Transcription
BIGDOG MOWER CO.BLACKJACKGeneral Service Manual200 South Ridge RoadHesston, Kansas67062121536REV A
REV A121536
Table of ContentsGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Big Dog Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Maintenance Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Understand Correct Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pre-Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operate Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12-12-12-22-22-22-3Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Standard Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Lever Stops Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transaxle Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14-24-44-64-9Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Evaporation System Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine RPM Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15-15-15-15-3Deck Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Deck Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deck Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Discharge Deck Anti-scalp Wheels . . . . . . . . . . . . . . . . . . . . . . . . .48"/54” Side Discharge Deck Belt Routing . . . . . . . . . . . . . . . . . . . . . . .121536toc-16-16-26-46-66-7REV A
48"/54” Rear Discharge Deck Belt Routing . . . . . . . . . . . . . . . . . . . . . . . 6-8Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Main Electrical Harness Schematic — Kohler . . . . . . . . . . . . . . . . . . . . . 7-1Main Electrical Harness Schematic — Kawasaki . . . . . . . . . . . . . . . . . . 7-2Main Harness to Fuel Gauge Voltage Convertor Schematic . . . . . . . . . 7-3Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Maintenance Locator Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1REV Atoc-2121536
GENERAL INFORMATIONBig Dog Service Programareas; minute dust particles are abrasive to close-toleranceengine and hydraulic assemblies.This manual is part of a service package for the Big Dog Blackjack mowers. Use of this manual in conjunction withother Big Dog mower and component manuals will providethe information necessary to service and maintain the BigDog Blackjack mower.Daily inspect mower for grass clippings and wire and stringtangles. The underside of the mower deck will collect a buildup of grass clippings and dirt, especially when grass is wet orhas high moisture content. This build-up will harden, restricting blade and air movement and will probably show a lesserquality of cut. Therefore it should be removed routinely.This General Service Manual is a service guide for use byService Technicians. It provides the necessary informationneeded to perform normal maintenance requirements onthese units.The Parts Manual provides a complete parts listing for theunit. Use this manual when ordering parts.The Operator's Manual provides fundamental operationalinformation and operational safety that is needed when operating the mower.The component manuals are furnished by the various manufacturers to be used for the troubleshooting and servicingof their components.Maintenance IntroductionRegular maintenance is the best prevention for downtimeor premature failure. The following pages contain suggestedmaintenance information and schedules which the operator/mechanic should follow on a routine basis.Remain alert for unusual noises, they could be signaling aproblem. Visually inspect the machine for any abnormal wearor damage. A good time to detect potential problems is whileperforming scheduled maintenance service. Correcting theproblem as quickly as possible is the best insurance.To do this it will be necessary to raise and block the deck,using jack stands or blocks, in the full up position and scrapethe build-up from underneath.Some repairs require the assistance of a trained servicemechanic and should not be attempted by unskilled personnel. Consult your Big Dog Mowers service center whenassistance is needed.Information included in this manual was current at the timeof printing, but subsequent production changes may causeyour machine to vary slightly in detail. Big Dog Mowersreserves the right to redesign and change the machine asdeemed necessary, without notification. If a change has beenmade to your machine which is not reflected in this servicemanual contact the Customer Service Department at BigDog Mowers for additional information.WarrantyWarranty repair must be performed by a Big Dog MowersAuthorized Dealer before warranty credit can be allowed.Work performed by anyone other than an Authorized Dealerwill invalidate the warranty claim and warranty credit will notbe approved.Clear away heavy build-up of grease, oil and dirt, especiallyin the engine compartment and under the seat platform1215361-1REV A
REV A1-2121536
