BigDog Mowers Stout MP Parts Manual

Transcription

1 BigDog Mowers Stout MP Parts Manual 00 South Ridge Road Hesston, Kansas 6706

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3 Table of Contents General Information Service Literature Options Available From Your Dealer Using This Manual Hardware Description Codes & Abbreviations Standard Torques Section Frame Lights Engine Guard Section Hydraulic Transmissions Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Brake Section Wheel & Tire Front Tire Breakdown Drive Wheel Breakdown Section Engine Engine Service Parts Fuel System Fuel System Service Parts Section 6 Battery Instrument Panel Section 7 " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware Section 8 Seat Seat Service Parts ROPS Foldable EX_08 c-

4 c- 990EX_08

5 General Information This manual covers Big Dog Stout MP models 98EX & 96EX. Service Literature PART NO. DESCRIPTION 609 OPERATOR S MANUAL 06EX WARRANTY STATEMENT 609 GENERAL SERVICE MANUAL Options Available From Your Dealer PART NO. DESCRIPTION 6 MULCH KIT " DECK 9 MULCH KIT 60" DECK BAG CATCHER " DECK 908 -BAG CATCHER 60" DECK 7 STEERING EXTENSION KIT 60 FLEX FORKS 6 CONTAINMENT KIT " DECK 66 CONTAINMENT KIT 60" DECK 087 SEAT SPRING KIT Note: When ordering parts, you must use the part number as shown for each part, not the index number. Always give the model and serial number to your parts and service representative. Note: Items sold in bulk such as seals and hoses are sold by the foot. Using This Manual This manual is part of a service package for the BigDog mowers. Use of this manual in conjunction with other Big- Dog mower and component manuals will provide the information necessary to service and maintain BigDog mowers. This Parts Manual provides a complete parts listing for the unit. Use this manual when ordering parts. Illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Excel Industries, Inc. reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts. The Service Manual is a service guide for use by Service Technicians. It provides the necessary information needed to perform normal maintenance requirements on these units. The Operator's Manual provides fundamental operational information 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 servicing of their products. 990EX_08 -

6 Hardware Description Codes & Abbreviations The following codes are used throughout this parts manual. Refer to this list when ordering parts. ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION CB CARRIAGE BOLT MB MACHINE BUSHING CE CLEVIS PIN MS MACHINE SCREW CN CLIP NUT NT NUT CP COTTER PIN SC SELF TAPPING CAP SCREW CS CAP SCREW SH SOCKET HEAD CW CUP WASHER SB SHOULDER BOLT FDRW FENDER WASHER SS SET SCREW FW FLAT WASHER OD OUTSIDE DIAMETER HX HEX HEAD ID INSIDE DIAMETER LW LOCK WASHER 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 Notes section next to the fastener. SIZE FT-LBS N-M SIZE FT-LBS N-M M.. 7 M M M M M M M M M0 0 M EX_08

7 Section Frame Lights Engine Guard EX_08 -

8 Frame EX_08

9 Frame INDEX NO. PART NO. QTY. DESCRIPTION 67 " FRAME (WITH DECALS & RIVET NUTS) " FRAME (WITH DECALS & RIVET NUTS) /8-6 THREAD RIVET NUT 8088 /6-8 THREAD RIVET NUT 609 BIGDOG STOUT MP LOGO DECAL BUMPER BIG DOG DECAL /8-6 THREAD HEX RIVET NUT CN.-8 X.0 MAX THK DECK HEIGHT DECAL RS STEERING DECAL PUMP BELT WARNING DECAL 7988 FUEL INDICATOR DECAL TOW VALVE DECAL 600 HOT DECAL ENGINE COMPARTMENT DECAL 6 N/A SERIAL NUMBER / SPEC DECAL LS STEERING DECAL MADE IN USA DECAL SAFE OPERATION DECAL 0 09 GREASE FITTING STRAIGHT NOTES:. In the event the serial number tag becomes damaged or illegible, please contact your dealer to order a replacement. 990EX_08 -

