BigDog Diablo General Service Manual

Hide thumbs Also See for Diablo:

Operator's manual (43 pages)

Table Of Contents

Table of Contents

Quick Links

Need help?

Do you have a question about the Diablo and is the answer not in the manual?

Questions and answers

Jeff randall

July 12, 2025

Need a replacement tire as the one i have in the front is defective and needs to be replaced. What type of tire is needed. my model is 942722. serial number is 22064598. Its a 72 inch blade.

Summary of Contents for BigDog Diablo

Page 1 BIGDOG MOWER CO. DIABLO ® ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 120124 REV C...
Page 2 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
Table of Contents General Information ........2-1 Service Program.
Page 4 Electrical ..........8-1 Electrical Schematic –...
Page 5: General Information
® This manual is part of a service package for the Big Dog engine and hydraulic assemblies. Diablo ® mowers. Use of this manual in conjunction with Daily inspect mower for grass clippings and wire and string ®...
Page 6 REV C 120124...
Page 7: Safety
SAFETY • Allow engine to cool before storing machine inside a building. • Keep fuel away from open flame or spark and store machine away from open flame or spark or pilot light such as on a water heater or appli- This safety alert symbol is used to call attention to a mes- ances.
Page 8: Operation Precautions
 Carefully read the operator’s manual and all manuals  Always keep engine and machine clean, removing furnished with the attachments. Learn the location accumulated dirt, trash and other material from and purpose of all controls, instruments, indicators machine. and labels. ...
Page 9: Maintenance Precautions
Clean up oil or fuel spillage. Allow machine to cool  Inspect electrical wiring for worn or frayed insulation. before storing. Install new wiring if wires are damaged.  Always wear adequate eye protection when servicing Prepare For Emergencies the hydraulic system and battery, or when grinding mower blades and removing accumulated debris.
Page 10 tive (black) battery cable(s) before disconnecting the If you spill acid on yourself: positive (red) cable(s). Always connect the positive • Flush your skin with water. (red) battery cable(s) before connecting the negative • Apply baking soda or lime to help neutralize the (black) cable(s).
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. Size ft-lbs N•m...
Page 12 REV C 120124...
Page 13: Power Unit Maintenance
POWER UNIT MAINTENANCE Steering Adjustments Untrained maintenance personnel should never attempt to make any adjustments or repairs to the Steering Control Lever Neutral Adjustment mower’s drive system while the engine is running. The mower’s steering has been factory adjusted to elimi- The following procedures should be performed by nate creeping when the steering control levers are in the neu- trained maintenance personnel only.
Page 14 #3) and reconnect them to the seat switch. This must be completed so that the safety circuit is functioning Steering control lever in neutral position properly. Figure 5-1 Do not operate the mower without plugging the mower’s wiring harness into the seat switch. This switch is an important part of the safety start inter- lock system.
Page 15 corresponding side, turn the stop (set screw) inward to 4. Pull the damper spring housing past the point that the stop the steering control levers slightly before the internal spring is engaged. Figure 5-6 pump bottoms out. Lock in place when the adjustment 5.
Page 16: Park Brake Adjustment
Park Brake Adjustment Steering Control Lever Adjustment The steering control levers can be adjusted for operator comfort. Never work under the machine or attachment 1. By loosening the nuts that attach the upper control unless it is safely supported with jack stands. lever to the lower lever the upper control lever can be •...
Page 17: Belts
counter clockwise one-half revolution. able here. However, if no brake resistance is noticed, Figure 5-10 the brake needs adjusted as follows: a. Loosen the brake linkage jam nuts. (Figure 5-12) Rotate the tire and at the same time rotate the turnbuckle to shorten the length of the brake linkage to increase the brake pressure.
Page 18: Hydraulic Pump Belt Adjustment
Hydraulic System Never pry a belt to get it on a pulley as this will cut or dam- age the fibers of the belt covering. IMPORTANT: Never use hydraulic or automatic transmis- Keep oil and grease away from belts, and never use belt sion fluid in this system;...
Page 19 IMPORTANT: Pre-fill the filter element with clean oil before installing, to prevent drawing air into the system Do not attempt any adjustments with the engine pump. running. Use extreme caution while working in or around all vehicle linkage! High temperatures can be generated.
Page 20 3. Bring the engine to maximum operating speed. Suggested temperature range 160°–210°F (71.1°– 98.9° C). Pumps Engine full throttle rpm setting 6. Tighten the flow meter restriction valve until the gauge PK (12) 3600 reads 300 psi (21 bar). CAUTION: Damage to the flow meter and/or re- Record the flow reading on the Bi-Directional Flow Meter.