SAFETY Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any gasolinespills.DANGERThis safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONALSAFETY for operators and other persons during the normaloperation and servicing of this equipment. If gasoline is spilled, do not attempt to start theengine but move the machine away from the areaof spillage and avoid creating any source of ignition until gasoline vapors have dissipated. Keep gasoline away from open flame or spark andstore machine away from open flame or spark orpilot light such as on a water heater or appliances. Refuel outdoors. Never refuel or drain the gasoline from the machine indoors.– denotes immediate hazards which WILL result insevere personal injury or death. Never attempt to start the engine when there is astrong odor of gasoline fumes present. Locateand correct the cause.WARNING Store gasoline in an approved container and keepit out of the reach of children. Never buy morethan a 30-day supply of gasoline. Do not fill fuel containers inside a vehicle or on atruck or trailer bed with interior carpets or plastictruck bed liners. Always place gasoline containers on the ground away from your vehicle beforefilling.– denotes a hazard or unsafe practice whichCOULD result in severe personal injury or death.Safe Servicing PracticesRefer to the Safety section of this manual for more detailedservice safety information.Understand Correct Service Be sure you understand a service procedure beforeyou work on the machine. Unauthorized modifications to the machine mayimpair the function and/or safety and affect machinelife. If it is necessary to make checks with the engine running, always use two people - with the operator at thecontrols, able to see the person doing the checking.Pre-Operation Precautions When practical, remove the machine from thetruck or trailer and refuel the machine with itswheels on the ground. If this is not possible, thenrefuel such machine on the truck or trailer using aportable container and not a fuel dispenser nozzle. If a fuel dispenser nozzle must be used, keepthe nozzle in contact with the rim of the fuel tankor container opening at all times until fueling iscomplete. Do not use a nozzle lock-open device. Never use gasoline for cleaning parts. Read and observe safety precautions elsewherein this manual. Gasoline is harmful or fatal if swallowed. Avoid prolonged breathing of vapors. Long-term exposure to vapors can cause seriousinjury and illness. Keep gasoline away from eyes and skin.Fuel Handling To avoid personal injury or property damage, useextreme care when handling gasoline. Gasoline isextremely flammable and the vapors are explosive. A fire or explosion from gasoline can burn youand others and can damage property. If gasoline is spilled on clothing, change clothingimmediately.Understand Machine Operation Only qualified and trained personnel should operatethe equipment. Observe the usual gasoline handling precautions: Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.121536 Keep face away from nozzle and fuel tank or fuelcontainer opening. Carefully read the operator’s manual and all manualsfurnished with the attachments. Learn the location2-1REV A
and purpose of all controls, instruments, indicatorsand labels.Wear Protective Clothing Do not operate or service the equipment while wearingsandals, tennis shoes, sneakers, shorts or any type ofloose fitting clothing. Long hair, loose clothing or jewelry may get tangled in moving parts. Always wearlong pants, safety glasses, ear protection and safetyshoes when operating or servicing this machine. Always wear adequate eye protection when servicingthe hydraulic system and battery, or when grindingmower blades and removing accumulated debris. Prolonged exposure to loud noise can cause impairment or loss of hearing. Always wear adequate ear protection, such asearplugs, when operating this equipment as prolonged exposure to uncomfortable or loud noisescan cause impairment or loss of hearing. Always keep engine and machine clean, removingaccumulated dirt, trash and other material frommachine. Never put hands or feet under any part of the machinewhile it is running. Never attempt to start engine when there is a strongodor of gasoline fumes present. Locate and correctcause. Keep all safety shields and covers in place, except forservicing. Do not touch hot parts of machine.General Maintenance Precautions Repairs or maintenance requiring engine power shouldbe performed by trained maintenance personnel only. Unless specifically required, DO NOT have the enginerunning when servicing or making adjustments to themower. Park the mower on level ground Do not wear radios or music headphones whileoperating the machinery. Safe operation requiresyour full attention. Disengage the deck clutch. Place the steering control levers in the park brakeposition.Operation Precautions Lower the deck. Stop the engine.Avoid Fire Hazards Clean flammable material from machine. Prevent fires bykeeping engine compartment, top of deck, exhaust area,battery, hydraulic lines, fuel line, fuel tank and operator’sstation clean of accumulated trash, grass clippings, andother debris. Always clean up spilled fuel and oil.Start Engine Safely Avoid possible injury or death from machine runaway. Do not start engine by shorting across starter terminals. Before you start the engine: Sit on the operator’s seat. Disconnect the negative battery cable. Wait for all movement to stop before adjusting,cleaning or repairing. Repairs or maintenance requiring engine powershould be performed by trained maintenance personnel only. To prevent carbon monoxide poisoning, operatethe engine in a well ventilated area only. Read and observe all safety warnings in this manual. Before working on or under the deck, make certainengine cannot be accidentally started. Move