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Summary of Contents for BigDog MOWER CO
- Page 1 BIGDOG MOWER CO. ® BLACKJACK General Service Manual 200 South Ridge Road Hesston, Kansas 67062 121536 REV A...
- Page 2 REV A 121536...
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Page 3: Table Of Contents
Table of Contents General Information ..........1-1 ®... - Page 4 48"/54” Rear Discharge Deck Belt Routing ..... . . 6-8 Electrical ............7-1 Main Electrical Harness Schematic —...
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Page 5: General Information
GENERAL INFORMATION areas; minute dust particles are abrasive to close-tolerance Big Dog ® Service Program engine and hydraulic assemblies. This manual is part of a service package for the Big Dog Daily inspect mower for grass clippings and wire and string ®... - Page 6 REV A 121536...
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Page 7: Safety
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... -
Page 8: Operation Precautions
and purpose of all controls, instruments, indicators Always keep engine and machine clean, removing and labels. accumulated dirt, trash and other material from machine. Wear Protective Clothing Never put hands or feet under any part of the machine while it is running. -
Page 9: Maintenance Precautions
• Allow the mower, especially the engine, to cool Never use an open flame to look for leaks anywhere on before storing inside a building. the equipment. Always wear adequate eye protection when: Never use an open flame as light anywhere on or around the equipment. - Page 10 • Prevent the battery terminals from touching any • Avoiding breathing fumes when electrolyte is metal mower parts when removing or installing added. the battery. • Avoiding spilling or dripped electrolyte. • Do not allow metal tools to short between the If you spill acid on yourself: battery terminals and metal mower parts.
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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 A 121536...
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Page 13: Power Unit Maintenance
POWER UNIT MAINTENANCE Steering Adjustments 1. Shut engine off, place steering control levers in the park brake position, disengage deck clutch, remove Steering control lever neutral adjustment ignition switch key and disconnect negative battery The mower’s steering has been factory adjusted to elimi- cable before doing any adjustments. -
Page 14: Control Lever Stops Adjustment
12. Raise the rear of the mower and remove the jack stands. Lower the mower. 13. Re-attach the negative battery cable. 14. Close the seat platform. Align handles ± .125” A. Clamp Figure 4-5 Figure 4-3 Control Lever Stops Adjustment 7. - Page 15 1. Raise the rear of the mower and block with certified Shown with steering control levers in the neutral position jack stands. The rear wheels need to be able to rotate freely and clear of all obstructions. 2. Chock the front tires. 3.
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Page 16: Transaxle Drive Belt
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 .25"... - Page 17 NOTE: Do not remove the deck drive belt from the deck This procedure will require that the mower be spindle pulleys. The belt will only need to be removed raised and blocked up off of the ground. from the electric clutch pulley at the rear of the mower. •...
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Page 18: Hydraulic System
Hydraulic System 6. Locate the tension idler spring. Securely clamp locking pliers onto the spring at the end located next to the idler arm. Figure 4-10 This mower is equipped with two integrated hydrostatic transmissions. Figure 4-14 7. Release the transaxle drive belt tension, using the locking pliers, to remove the tension spring from the IMPORTANT: Never use hydraulic or automatic transmis- idler arm. - Page 19 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 4-16 7.
- Page 20 Air creates inefficiency because its compression and Shown with steering control levers in the neutral position expansion 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 mainte- nance or the oil has been changed.
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Page 21: Tires
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. - Page 22 REV A 4-10 121536...
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Page 23: Engine Maintenance
ENGINE MAINTENANCE General Engine Maintenance IMPORTANT: All oil drips or spills must be cleaned off of the exhaust system before operating the machine. Detailed instructions and recommendations for break-in 8. Clean the oil drain hose and store it appropriately. and regular maintenance are specified in the Engine Owner’s Figure 5-1 &... -
Page 24: Fuel Evaporation System Filter
A. Fuel evaporation system filter Figure 5-3 REV A 121536... -
Page 25: Engine Rpm Settings
Engine RPM Settings The engine’s 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: Kohler KT740 ENGINE SPEED MODEL NO. ENDING WITH: HIGH IDLE MODEL NO. - Page 26 REV A 121536...
