BigDog® Mowers R PowerBar General Service Manual
Contents
1. Fig 6 12 115689 0212 6 5 54 Deck Belt Routing Tensioning 8 25 9 25 SD ID Fig 6 13 60 Deck Belt Routing Tensioning 8 25 9 25 Fig 6 14 6 6 115689 0212 ELECTRICAL Electrical Schematic Kawasaki BLK 4 1 N38 orb RED 4 1347197 134 913479 48139940 18311v8 09 Aq pase bid 55 das mme T74LN3N ch HOLIMS IYYLNIN IT MAGAS 91 1229 7 1 115689 0212 115689 0212 MAINTENANCE SCHEDULE BigDog Mowers R PowerBar Maintenance Schedule REFER TO FIGURE 8 1 FIGURE 8 2 FIGURE 8 3 8 FIGURE 8 4 WEEKLY MONTHLY ANNUALLY OR 40 OR 100 OR 300 HOURS HOURS HOURS Verify safety start interlock system Prior to each use SERVICE AT INTERVAL2. 1 Engine Oil Fill 8 Dipstick 2 Fuel Filter 15 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 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Gauge Wheel Tires 14 Front Gauge Wheel Zerks 2 15 Deck Belt 16 Blades 17 Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter Figure 8 2 8 2 115689 0212 Figure 8 3 oe ES 8 4 Engine Oil Fill amp Dipstick Fuel Filter Engine Air Cleaner Engine Oil Drain Valve Battery Fuel Tank Engine Oil Filter Deck Lift Pivot Zerks 4 Park Brake Switch 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Gauge Wheel Tires 14 Front Gauge Wheel Zerks 2 15 Deck Belt 16 Blades 17 Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 115689_0212 8 3 8 4 115689 0212 TROU
3. Figure 5 3 5 2 115689 0212 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 FR651 FR691 FR730 ENGINE SPEEDS MODEL NO ENDING WITH HIGH IDLE MODEL NO WITHOUT EXTENSION 3600 50 RPM NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown 1 EX or CE Example 922222 no extension 922222 EX 922222 CE 115689_0212 5 3 5 4 115689 0212 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 to level deck The recommended pressures are as follows Drive wheels tire pressure 8 12 psi Gauge wheels tire pressure 8 12 psi WARNING Stop engine Make sure deck clutch switch is in the down OFF position Place PowerBar steering in neutral and engage the park brake before leaving machine 2 Park the unit on a flat surface 3 Place 3 high deck support blocks two stacked 2 x 4 blocks can be used to create a 3 high support at the four corners of the deck as shown NOTE Back of deck will automatically be set 1 4 higher Figure 6 1 4 Place the height stop in the D hole with th
4. 6 3 Operate Machine Safely 2 2 Operation Precautions 2 2 Park brake spring adjustment 4 2 PowerBar neutral adjustment 4 1 Pre Operation Precautions 2 1 Purging procedure 2 0 4 6 Safe servicing practices 2 1 Service 1 1 Special 3 1 Standard torques EE 3 1 Steering adjustments 4 1 Steering damper adjustment 4 2 O 4 6 Understand Correct Service 2 1 Warranty u een 1 1
5. 4 115689 0212 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 FT LBS FT LBS 32 4 IN LBS 12 IN LBS 98 4 IN LBS 204 IN LBS 26 4 IN LBS 54 IN LBS 92 4 IN LBS 222 IN LBS 750 260 350 16 160 215 875 420 565 M20 320 435 Special Torques DESCRIPTION FT LBS Nm Wheel lug nuts 1 65 75 88 14 101 7 Blade spindle bolt top 118 160 01 Blade spindle bolt bottom 118 160 01 Electric Clutch mounting bolt 3 45 48 61 65 Front wheel axle bolt 73 99 Transaxle hub nut 275 339 Transaxle pump pulley nut 45 55 61 74 6 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 Ibs 1156891_0212 3 1 A WARNING 4 Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts Failure to cor rectly torque these items may result in the loss of a wheel or blade wh
6. 6 2 Place the PowerBar handle in the neutral position Figure 4 12 Disengage the deck clutch switch PowerBar handle Figure 4 12 3 With the bypass valve open and the engine running slowly rotate the PowerBar handle in both forward and reverse directions 5 or 6 times Figure 4 13 4 With the bypass valve closed and the engine running slowly rotate the PowerBar handle in both forward and reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine 5 It may be necessary to repeat Steps 3 and 4 until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged Right rod shown Figure 4 13 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 Gauge wheels 8 12 psi 55 83 KPa 115689 0212 If you wish to use non pneumatic tires on your BigDog mower the tires must be an approved tire purchased from BigDog Mowers Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires 115689_0212 4 7 115689 0212 ENGINE MAINTENANCE General Engine Maintenance IMPORTANT Detailed instructions and recommendations for break in and regular maintenance are specified
7. If this is not possible then refuel such equipment on the truck or trailer using a portable container and not a fuel dis penser 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 com plete 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 A 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 con tainer opening Keep fuel away from eyes and skin If fuel is spilled on clothing change clothing immedi ately Understand Machine Operation A Only qualified and trained personnel should operate the equipment A Carefully read the owner s manual and all manuals fur nished with the attachments Learn the location and pur pose of all controls instruments indicators and labels Wear Protective Clothing A 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 jew elry may get tangled in moving parts Always wear long pants safety glasses ear protection and safety shoes when operating or servicing this machine A Always wear adequate eye protection