control levers to the neutral/brake position.Operate Machine Safely Refer to the unit’s operator’s manual for completesafety information on safe machine operation. Always maintain a safe distance from people and petswhen mowing Always be aware of what is behind the machine beforebacking up. Never leave machine unattended with ignition key inswitch, especially with children present. Follow daily and weekly checklists, making sure hosesare tightly secured and bolts are tightened.REV A Remove the ignition key.2-2 Always keep belt covers on mower deck for safety aswell as for cleanliness except when changing or checking the belt. Use a stick or similar instrument to clean under themower making sure that no part of the body, especiallyarms and hands are under mower. Clean flammable material from mower. Prevent fires bykeeping the engine compartment, top of the deck,exhaust area, battery, fuel line, fuel tank and operator’sstation clean of accumulated trash, grass clippings, andother debris. Always clean up spilled fuel and oil. Prevent fires by keeping the engine and exhaust areasclear of grass clippings and other debris. Do not backmower into flammable materials.121536
Allow the mower, especially the engine, to coolbefore storing inside a building. Never use an open flame to look for leaks anywhere onthe equipment. Always wear adequate eye protection when: Never use an open flame as light anywhere on oraround the equipment. servicing the hydraulic system When preparing engine for storage, remember that fuelstabilizer is volatile and therefore dangerous. Seal andtape openings after adding the inhibitor. Keep container tightly closed when not in use. servicing the battery grinding mower blades and removing accumulated debris. Never attempt to make any adjustments or repairs tothe mower drive system, mower deck or any attachment while the engine is running or deck clutch isengaged. Exercise caution when releasing spring tension fromany of the belt idlers or when working with any of thedeck lift components. Never work under the machine or attachment unless itis safely supported with jack stands. Make certain machine is secure when it is raisedand placed on the jack stands.Prepare For Emergencies Be prepared if a fire starts. Keep a first aid kit and fire extinguishers available. Keep emergency numbers for doctor, ambulance service, hospital, and fire department near the telephone.Prevent Battery Explosions Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to theState of California to cause cancer and reproductiveharm. Wash hands after handling. The jack stands should not allow the machine tomove when the engine is running and the drivewheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of2000 pounds (907 kg) to block the unit up. Charge batteries in a well-ventilated open area, awayfrom sparks and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools. Use in pairs only. Follow the instructions supplied with the jackstands. Avoid skin and clothing contact with battery acid. Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good working condition. Never tamper with safety devices. Check their properoperation regularly. Exercise caution when working under the deck as themower blades are extremely sharp. Wrap the blade(s)or wear gloves and use extra caution when servicingthem. Use only genuine Big Dog Mowers replacement partsto ensure that original standards are maintained. The mower may not comply with the appropriatesafety standards if aftermarket parts, accessories, or attachments are used. Always wear eye protection when checking thebattery. Acid can cause serious injury to skin andeyes. If contact occurs, flush area with cleanwater and call a physician immediately. Acid willalso damage clothing. Do not drink the battery electrolyte. Do not allow open flame near the battery whencharging. Hydrogen gas forms inside the battery. This gasis both toxic and flammable and may cause anexplosion if exposed to flame. Always disconnectthe negative (black) battery cable(s) before disconnecting the positive (red) cable(s). Alwaysconnect the positive (red) battery cable(s) beforeconnecting the negative (black) cable(s). Do not overfill the battery.Maintenance PrecautionsAvoid Fire Hazards Be prepared if an accident or fire should occur. Knowwhere the first aid kit and the fire extinguishers arelocated and how to use them. Provide adequate ventilation when charging batteries. Do not smoke near battery. Never check fuel level with an open flame.121536 Inspect electrical wiring for worn or frayed insulation.Install new wiring if wires are damaged.2-3 Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, usesoap and water. Be careful not to get soap andwater into the battery. Clean the battery terminals with a solution of four parts water and onepart baking soda when they become corroded. Shorts caused by battery terminals or metal toolstouching metal mower components can cause sparks.Sparks can cause a battery gas explosion which willresult in personal injury.REV A