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Page 27: Deck Adjustments
DECK ADJUSTMENTS Deck Leveling Rear discharge deck shown 1. Park the mower on a hard, flat surface. 2. Check tire pressures (8 – 12 psi) to make certain the tires are properly inflated before starting to level deck. Stop engine. Make sure deck clutch switch is in the down (OFF) position. -
Page 28: Blades
After grinding the blades, check for balance. Blade balanc- ing can be done by placing the blade on an inverted line punch or 5/8" bolt. A commercial balancing tool is also avail- able through most hardware supply stores. The blade should not lean or tilt. When spinning the blade slowly it should not wobble. - Page 29 End view of blades, comparing twisted and straightened blades. Exercise caution when working under the deck as the mower blades are extremely sharp. Wearing gloves is advisable when working around or with the blades. A. Twisted blade edge — C. Cutting plane replace blade D.
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Page 30: Deck Belt
IMPORTANT: The blade sail (curved part) must be Deck belt adjustment pointing upward toward the inside of the deck to The spindle belt tension remains constant by means of a ensure proper cutting. tension idler and spring. There is no tension adjustment of this belt. - Page 31 Deck belt replacement Rear discharge deck shown Allow the engine and muffler to cool before pro- ceeding with the following procedure. Exercise caution when releasing spring tension from the belt idler. 1. This procedure does not require engine power, there- A.
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Page 32: Rear Discharge Deck Anti-Scalp Wheels
9. Re-attach the negative battery cable. Rear discharge deck shown Never operate the mower without the deck covers in place. Rear Discharge Deck Anti-scalp Wheels Make sure to keep the rear anti-scalp wheels free of debris. They must be able to spin freely. Rear discharge deck shown A. -
Page 33: 48"/54" Side Discharge Deck Belt Routing
The following notes are the same for the different decks shown. 1. There is no tension adjustment of this belt 2. Route belt as shown. 48"/54” Side Discharge Deck Belt Routing Figure 6-18 121536 REV A... -
Page 34: 48"/54" Rear Discharge Deck Belt Routing
48"/54” Rear Discharge Deck Belt Routing Figure 6-19 REV A 121536... -
Page 35: Electrical
ELECTRICAL Main Electrical Harness Schematic — Kohler 121536 REV A... -
Page 36: Main Electrical Harness Schematic - Kawasaki
Main Electrical Harness Schematic — Kawasaki REV A 121536... -
Page 37: Main Harness To Fuel Gauge Voltage Convertor Schematic
Main Harness to Fuel Gauge Voltage Convertor Schematic 121536 REV A... - Page 38 REV A 121536...
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Page 39: Maintenance
MAINTENANCE Maintenance Schedule Refer to Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, Figure 8-5, Figure 8-6 & Figure 8-7 WEEKLY ANNUALLY SERVICE AT OR 40 OR 100 INTERVALS INDICATED 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 40: Maintenance Locator Chart
Maintenance Locator Chart Mowers with Kohler Engines 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. Park Brake Switch (2) 9. - Page 41 Figure 8-3 Figure 8-4 Figure 8-5 Figure 8-6 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. Park Brake Switch (2) 9.
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Page 43: Troubleshooting
TROUBLESHOOTING PROBABLE SUGGESTED SYMPTOMS PROBABLE SUGGESTED CAUSES REMEDIES SYMPTOMS CAUSES REMEDIES Mower circles or veers in Steering linkage needs Adjust linkage one direction adjustment Starting motor does not Steering control levers not Place steering control crank in park brake position or levers in park brake posi- Loose steering linkage Tighten linkage... - Page 44 REV A 121536...
- Page 45 INDEX PAGE PAGE Avoid Acid Burns Mower Blade Maintenance ............2-4 ........6-2 Avoid Fire Hazards Mower Blade Replacement ..........2-2 ........6-3 Blades Operate Machine Safely ...............6-2 ..........2-2 Deck Belt Operation Precautions ..............6-4 ..........2-2 Deck Belt Adjustment Park Brake Spring Adjustment ..........6-4 ........
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I have a big dog zero turn mower. It needs a new battery. What size, brand ,etc. do I need to get?