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Bigdog Mower Co. ALPHA MPX General Service Manual Download Page 1

125277

REV A

BIGDOG

®

 MOWER CO. ALPHA

®

 MPX

General Service Manual

200 South Ridge Road

Hesston, Kansas

67062

Summary of Contents for ALPHA MPX

Page 1: ...125277 REV A BIGDOG MOWER CO ALPHA MPX General Service Manual 200 South Ridge Road Hesston Kansas 67062 ...

Page 2: ...nt 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 materi...

Page 3: ...ions 2 2 Maintenance Precautions 2 3 Torque 3 1 Standard Torques 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Park Brake Spring Adjustment 4 4 Transaxle Drive Belt 4 5 Hydraulic system 4 7 Tires 4 10 Engine Maintenance 5 1 General Engine Maintenance 5 1 Engine Oil and Filter 5 1 Engine Air Filter 5 1 Fuel Evaporation System Filter 5 2 Fuel and Evaporative System Line...

Page 4: ...REV A 125277 Electrical 7 1 Maintenance 8 1 Troubleshooting 9 1 ...

Page 5: ...g the problem as quickly as possible is the best insurance Clear away heavy build up of grease oil and dirt especially in the engine compartment and under the seat platform areas minute dust 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 cl...

Page 6: ...REV A 1 2 125277 ...

Page 7: ...on 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 conta...

Page 8: ...tion on safe machine operation Always maintain a safe distance from people and pets when mowing Always be aware of what is behind the machine before backing up Never leave machine unattended with ignition key in switch especially with children present Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always keep engine and machine clean removing accum...

Page 9: ...ld occur Know where the first aid kit and the fire extinguishers are located and how to use them Provide adequate ventilation when charging batteries Do not smoke near battery Never check fuel level with an open flame Never use an open flame to look for leaks anywhere on the equipment Never use an open flame as light anywhere on or around the equipment When preparing engine for storage remember th...

Page 10: ...disconnecting the positive red cable s Always connect the positive red battery cable s before connecting the negative black cable s Avoid Acid Burns 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 A...

Page 11: ...bs N m Size ft lbs N m 10 32 4 IN LBS 3 6 M3 12 IN LBS 1 3 250 98 4 IN LBS 11 1 M4 26 4 IN LBS 3 312 204 IN LBS 23 M5 54 IN LBS 6 1 375 30 40 M6 92 4 IN LBS 10 4 438 48 65 M8 222 IN LBS 25 500 73 99 M10 37 50 562 105 143 M12 64 87 625 145 200 M14 103 140 750 260 350 M16 160 215 875 420 565 M20 320 435 Description ft lbs N m Wheel lug nuts 1 70 95 Blade spindle bolt top 73 99 Blade spindle bolt bot...

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Page 13: ...tery cable before doing any adjustments 2 Raise the rear of the mower and block with certified jack stands Remove the rear wheels 3 Chock the front tires 4 Make sure both steering control levers are in the park brake position Figure 4 1 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 s...

Page 14: ...jack stands Lower the mower 13 Re attach the negative battery cable 14 Close the seat platform Steering Damper The steering damper is spring loaded to return the steering control levers to the neutral position from the reverse position This gives the operator a sense of neutral during operation If the mower does not return to neutral from reverse then adjust as follows To set the steering dampers ...

Page 15: ...er harness female spades together Figure 4 8 5 Start the engine and move both steering control levers forward against the stops in the steering cover 6 Determine if the drive wheels are rotating equally or if one is faster than the other If the wheels are not the same speed proceed to the next step A Steering control levers Figure 4 5 A Rear ball stud B Damper spring housing Figure 4 6 A A A B Kee...

Page 16: ...tform and secure in place Park Brake Spring Adjustment Occasionally check the park brake spring adjustment using the following method 1 Shut engine off place steering control levers in the park brake position disengage deck clutch remove ignition switch key and disconnect negative battery cable before doing any adjustments 2 Make sure steering control levers are in the park brake position 3 Adjust...

Page 17: ...pring There is no tension adjustment of this belt Figure 4 11 NOTE Inspect the belt every month and replace as needed Replace the belt every two 2 years Transaxle Drive Belt Replacement 1 Park the mower on a flat surface and stop the engine Make sure deck clutch switch is in the down OFF position Place the steering control levers in the park brake position Remove ignition key Make sure the blades ...

Page 18: ...ure 4 14 10 Make sure the transaxle drive belt is routed correctly around the tension idler before attaching the tension spring Using the locking pliers re attach the tension spring to the idler arm to re tension the transaxle drive belt Remove the locking pliers from the tension spring Figure 4 14 11 Reroute the deck drive belt around the electric clutch pulley Make certain the belt is routed pro...

Page 19: ...he specified oil shown 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 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 17 A standard oil filter wrench is used to change filter t...

Page 20: ...t steps 2 6 for the opposite side transaxle 8 Drain oil filters of all free flowing oil prior to disposal Place used oil in appropriate containers 9 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 19 10 Remove the cap from the transaxle s expansion tank 11 Fill with SAE 20W50 motor oil 15W50 synthetic...

Page 21: ...the engine running slowly move the steering control lever in both forward and reverse directions 5 or 6 times Figure 4 21 6 With the bypass valve closed and the engine running slowly move the steering control lever in both forward and reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine When washing the mower direct the spray away especially if usin...

