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Summary of Contents for Bigdog Mower Co. STOUT MP
- Page 1 BIGDOG MOWER CO. STOUT ® ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 121366 REV E...
- Page 2 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.
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Page 3: Table Of Contents
Table of Contents General Information ..........1-1 BigDog Service Program . - Page 4 Electrical ............7-1 Main Electrical Harness Schematic .
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Page 5: General Information
GENERAL INFORMATION Clear away heavy build-up of grease, oil and dirt, especially BigDog Service Program ® in the engine compartment and under the seat platform areas; minute dust particles are abrasive to close-tolerance This manual is part of a service package for the BigDog ®... - Page 6 REV E 121366...
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Page 7: Safety
SAFETY • 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 This safety alert symbol is used to call attention to a gasoline spills. -
Page 8: Operation Precautions
Understand Machine Operation Never leave machine unattended with ignition key in switch, especially with children present. Only qualified and trained personnel should operate Follow daily and weekly checklists, making sure hoses the equipment. are tightly secured and bolts are tightened. ... -
Page 9: Maintenance Precautions
Use a stick or similar instrument to clean under the Never use an open flame to look for leaks anywhere on mower making sure that no part of the body, especially the equipment. arms and hands are under mower. ... - Page 10 Sparks can cause a battery gas explosion which will If you spill acid on yourself: result in personal injury. • Flush your skin with water. • Prevent the battery terminals from touching any • Apply baking soda or lime to help neutralize the metal mower parts when removing or installing acid.
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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 N•m... - Page 12 REV E 121366...
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Page 13: Power Unit Maintenance
POWER UNIT MAINTENANCE Steering Adjustments Untrained maintenance personnel should never Steering control lever neutral adjustment attempt to make any adjustments or repairs to the mower’s drive system while the engine is running. The mower’s steering has been factory adjusted to The following procedures should be performed by eliminate creeping when the steering control levers are in the trained maintenance personnel only. - Page 14 7. 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 lever in the neutral position. • Adjust the steering rod back the opposite direction to the point when the wheel stops rotating.
- Page 15 9. Once both sides are properly adjusted, check them together to make sure everything is working properly. Never operate the mower with the seat platform improperly secured. The seat platform must be Shown with steering control lever in the neutral position securely latched/bolted to prevent the seat from moving/tilting in the event of mower tipping or rollover.
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Page 16: Steering Control Lever Stops
2. On one side measure the park brake spring. It should be compressed to 1.43"–1.48" (36.3–37.6mm). If it is Untrained maintenance personnel should never not, adjust the nylock nut until the proper spring attempt to make any adjustments or repairs to the compression is achieved. -
Page 17: Belts
9. IMPORTANT: Unbolt the seat platform from the mower frame. • Disconnect the two female spade connectors from each other (from step #3). • Reconnect the two female spade connectors to the seat switch. This must be completed so that safety circuit functioning... -
Page 18: Hydraulic Pump Belt Adjustment
Hydraulic Pump Belt Adjustment 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 The transmission drive belt tension remains constant by hours, whichever comes first. - Page 19 transaxle. Torque plugs to 180 in.–lbs. Clean up any Fluid changing procedure oil that leaked from the ports. Figure 4-15 1. Park the unit on a level surface. 11. Continue to fill the transaxles through the expansion • Place the steering control levers in the park brake tank until the “Full Cold”...
- Page 20 The following procedures are best performed first with the vehicle drive wheels off the ground and 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.
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Page 21: Tires
9. Unbolt or unlatch the seat platform from the mower Shown with steering control lever in the neutral position frame. If the seat platform has a latch, unlatch it and pivot it forward to allow access to the seat switch on the underneath side of the seat. - Page 22 REV E 4-10 121366...
