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121536

i-1

REV A

INDEX

PAGE

Avoid Acid Burns

.......................................................2-4

Avoid Fire Hazards

..............................................2-2

2-3

Blades

.......................................................................6-2

Deck Belt

...................................................................6-4

Deck Belt Adjustment

................................................6-4

Deck Belt Replacement

..............................................6-5

Deck Leveling

............................................................6-1

Draining the Engine Oil

...............................................5-1

Engine Air Filter

.........................................................5-1

Engine Oil and Filter

...................................................5-1

Engine RPM settings

..................................................5-3

Fuel Evaporation System Filter

..................................5-1

Fuel Handling

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

General Engine Maintenance

......................................5-1

General Maintenance Precautions

..............................2-2

Hydraulic System

.......................................................4-6

Main Electrical Harness Schematic — Kawasaki

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

Main Electrical Harness Schematic — Kohler

..............7-1

Main Harness to Fuel Gauge Voltage

Convertor Schematic

.................................................7-3

Maintenance Introduction

..........................................1-1

Maintenance Locator Chart

........................................8-2

Maintenance Precautions

..........................................2-3

Mower Blade Maintenance

........................................ 6-2

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

Purging Procedure

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

Rear Discharge Deck Anti-scalp Wheels

..................... 6-6

Rear Discharge Deck Belt Routing

............................. 6-8

Safe Servicing Practices

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

Side Discharge Deck Belt Routing

.............................. 6-7

Special Torques

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

Standard Torques

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

Start Engine Safely

................................................... 2-2

Steering Adjustments

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

Steering Control Lever Neutral Adjustment

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

Tires

......................................................................... 4-9

Understand Correct Service

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

Understand Machine Operation

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

Warranty

................................................................... 1-1

Wear Protective Clothing

........................................... 2-2

Содержание MOWER CO

Страница 1: ...121536 REV A BIGDOG MOWER CO BLACKJACK General Service Manual 200 South Ridge Road Hesston Kansas 67062...

Страница 2: ...REV A 121536...

Страница 3: ...nance Precautions 2 3 Torque 3 1 Standard Torques 3 1 Special Torques 3 1 Power Unit Maintenance 4 1 Steering Adjustments 4 1 Control Lever Stops Adjustment 4 2 Transaxle Drive Belt 4 4 Hydraulic Syst...

Страница 4: ...lt Routing 6 8 Electrical 7 1 Main Electrical Harness Schematic Kohler 7 1 Main Electrical Harness Schematic Kawasaki 7 2 Main Harness to Fuel Gauge Voltage Convertor Schematic 7 3 Maintenance 8 1 Mai...

Страница 5: ...ay 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 Da...

Страница 6: ...REV A 1 2 121536...

Страница 7: ...ances Refuel outdoors Never refuel or drain the gaso line 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...

Страница 8: ...present Follow daily and weekly checklists making sure hoses are tightly secured and bolts are tightened Always keep engine and machine clean removing accumulated dirt trash and other material from ma...

Страница 9: ...he 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 dangerous Seal and tape open...

Страница 10: ...ore 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 e...

Страница 11: ...ze 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...

Страница 12: ...REV A 3 2 121536...

Страница 13: ...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...

Страница 14: ...ay be adjusted to help drive straight when the steering control levers are pushed forward against the stops IMPORTANT Make sure the hydraulic system oil is at operating temperature before beginning th...

Страница 15: ...der the seat platform on the side which is rotating too fast Tighten the cap screw on the top of the steering cover to adjust the drive straight bracket up to stop the steering control lever sooner Re...

Страница 16: ...slip excessively Never pry a belt to get it on a pulley as this will cut or dam age the fibers of the belt covering Keep oil and grease away from belts and never use belt dressings Any of these will...

Страница 17: ...he mower 4 Raise the rear of the mower and block with certified jack stands 5 Remove the deck drive belt from the electric clutch pulley located on the engine shaft Figure 4 10 This procedure will req...

Страница 18: ...ntegrated hydrostatic transmissions Figure 4 14 IMPORTANT Never use hydraulic or automatic transmis sion fluid in this system use only the specified motor oil Remember dirt is the primary enemy of any...

Страница 19: ...fill Figure 4 17 10 Remove the cap from the transaxle s expansion tank 11 Fill with 20W50 motor oil until oil just appears at the bottom of each transaxles top port approximately 2 qts per transaxle I...

Страница 20: ...forward and reverse directions 5 or 6 times Figure 4 19 4 With the bypass valve closed and the engine running slowly move the control lever in both forward and reverse directions 5 or 6 times Check th...