8. damage use extreme care in handling fuel Fuel is extremely flamma ble and the vapors are explosive A Observe usual fuel handling precautions Do not smoke while refueling Extinguish all ciga rettes cigars pipes and other sources of ignition Do not remove fuel cap or fill tank with engine run ning 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 115689_0212 2 1 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
9. front just becomes tight making sure that the deck stays tight against the block While keeping the chain tight tighten the nuts against the deck lift block on the height indicator rod just enough to carry most of the deck weight on that side the block should be able to move with only a slight drag Figure 6 2 Jam nuts tightly together against the deck lift block Go to the right front of the mower Loosen the hardware that clamps the adjuster to the deck lift arm Figure 6 4 Loosen the 5 16 jam nut on the adjuster lift chain and back the adjuster bolt out to allow the adjuster to move up and down freely Figure 6 4 Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough to carry the weight of the front of the deck on that side to check move the blocks back and forth they should move with a slight drag Figure 6 1 18 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 6 4 19 Tighten the hardware holding the chain and adjuster onto the deck lift arm Figure 6 4 Deck lift arm Figure 6 4 20 Go to the right rear of the mower 21 Make sure that there is still slack in the chain If not loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain Figure 6 5 22 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the block it should
10. lic pump Poor compression Steering linkage needs adjustment Tow valve open See your dealer Adjust linkage Close tow valve SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES Mower jerky when starting or operates in one direc tion only Mower creeps when Pow erBar is in neutral Steering control linkage needs adjustment Adjust linkage Transaxle component faulty Contact your dealer Tow valves not closed com pletely Loose steering linkage Steering linkage needs adjustment Close tow valves Adjust linkage Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Wheel motors faulty Tires improperly inflated Transaxle component faulty Contact your dealer Adjust air pressure to 8 12 psi 55 83 KPa Contact your dealer Mower creeps when park ing brake engaged There is abnormal vibra tion Blades do not rotate Steering linkage out of adjustment Adjust steering linkage Brakes need adjustment The engine mounting bolts are loose The engine pulley idler pul ley or blade pulley is loose The engine pulley is dam aged Adjust parking brakes Tighten the engine mount ing bolts Tighten the appropriate pul ley Contact your dealer The cutting blade s is are bent or unbalanced Install new cutting blade s A blade mounting bolt is loose Tighten the blade
11. when servicing the hydraulic system and battery or when grinding mower blades and removing accumulated debris A 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 impairment or loss of hearing Do not wear radios or music headphones while operat ing the machinery Safe operation requires your full attention Operation Precautions Avoid Fire Hazards A 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 A Avoid possible injury or death from machine runaway A Do not start engine by shorting across starter terminals A Before you start the engine e Sit on the operator s seat Place PowerBar steering in neutral Engage the park brake Operate Machine Safely A Refer to unit s operator s manual for complete safety information on safe machine operation A Always maintain a safe distance from people and pets when mowing A Always be aware of what is behind the machine before backing up A Never leave machine unattended with ignition key in switch especially with children present A Foll
12. BLESHOOTING SYMPTOMS Starting motor does not crank The engine will not start starts hard or fails to keep running PROBABLE CAUSES Park brake not engaged or switch not adjusted Deck clutch switch engaged Weak or dead battery SUGGESTED REMEDIES Place the park brake lever in the engaged position or re adjust switch Disengage clutch switch Recharge or replace Electrical connections are corroded or loose Check the electrical con nections For additional causes No fuel or line plugged Fuel valve is turned off See engine manual Fill tank or replace line See Fuel System section for more details Open the fuel valve There is incorrect fuel in the fuel system Drain the tank and replace the fuel with the proper type There is dirt in the fuel filter Dirt water or stale fuel in the fuel system The is not on Numerous Replace the fuel filter Contact your dealer Move the choke lever to ON See engine manual Engine Runs with continuous mis firing or engine runs unevenly or erratically Numerous See engine manual Loss of power or system will not operate in either direction Restrictions in air cleaner Service air cleaner Hydraulic line blockage Internal interference or leakage in wheel motor Insufficient hydraulic oil supply See your dealer See your dealer Check level in reservoir Have dealer check hydrau
13. BigDog Mowers R PowerBar General Service Manual EXCEL INDUSTRIES P O Box 7000 Honi Kansas 67062 2097 115689 0212 AA WARNING AA 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 Requirements 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 The Engine Owner s Manual provides information regarding the 0 5
