BigDog Alpha Service Manual
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BigDog Alpha Service Manual

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BigDog
®
Mowers Alpha
General Service Manual
200 South Ridge Road
Hesston, Kansas
67062
119293
REV B

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  • Page 1 BigDog ® Mowers Alpha General Service Manual 200 South Ridge Road Hesston, Kansas 67062 119293 REV B...
  • Page 2 WARNING WARNING WARNING 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.

  • Page 3: Table Of Contents

    General Information ........1-1 ® BigDog Mowers Service Program ..... . 1-1 Maintenance Introduction .
  • Page 4 Electrical ..........7-1 Electrical Schematic —...

  • Page 5: General Information

    ® Daily inspect mower for grass clippings and wire and string This manual is part of a service package for the BigDog Alpha mowers. Use of this manual in conjunction with other tangles. The underside of the mower deck will collect a build-up ®...
  • Page 6 REV B 119293...

  • Page 7: Safety

    SAFETY • 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. This safety alert symbol is used to call attention to a message •...

  • Page 8: Operation Precautions

    Wrap the blade(s) or  Keep all safety shields and covers in place, except for wear gloves and use extra caution when servicing them.  Use only genuine BigDog servicing. ® Mower replacement parts to ...
  • Page 9  Inspect electrical wiring for worn or frayed insulation.  Shorts caused by battery terminals or metal tools touch- Install new wiring if wires are damaged. ing metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in per- Prepare For Emergencies sonal injury.
  • Page 10 REV B 119293...

  • Page 11: Torque

    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. 32.4 IN.-LBS.
  • Page 12 REV B 119293...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 2. Raise the rear of the mower and block with certified jack stands. Remove the rear wheels. 3. Chock the front tires. Steering control lever neutral adjustment 4. Make sure both steering control levers are in the park The mower’s steering has been factory adjusted to eliminate brake position.
  • Page 14 Control lever stops adjustment. WARNING Clamp Keep hands, hair, clothing, etc., clear of the rotating drive wheels/hubs during this process. Exercise extreme cau- tion. The steering control lever stops may be adjusted to help drive straight when the steering control levers are pushed forward against the stops.

  • Page 15: Park Brake Spring Adjustment

    Drive straight bracket Cap screws Seat switch Female Female spade spade Figure 4-8 1. Shut engine off, place steering control levers in the park Mower harness brake position, disengage deck clutch, remove ignition switch key and disconnect negative battery cable before doing any adjustments.
  • Page 16 erwise, the belt will lose power and slip excessively. Belt replacement Never pry a belt to get it on a pulley as this will cut or damage the fibers of the belt covering. WARNING Keep oil and grease away from belts, and never use belt dress- ings.
  • Page 17 Transaxle Spring mount drive belt Transaxle drive pulley Idler arm Transaxle drive pulley Engine pulley Tensioning Idler spring Electric Deck Deck clutch cover cover pulley Deck drive belt Figure 4-14 Figure 4-12 Viewed from top of the mower for easier access upon re-assembly. Transaxle WARNING drive pulley...

  • Page 18: Tires

    Front wheels ..... 8-12 psi (55-83 KPa) 15. Lower the mower. ® 16. Re-attach the negative battery cable. If you wish to use non-pneumatic tires on your BigDog mower the tires must be an approved tire purchased from Big- Tires ®...

  • Page 19: Engine Maintenance

    ® All BigDog Alpha mowers have a fuel evaporation system Change the engine oil and filter after the first 5 hours of oper- filter. This filter must be checked and replaced every 100 hours ation and then per the engine manufacturer’s recommendations or annually whichever comes first.

  • Page 20: Engine Rpm Settings

    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: FR651 / FR691 ENGINE SPEED MODEL NO. ENDING WITH: HIGH IDLE MODEL NO.

  • Page 21: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling 1. Park the mower on a hard, flat surface. 2. Check tire pressures (8 – 12 psi) to make certain the tires are properly inflated before starting to level deck. WARNING Stop engine. Make sure deck clutch switch is in the down (OFF) position.
  • Page 22 9. To allow for easier access when tightening the adjusting hardware, lower the deck to its lowest position. Measure to 3/8” drive extension top of deck Figure 6-6 10. Tighten the cam hardware. IMPORTANT: When tightening the cam hardware you must tighten the inner nut while holding the bolt and outer nut to keep the cam from rotating and changing the adjustment.
  • Page 23 Lock nut Inner nut Figure 6-10 Tighten the inner nut to prevent slipping of the adjustment. Figure 6-8 Front center of deck Figure 6-9 119293 REV B...

  • Page 24: Blades

    Blades Lay the blade on a flat surface and check for distortion (Fig- ure 6-12 & Figure 6-13). Replace any distorted blade. 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 efficiency and well groomed turf.

  • Page 25: Deck Belt

    Mower blade replacement when using the blade lock tool (381442) as it requires two blades to work properly. 5. Inspect the blade for damage. If the blade is damaged, WARNING replace it. If the blade is not damaged, either sharpen it or replace it with a new blade or another sharpened used blade.
  • Page 26 Spring mount Tensioning Idler spring Boss Spindle shaft face Figure 6-16 Deck belt replacement Blade WARNING Allow the engine and muffler to cool before proceeding with the following procedure. Figure 6-15 WARNING ings. Any of these will destroy the belt composition in a very short time.
  • Page 27 Tension idler spring Spring mount Tension spring Deck hook (604462) cover Deck cover Figure 6-20 WARNING Figure 6-18 Never operate the mower without the deck covers in place. Deck Deck cover cover Electric clutch pulley Figure 6-19 Deck drive belt 8.

  • Page 28: 36"/42" Deck Belt Routing

    The following notes are the same for the different decks shown. NOTE: 1. There is no tension adjustment of this belt 2. Route belt as shown. 36”/42" Deck Belt Routing Figure 6-22 52" Deck Belt Routing Figure 6-23 REV B 119293...

  • Page 29: Electrical

    ELECTRICAL Electrical Schematic — Kawasaki 119293 REV B...
  • Page 30 REV B 119293...

  • Page 31: Maintenance

    MAINTENANCE Maintenance Schedule Refer to Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, & Figure 8-5 WEEKLY ANNUALLY SERVICE AT OR 40 OR 100 INTERVALS INDICATED HOURS HOURS Verify safety start interlock system Prior to each use Visually inspect unit for loose hardware and/or damaged parts Prior to each use Visually inspect tires Prior to each use...

  • Page 32: Maintenance Locator Chart

    Maintenance Locator Chart Figure 8-1 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tank 7. Engine Oil Filter 8. Park Brake Switch (2) 9. Drive Tire 10.

  • Page 33: Troubleshooting

    TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Mower creeps when Steering linkage needs Adjust linkage steering control levers are adjustment Starting motor does not Steering control levers not Place steering control in neutral crank in park brake position or levers in park brake posi- switch not adjusted tion or re-adjust switch...
  • Page 34 REV B 119293...
  • Page 35 INDEX PAGE PAGE Belt adjustment ............4-4 Maintenance precautions ........2-2 Belt replacement............4-4 Maintenance Schedule ..........8-1 Blades...............6-4 Mower blade replacement ........6-5 Control lever stops adjustment .......4-2 Operate machine safely ..........2-2 Deck belt ..............6-5 Operation Precautions..........2-2 Deck belt adjustment..........6-6 Park brake spring adjustment .........4-3 Deck belt replacement ..........6-6 Pre-operation precautions........2-1 Deck Belt Routing............6-8...

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