BigDog Diablo MP General Service Manual
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BigDog Diablo MP General Service Manual

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BIGDOG
MOWER CO. DIABLO
MP
®
®
General Service Manual
200 South Ridge Road
Hesston, Kansas
67062
120125
REV D

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Summary of Contents for BigDog Diablo MP

  • Page 1 BIGDOG MOWER CO. DIABLO ® ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 120125 REV D...
  • 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 ........1-1 Big Dog Mower Service Program .
  • Page 4 Deck Belt Adjustment ....... . . 6-4 60" & 72" Deck Belt Routing & Tensioning ....6-6 Electrical .

  • Page 5: General Information

    GENERAL INFORMATION Clear away heavy build-up of grease, oil and dirt, especially ® Big Dog Mower Service Program in the engine compartment and under the seat platform areas; minute dust particles are abrasive to close-tolerance This manual is part of a service package for the Big Dog ®...
  • Page 6 REV D 120125...

  • Page 7: Safety

    SAFETY • Do not remove fuel cap or fill tank with engine run- ning or while engine is hot. Clean up any gasoline spills. • If gasoline is spilled, do not attempt to start the engine but move the machine away from the area This safety alert symbol is used to call attention to a mes- of spillage and avoid creating any source of igni- sage intended to provide a reasonable degree of PERSONAL...

  • Page 8: Operation Precautions

    and purpose of all controls, instruments, indicators  Always keep engine and machine clean, removing and labels. accumulated dirt, trash and other material from machine. Wear Protective Clothing  Never put hands or feet under any part of the machine while it is running.

  • 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 • Always disconnect the negative (black) battery • Avoiding spilling or contacting dripped electro- cable(s) before disconnecting the positive (red) lyte. cable(s). If you spill acid on yourself: • Always connect the positive (red) battery cable(s) • Flush your skin with water. before connecting the negative (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 D 120125...

  • Page 13: Power Unit Maintenance

    POWER UNIT MAINTENANCE Steering Adjustments 3. Raise the seat platform and disconnect the mower har- ness from the seat switch. Bypass the seat switch by connecting the two mower harness female spades Steering control lever neutral adjustment together. Figure 4-1 The mower’s steering has been factory adjusted to elimi- nate creeping when the steering control levers are in the neu- tral position.
  • Page 14 Steering control levers in neutral position Never operate the mower with a non-functioning seat switch. Always reconnect the seat switch to the mower harness. 13. Check to make sure all tools or obstructions are removed from under the mower. 14. Raise the rear of the mower and remove the jack stands.
  • Page 15 2. Place the steering control lever in the neutral position. Figure 4-6 3. Loosen the steering damper’s front ball stud. Figure 4-7 4. Pull the damper spring housing past the point that the internal spring is engaged. Figure 4-7 5. Release the damper spring housing and allow the internal spring to bring the housing back to the neutral position.

  • Page 16: Park Brake Adjustment

    A. Align handles ± .125" Figure 4-9 A. Steering damper spring housing B. Rear ball stud 2. Raise the rear of the mower and block with certified jack stands. The rear wheels need to be able to rotate Figure 4-7 freely and clear of all obstructions.

  • Page 17: Belts

    8. Rotate the tire. If the brake is adjusted properly the tire will still rotate but friction will start to become notice- able here. However, if no brake resistance is noticed, the brake needs adjusted as follows: a. Loosen the brake linkage jam nuts. (Figure 4-13) 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

    Inspect the belt pulley grooves and flanges for wear. A new Bottom View belt, or one in good condition, should never run against the bottom of the groove. Replace the pulley when this is the case, 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.
  • Page 19 Remember, dirt is the primary enemy of any hydraulic sys- tem. Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause seri- ous injury. Foreign fluid injected into the skin must be surgically removed within a few hours by a doc- tor, familiar with this form of injury, or gangrene may result.