14. E If neutral is set properly you should not hear the 7 Lower and secure the seat latch 8 To check rotate the PowerBar handle to the reverse 13 14 15 16 17 transmission whine Turn the engine off Tighten the jam nuts on the steering control rod Figure 4 4 Check to make sure you have all fasteners tightened to the correct torque specifications Repeat steps 5 thru 13 for the left side Once both sides are properly adjusted check them together to make sure everything is working properly 4 2 position and release The PowerBar handle should rotate back to the neutral position If not repeat steps 3 through 5 Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 1 Park the machine on level ground Place PowerBar 115689 0212 Steering damper Steering control nut rod Jam Steering damper stud V Steering damper barrel Figure 4 5 Figure 4 6 WARNING Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and crackin
15. Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep Engine Owners Manual with your unit Should the Engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered per the information found 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 removed or rendered inoperative by any person 115689_0212 115689 0212 Table of Contents General Information 4 4 42 barr dd 1 1 BigDog Mower Service 1 1 Maintenance Introduction 1 1 Warranty weet a A A A Rave 1 1 SUM EE 2 1 Safe Servicing Practices 2 1 Understand Correct 2 1 Pre Operation Precautions oa 2 1 Operation lt 2 2 Operate Machine 2 2 Ge
16. S INDICATED Visually inspect unit for loose hardware and or damaged parts Prior to each use Visually inspect tires Prior to each use Check oil level engine 1 Prior to each use or every 4 hours Clean air intake screen 4 Prior to each use or every 4 hours Check fuel level Prior to each use Blades sharpen amp securely fastened Prior to each use Discharge chute securely in place amp in lowest position Prior to each use Replace air cleaner paper element if equipped 4 As needed Clean engine and transaxle compartment Daily Change transaxle oil and filter 7 Every 200 hours or 2 years Grease deck height pivots Grease gauge wheel bearings Change engine oil and filter 1 3 Check battery connections Check tire pressure with a gauge Check hydraulic oil level XJ X XxX XxX XxX XxX Clean engine exterior a Check pump and deck belt tension and condition 5 Check fuel system 6 Check hydraulic lines Tighten lug nuts on wheels 2 Change fuel filter x Check ROPS mounting hardware 9 Replace fuel evaporation system filter 8 X NOTES 1 huy gt Initial oil change is after 5 hours of operation Thereafter change oil after every 40 hours operation Change more often under dusty or dirty conditions and during hot weather periods Torque initially and after first 2 hours of operation Change engine oil filter per the engine
17. airs only Follow the instructions sup plied with the vehicle stands AA WARNING 4 Keep hands hair clothing etc clear of the cooling fans on top of the transmissions Exercise extreme caution A WARNING A Untrained maintenance personnel should never attempt to make any adjustments or repairs to the mower s drive system while the engine is running The following proce dures should be performed by trained maintenance personnel only 1 Raise the rear of the mower and block with certified jack stands The rear wheels need to be able to rotate freely and clear of all obstructions Chock the front tires 3 Engage the park brakes Figure 4 1 gt 115689 0212 4 1 Park brake lever shown in park brake engaged position Figure 4 1 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 together Figure 4 2 Figure 4 2 Loosen the jam nuts on each end of the steering control rod assemblies Figure 4 4 Place the PowerBar handle in the neutral position Figure 4 3 Loosen the nuts on the rear steering damper ball studs 18 IMPORTANT With the engine off disconnect the two female spade connectors from each other from step 3 and reconnect them to the seat switch This must be completed so that the safety circuit is functioning properly Figure 4 2 Do not operate the mower without plugging the mow
18. atic Kawasaki 7 1 Maintenance Schedule 8 1 BigDog Mowers Series PowerBar Maintenance Locator Chart 8 2 Troubleshooting oa 9 1 TOC 1 TOC 2 115689 0212 GENERAL INFORMATION BigDog Mower Service Program This manual is part of a service package for the BigDog R PowerBar mowers Use of this manual in conjunction with other BigDog mower and component manuals will provide the information necessary to service and maintain BigDog R PowerBar mowers This General Service Manual 15 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 f
19. d while holding the PowerBar handle in the neutral position Now adjust the steering rod back the opposite direction to the point when the wheel stops rotating From that point turn the steering rod an ball stud goes through a hole in the mower frame then the damper is not adjustable Figure 4 4 amp Figure 4 5 If the steering damper is adjustable then use the following procedure 1 Park the machine on level ground Place PowerBar handle in the neutral position engage the park brake disengage deck clutch lower deck and remove the ignition switch key additional Y turn in the same direction This ensures that 2 Release the seat H latform latch Raise seat latform and the steering rod is adjusted so that the transmission disconnect negative battery cable before doing any control arm is centered in the neutral band of the adjustments transmission Figure 4 4 3 Loosen the steering damper s rear ball stud Figure 4 5 12 Rotate the PowerBar handle forward and backward d Pull the damper A AN making sure that the wheel rotates forward and backward of 1 25 between the end of the damper and the barrel of correctly Return the PowerBar handle to neutral and re the damper Figure 4 3 check to make sure the wheel has stopped in the neutral 5 Tighten the nut on the steering damper s rear ball stud position Place the park brake lever in the engaged Pee q position 6 Reconnect the negative battery cable NOT