Page 22: ...e transaxle is considered purged 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 Front wheels 8 12 psi 55 83 KPa Only pneumatic tires are approved for use on this mower Warranty claims will be denied on any mower equipped with non pneumatic tires A Bypass valve rod B Slot with left rod shown in...

Page 23: ... and clear it of debris that might block the flow of the engine oil 3 Attach one end of the hose onto the oil drain valve nipple Make sure the hose is pushed all the way onto the oil drain valve nipple Figure 5 1 4 Position the loose end of the hose forward and down in front of the right side transmission so that it can drain into a suitable oil drain container 5 With the hose in position use a 10...

Page 24: ... the 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 fuel tank as shown It connects the fuel tank to the engine s fuel pump Figure 5 4 The vapor lines are connected to the fuel tank as shown They connect the fuel tank to the engine s vapor port Figure 5 5 A Fuel evaporation syst...

Page 25: ... should be set as follows NOTE Model numbers may or may not end with an extension after the number There are several different extensions that may be shown i e EX or CE 14 Example 922222 no extension 922222 EX 922222 CE 922222 US KAWASAKI FR691V FR730V ENGINE SPEED MODEL NO ENDING WITH HIGH IDLE Model NO without extension Model NO with US extension Model NO with EX extension 3600 50 rpm ...

Page 26: ...REV A 5 4 125277 ...

Page 27: ...slide the block out from under the deck without feeling any resistance Figure 6 3 IMPORTANT Raise the deck just enough so that the block can be moved without any resistance from the deck Repeat at the other deck leveling positions Blades Mower blade maintenance Refer to the Mower Blade Replacement section for blade removal and installation Check the mower blades daily as they are the key to power ...

Page 28: ...ower should be performed by trained maintenance personnel only Unless specifically required DO NOT have the engine running when servicing or making adjustments to the mower Park the mower on level ground Disengage the deck clutch Place the steering control levers in the park brake position Lower the deck Stop the engine Remove the ignition key Disconnect the negative battery cable Block up mower w...

Page 29: ... D Cutting edge Figure 6 6 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 Use only certified jack stands Use only appropriate jack stands with a minimum weight rating of 2000 pounds 907 kg to block the unit up Use in pairs only Follow the instructions supplied with the jack sta...

Page 30: ...ley when this is the case otherwise the 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 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 id...

Page 31: ...ey located on the engine shaft Figure 6 9 7 Route the new deck drive belt around the clutch pulley spindle pulleys and stationary idler pulley Make certain the belt is routed properly Figure 6 10 8 Re tension the deck drive belt by pulling on the deck belt idler spring and hooking it in the spring mount on the deck Figure 6 8 9 Install the deck covers Figure 6 8 10 Re attach the negative battery c...

Page 32: ...REV A 6 6 125277 The following notes are the same for the different deck sizes 1 There is no tension adjustment of this belt 2 Route belt as shown Deck Belt Routing Figure 6 10 ...

Page 33: ...18 BLK 18 BLK 18 RED BLK 18 BLK 18 MASTER FUSE 15A PUR 14 TAN 18 RELAY RED 14 BLK 16 BLACK 14 ORG 14 HOUR METER BLK 18 ORG 18 GROUND SPLICE SWITCH IGNITION B G R K S START KILL RELAY CLUTCH SWITCH CLUTCH ENGINE BATTERY NEUTRAL SWITCH NEUTRAL SWITCH SEAT SWITCH STARTER SOLENOID RED BLK 18 RED 14 BRN 18 ORG RED 16 TAN 18 TAN RED 18 TAN RED 18 TAN RED 18 TAN RED 18 BLK 8 RED 8 RED 8 BRN 18 PUR 14 ORG...

Page 34: ...REV A 7 2 125277 Light Harness Schematic HOUR METER HARNESS LIGHT RH LIGHT LH ...

Page 35: ...f use or 1 year whichever comes first Thereafter replace filter and oil in each transmission every 2 years or 200 hours whichever comes first After completing maintenance cycle 100 hours repeat cycle Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 SERVICE AT INTERVALS INDICATED WEEKLY OR 40 HOURS ANNUALLY OR 100 HOURS Verify safety start interlock system Prior to each use Visually i...

Page 36: ... Drain Valve 5 Battery 6 Fuel Tank 7 Engine Oil Filter 8 Park Brake Switch 2 9 Drive Tire 10 Pump Belt 11 Engine Air Intake Screen 12 Front Wheel Tires 13 Hydraulic Oil Expansion Tank 14 Deck Belt 15 Blades 16 Fuel Evaporation System Filter Figure 8 2 Figure 8 3 Figure 8 1 2 3 4 5 6 7 9 9 8 8 11 12 13 1 16 10 15 14 15 ...

Page 37: ...rol linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Transaxle component faulty Contact your Dealer Mower creeps when steering control levers are in neutral Steering linkage needs adjustment Adjust linkage Mower circles or veers in one direction Steering linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Tires improperly inflated Adjust air...

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Page 39: ... Engine Maintenance 5 1 General Maintenance Precautions 2 2 Hydraulic System 4 7 Maintenance Introduction 1 1 Maintenance Locator Chart 8 2 Maintenance Precautions 2 3 Mower Blade Maintenance 6 1 Mower Blade Replacement 6 3 Operate Machine Safely 2 2 Operation Precautions 2 2 Park Brake Spring Adjustment 4 4 Pre operation Precautions 2 1 Prepare for Emergencies 2 3 Prevent Battery Explosions 2 3 P...

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