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Page 23: Engine Maintenance
ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner’s Manual. Please refer to this manual for engine servicing, lubricating levels with quality viscosity recommendations, bolt torques, etc. The engine warranty is backed by the engine manufacturer. - Page 24 A. Safety filter Figure 5-3 Recommended Service Procedure A. Air cleaner canister C. Clamp B. Dust cap 1. Release clamps and remove element. Clean the air cleaner canister with a damp cloth. Figure 5-4 2. Before installing a new element, inspect it by placing a It is important to note that whenever an air filter element is bright light inside and rotating the element slowly, cleaned by any method, the person or company performing...
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Page 25: Fuel & Evaporative System Line Routings
A. Fuel tank B. Fuel line Figure 5-6 A. Fuel evaporation system filter Figure 5-5 Fuel & Evaporative System Line Routings These mowers have a fuel evaporative system installed. There are two different types of rubber hoses that are connected to the fuel tank. One is the fuel hose that is part of the fuel system. -
Page 26: 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 idle speeds should be set as follows: Kawasaki FX691 / FX730 ENGINE SPEEDS MODEL NO. -
Page 27: Deck Adjustments
DECK ADJUSTMENTS Deck Leveling Leveling the deck must be done in the following manner and order: 1. Check tire pressures to make certain they are properly inflated before starting level deck. recommended pressures are as follows: Drive wheels tire pressure ..8–12 psi Front wheels tire pressure. -
Page 28: Blades
line punch or 5/8" bolt. A commercial balancing tool is also available through most hardware supply stores. 9.50" The blade should not lean or tilt. When spinning the blade slowly it should not wobble. Balance the blade before reinstalling. Lay the blade on a flat surface and check for distortion. Replace any distorted blade. -
Page 29: Belts
When mounting blades, rotate them after installation to End view of blades, comparing twisted and straightened ensure blade tips do not touch each other or sides of the blades. mower. Belts Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of: •... - Page 30 Deck Belt Installation Side Discharge Deck Shown When replacing a deck belt use the following procedure: 1. Route the belt around all the pulleys except the left deck spindle. 2. Grasp the belt at the two locations shown and pull the belt over the left spindle pulley.
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Page 31: Deck Belt Routing And Tensioning
Deck Belt Routing and Tensioning The following notes are the same for the different decks that are available. 1. There is no tension adjustment of this belt 2. Route belt as shown. Figure 6-9 121366 REV E... - Page 32 REV E 121366...
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Page 33: Electrical
ELECTRICAL Main Electrical Harness Schematic 121366 REV E... -
Page 34: Main Harness To Fuel Gauge Voltage Convertor Schematic
Main Harness to Fuel Gauge Voltage Convertor Schematic Mowers prior to serial number 17065997 Mowers with serial number 17065997 and later BLK (20) ORG (20) PIN 1 PIN 1 BLK (20) PIN 2 PIN 2 ORG (20) PIN 3 PIN 3 GRN (20) PIN 4 PIN 4... -
Page 35: Maintenance
MAINTENANCE Maintenance Schedule Refer to Figure 8-1, Figure 8-2, & Figure 8-3 WEEKLY MONTHLY * ANNUALLY SERVICE AT OR 40 OR 100 OR 300 INTERVALS INDICATED 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 Prior to each use... -
Page 36: Maintenance Locator Chart
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. - Page 37 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.
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Page 39: Troubleshooting
TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Mower creeps when Steering linkage needs Adjust linkage steering control levers are adjustment Starting motor does not Steering control levers not Place steering control in neutral crank in park brake position or levers in park brake posi- switch not adjusted tion or re-adjust switch... - Page 40 REV E 121366...
- Page 41 INDEX PAGE PAGE Avoid Acid Burns .............2-4 Maintenance Precautions ........2-3 Avoid Fire Hazards ..........2-2 Maintenance Schedule .......... 8-1 Belts ..............4-5 Mower Blade Maintenance ........6-2 Blades ...............6-1 Mower Blade Removal ........... 6-3 Deck Belt Adjustment ..........6-3 Operate Machine Safely ........2-2 Deck Leveling ............6-1 Operation Precautions ...........
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