20. e 4 8 Check oil level in hydraulic system after every 50 hours of operation or weekly whichever occurs first Check more often if system appears to be leaking or otherwise malfunctioning Fluid level should be at the Full Cold line on the expansion tank Use only SAE 20W50 SL SM service motor oil Initial system oil and filter change must be after the first 75 hours of use or year whichever comes first Thereafter replace filter and oil in each transmission every 2 years or 200 hours whichever comes first NOTE The filter guard must be removed to access filter Each transmission s filter is located per Figure 4 9 A standard oil filter wrench is used to change filter threads are right handed Use a BigDog Mowers approved filter element A A WARNING When washing the mower direct the spray away espe cially if using a power washer from the transmission s seals to prevent water intrusion and to ensure component performance 115689_0212 115689_0212 Figure 4 9 Fluid changing procedure 1 Park the machine on level ground Place PowerBar steering in neutral engage the park brake disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable Remove the three 1 4 filter guard screws and filter guard Clean any loose debris from around the filter Figure 4 10 45 10 11 13 Filter guard Figure 4 10 Place an oil drain pan beneath the oil filte
21. e flat side of the height adjusting stop against the stop handle Block Zeg Block Block Block Figure 6 1 5 Clamp the height adjusting stop against the stop handle This will assure that the height will not move during the setting process Otherwise spring pressure from the deck lift springs will tend to pull the stop away from the handle Figure 6 2 6 Loosen all nuts on the deck lift threaded rods until all the deck lift chains are loose and the deck is sitting tightly on all four blocks Figure 6 2 Figure 6 3 amp Figure 6 4 7 Loosen the two nuts on the front of height indicator so that the foot pedal 15 free Figure 6 2 8 Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 right side Figure 6 3 115689 0212 6 1 Height in Clamp here dicator bar Deck lifting chain A E 10 11 12 13 14 15 16 17 Figure 6 3 Start the leveling process on the left front of the mower Push or pull on the deck lift foot pedal until the chain on the left
22. efficiency because its compression and 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 maintenance or the oil has been changed The resulting symptoms in hydrostatic systems may be 1 Noisy operation 2 Lack of power or drive after short term operation 3 High operation temperature and excessive expansion of oil Before starting make sure the transaxle is at the proper oil level If it is not fill to the specifications outlined in this manual The following procedures are best performed with the vehicle drive wheels off the ground 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 1 Raise and block the mower up so the drive wheels are off of the floor 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 mini mum weight rating of 2000 pounds to block the unit up Use in pairs only Follow the instructions supplied with the vehicle stands WARNING 4
23. emove ignition switch key and disconnect negative bat tery cable for maximum safety A Except when changing or checking belt always keep belt covers on mower deck for safety as well as cleanliness A 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 A 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 A Never attempt to make any adjustments or repairs to the mower drive system mower deck or any attachment while the engine 15 running or deck clutch 15 engaged A Never work under the machine or attachment unless it is safely supported with jack stands Make certain machine 1s 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 appro priate 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 A Keep nuts and bolts tight especially the blade attachment bolts Keep equipmen
24. er s wiring harness into the seat switch This switch 15 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 harness WARNING PowerBar handle Figure 4 3 The dampers must be allowed to slide in the slots in the mower frame Figure 4 5 NOTE If the mmower does not have these slots then one end of the damper must be removed from the steering damper stud S Start the engine 9 Disengage the park brakes 10 Place the PowerBar handle in the neutral position and hold it This operation is extremely dangerous Pay close atten tion when adjusting the steering control rod so you do not get your fingers tools or anything else close to the trans WARNING Never operate the mower with a non functioning seat switch Always reconnect the seat switch to the mower harness 19 Check to make sure all tools or obstructions are removed from under the mower 20 Raise the rear of the mower and remove the jack stands Lower the mower WARNING Steering damper adjustment The steering damper may or may not be adjustable If the steering damper s rear ball stud goes through a slot in the mower frame then it is adjustable If the steering damper s rear mission s cooling fans 11 Beginning with the right side of the mower adjust the steering control rod so that the right side wheel starts rotating forwar
