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BIGDOG MOWER CO. TROOPER ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 122832 REV A...
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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.
This manual is part of a service package for the Big Dog ® engine and hydraulic assemblies. TROOPER mowers. Use of this manual in conjunction with other Big Dog mower and component manuals will provide Daily inspect mower for grass clippings and wire and string ®...
SAFETY • Do not remove fuel cap or fill tank with engine run- ning or while engine is hot. Clean up any gasoline spills. • If gasoline is spilled, do not attempt to start the engine but move the machine away from the area This safety alert symbol is used to call attention to a mes- of spillage and avoid creating any source of igni- sage intended to provide a reasonable degree of PERSONAL...
and purpose of all controls, instruments, indicators Never leave machine unattended with ignition key in and labels. switch, especially with children present. Follow daily and weekly checklists, making sure hoses Wear Protective Clothing are tightly secured and bolts are tightened. ...
Maintenance Precautions 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. Avoid Fire Hazards Keep your machine clean and remove any deposits of ...
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• Electrolyte may overflow and damage paint, wir- Avoid Acid Burns ing or structure. When cleaning the battery, use Sulfuric acid in battery electrolyte is poisonous. It is soap and water. Be careful not to get soap and strong enough to burn skin, eat holes in clothing and water into the battery.
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 N•m...
POWER UNIT MAINTENANCE Steering Adjustments 2. Chock the front tires. 3. Insert a 1/4” pin through the opening in the mower frame and into the steering control lever. This ensures Steering control lever neutral adjustment that the steering control lever is in the neutral position. The mower’s steering has been factory adjusted to elimi- Figure 4-1 nate creeping when the steering control levers are in the neu-...
10. Raise the rear of the mower and remove the jack 3. Move the steering control lever forward until the pump stands. Lower the mower. lever bottoms out. 4. Loosen the jam nut on the steering control lever stop screw. Figure 4-4 5.
To adjust the stops for driving straight when steering control levers are against the stops during operation: Before considering any adjustment, check the tire air pres- sure. Unequal tire pressure will cause the mower to drift to one side. Refer to tire pressure information in the Tires sec- tion for detailed information.
Keep oil and grease away from belts, and never use belt Left side shown dressings. Any of these will destroy the belt composition in a very short time. Hydraulic Pump Belt Adjustment The transmission drive belt tension remains constant by means of a tension idler and spring.
Use the hydraulic reservoir’s sight glass to check the reser- voir fluid level. The oil level should be approximately in the middle of the sight glass. Figure 4-9 Only use full synthetic 15W50 oil in the hydraulic system. NOTE: The reservoir (Figure 4-10) will require approxi- mately 1.0 U.S.
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Potential for serious injury! Never work under the machine or attachment unless it is safely sup- ported with jack stands. To prevent possible injury to the servicing technician and/or bystanders, ensure the vehicle is properly secured. • Make certain machine is secure when it is raised and placed on the jack stands.
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Bi-Directional Flow Testing Procedures CAUTION: Damage to the flow meter and/or re- calibration may result from testing at input speeds that 1. Use approved jack stands to raise the drive wheels off exceed the above recommendations. the floor. 5. Operate without any load for approximately 30 sec- Never work under the machine or attachment onds to 1 minute.
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Test Example: PG/PL or PJ Pump RESTRICTION VALVE BI-DIRECTIONAL FLOW METER 300 psi (21 bar) reading 7 gpm (26 l/min) (1st reading) CONNECTIONS TO THE FWD/RVS LINES DIS- CONNECTED FROM WHEEL MOTOR RESTRICTION VALVE BI-DIRECTIONAL 1100 psi (76 bar) reading 3 gpm (11 l/min) (2nd reading) FLOW METER...
Jackshaft Replacement The following procedures should be performed with the vehicle drive wheels off the ground, then repeated under nor- mal operating conditions. The following procedures should be performed when replacing the jackshaft assembly or the attached hydraulic Potential for serious injury! Never work under the pump.
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) Only pneumatic tires are approved for the drive tires on this mower.
ENGINE MAINTENANCE General Engine Maintenance Kawasaki engines 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 recommenda- tions, bolt torques, etc. The engine warranty is backed by the manufacturer.