10 Lights BOTTOM BB BOTTOM OF THE MOWER - 990EX_08

11 Lights INDEX NO. PART NO. QTY. DESCRIPTION 6000 LIGHT 60 CS #8- X.00 PH TRX THREAD FORMING 607 WIRE HARNESS 6007 PUSH BUTTON MOUNT WIRE TIE NOTES: 990EX_08 -

12 Engine Guard EX_08

13 Engine Guard INDEX NO. PART NO. QTY. DESCRIPTION 67 BUMPER (WITH DECAL) 988 ENGINE GUARD SCREEN NT.-8 HX FLK ZNYC 06 8 CB.-8 X.7 FUL ZN 6007 BIG DOG DECAL PLASTIC WHEEL ASSEMBLY 7 67 FW.0 X. X.87 SPL NT.00- NL G CS.7-6 X. HX G FW.06 X.8 X.060 SAE CS.00- X. HX G FW. X.06 X.090 SAE 0997 PLASTIC WHEEL 099 NT.00- HX JAM ZNYC NOTES: 990EX_08-7

14 -8 990EX_08

15 Section Hydraulic Transmissions Transmission Assembly Transmission Service Parts Steering Steering Sub-Assembly Brake EX_08 -

16 Hydraulic Transmissions EX_08

17 Hydraulic Transmissions INDEX NO. PART NO. QTY. DESCRIPTION 0888 CS.-8 X. HX G FW. X.687 X.0/.080H CS.-8 X.0 HX G 000 WIRE TIE 0007 CS.6- X.7 HX G IDLER PULLEY.00" OD SPRING / COIL PL FW.78 X. X.0 ZN BUSHING 0 77 PUMP TENSIONER 096 FW.760 X.6 X.08 ZNYC 6008 SB.70 X.00 SH.6-60 BELT, A SEC, 67.6 EL N/A TRANSMISSION ASSEMBLY 07 8 NT.-8 HX G ZNYC OVERFLOW TANK (WITH CAP) OVERFLOW TANK CAP FW.8 X.6 X.0/.080 HD ZN/YL NT.0-0 HX ZY NL CS.0-0 X.7 HX G TOW LINK ROD 08 CP.06D X.00 LG HML Z NOTES: 990EX_08 -

18 Transmission Assembly EX_08

19 Transmission Assembly INDEX NO. PART NO. QTY. DESCRIPTION 607 LS TRANSMISSION 6070 RS TRANSMISSION HYDRAULIC FITTING, DEG 6000 SPRING CLAMP 6008 OVERFLOW HOSE 6 07 NT.-8 HX G ZNYC FW. X.687 X.0/.080H SPRING CLAMP OVERFLOW HOSE FITTING, 90-9/6 SAE 789 BALL STUD 600 STEERING DAMPER 060 CS.7-6 X.00 G ZNYC 799 FW.06 X.00 X. HRD Z SPACER TUBE CAPLOCK. Torque to 0 ft-lbs. NOTES: 990EX_08 -

20 Transmission Service Parts INDEX NO. PART NO. QTY DESCRIPTION 609 FAN/PULLEY KIT RETAINING CLIP 60 BRAKE ARM OIL FILTER 6087 PUMP ARM & HARDWARE SPACER BOLT HUB KIT LS FILTER GUARD RS FILTER GUARD (NOT SHOWN) CHARGE COVER KIT (WITH O-RING) 0 60 O-RING NOTES: EX_08

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22 Steering STEERING SUB-ASSEMBLY EX_08

23 Steering INDEX NO. PART NO. QTY DESCRIPTION 789 LOCK COLLAR 0.77 ID 06 NT.- HX NL ZN 768 FW. X.687 X.0/.080H PUMP ROD 006 CS.7-6 X.7 HX G NT.7-6 HX JAM G Z CS.0-0 X.7 HX G FW.8 X.6 X.0/.080H STEER TUBE SUPPORT CS.-8 X.00 HX G 69 PLATED PIVOT TUBE LW. INT-EXT TOOTH 07 NT.-8 HX G ZNYC 789 BALL STUD 097 NT.0-0 HX G ZNYC SPACER 7 0 NT.- HX ZNYC. Part of the Transmission Assembly. NOTES: 990EX_08-9

