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Bigdog Mower Co. STOUT MP, General Service Manual, Page: 4 / 41

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Summary of Contents for STOUT MP

Page 1: ...121366 REV E BIGDOG MOWER CO STOUT MP General Service Manual 200 South Ridge Road Hesston Kansas 67062 ...

Page 2: ...ent 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 mater...

Page 3: ...ons 2 3 Torque 3 1 Standard Torques 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Steering Control Lever Stops 4 4 Belts 4 5 Hydraulic Pump Belt Adjustment 4 6 Hydraulic System 4 6 Tires 4 9 Engine Maintenance 5 1 General Engine Maintenance 5 1 Engine Oil and Filter 5 1 Engine Air Filter 5 1 Fuel Evaporative System Line Routings 5 3 Engine RPM Settings 5 4 Deck Adjust...

Page 4: ...66 Electrical 7 1 Main Electrical Harness Schematic 7 1 Main Harness to Fuel Gauge Voltage Convertor Schematic 7 2 Main Harness to Lights Schematic 7 2 Maintenance 8 1 Maintenance Locator Chart 8 2 Troubleshooting 9 1 ...

Page 5: ... 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 cli...

Page 6: ...REV E 1 2 121366 ...

Page 7: ...rk and store machine away from open flame or spark or pilot light such as on a water heater or appliances Refuel outdoors Never refuel or drain the gasoline from the machine indoors Never attempt to start the engine when there is a strong odor of gasoline fumes present Locate and correct the cause Store gasoline in an approved container and keep it out of the reach of children Never buy more than ...

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: ...xtinguishers 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 that fuel stabilizer is volatile and therefore dangero...

Page 10: ...he 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 Avoiding breathing fumes when electrolyte is added Avoid...

Page 11: ...r Size ft lbs 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 Size ft lbs N m Wheel lug nuts 1 70 95 Blade spindle bolt top 70 95 Blade spindle bolt...

Page 12: ...REV E 3 2 121366 ...

Page 13: ...ing the two mower harness female spades connectors together Figure 4 1 Figure 4 2 Re attach the seat platform to the mower frame 4 Loosen the jam nuts on each end of the steering control rod assemblies Figure 4 5 5 Set both steering control levers in the park brake position Figure 4 3 NOTE Both steering control levers need to be in the park brake position when starting the engine but need to be mo...

Page 14: ...mission Figure 4 6 Move the steering control lever forward and backward making sure that the wheel rotates forward and backward correctly Return the steering control lever to neutral and re check to make sure the wheel has stopped in the neutral position Place the steering control lever in the park brake position If neutral is set properly you should not hear the transmission whine 8 Repeat steps ...

Page 15: ...Occasionally check the park brake spring adjustment using the following method 1 This procedure does not require engine power therefore Park the mower on level ground Disengage the deck clutch Place the steering control levers in the park brake position Stop the engine Remove the ignition key Disconnect the negative battery cable Shown with steering control lever in the neutral position A Steering...

Page 16: ...ally If one is rotating faster that the other proceed to the next step 6 Return the steering control levers to the park brake position and shut the engine off A Nylock nut B Park brake spring C Park brake rod Figure 4 7 This procedure will require that the unit to be raised to allow the drive wheel to rotate Block the mower up off of the ground using only appropriate vehicle stands minimum weight ...

Page 17: ...cate failure trim ravelings with a sharp knife 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 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...

Page 18: ...etic oil or 20W50 synthetic oil when changing the system oil and filter When the hydraulic system oil is cold the fluid level should be at the Full Cold line on the expansion tank 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 hours whichever comes first Each trans...

Page 19: ... 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 15 11 Continue to fill the transaxles through the expansion tank until the Full Cold line is reached on the expansion tank 12 Re install the expansion tank cap by hand Be careful not to overtighten 13 Proceed to the purge procedure IMPORTANT Purging procedure...

Page 20: ...d reverse directions 5 or 6 times Check the oil level and add oil as required after stopping the engine 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...

Page 21: ...mmended pressures are Drive wheels 8 12 psi 55 83 KPa Front wheels 8 12 psi 55 83 KPa If you wish to use non pneumatic tires on your BigDog mower the tire must be a BigDog Mower approved tire Warranty claims will be denied on any mower equipped with unapproved non pneumatic tires Shown with steering control lever in the neutral position A Steering control lever Figure 4 18 A Bypass valve rod B Tra...

Page 22: ...REV E 4 10 121366 ...

Page 23: ...cate 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 drain 4 After oil is drained close the valve by twisting it clockwise 5 Once the valve is closed clean up any spilled oil IMPORTANT All oil drips or spills must be c...