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Kawasaki FS541V engine Kawasaki FX691V/FX730V engine A. Air filter cover A. Pre-cleaner C. Dust cap Figure 5-3 B. Air cleaner canister D. Clamp Canister type Figure 5-5 Perform engine air filter maintenance per the Maintenance Kohler ECV730/ECV740 engine Schedule shown elsewhere in this manual. A specially designed dry filter is standard equipment on these mowers and supplies clean combustion air to the engine.
filter more efficient at stopping dirt from entering the engine. Kawasaki FX691V/FX730V engine This is referred to as barrier filtration. Of course, at some point the filter media becomes too clogged to allow air to pass. The mowing conditions will determine the frequency of air filter element changing.
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48"/52"/60" Mowers with Kawasaki engines 36" Mowers with Kawasaki engines A. Fuel tank B. Fuel line Figure 5-11 A. Fuel tank B. Fuel line The vapor lines are connected to the fuel tank as shown. They connect the fuel tank to the engine’s vapor port. Figure 5-9 Figure 5-12, Figure 5-13 &...
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48"/52"/60" Mowers with Kohler engines A. Fuel tank C. Fuel evaporation sys- B. Vapor lines tem filter Figure 5-13 36" Mowers with Kawasaki engines A. Fuel tank C. Fuel evaporation sys- B. Vapor lines tem filter Figure 5-14 122832 REV A...
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: Kawasaki FS541 ENGINE SPEEDS MODEL NO. ENDING WITH: HIGH IDLE Model NO.
DECK ADJUSTMENTS Deck Leveling 48”/52”/60” Decks Leveling the deck must be done in the following manner and order: 1. Check tire pressures to make certain they are properly inflated before starting to level deck. The recom- mended pressures are as follows: Drive wheels tire pressure.
of the other hook. Tighten the jam nut on the other side once Repairs or maintenance requiring engine power the distance is set. Figure 6-4 should be performed by trained maintenance per- sonnel only. Unless specifically required, DO NOT have the engine running when servicing or making adjust- ments to the mower.
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Lay the blade on a flat surface and check for distortion End view of blades, comparing twisted and straightened blades. (Figure 6-6 & Figure 6-7). Replace any distorted blade. Do not sharpen to original pattern (below). It A. Twisted blade edge — C.
When mounting blades, rotate them after installation to 36” Deck shown ensure blade tips do not touch each other or sides of the mower. Belts Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of: • severe cuts •...
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3. Remove the deck covers. Figure 6-10 36” Deck shown 36” Deck shown A. 1/2” drive breakover bar D. 1/2” square hole B. Deck drive belt E. 1/2” drive extension A. Deck covers C. Idler arm plate Figure 6-10 Figure 6-12 4.
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10. Re-install the belt guide shoulder bolt. Make sure the belt is routed between the shoulder bolt and the pulley. Figure 6-11 11. Re-install the deck covers. Figure 6-10 12. Re-attach the negative battery cable. Never operate the mower without the deck covers in place.
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6. Remove the deck drive belt from the electric clutch 48”/52”/60” Decks pulley located on the hydraulic pump jack shaft. Figure 6-19 7. Route the new deck drive belt around the clutch pulley, right and center spindle pulleys and idler pulleys. Make certain the belt is routed properly.
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A. Electric clutch pulley Figure 6-19 REV A 122832...
Neutral Switch Adjustment Operator Presence Switch Adjustment The operator presence switch will need to be adjusted if If the engine does not start unless one or both of the steer- the engine dies when the deck clutch is engaged and while ing control levers is moved, then one or both of the neutral the park brake is disengaged: switches will need to be adjusted.
MAINTENANCE SCHEDULE Maintenance Schedule Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, Figure 8-5, & Figure 8-6 WEEKLY MONTHLY SERVICE AT ANNUALLY OR 50 OR 100 INTERVALS INDICATED OR 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...
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Pump drive belt only - Inspect belt every 100 hours and replace if worn or cracking is noticed. Check spring tension adjustment. Otherwise, replace belt every 400 hours or 2 years whichever comes first. Check and adjust spring tension after 50 hours of use as outlined in the Hydraulic Pump Belt Adjustment section of the General Service Manual (122832).
TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Mower jerky when starting Steering control linkage Adjust linkage or operates in one direc- needs adjustment Starting motor does not Park brake lever not in park Place park brake lever in tion only crank brake position...
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