25. etal mower parts when removing or installing the battery Do not allow metal tools to short between the battery terminals and metal mower parts A 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 per sonal injury Always disconnect the negative black bat Prepare For Emergencies A Be prepared if a fire starts A Keepafirst aid kit and fire extinguishers available A Keep emergency numbers for doctor ambulance service hospital and fire department near the telephone Prevent Battery Explosions A 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 A Charge batteries in an open well ventilated area away from sparks and flames Unplug charger before connect ing or disconnecting from battery Wear protective cloth ing and use insulated tools tery cable s before disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s A 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 con tact occurs flush area with clean water and call physi cian immediately Acid will also damage clothing D
26. g 115689 0212 6 3 of the blade which can cause serious injury Mower blades are sharp cut Wrap the blade s or wear gloves and use extra caution when servicing them WARNING Resharpening pattern Do not sharpen to original pattern below It is easier to get a straight cutting edge following the resharpening pattern shown above Original edge Figure 6 8 Warped Blade Replace Cutting plane Straight Blade Comparison of Warped and Straight Blades Figure 6 9 Cutting edge Twisted Blade Edge replace Cutting Plane o edge Straight Blade Edge End view of blades comparing twisted and straightened blades Figure 6 10 Belts Inspect belts frequently for wear and serviceability Replace a belt that shows signs of severe cuts tears separation weather checking and cracking or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering con trol levers in the park brake position immediately Inspect the machine and involve your BigDog Mow ers dealer to resolve the problem before continuing to WARNING A operate Inspect the belt pulley grooves and flanges for wear A new belt or one in go
27. g or burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings Never operate the mower with the seat latch un installed or unsecured The seat platform must be securely latched to prevent seat from moving tilting in the event of mower tipping or rollover handle in neutral engage the park brake disengage deck clutch lower deck remove ignition switch key and disconnect negative battery cable before doing any maintenance 2 On one side measure the park brake spring It should be compressed to 1 50 If it is not adjust the nylock nut until the proper spring compression is achieved Figure 4 6 Repeat for other side 4 Reconnect the negative battery cable 2 115689 0212 4 3 with a sharp knife WARNING If the pump belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the steering con trol levers in the park brake position immediately Inspect the machine and involve your BigDog Mow ers dealer to resolve the problem before continuing to operate Inspect the belt pulley grooves and flanges for wear A new belt or one in good condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or damage the fibers of the bel
28. ich can cause serious damage or personal injury 3 2 1156891_0212 POWER UNIT MAINTENANCE Steering Adjustments PowerBar neutral adjustment The mower s steering has been factory adjusted to eliminate creeping when the PowerBar lever is in the neutral position However should the mower begin to creep the steering linkage can be adjusted Before considering any adjustment check the tire air pressure Unequal tire pressure will cause the mower to drift to one side Refer to tire pressure information in the Tires section for detailed information NOTE Proper park brake adjustment must be completed before the PowerBar neutral adjustment can be done Refer to the Park Brake Spring Adjustment section for detailed informa tion Fine adjustment to the unit s steering is made with the transmission s control rod Neutral is properly adjusted when the PowerBar lever is in the neutral position and the transmissions do not whine If this occurs the steering control linkage may be adjusted as follows AA WARNING 4 This procedure will require that the unit to 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 Stay clear and exercise caution when rotating wheels to prevent injury Use only appropriate vehicle stands with a minimum weight rating of 2000 pounds to block the unit up Use in p