  • Page 20: Bi-Directional Flow Testing Procedures

    PY (21) Series Pumps require two 771311 adapter fittings. CAUTION: Ensure all fittings and hoses are attached securely. This test is being completed on the vehicle’s high pressure system lines. Failure to perform this properly could result in bodily injury. Bi-Directional Flow Testing Procedures 1.
  • Page 21 Test Example: PY Pump RESTRICTION VALVE 300 psi (21 bar) reading7 gpm (26 l/min)(1st reading) BI-DIRECTIONAL FLOW METER CONNECTIONS TO THE FWD/RVS LINES DIS- CONNECTED FROM WHEEL MOTOR 1100 psi (76 bar) reading3 gpm (11 l/min)(2nd reading) PY (21) 300 psi (21 bar) reading7 gpm (26 l/min)(1st reading) 1100 psi (76 bar) reading-3 gpm (11 l/min)(2nd reading) RESTRICTION VALVE 4 gpm (15 l/min)(the difference)

  • Page 22: Tires

    The following procedures should be performed with the 3. It may be necessary to repeat Steps 1 and 2 until all vehicle drive wheels off the ground, then repeated under nor- the air is completely purged from the system. When mal operating conditions.

  • 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

    A. Safety filter Figure 5-3 looking for any holes or tears in the paper. Also check A. Air cleaner canister C. Clamp gaskets for cuts or tears. Do not attempt to use a dam- B. Dust cap aged element which will allow abrasive particles to Figure 5-4 enter the engine.

  • Page 25: Fuel & Evaporative System Line Routings

    This filter must be replaced every 500 hours or annually Models: 933259, 933267, 933275, 933275EX, 933283, whichever comes first. Figure 5-5 933283EX, 933291, 933291EX Models with fuel evaporation system filter 933259, 933267, 933275, 933283, 933291, 935072, 935080, 935106, 935106EX, 935114, 935114EX, 935122, 935122EX Models without a fuel evaporation system filter 933275EX, 933283EX, 933291EX...
  • Page 26 Models: 933259, 933267, 933275, 933275EX, 933283, Export (EX or AU) mowers 933283EX, 933291, 933291EX Models: 933275EX, 933283EX, 933291EX A. Fuel tank C. Vapor line A. Fuel tank C. Fuel shutoff valve B. Tee D. Fuel evaporation system B. Fuel line D.
  • Page 27 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 FX850 & FX1000 Engine Speed Model No.
  • Page 28 REV D 120125...

  • Page 29: Deck Adjustments

    DECK ADJUSTMENTS Deck Leveling deck is sitting tightly on all four blocks. Figure 6-3, Figure 6-4 & Figure 6-7 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 30 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 31: 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 32: 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 33 A. Spring chain B. Spring chain anchor point C. Idler spring Figure 6-11 120125 REV D...

  • Page 34: 60" & 72" Deck Belt Routing & Tensioning

    NOTE: The following notes are the same for the two different decks shown. 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. 60"...

  • Page 35: Electrical

    ELECTRICAL Electrical Schematic – Kawasaki Used on Models: 933259, 933283, 933275, 933291, 933267, 933275EX, 933291EX, 933283EX 120125 REV D...
  • Page 36 Electrical Schematic – Kawasaki Used on Models: 935080, 935106, 935122, 935106EX, 935122EX, 935072, 935114, 935114EX REV D 120125...

  • Page 37: Maintenance

    MAINTENANCE Maintenance Schedule Refer to Figure 8-1, Figure 8-2, Figure 8-3, Figure 8-4, & Figure 8-5 WEEKLY MONTHLY * ANNUALLY SERVICE AT OR 40 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...
  • Page 38 Pump drive belt only - Inspect belt every 100 hours and replace if worn or cracking is noticed. Check spring tension adjustment. Otherwise, replace belt every 400 hours or 2 years whichever comes first. Check and adjust spring tension after 50 hours of use as outlined in the Hydraulic Pump Belt Adjustment section of the General Service Manual (120125).

  • Page 39: Maintenance Locator Chart

    Maintenance Locator Chart Models: 933259, 933283, 933275, 933291, 933267, 933275EX, 933291EX, 933283EX Figure 8-1 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 40 Models: 935080, 935106, 935122, 935106EX, 935122EX, 935072, 935114, 935114EX Figure 8-3 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.
  • Page 41 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. Front Wheel Bearing Zerks (2) 10. Engine Oil Filter 11.
  • Page 42 REV D 120125...

  • Page 43: Troubleshooting

    TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES SUGGESTED SYMPTOMS PROBABLE CAUSES REMEDIES Mower jerky when starting Steering control linkage Adjust linkage 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 Pump or wheel motors...
  • Page 44 REV D 120125...
  • Page 45 INDEX PAGE PAGE Avoid Acid Burns ......2-4 Maintenance Precautions ....2-3 Avoid Fire Hazards .

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