Page 21 Test Example: PK (12) Pump RESTRICTION VALVE BI-DIRECTIONAL FLOW METER 300 psi (21 bar) reading 9 gpm (34 l/min) (1st reading) CONNECTIONS TO THE FWD/RVS LINES DIS- CONNECTED FROM WHEEL MOTOR RESTRICTION VALVE BI-DIRECTIONAL 1100 psi (76 bar) reading 5 gpm (19 l/min) (2nd reading) FLOW METER PK (12)
Page 22: Tires
The following procedures should be performed with the 1. With the bypass valve open and the engine running, vehicle drive wheels off the ground, then repeated under nor- slowly move the directional control in both forward mal operating conditions. and reverse directions (5 or 6 times), as air is purged from the unit, the oil level will drop.
Page 23: Engine Maintenance
ENGINE MAINTENANCE General Engine Maintenance Detailed instructions and recommendations for break-in and regular maintenance are specified in the Engine Owner’s Manual. Please refer to this manual for engine servicing, lubricating oil levels with quality and viscosity recommenda- tions, bolt torques, etc. The engine warranty is backed by the manufacturer.
Page 24: Fuel Evaporation System Filter
The mowing conditions will determine the frequency of air filter element changing. Fuel Evaporation System Filter ® All BigDog Diablo mowers with a 9xxxxx (i.e. 922222) ® model number have a fuel evaporation system filter.
Page 25: Fuel & Evaporative System Line Routings
Fuel & Evaporative System Line Routings ® BigDog Diablo mowers with a 9xxxxx (i.e. 922222) model ® number, have two rubber hoses that are connected to the fuel tanks. One is the fuel hose that is part of the fuel system.
Page 26: 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 high idle speeds, with no load, should be set as follows: Kawasaki FX691, FX730, & FX850 ENGINE SPEED MODEL NO.
Page 27: Deck Adjustments
DECK ADJUSTMENTS Deck Leveling deck is sitting tightly on all four blocks. Figure 7-3, Figure 7-4 & Figure 7-7 Leveling the deck must be done in the following manner 7. Loosen the two nuts on the front of height indicator so and order: that the foot pedal is free.
Page 28 12. While keeping the chain tight, tighten the nuts against the deck lift block on the height indicator rod, just enough to carry most of the deck weight on that side — the block should be able to move with only a slight drag.
Page 29: Blades
After grinding the blades, check for balance. Blade balanc- Left side ing can be done by placing the blade on an inverted line punch or 5/8" bolt. A commercial balancing tool is also avail- able through most hardware supply stores. The blade should not lean or tilt.
Page 30: Belts
Properly compressed cup washers maintain the correct End view of blades, comparing twisted and straightened blades. compression load on the blades. Replace the cup washers if they are cracked or flattened. IMPORTANT: The blade sail (curved part) must be point- ing upward toward the inside of the deck to ensure proper cutting.
Page 31 Do not over tension the spring to compen- IMPORTANT: sate for a badly worn belt or pulley. A. Spring chain C. Idler spring B. Spring chain anchor point Figure 7-11 120124 REV C...
Page 32 The following notes are the same for the different decks shown. NOTE: Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (82.6mm) cut height. 2. Route belt as shown. 52", 60”...
Page 33: Electrical
ELECTRICAL Electrical Schematic – Kawasaki 120124 REV C...
Page 34 REV C 120124...
Page 35: Maintenance Schedule
MAINTENANCE SCHEDULE Maintenance Schedule Refer to Figure 9-1, Figure 9-2, & Figure 9-3 WEEKLY MONTHLY * ANNUALLY SERVICE AT OR 50 OR 100 OR 500 INTERVALS INDICATED HOURS 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 36: Maintenance Locator Chart
* After completing maintenance cycle (500 hours), repeat cycle. Maintenance Locator Chart Figure 9-1 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8.
Page 37 Maintenance Locator Chart 1. Engine Oil Fill & Dipstick 2. Fuel Filter 3. Engine Air Cleaner 4. Engine Oil Drain Valve 5. Battery 6. Fuel Tanks 7. Hydraulic Oil Reservoir 8. Hydraulic Oil Filter 9. Gauge Wheel Bearing Zerks (2) 10.
Page 38 REV C 120124...
Page 39: Troubleshooting
TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Mower jerky when start- Steering control linkage Adjust linkage ing or needs adjustment Starting motor does not Steering control levers not Place steering control operates in one direction crank in park brake position or levers in park brake posi- only...
Page 40 SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Uneven cutting height The blade(s) are not sharp Sharpen the blades A cutting blade(s) is/are Install new cutting blade(s) bent The deck is not level Level the deck per the Deck leveling and height adjust- ment section of the parts manual An anti-scalp wheel is not...
Page 41 INDEX PAGE PAGE Avoid Acid Burns ......3-4 Maintenance Precautions ....3-3 Avoid Fire Hazards .