24 Steering Sub-Assembly INDEX NO. PART NO. QTY. DESCRIPTION 7860 STEERING BAR GRIP 6087 STEERING BAR (WITH GRIP) 7679 FW.06 X.8 X.060 SAE CS.7-6 X.7 HX G NT.7-6 NL G RIGHT STEERING ARM 078 LEFT STEERING ARM (NOT SHOWN) BUSHING RS STEER PIVOT 0788 LS STEER PIVOT (NOT SHOWN) NOTES: EX_08

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26 Brake STEERING ARM MOWER FRAME HYDRAULIC TRANSMISSION - 990EX_08

27 Brake INDEX NO. PART NO. QTY. DESCRIPTION NT.7-6 NL G 7679 FW.06 X.8 X.060 SAE SWITCH 0008 CS.7-6 X.0 HX G Z 600 BRAKE ROD ASSEMBLY 6 00 NT.7-6 HX G ZNY 7 06 NT.- HX NL ZN FW. X.687 X.0/.080H BUSHING LS BRAKE BELL CRANK 0789 RS BRAKE BELL CRANK 0806 CS.7-6 X.0 HX G SHORT BRAKE LINK ROD 60 SPRING 090 LS BRAKE SPRING LINK 090 RS BRAKE SPRING LINK (NOT SHOWN) CS.0-0 X.7 HX G NT.0-0 HX FL LK ZNY OVERTRAVEL SPRING NOTES: 990EX_08 -

28 - 990EX_08

29 Section Wheel & Tire Front Tire Breakdown Drive Wheel Breakdown EX_08 -

30 Wheel & Tire EX_08

31 Wheel & Tire INDEX NO. PART NO. QTY. DESCRIPTION 6079 TIRE/WHEEL ASSEMBLY X WHEEL BACKUP PLATE WHEEL NUT 709 CS.00- X. HX G ZN 67 FW.0 X. X.87 SPL FW. X.7 X. ZNY 7 78 BEARING SPACER 9 N/A FRONT TIRE X Torque to 6 7 ft-lbs. NOTES: 990EX_08 -

32 Front Tire Breakdown EX_08

33 Front Tire Breakdown INDEX NO. PART NO. QTY. DESCRIPTION 90 FORK 07 CS.70-0 X 9.0 HX ZY 096 FW.760 X.6 X.08 ZNYC 060 NT.70-0 HX ZY NL 6099 TIRE/WHEEL X WHEEL BEARING BEARING SPACER WHEEL 6 X TIRE VALVE NOTES: 990EX_08 -

34 Drive Wheel Breakdown INDEX NO. PART NO. QTY. DESCRIPTION 6078 TIRE X WHEEL 0 X VALVE STEM NOTES: EX_08

35 Section Engine Engine Service Parts Fuel System Fuel System Service Parts EX_08 -

36 Engine EX_08

37 Engine INDEX NO. PART NO. QTY. DESCRIPTION N/A KAWASAKI FX69V & FX70V ENGINE 600 MUFFLER 066 CS.-8 X.000 HX G FW. X.687 X.0/.080H 96 CLUTCH ANCHOR NT.-8 HX G ZNYC OIL DRAIN VALVE 8 06 CB.-8 X.70 FUL ZN MUFFLER SHIELD CS.7-6 X. HXG P8 77 KEY / SQ X 0.66 LG 60 PULLEY 7679 FW.06 X.8 X.060 SAE 6078K CLUTCH KIT 000 WIRE TIE 6 79 CLUTCH HARNESS PIGTAIL FW. X. X.9 HRD CS.7-0 X.0 HXG P8 NOTES:. Supplied with the engine.. Torque the bolt to 8 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque the bolt to 0 ft-lbs. Replace (do not reuse) the cap screw if it s removed or loosened. Use only hand tools to install this fastener.. Torque the nuts to ft-lbs. 990EX_08 -