29. in the Engine Owner s Manual Please refer to this manual for engine servic ing lubricating oil levels with quality and viscosity recommen dations bolt torques etc The engine warranty is backed by the manufacturer Special attention should be paid to applicable data which will not be duplicated here Engine Oil and Filter If the engine has been running and is up to operating tem perature allow the engine to cool before changing the oil Engine and engine oil will be very hot so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil WARNING Check engine oil daily and after every 4 hours of operation Machine must be setting level when checking oil Refer to engine manual and maintenance schedule for oil recommendation and capacities Change the engine oil and filter after the first 5 hours of operation and per the engine manufacturer s recommendations after that If mower is being operated in extremely dirty conditions then it is recommended oil be changed more frequently IMPORTANT When removing the oil filter take precautions to minimize oil spillage on the exhaust system Draining the engine oil 1 Locate the oil drain valve on the engine Figure 5 1 2 Position a suitable oil drain container under the machine below the oil drain valve 3 Twist the valve counterclockwise to open the valve Allow 10 minutes for engine oil to adequately drai
30. manufacturers recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items Service more often under dusty or dirty conditions Pump drive belt only Inspect every 6 months or 100 hours and replace if worn or cracking is noticed Otherwise replace every 200 hours or 2 years which ever comes first Check fuel system for any cracks or leaks including but not limited to fuel line hoses fuel valve vent line hoses vent valve vapor valve carbon canister and grommets Initial system oil and filter change must be after the first 75 hours of use 1 year whichever comes first Thereafter replace filter and oil in each transaxle every 2 years or 200 hours whichever comes first More often under dusty or dirty conditions and during hot weather Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first REFERENCES A Refer to Engine Owner s Manual NOTE After completing maintenance cycle 300 hours repeat cycle 11 5689 0212 8 1 BigDog Mowers Series PowerBar Maintenance Locator Chart
31. mounting bolt Spindle bearing is worn or loose A blade spindle is bent The deck drive belt is worn loose or broken Replace or tighten spindle bearing Contact your dealer Install a new deck drive belt The deck drive belt is off the pulley Install the deck drive belt and check for a reason m clutch is not engag ing Check and or replace 10 amp fuse Contact your dealer The traction drive belt is worn loose or broken Install a new traction drive belt Air in system For additional causes Check filter and fittings See engine manual Air cooled engine over heating Low engine oil pressure Air intake screen or clean ing fins clogged Clean screen and fin For additional causes Low oil level Oil diluted or too light See engine manual Change oil and check for source of contamination Failed oil pump Contact your dealer High oil consumption 115689 0212 Numerous Contact your dealer 9 1 Uneven cutting height The blade s are not sharp A cutting blade s is are bent The deck is not level An anti scalp wheel is not set correctly The underside of the deck is dirty Tires improperly inflated Sharpen the blades Install new cutting blade s Level the deck per the Deck leveling and height adjustment section of the General Service Manual Adjust the height of the anti scalp wheel Clean the u
32. move with a slight drag Figure 6 1 23 Tighten the other nut on the opposite side of the block and jam them tightly together against the block N fez rear of deck that side to check move blocks back and forth they should move with a slight drag Figure 6 1 27 Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving Figure 6 6 28 Tighten the hardware holding the chain and adjuster onto the deck lift arm Figure 6 6 Adjuster bolt 3 6 Jam Nut A EIN Adjuster Chain Figure 6 6 29 Compress the deck lift assist springs so that there is 1 2 of space between the front nut on the spring and the rear nut on the deck lift block Typical both sides Figure 6 7 30 When completed all chains will be tight and deck cutting height will be set to the deck height indicator AAA STE E A fi 7 En E Pi 71 TR Figure 6 5 24 Go to the left rear of the mower 25 Loosen the 5 16 jam nut on the adjuster lift chain and back the adjuster b
33. n 4 After oil is drained close the valve by twisting it clockwise 5 Once the valve 15 closed clean up any spilled oil IMPORTANT All oil drips or spills must be cleaned off of the exhaust system before operating the machine Engine Air Filter Perform engine air filter maintenance per the engine s owner s manual Fuel evaporation system filter All BigDog R PowerBar mowers have fuel evaporation system filter This filter must be checked and replaced every 300 hours or annually whichever comes first Figure 5 2 Fuel 8 evaporative system line routings On BigDog Mower R PowerBar mowers there are two 115689_0212 5 1 N Fuel evaporation system filter Figure 5 2 rubber hoses that are connected to each fuel tank One is the fuel hose that is part of the fuel system The other is the vapor line that is part of the fuel evaporative system The fuel hose is connected to the port on the side wall of the fuel tank It connects the fuel tank to the fuel shutoff valve Figure 5 3 The vapor line is connected to the port in the top of the fuel tank It connects the fuel tank to the engine s vapor port Figure 5 2 Gas upport Fuel line o Fuel line 222 20 Sg