Page 24: ...ant to note that whenever an air filter element is cleaned by any method the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on The warranty for air filters expires upon cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the filter manufacturer s control Therefore on a dust ingested...

Page 25: ...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 6 The vapor lines are connected to the fuel tank as shown They connect the fuel tank to the engine s vapor port Figure 5 7 A Fuel evaporation system filter Figure 5 5 A A Fuel tank B Fuel line Figure 5 6 A Fuel tank B Vapor lines C...

Page 26: ...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 AU or CE Example 922222 no extension 922222 EX 922222 CE 922222 US 922222 AU Kawasaki FX691 FX730 ENGINE SPEEDS MODEL NO ENDING WITH LOW IDLE HIGH IDLE Model NO without extension Model NO with EX extension Model NO with US extension 1900 100 rpm 3600 5...

Page 27: ... the pedal 8 Unscrew the nut from the eyebolt and slide the eyebolt out of the mount This removes the tension from the deck lift assist spring Figure 6 3 9 Pull the pedal rearward so that the transport latch is held firmly against the deck height adjusting stop pin and the play in the pivot joint is removed secure the pedal in this position a bungee cord may be used 10 Tighten the four deck links ...

Page 28: ... tool is also available through most hardware supply stores 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 Figure 6 5 Figure 6 6 A Deck lift assist spring B Eyebolt C Nut D Lock nut Figure 6 3 Mower blades are sharp and can cut Wrap the b...

Page 29: ...signs of severe cuts tears separation weather checking cracking burns caused by slipping Slight raveling of belt covering does not indicate failure trim ravelings with a sharp knife 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 the belt will lose power and...

Page 30: ...indle 2 Grasp the belt at the two locations shown and pull the belt over the left spindle pulley Figure 6 8 3 Release the belt Keep hands clear when pulling belt over the pulley to prevent pinching Do not get hand or fingers between pulley and belt WARNING Side Discharge Deck Shown A Grasp belt here Figure 6 8 A A Grasp the belt here and pull over the pulley ...

Page 31: ...21366 6 5 REV E 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 ...

Page 32: ...REV E 6 6 121366 ...

Page 33: ...121366 7 1 REV E ELECTRICAL Main Electrical Harness Schematic ...

Page 34: ...or to serial number 17065997 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 24 12V DC 5V DC CONVERTER ORG 20 ORG 20 ORG 20 BLK 20 GRN 20 YEL BLK BLK BLK 20 FUEL GAUGE CONNECTOR HARNESS CONNECTOR 3A FUSE BLK 16 BLK 16 RED 20 Mowers with serial number 17065997 and later ...

Page 35: ...0 hours of operation or yearly whichever comes first 10 Refer to engine owner s manual for engine service information After completing maintenance cycle 300 hours repeat cycle Maintenance Schedule Refer to Figure 8 1 Figure 8 2 Figure 8 3 SERVICE AT INTERVALS INDICATED WEEKLY OR 40 HOURS MONTHLY OR 100 HOURS ANNUALLY OR 300 HOURS Verify safety start interlock system Prior to each use Visually insp...

Page 36: ...ry 6 Fuel Tank 7 Engine Oil Filter 8 Deck Lift Pivot Zerks 4 9 Park Brake Switch 2 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Wheel Tires 14 Front Wheel Zerks 2 15 Deck Belt 16 Blades 17 Hydraulic Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 9 6 17 19 10 5 2 8 14 13 13 14 8 9 6 4 7 12 3 10 17 1 15 16 16 16 ...

Page 37: ...5 Battery 6 Fuel Tank 7 Engine Oil Filter 8 Deck Lift Pivot Zerks 4 9 Park Brake Switch 2 10 Drive Tire 11 Pump Belt 12 Engine Air Intake Screen 13 Front Wheel Tires 14 Front Wheel Zerks 2 15 Deck Belt 16 Blades 17 Hydraulic Oil Expansion Tank 18 Hydraulic Oil Filter 19 Fuel Evaporation System Filter 11 10 18 18 10 ...

Page 38: ...REV E 8 4 121366 ...

Page 39: ...n only Steering control 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...

Page 40: ...REV E 9 2 121366 ...

Page 41: ...arness to Fuel Gauge Voltage Convertor Schematic 7 2 Main Harness to Lights Schematic 7 2 Maintenance Introduction 1 1 Maintenance Locator Chart 8 2 Maintenance Precautions 2 3 Maintenance Schedule 8 1 Mower Blade Maintenance 6 2 Mower Blade Removal 6 3 Operate Machine Safely 2 2 Operation Precautions 2 2 Pre Operation Precautions 2 1 Prepare for Emergencies 2 3 Prevent Battery Explosions 2 3 Safe...

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