38 Engine A FUSE 0 A VAPOR TEE B - 990EX_08

39 Engine INDEX NO. PART NO. QTY. DESCRIPTION NEGATIVE BATTERY CABLE POSITIVE BATTERY CABLE 088 8" /" FUEL LINE 60 CLAMP, /6" 000 HOSE CLAMP 606 " /6" VAPOR LINE 89 GROUND STRAP LW.7 INT-EXT TOOTH NOTES: FUEL & VAPOR LINE LENGTHS A B 8" FILTER TO FUEL VALVE (FUEL) " ENGINE PORT TO TEE (VAPOR). Part of the wire harness. 990EX_08 -

40 Engine Service Parts INDEX NO. PART NO. QTY. DESCRIPTION 786 MAIN AIR FILTER 7879 SAFETY AIR FILTER 608 OIL FILTER IN-LINE FUEL FILTER 768 VACUATOR VALVE NOTES: EX_08

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42 Fuel System A B EX_08

43 Fuel System INDEX NO. PART NO. QTY DESCRIPTION 607 LS FUEL TANK 607 RS FUEL TANK FUEL CAP,." 088 6" /" FUEL LINE 000 HOSE CLAMP CS.-8 X.7 HX G FW. X.687 X.0/.080H 8 07 NT.-8 HX G ZNYC CS.7-6 X.7 HX G FW.06 X.00 X. HRD Z 709 FUEL VALVE -WAY LOOP CLAMP 000 WIRE TIE NOTES: FUEL & VAPOR LINE LENGTHS A B " LEFT TANK TO VALVE (FUEL) " RIGHT TANK TO VALVE (FUEL). Torque to 7 ft-lbs. 990EX_08-9

44 Fuel System Service Parts INDEX NO. PART NO. QTY. DESCRIPTION 607 SUCTION HOSE ASSY 9." 789 GROMMET NOTES: EX_08

45 Section 6 Battery Instrument Panel EX_08 6-

46 Battery EX_08

47 Battery INDEX NO. PART NO. QTY. DESCRIPTION 768 CS.-8 X.00 HX G 768 FW. X.687 X.0/.080H 87 BATTERY CLAMP STRAP 099 CS.0-0 X.7 HX G LW.0 INT-EXT TOOTH Z NT.0-0 HX G ZNYC RED BATTERY CABLE BOOT GM.0 X. X.7 NOTES: 990EX_08 6-

48 Instrument Panel 0 0A FUSE A FUSE EX_08

49 Instrument Panel INDEX NO. PART NO. QTY. DESCRIPTION CHOKE CABLE PTO SWITCH 77 RED INDICATOR LIGHT KEY ASSEMBLY CB 0- X.00 ZYNC NT #0- HX NL ZN IGNITION SWITCH FW.9 X.00 X.08 ZNYC THROTTLE CABLE CS.0-0 X.00 HX G 768 FW.8 X.6 X.0/.080 HD ZN/YL 6068 INSTRUMENT PANEL DECAL 06 INSTRUMENT PANEL (WITH DECAL) WIRE TIE HOUR METER WIRE HARNESS SEALED RELAY (WITH BRACKET) 8 0 CLUTCH CONNECTOR REPAIR KIT. Part of the wire harness. NOTES: 990EX_08 6-

50 EX_08

51 Section 7 " Service Deck " Deck Pulleys & Spindles " Deck " Service Deck " Deck Pulleys & Spindles " Deck Deck Lift Deck Mounting Hardware EX_08 7-

52 " Service Deck EX_08

53 " Service Deck INDEX NO. PART NO. QTY DESCRIPTION 0 " DECK (WITH DECALS & HARDWARE) 789 BELT ROUTING DECAL CN.-8 X.0 MAX THK 60 DANGER/OBJECTS DECAL 7997 " DECK ID DECAL 6 60 DANGER/CHUTE DECAL NOTES: 990EX_08 7-