Страница 21: ...at the tires have the same amount of air pressure The recommended pressures are Drive wheels 8 12 psi 55 83 KPa Only pneumatic tires are approved for the drive tires on this mower Warranty claims will...

Страница 22: ...REV A 4 10 121536...

Страница 23: ...e hose onto the oil drain valve nip ple Make sure the hose is pushed all the way onto the valve Figure 5 1 Figure 5 2 4 Position the loose end of the hose forward and down in front of the right side t...

Страница 24: ...REV A 5 2 121536 A Fuel evaporation system filter Figure 5 3 A...

Страница 25: ...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 Kohler KT740 ENGINE SPEED MODEL NO ENDING...

Страница 26: ...REV A 5 4 121536...

Страница 27: ...in in the E position Figure 6 3 IMPORTANT Make sure the deck lock pin is in the transport upper position Figure 6 4 7 Lower the deck until it is resting on the blocks 8 Tighten all hardware holding th...

Страница 28: ...alancing tool is also avail able through most hardware supply stores The blade should not lean or tilt When spinning the blade slowly it should not wobble Balance the blade before rein stalling Lay th...

Страница 29: ...When attaching the blade to the spindle shaft do not re use spindle bolts which have stripped worn or undercut threads Torque bolts on spindles to 118 ft lbs 160 N m when reinstalling blades End view...

Страница 30: ...ase otherwise the belt will lose power and slip excessively Never pry a belt to get it on a pulley as this will cut or dam age the fibers of the belt covering Keep oil and grease away from belts and n...

Страница 31: ...belt by releas ing the deck tension idler spring Figure 6 14 Figure 6 15 5 Remove the deck drive belt from the deck spindle pul leys and idler pulleys Figure 6 14 Figure 6 15 6 Remove the deck drive b...

Страница 32: ...battery cable Rear Discharge Deck Anti scalp Wheels Make sure to keep the rear anti scalp wheels free of debris They must be able to spin freely Rear discharge deck shown A Tension idler spring B Deck...

Страница 33: ...121536 6 7 REV A The following notes are the same for the different decks shown 1 There is no tension adjustment of this belt 2 Route belt as shown 48 54 Side Discharge Deck Belt Routing Figure 6 18...

Страница 34: ...REV A 6 8 121536 48 54 Rear Discharge Deck Belt Routing Figure 6 19...

Страница 35: ...RG 18 ORG 18 ORG 18 30A PUR 12 BLK 16 BLK 18 ACTUATOR CONTROL 1 2 15A RED 14 ORG 18 ORG 18 WHT RED 20 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 BLK 20 PIN 7 PIN 8 PIN 1 PIN 2 PIN 3 BLK 20 GRN WHT 20 GRN WHT...

Страница 36: ...PIN 2 PIN 3 GRN WHT 20 1 2 ORG 18 LIGHT CONNECTOR 1 2 A B LIMIT SWITCH RED 12 RED 12 RED BLK 18 RED 8 ORG 12 BRN 18 ORG BLU 18 RED BLU RED WHT ORG WHT 18 ORG RED 16 TAN WHT 18 BLK 8 BLK 12 BREAKER EX...

Страница 37: ...121536 7 3 REV A Main Harness to Fuel Gauge Voltage Convertor Schematic...

Страница 38: ...REV A 7 4 121536...

Страница 39: ...r first 2 hours of operation 3 Change engine oil filter per the engine manufacturer s recommendations Refer to Engine Owner s Manual for recommendations and other maintenance items 4 Service more ofte...

Страница 40: ...t 11 Engine Air Intake Screen 12 Front Wheel Tires 13 Front Wheel Zerks 2 14 Hydraulic Oil Expansion Tank 15 Deck Belt 16 Blades 17 Fuel Evaporation System Filter 18 Frame Pivot Zerks 4 19 Frame Pivot...

Страница 41: ...nk 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 Front Wheel Zerks 2 14 Hydraulic Oil Expansion Tank 15 Deck Belt 16 Blades 17...

Страница 42: ...REV A 8 4 121536...

Страница 43: ...ing or operates in one direc tion only Steering control linkage needs adjustment Adjust linkage Loose steering linkage Tighten linkage Transaxle component faulty Contact your Dealer Mower creeps when...

Страница 44: ...REV A 9 2 121536...

Страница 45: ...Schematic 7 3 Maintenance Introduction 1 1 Maintenance Locator Chart 8 2 Maintenance Precautions 2 3 Mower Blade Maintenance 6 2 Mower Blade Replacement 6 3 Operate Machine Safely 2 2 Operation Preca...

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