ........10-1 108936BD_ 0812...

  • Page 5: General Information

    Remain alert for unusual noises, they could be signaling a Warranty problem. Visually inspect the machine for any abnormal wear or damage. A good time to detect potential problems is while Warranty repair must be performed by a BigDog ® Mowers performing scheduled maintenance service. Correcting the Authorized Dealer before warranty credit can be allowed.
  • Page 6 REV E 108936BD_0812...

  • Page 7: Safety

    SAFETY • 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. This safety alert symbol is used to call attention to a message •...

  • Page 8: Operation Precautions

    Locate and correct cause. wear gloves and use extra caution when servicing them.  Keep all safety shields and covers in place, except for ®  Use only genuine BigDog Mower replacement parts to servicing. ensure that original standards are maintained ...
  • Page 9 tape openings after adding the inhibitor. Keep container parts water and one part baking soda when they tightly closed when not in use. become corroded.  Inspect electrical wiring for worn or frayed insulation.  Shorts caused by battery terminals or metal tools touch- Install new wiring if wires are damaged.
  • Page 10 REV E 108936BD_0812...

  • Page 11: Torque

    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 FT-LBS SIZE...
  • Page 12 REV E 108936BD_0812...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 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 Steering control lever neutral adjustment together. Figure 5-1 The mower’s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral posi- tion.
  • Page 14 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 Jam nut levers are pushed forward against the stops.
  • Page 15 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.

  • Page 16: Park Brake Adjustment

    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.

  • Page 17: Belts

    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 Control lever Inspect the belt every 100 hours and replace as needed. Replace the belt every 400 hours or every two (2) years which- ever comes first.
  • Page 18 A standard oil filter wrench is used to change filter, threads are connected in either direction into the forward and reverse high pressure system lines. right handed. Use a BigDog ® Mowers approved filter element NOTE: The following adapter fittings will be required when only.
  • Page 19 rise. 7. Increase the pressure to 1100 PSI (76 bar). NOTE: Raising the system oil temperature will make a Record the flow reading on the Bi-Directional Flow difference in the readings you receive. It has been Meter. determined that to complete this test accurately, the oil 8.

  • Page 20: Tires

    Front wheels ..... 8-12 psi (55-83 KPa) up. Use in pairs only. Follow the instructions supplied with the vehicle stands. If you wish to use non-pneumatic tires on your BigDog ® mower the tires must be an approved tire purchased from Big- 1.

  • Page 21: Engine Maintenance

    Allow A specially designed dry filter is standard equipment on some 10 minutes for engine oil to adequately drain. BigDog mowers which supplies clean combustion air to the ® 7. After oil is drained, close the valve by pushing in on the engine.

  • Page 22: Fuel Evaporation System Filter

    3. Reinstall the dust cup. Make sure it seals all the way around the air cleaner body, then tighten the clamps. All BigDog X Series mowers with a 9xxxxx (i.e. 922222) ® 4. Check all fittings and clamps periodically for tightness model number, produced after serial number 11010000, have a and inspect hoses for holes or cracks.
  • Page 23 Fuel evaporation system filter Figure 6-5 Fuel tank Fuel shutoff valve Fuel line Seat support Fuel tank Figure 6-6 Fuel tank Vapor line Fuel evaporation system filter Fuel tank Figure 6-7 108936BD_0812 REV E...

  • Page 24: Engine Rpm Settings

    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.

  • Page 25: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling right side). Figure 7-4 10. Jam both nuts against the block. Leveling the deck must be done in the following manner and order: 1. Check tire pressures to make certain they are properly Clamp here inflated before starting to level deck. The recommended pressures are as follows: Drive wheels .

  • Page 26: Blades

    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 7-6 27. Compress the deck lift assist springs so that there is 1” (2.54cm) of space between the front nut on the spring and Figure 7-4 the rear nut on the deck lift block.
  • Page 27 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 ®...

  • Page 28: Belts

    Cutting edge Spring chain Spring chain anchor point Twisted Blade Edge (replace) Cutting Plane Cutting edge Straight Blade Edge End view of blades, comparing twisted and straightened blades Idler spring Figure 7-10 Belts Inspect belts frequently for wear and serviceability. Replace a Figure 7-11 belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping.
  • Page 29 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”...
  • Page 30 REV E 108936BD_0812...

  • Page 31: Electrical

    ELECTRICAL Electrical Schematic – Briggs & Stratton 108936BD_0812 REV E...

  • Page 32: Electrical Schematic - Kawasaki

    Electrical Schematic – Kawasaki REV E 108936BD_0812...

  • Page 33: Electrical Schematic - Kohler

    Electrical Schematic – Kohler 108936BD_0812 REV E...
  • Page 34 REV E 108936BD_0812...

  • Page 35: Maintenance Schedule

    Maintenance Schedule Refer to Figure 9-1, Figure 9-2, Figure 9-3 & Figure 9-4 WEEKLY MONTHLY ANNUALLY SERVICE AT INTERVALS INDICATED Every 40 Every 100 EVERY 500 HOURS HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and/or damaged parts Prior to each use Visually inspect tires...

  • Page 36: Maintenance Locator Chart

    BigDog™ Mowers Series X Maintenance Locator Chart 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.
  • Page 37 BigDog™ Mowers Series X Maintenance Locator Chart 1. Deck Pusher Arm Zerks (2) 2. Deck Belt 3. Spindle Housing Zerk (3) 4. Blades 5. Fuel evaporation system filter Figure 9-3 Figure 9-4 108936BD_0812 REV E...
  • Page 38 REV E 108936BD_0812...

  • Page 39: Troubleshooting

    The engine mounting Tighten the engine mount- bolts are loose ing bolts Dirt, water or stale fuel in Contact your BigDog™ the fuel system Mowers Dealer The engine pulley, idler Tighten the appropriate pulley or blade pulley is...
  • Page 40 SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Steering control linkage Adjust linkage needs adjustment Mower jerky when starting or Pump or wheel motors See your dealer operates in one direction faulty only Tow valves not closed Close tow valves completely REV E 10-2 108936BD_0812...
  • Page 41 INDEX PAGE PAGE Belts..............5-5 Maintenance Locator Chart......9-2 Blades...............7-2 Maintenance precautions ........3-2 Control lever stops ..........5-2 Maintenance Schedule ..........9-1 Deck Belt adjustment ..........7-4 Mower blade maintenance ........7-2 Deck leveling............7-1 Mower blade removal ..........7-3 Electrical Schematic — Briggs & Stratton .....8-1 Operate machine safely ..........3-2 Electrical Schematic –...

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