54 " Deck Pulleys & Spindles EX_08

55 " Deck Pulleys & Spindles INDEX NO. PART NO. QTY. DESCRIPTION 796 CS.6- X.0 HX G 088 FW.6 X.00 X. ZNYC 6007 DUST SHIELD WITH OFFSET 7886 IDLER PULLEY, NHI.0" IDLER SLIDE TENSION SPRING 7 98 CHAIN CS.-8 X. FLT SH IDLER SLIDE CS.6- X. HX G Z 07 FW X.70 X 0.60HD DRIVE PULLEY.68 OP 00 NT.7-6 HX G ZNY 7679 FW.06 X.8 X.060 SAE 006 CS.7-6 X.7 HX G BLADE SPINDLE FW. X.687 X.0/.080H NT.-8 HXZY NL NT.00- HX G8 ZY NL PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) FW. X.06 X.090 SAE 080 CS.-8 X.7 HX G 09 HEAVY DUTY PULLER 07 NT.-8 HX G ZNYC CS.00- X. HX G PLASTIC WHEEL NT.00- HX JAM ZNYC. Torque to 8 ft-lbs. NOTES: 990EX_08 7-

56 " Deck DISCHARGE CHUTE FRONT WALL EX_08

57 " Deck INDEX NO. PART NO. QTY. DESCRIPTION BELT, B " EL 6079 LS PULLEY COVER 6078 RS PULLEY COVER 080 CS.-8 X.7 HX G 797 FW. X.00 X. HRD Z DISCHARGE CHUTE TORSION SPRING CHUTE PIN CHUTE BRACKET CHUTE ADAPTER PLATE 09 CB.7-6 X.00 STD CD NT.7-6 HXZY NL 7679 FW.06 X.8 X.060 SAE 60 BLADE, 8.0"-L-F-CW BLADE, F8.0"-H-F-CW BLADE, 8.0"-MUL-F-CW 7977 BLADE, 8.0"-GAT-F-CW 787 CW.6. X.87 PNT CS.6- X. HX G Z NT.-8 HXZY NL "A" BLOWOUT BAFFLE 9 06 CB.-8 X.7 FUL ZN FW. X.687 X.0/.080H NOTES:. Torque to 8 ft-lbs.. Do not torque the nut; the discharge chute must pivot freely. 990EX_08 7-7

58 60" Service Deck EX_08

59 60" Service Deck INDEX NO. PART NO. QTY. DESCRIPTION " DECK (WITH DECALS & HARDWARE) 789 BELT ROUTING DECAL CN.-8 X.0 MAX THK 60 DANGER/OBJECTS DECAL 60 DANGER/CHUTE DECAL " DECK DECAL NOTES: 990EX_08 7-9

60 60" Deck Pulleys & Spindles EX_08

61 60" Deck Pulleys & Spindles INDEX NO. PART NO. QTY. DESCRIPTION 796 CS.6- X.0 HX G 088 FW.6 X.00 X. ZNYC 6007 DUST SHIELD WITH OFFSET 7886 IDLER PULLEY, NHI.0" IDLER SLIDE TENSION SPRING 7 79 CHAIN, LINK CS.-8 X. FLT SH IDLER SLIDE UHMW CS.6- X. HX G Z 07 FW X.70 X 0.60HD 607 DECK DRIVE PULLEY 00 NT.7-6 HX G ZNY 7679 FW.06 X.8 X.060 SAE 7806 BLADE SPINDLE CS.7-6 X.7 HX G PLASTIC WHEEL ASSEMBLY (WITH HARDWARE) FW. X.06 X.090 SAE NT.00- HX G8 ZY NL FW. X.687 X.0/.080H NT.-8 HX ZY NL 09 HEAVY DUTY PULLER 07 NT.-8 HX G ZNYC 080 CS.-8 X.7 HX G CS.00- X. HX G PLASTIC WHEEL NT.00- HX JAM ZNYC. Torque to 8 ft-lbs. NOTES: 990EX_08 7-