Prevent the battery terminals from touching anymetal mower parts when removing or installingthe battery. Avoiding breathing fumes when electrolyte isadded. Do not allow metal tools to short between thebattery terminals and metal mower parts.If you spill acid on yourself: Avoiding spilling or dripped electrolyte. Incorrect battery cable routing could cause damage tothe mower and battery cables. This can cause sparkswhich can cause a battery gas explosion which willresult in personal injury. Always disconnect the negative (black) batterycable(s) before disconnecting the positive (red)cable(s). Flush your skin with water. Apply baking soda or lime to help neutralize theacid. Flush your eyes with water for 10-15 minutes. Getmedical attention immediately.If acid is swallowed: Drink large amounts of water or milk. Always connect the positive (red) battery cable(s)before connecting the negative (black) cable(s). Then drink milk of magnesia, beaten eggs or vegetable oil. Get medical attention immediately.Avoid Acid Burns Sulfuric acid in battery electrolyte is poisonous. It isstrong enough to burn skin, eat holes in clothing andcause blindness if splashed in eyes.Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves.REV A2-4121536
TORQUEStandard TorquesThe following chart lists the standard torque values for the threaded fasteners found in this manual. Torque all cap screws, nutsand set screws to these values unless a different torque is shown in the Special Torques section.Sizeft-lbsN mSizeft-lbsN m#1032.4 IN.-LBS.3.6M312 IN.-LBS.1.3.25098.4 IN.-LBS.11.1M426.4 IN.-LBS.3.312204 IN.-LBS.23M554 IN.-LBS.6.1.3753040M692.4 IN.-LBS.10.4.4384865M8222 pecial TorquesSizeft-lbsN mWheel (lug) nuts 17095Blade spindle bolt top7399Blade spindle bolt bottom118160Electric Clutch mounting bolt 34763Front wheel axle boltTighten the nut, then back it offuntil the wheel spins freelyTransaxle hub nut200271Transaxle pump pulley nut5067Engine torques2N/AN/A1. Lug nuts only – It is recommended that these bechecked after the first two (2) hours of operation andevery 50 hours and following removal for repair orreplacement.2. Engine torque values – Refer to the respective engineowner’s manual.WARNINGNOTE:Particular attention must be given to tighteningthe drive wheel lug nuts and blade spindle bolts.Failure to correctly torque these items may resultin the loss of a wheel or blade, which can causeserious damage or personal injury.3. If clutch mounting bolt is loosened or removed, do notre-use. Replace with a new bolt. Use only hand tools toinstall this fastener.1215363-1REV A
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POWER UNIT MAINTENANCESteering Adjustments1.Shut engine off, place steering control levers in thepark brake position, disengage deck clutch, removeignition switch key and disconnect negative batterycable before doing any adjustments.2.Raise the rear of the mower and block with certifiedjack stands. Remove the rear wheels.3.Chock the front tires.4.Make sure both steering control levers are in the parkbrake position. Figure 4-1Steering control lever neutral adjustmentThe mower’s steering has been factory adjusted to eliminate creeping when the steering control levers are in the neutral position. However, should the mower begin to creep, thesteering control lever linkage can be adjusted.Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the mower to drift toone side. Refer to the tire pressure information in the Tiressection for detailed information.NOTE: Proper park brake adjustment must be completedbefore the steering control lever neutral adjustment can bedone. Refer to the Park Brake Spring Adjustment section fordetailed information.Shown with steering control levers in the park brakepositionFine adjustment to the unit’s steering is made with thetransmission’s control rod.AANeutral is properly adjusted when the steering controllevers are in the park brake position and the transmissionsdo not “whine”.WARNINGIf this occurs, the steering control linkage may be adjustedas follows:This procedure will require that the unit be raisedto allow the drive wheel to rotate. A. Steering control leverBlock the mower up off of the ground usingonly appropriate vehicle stands (minimumweight rating of 2000 pound)s. Use in pairsonly. Follow the instructions supplied withthe vehicle stands.Figure 4-15.Loosen the nuts adjacent to the steering bushing.Figure 4-2 Do not allow the wheels to come in contactwith the floor or any object that would permitthe unit to propel itself.AWARNINGWARNING To prevent injury stay clear and exercise caution when rotating the wheels.121536Exercise extreme caution when the transmissionsare engaged.B Keep hands, hair, clothing, etc., clear of thecooling fans on top of the transaxles to prevent entanglement.A. BushingUntrained maintenance personnel should neverattempt to make any adjustments or repairs to themower’s drive system while the engine is running.The following procedures should be performed bytrained maintenance personnel only.B. NutsFigure 4-26.4-1Place a clamp on the transmission pump arm asshown in Figure 4-3.REV A
