BigDog Series X General Service Manual Download Page 3

Page: 3 / 41

108936BD_0812

c-1

Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Pre-Operation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Operate Machine Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . 3-2

Maintenance Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Park brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Hydraulic Pump Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Fuel evaporation system filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Fuel & evaporative system line routings. . . . . . . . . . . . . . . . . . . 6-2

Engine RPM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Deck Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Deck Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Electrical Schematic – Briggs & Stratton . . . . . . . . . . . . . . . . . 8-1

Electrical Schematic – Kawasaki . . . . . . . . . . . . . . . . . . . . . . . 8-2

Electrical Schematic – Kohler . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Summary of Contents for Series X

Page 1: ...108936BD_0812 REV E BigDog Mowers Series X General Service Manual P O Box 7000 Hesston Kansas 67062 2097...

Page 2: ...duct 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...

Page 3: ...ntenance 5 1 Steering Adjustments 5 1 Park brake adjustment 5 4 Belts 5 5 Hydraulic Pump Belt Adjustment 5 5 Hydraulic system 5 5 Tires 5 8 Engine Maintenance 6 1 General Engine Maintenance 6 1 Engine...

Page 4: ...c 2 108936BD_ 0812 Troubleshooting 10 1...

Page 5: ...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 o...

Page 6: ...REV E 2 2 108936BD_0812...

Page 7: ...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 traile...

Page 8: ...e must be operated in an enclosed area Before working on or under the deck make certain engine cannot be accidentally started Shut engine off remove ignition switch key and disconnect negative bat ter...

Page 9: ...rolyte 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...

Page 10: ...REV E 3 4 108936BD_0812...

Page 11: ...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 14...

Page 12: ...REV E 4 2 108936BD_0812...

Page 13: ...he seat switch Bypass the seat switch by connecting the two mower harness female spades together Figure 5 1 4 Start the engine 5 Position the steering control lever in the neutral position and observe...

Page 14: ...e mower engine must not be running 2 Check to make sure the steering control levers are against the stops before the pumps are bottomed out internally 3 To do this gently and slowly move the steering...

Page 15: ...ernal spring is engaged Figure 5 7 5 Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position 6 Tighten the nut on the steering damper s front...

Page 16: ...o become noticeable here However if no brake resistance is noticed the brake needs adjusted as follows a Loosen the brake linkage jam nuts Figure 5 13 Rotate the tire and at the same time rotate the t...

Page 17: ...nt by means of a tension idler and spring There is no tension adjustment of this belt Figure 5 14 Inspect the belt every 100 hours and replace as needed Replace the belt every 400 hours or every two 2...

Page 18: ...rm this properly could result in bodily injury Testing Procedures 1 Use approved jack stands to raise the drive wheels off the floor 2 Open the restriction valve all the way 3 Bring the engine to maxi...

Page 19: ...pm 19 l min 2nd reading 4 gpm 15 l min the difference Subtract the 1st reading from the 2nd In this example 4 gpm difference would indicate further pump examination Purging Procedures Due to the affec...

Page 20: ...smoothly forward and reverse at normal speeds purging is com plete Tires It is important for level mowing that the tires have the same amount of air pressure The recommended pressures are Drive wheel...

Page 21: ...t to the left side of the mower so that it can drain into a suitable oil drain container 6 With the hose in position twist the valve counterclockwise and pull out to open the valve Allow 10 minutes fo...

Page 22: ...ple The media in the filter must be porous to allow air to pass through it When dirty air passes through the filter the dirt plugs some of the holes in the media and actually acts as part of the filte...

Page 23: ..._0812 6 3 REV E Figure 6 5 Figure 6 6 Figure 6 7 Fuel evaporation system filter Fuel shutoff valve Fuel tank Fuel tank Fuel line Seat support Fuel evaporation system filter Vapor line Tee Fuel tank Fu...

Page 24: ...nd with an extension after the number There are several different extensions that may be shown i e EX or CE Example 922222 no extension 922222 EX 922222 CE 922222 US Briggs Stratton 26 hp ENGINE SPEED...

Page 25: ...pedal is free Figure 7 3 Figure 7 7 8 Start the leveling process on the left front of the mower 9 Set the amount of threads protruding on the deck lift rod from the lift block at approximately 1 2 54...

Page 26: ...25 Tighten the appropriate nut until the chain just becomes tight and carries most of the deck weight Check by moving the block it should move with a slight drag Figure 7 7 26 Tighten the other nut o...

Page 27: ...y 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 ting IMPORTANT When mounting blades rotate them after instal...

Page 28: ...ts 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 sprin...

Page 29: ...r the different decks shown 1 Spring length after tensioning new belt Measured from outside of hook to outside of hook with deck set at 3 8 26cm cut height 2 Route belt as shown 52 60 72 Side Discharg...

Page 30: ...REV E 7 6 108936BD_0812...

Page 31: ...108936BD_0812 8 1 REV E ELECTRICAL Electrical Schematic Briggs Stratton...

Page 32: ...REV E 8 2 108936BD_0812 Electrical Schematic Kawasaki...

Page 33: ...108936BD_0812 8 3 REV E Electrical Schematic Kohler...

Page 34: ...REV E 8 4 108936BD_0812...

Page 35: ...s Manual for engine service information NOTE After completing maintenance cycle 500 hours repeat cycle Maintenance Schedule Refer to Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 SERVICE AT INTERVALS IN...

Page 36: ...Oil Fill Dipstick 2 Fuel Filter 3 Engine Air Cleaner 4a Engine Oil Drain Valve Briggs Stratton 4b Engine Oil Drain Valve Kohler Kawasaki 5 Battery 6 Fuel Tanks 7 Hydraulic Oil Reservoir 8 Hydraulic Oi...

Page 37: ...812 9 3 REV E BigDog Mowers Series X Maintenance Locator Chart Figure 9 3 3 1 3 3 1 2 4 4 4 1 Deck Pusher Arm Zerks 2 2 Deck Belt 3 Spindle Housing Zerk 3 4 Blades 5 Fuel evaporation system filter Fig...

Page 38: ...REV E 9 4 108936BD_0812...

Page 39: ...rence or leakage in wheel motor See your dealer Air cooled engine overheating Air intake screen or cool ing fins clogged Clean screen and fin For additional causes See engine manual Low engine oil pre...

Page 40: ...n starting or operates in one direction only Steering control linkage needs adjustment Adjust linkage Pump or wheel motors faulty See your dealer Tow valves not closed completely Close tow valves SYMP...

Page 41: ...ngine maintenance 6 1 General maintenance precautions 3 2 Hydraulic pump belt adjustment 5 5 Hydraulic system 5 5 Maintenance introduction 2 1 Maintenance Locator Chart 9 2 9 3 Maintenance precautions...

Search results

Summary of Contents for Series X

Reviews:

Related manuals for Series X

Brands by name

Popular brands

BigDog Series X, General Service Manual

Search results

Summary of Contents for Series X

Reviews:

Related manuals for Series X

Brands by name

Popular brands