62 60" Deck DISCHARGE CHUTE FRONT WALL 7-990EX_08

63 60" Deck INDEX NO. PART NO. QTY. DESCRIPTION DISCHARGE CHUTE 608 TORSION SPRING 608 CHUTE PIN NT.7-6 HXZY NL 7679 FW.06 X.8 X.060 SAE CHUTE BRACKET CHUTE ADAPTOR PLATE 8 09 CB.7-6 X.00 G ZNY CS.-8 X.7 HX G FW. X.687 X.0/.080H 88 RS PULLEY COVER 88 LS PULLEY COVER 607 BELT, B BLADE, 0.0"-L-F-CW 79 BLADE, 0.0"-MUL-F-CW 790 BLADE, 0.0"-GAT-F-CW 7968 BLADE, F0.0"-H-F-CW 787 CW.6 X. X.87 PNT CS.6- X. HX G Z 7 06 CB.-8 X.7 FUL ZN NT.-8 HXZY NL 9 8 BLOWOUT BAFFLE NOTES:. Torque to 8 ft-lbs.. Do not torque the nut; the discharge chute must pivot freely. 990EX_08 7-

64 Deck Lift EX_08

65 Deck Lift INDEX NO. PART NO. QTY DESCRIPTION 88 STOP HANDLE 88 HEIGHT ADJ STOP 7888 DECK LIFT INDICATOR 609 DECK LIFT ROD CS.7- X.7 HX G ZN 6 60 DECK LIFT CHAIN NT.7- HX FL ZN FW.78 X.0 X.0 ZN E-CLIP.00 X.6 X CS.-8 X.0 FUL THD ZN 07 NT.-8 HX G ZN 88 DECK LEVELER YOKE FW. X.06 X.09 SAE HRD ZN 789 CE.70 X. X.7 HEADLESS 7899 DECK LIFT SPRING CS.7- X.7 FUL THD G ZN NOTES: 990EX_08 7-

66 Deck Mounting Hardware EX_08

67 Deck Mounting Hardware INDEX NO. PART NO. QTY DESCRIPTION CS.00- X.00 GR ZN NT.00- HX G ZN NOTES: 990EX_08 7-7

68 EX_08

69 Section 8 Seat Seat Service Parts ROPS Foldable EX_08 8-

70 Seat EX_08

71 Seat INDEX NO. PART NO. QTY. DESCRIPTION 607 SEAT 080 CS.-8 X.7 HX G FW. X.687 X.0/.080H 6088 SEAT LATCH ASSEMBLY 0988 SEAT PAN (WITH DECAL) NT.-8 HX NL G 7 07 NT.-8 HX G ZNYC CS.7-6 X. HX G FW.06 X.8 X.060 SAE SEAT SPRING 0 LB/IN 090 SEAT PAN STOP 060 CS.-8 X.87 HX G ZN 000 WIRE TIE 9099 FLOOR PAN 608 BATTERY WARNINGS DECAL NT NL G NOTES:. Do not torque; the seat pan and the seat pan stop must pivot freely. 990EX_08 8-

72 Seat Service Parts 6 INDEX NO. PART NO. QTY. DESCRIPTION 6007 ARMRESTS (PAIR) 6006 SEAT BACK 600 SEAT BOTTOM 609 SEAT BELT 609 STANDARD SLIDES (PAIR) SEAT SWITCH NOTES: 8-990EX_08

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74 ROPS Foldable EX_08

75 ROPS Foldable INDEX NO. PART NO. QTY. DESCRIPTION 609 ROPS KIT (WITH DECALS, SEAT BELT & HARDWARE) CS.00- X.0 HX G 607 ROPS STOP 07 6 NT.00- UNT LK G8 ZN 6070 HAND KNOB LYNCH PIN W/ LANYARD FW. X.06 X.090 SAE ROPS DECAL. Torque to ft-lbs. NOTES: 990EX_08 8-7

76 EX_08