12. Raise the rear of the mower and remove the jackstands. Lower the mower.13. Re-attach the negative battery cable.14. Close the seat platform.AAlign handles .125”A. ClampFigure 4-5Figure 4-37. Tighten the nuts against steering bushing (Figure 4-4).Verify that the pump arms are still in the neutral position.Control Lever Stops AdjustmentThe steering control lever stops may be adjusted to helpdrive straight when the steering control levers are pushedforward against the stops.WARNINGAThis procedure will require that the unit to beraised to allow the drive wheel to rotate. Block the mower up off of the ground usingonly appropriate vehicle stands (minimumweight rating of 2000 pound)s. Use in pairsonly. Follow the instructions supplied withthe vehicle stands. Do not allow the wheels to come in contactwith the floor or any object that would permitthe unit to propel itself.B To prevent injury stay clear and exercise caution when rotating the wheels.Figure 4-48. Move the steering control levers out of the park brakeposition and push fully forward, verify that the pumparm does not bottom out against the stop on the transmission. Move the levers to the full reverse positionand release. Verify that the levers return near to theneutral position.9. The steering control levers should be adjusted so thatthey align vertically with each other when in the neutral position (Figure 4-5). Space between ends of steering control handles to be .50” .25”. Figure 4-510. Check to make sure all tools or obstructions areremoved from under the mower.11. Re-install the rear wheels. Torque lug nuts to 70 ft.-lbs.(95 N m)REV A4-2WARNINGB. NutsWARNINGA. BushingExercise extreme caution when the transmissionsare engaged. Keep hands, hair, clothing, etc., clear of thecooling fans on top of the transaxles to prevent entanglement.Untrained maintenance personnel should neverattempt to make any adjustments or repairs to themower’s drive system while the engine is running.The following procedures should be performed bytrained maintenance personnel only.IMPORTANT: Make sure the hydraulic system oil is atoperating temperature before beginning this procedure.121536
1. Raise the rear of the mower and block with certifiedjack stands. The rear wheels need to be able to rotatefreely and clear of all obstructions.Shown with steering control levers in the neutral position2. Chock the front tires.3. Raise the seat platform. Disconnect the mower harness from the seatswitch. Bypass the seat switch by connecting the twomower harness female spades together.Figure 4-6 Lower the seat platform.AA. Steering control leverAFigure 4-7sooner. Repeat this procedure until both drive wheelsrotate at the same speed. Figure 4-8B8.BCTighten the cap screws under the seat platform onboth sides to lock the drive straight brackets in place.Snug the cap screws on the top of the steering coverso they don't move during operation.ADCBA. Seat switchB. Female spadesC. Mower harnessFigure 4-64. Start the engine. Move both steering control levers forward against the stops located inside the steering covers.5. Determine if the drive wheels are rotating equally or ifone is faster than the other. If the wheels are not rotating at the same speed, proceed to the next step. If theyare rotating at the same speed proceed to step 8.6. Shut engine off and place the steering control levers inthe park brake position. Figure 4-77. Loosen the cap screw under the seat platform on theside which is rotating too fast. Tighten the cap screwon the top of the steering cover to adjust the drivestraight bracket up to stop the steering control leverA. Top cap screwB. Side cap screwC. Drive-straight bracketD. Steering control leverFigure 4-89.IMPORTANT: Lower the seat platform and secure inplace. Disconnect the two female spade connectorsfrom each other (from step #3). Reconnect them to the seat switch. This must becompleted so that the safety circuit is functioning properly. Figure 4-6 Re-attach the seat platform to the mower frame.1215364-3REV A
WARNINGDo not operate the mower without plugging themower’s wiring harness into the seat switch. Thisswitch is an important part of the safety startinterlock system. Serious injury can result if theseat switch is not plugged into the mower’s wiringharness.WARNINGNever operate the mower with a non-functioningseat switch. Always reconnect the seat switch to themower harness.B.25"AA. NutB. SpringPark brake spring adjustmentOccasionally check the park brake spring adjustment usingthe following method:1. This procedure does not require engine power, therefore: Park the mower on level ground.Figure 4-9Transaxle belt adjustmentThe transaxle drive belt tension remains constant bymeans of a tension idler and spring. There is no tensionadjustment of this belt. Figure 4-10 Place the steering control levers in the park brakeposition. Stop the engine. Remove the ignition key. Disconnect the negative battery cable.2. Make sure steering control levers are in the park brakeposition.3. Adjust the nylock nut on the end of the brake rod sothat 0.25" of thread is showing. Repeat for other side.Figure 4-9WARNINGIMPORTANT: Inspect the belt every month and replace asneeded. Replace the belt every two (2) years. Disengage the deck clutch.If the transmission belt fails, loss of control willoccur especially when operating on a slope. If youlose steering control while operating the machine,place the steering control levers in the park brakeposition immediately. Inspect the machine andinvolve your dealer to resolve the problem.FFC4. Reconnect the negative battery cable.5. Close seat platform and re-install seat platform hardware.Transaxle Drive BeltInspect belts frequently for wear and serviceability.Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, o
121536 REV A BIGDOG . MOWER CO. BLACKJACK. General Service Manual. 200 South Ridge Road Hesston, Kansas