34. nderside of the deck Adjust air pressure to 8 12 psi 55 83 KPa A blade spindle is bent Contact your dealer 9 2 115689 0212 PAGE Belts eise beige elek 4 3 6 4 Blades mt law atl eh a iit Leta 6 2 Deck Belt adjustment 6 4 Deck Belt Routing 8 Tensioning 6 5 Deck leveling 6 1 Electrical Schematic 7 1 Engine air MeF sic Aine 5 1 Engine oil and filter sses teares 5 1 Engine RPM settings 5 3 Fluid changing procedure 4 5 Fuel evaporative system line routings 5 1 Fuel evaporation system filter 5 1 General engine maintenance 5 1 General Maintenance Precautions 2 2 Hydraulic pump belt adjustment 4 4 Hydraulic 4 4 Maintenance introduction 1 1 Maintenance locator chart 8 2 Maintenance Precautions 2 2 115689 0212 1 1 Maintenance Schedule 8 1 Mower blade maintenance 6 2 Mower blade removal
35. neral Maintenance 5 2 2 Maintenance lt 2 2 TOQUE cmd as a Bene de ds 3 1 standard estar aro DE a 3 1 Special TOQUES ae RE RA 3 1 Power Unit Maintenance 4 1 Steering Adjustments le 4 1 Park Brake Spring Adjustment mo 4 2 Belial o ed 4 3 Hydraulic Pump Belt 4 4 Flydrauliesysiem EE 4 4 A 4 6 Engine 5 1 General Engine 5 1 Engine Oil and Filter 5 1 Engine Air Fiter ta a 5 1 Fuel evaporation system 5 1 Fuel evaporative system line 05 5 1 Engine RFM SEHINgS EE maa rain 5 3 Deck Adjustments 6 1 Deck Leveling a Ae BCEE 6 1 ld a a 6 2 its supieron 6 4 Deck belt adjustment cs 6 4 48 Deck Belt Routing 8 Tensioning 6 5 54 Deck Belt Routing 8 Tensioning 6 6 60 Deck Belt Routing 8 Tensioning 6 6 Electrical ae See ee a eli a k e ka 7 1 Electrical Schem
36. o 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 posi tive red cable s Always connect the positive red Apply baking soda or lime to help neutralize the acid battery cable s before connecting the negative black Flush with water for 10 15 minutes Get cable s medical attention immediately If acid is swallowed Drink large amounts of water or milk Then drink milk of magnesia beaten eggs or vegetable oil A Get medical attention immediately Avoid Acid Burns A 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 e Avoiding breathing fumes when electrolyte is added Avoiding spilling or dripped electrolyte If you spill acid on yourself Flush your skin with water 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 bat tery Clean the battery terminals with a solution of four 115689 0212 2 3 2
37. od condition should never run against the bottom of the groove Replace the pulley when this is the case otherwise belt will lose power and slip excessively 6 4 Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will destroy the belt composition in a very short time Deck belt adjustment The spindle belt tension remains constant by means of a tension idler and spring The spring tension should be such that the belt does not slip under normal operating load conditions assuming the belt is not excessively worn or damaged As the belt stretches and wears in adjustment may become necessary To increase belt tension move the spring chain one or more link s at the anchor point on the deck frame Figure 6 11 IMPORTANT Do not over tension the spring to compensate for a badly worn belt or pulley Spring chain Spring chain anchor point N NN 4 spring S Figure 6 11 115689 0212 NOTE The following notes are the same for the three different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at cut height 2 Route belt as shown 48 Deck Belt Routing 8 Tensioning
38. olt out to allow the adjuster to move up and down freely Figure 6 6 26 Tighten the adjuster bolt until the chain just becomes tight Then tighten just enough to carry the weight of the 6 2 Figure 6 7 Blades Mower blade maintenance Check the mower blades daily they are the key to power efficiency and well groomed turf Keep them sharp a dull blade will tear rather than cut the grass leaving a brown ragged top on the grass within a few hours A dull blade also requires more power from the engine 115689 0212 Replace any blade which is bent cracked or broken WARNING Never attempt to straighten a bent blade by heating or weld a cracked or broken blade as the blade may break and cause serious injury Replace worn or damaged IMPORTANT When mounting blades rotate them after installation to ensure blade tips do not touch each other or sides of the mower Failure to correctly torque the bolt may result in the loss WARNING A blades Never work with blades while engine is running or deck clutch switch is engaged on Always place deck clutch switch in the disengaged position place PowerBar in neutral engage the park brake turn engine off and dis connect negative battery cable Block up mower when you must work under it Wear gloves when handling blades Always check for blade damage if mower strikes rock branch or other foreign object during mow A A Always wear adeq
39. or 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 115689_0212 1 1 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 15 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 Ifa change has been made to your machine which is not reflected in this se
40. ow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened A Always keep engine and machine clean removing accu mulated dirt trash and other material from machine A Never put hands or feet under any part of the machine while it is running A Never attempt to start engine when there is a strong odor of gasoline fumes present Locate and correct cause A Keep all safety shields and covers in place except for servicing A Do not touch hot parts of machine General Maintenance Precautions A Repairs or maintenance requiring engine power should be performed by trained maintenance person nel only A Never run the engine in an enclosed area unless exhaust 18 vented to the outside Exhaust gases contain carbon monoxide which is an odorless and deadly poison A Unless specifically required DO NOT have engine run ning when servicing or making adjustments to mower Park the machine on level ground Place PowerBar steer ing in neutral engage the park brake disengage deck clutch lower deck remove ignition switch key and dis connect negative battery cable before doing any mainte nance Wait for all movement to stop before adjusting 2 2 cleaning or repairing To prevent carbon monoxide poi soning be sure proper ventilation is available when engine must be operated in an enclosed area A Before working on or under the deck make certain engine cannot be accidentally started Shut engine off r
41. r and remove the oil filter from the transaxle After the oil has been drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface Re install the filter guard with three 1 4 screws Torque the screws to 65 in Ibs each Figure 4 10 Repeat steps 2 6 for the opposite side transaxle Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers IMPORTANT Remove the top port plug from both transaxles prior to filling with oil This will allow the transaxles to vent during oil fill Figure 4 11 Remove the cap from the transaxle s expansion tank Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 qts per transaxle Install the top port plug into each transaxle Torque plugs to 180 in lbs Clean up any oil that leaked from the ports Figure 4 11 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expansion tank Re install the expansion tank cap by hand Be careful not to overtighten 14 Proceed to the purge procedure Top port plug Figure 4 11 Purging procedure Due to the affects air has on efficiency in hydrostatic drive applications it is critical that it is purged from the system Air creates in
42. rvice manual contact the Customer Service Department at BigDog Mowers for additional information Warranty Warranty repair must be performed by 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 1 2 115689 0212 SAFETY 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 DANGER WARNING 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 A Be sure you understand a service procedure before you work on the machine A 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 A To avoid personal injury or property
43. t covering Keep oil and grease away from belts and never use belt 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 There is no tension adjustment of this belt Figure 4 7 NOTE Inspect the belt every 100 hours and replace as needed Replace the belt every 200 hours or every two 2 years whichever comes first If the transmission belt fails loss of control will occur especially when operating on a slope If you lose steering control while operating the machine place the park brake lever in the engaged up position immediately Inspect the machine and involve your dealer to resolve the prob lem A WARNING 4 4 Bottom View Hydraulic pump belt Tension idler Figure 4 7 Hydraulic system This mower is equipped with two integrated hydrostatic transmissions Figure 4 8 IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only motor oil as specified Remember dirt is the primary enemy of any hydraulic system The hydraulic expansion tank is located in front of the engine and under the operator s platform Figur
44. t in good working condition A Never tamper with safety devices Check their proper operation regularly A 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 A Use only genuine BigDog Mower replacement parts to ensure that original standards are maintained Maintenance Precautions Avoid Fire Hazards A 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 A Provide adequate ventilation when charging batteries A Do not smoke near battery A Never check fuel level with an open flame A Never use an open flame to look for leaks anywhere on the equipment A Never use an open flame as light anywhere on or around the equipment A 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 115689 0212 A Inspect electrical wiring for worn or frayed insulation Install new wiring if wires are damaged parts water and one part baking soda when they become corroded A 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 per sonal injury Prevent the battery terminals from touching any m
45. uate eye protection when grinding mower blades WARNING WARNING Mower blade removal Use a 15 16 wrench to remove the 5 8 cap screw holding the blade to the spindle shaft from underneath 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 BigDog Mowers dealer for more information Sharpen the blades on a grinder following pattern as shown Figure 6 8 Touch up sharpening can be done with a file Check the blades for balance following grinding A commercial balancing tool is available through most hardware supply stores or balancing can be done by placing the blade on an inverted line punch or 5 8 bolt Blade should not lean or tilt Spin the blade slowly blade should not wobble If blade is out of balance true it up before reinstalling Lay the blade on a flat surface and check for distortion Figure 6 9 amp Figure 6 10 Replace any distorted blade Do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 foot pounds 160 0 Nm when reinstalling blades Properly compressed cup washers maintain the correct compression load on the blades Replace the cup washers if they are cracked or flattened IMPORTANT The blade sail curved part must be point ing upward toward the inside of the deck to ensure proper cut tin
Download Pdf Manuals
Related Search