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Summary of Contents for Bigdog Mower Co. DIABLO
- Page 1 BIGDOG MOWER CO. DIABLO ® ® General Service Manual 200 South Ridge Road Hesston, Kansas 67062 123936 REV B...
- Page 2 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.
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Page 3: Table Of Contents
Table of Contents General Information ..........1-1 Service Program . - Page 4 Deck Belt Adjustment......... 6-3 Electrical .
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Page 5: General Information
This manual is part of a service package for the BigDog ® engine and hydraulic assemblies. Diablo mowers. Use of this manual in conjunction with other ® BigDog mower and component manuals will provide the Daily inspect mower for grass clippings and wire and string ®... - Page 6 REV B 123936...
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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 This safety alert symbol is used to call attention to a appliances. -
Page 8: Operation Precautions
Observe usual fuel handling precautions: Wear Protective Clothing • Do not smoke while refueling. Extinguish all Do not operate or service the equipment while wearing cigarettes, cigars, pipes and other sources of sandals, tennis shoes, sneakers, shorts or any type of ignition. -
Page 9: General Maintenance Precautions
Never attempt to start engine when there is a strong Always wear adequate eye protection when servicing odor of gasoline fumes present. Locate and correct the hydraulic system and battery, or when grinding cause. mower blades and removing accumulated debris. ... - Page 10 Prepare for Emergencies Shorts caused by battery terminals or metal tools touching metal mower components can cause sparks. Be prepared if a fire starts. Sparks can cause a battery gas explosion which will Keep a first aid kit and fire extinguishers available. result in personal injury.
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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 B 123936...
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Page 13: Power Unit Maintenance
POWER UNIT MAINTENANCE Steering Adjustments NOTE: Proper park brake adjustment must be completed before the steering control lever neutral adjustment can be done. Refer to the Park Brake Adjustment section for detailed Steering Control Lever Neutral Adjustment information. The mower’s steering has been factory adjusted to Fine adjustment to the unit’s steering is made with the eliminate creeping when the steering control levers are in the transmission’s control rod. - Page 14 Steering control lever in neutral position A. Female spades C. Mower harness B. Seat switch harness A. Park brake slot B. Steering control lever Figure 4-2 Figure 4-3 4. Start the engine. 8. If wheel(s) are rotating in reverse, then loosen the jam 5.
- Page 15 4. Do this for each side, then after the adjustment, fill the sockets of the set screws with a tamper-proof sealant. 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.
- Page 16 9. To check, move the steering control lever to the reverse position and release. The steering control lever should return to the neutral position. If not, repeat steps 1 through 6. Shown with steering control levers in neutral position A. Jam nut C.
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Page 17: Park Brake Adjustment
Park Brake Adjustment 2. Adjust the steering control levers so that they align with each other when in the neutral position. Figure 4-10 Never work under the machine or attachment unless it is safely supported with jack stands. • Make certain machine is secure when it is raised and placed on the jack stands. - Page 18 6. Try to rotate the tire by hand. The tire should rotate. 7. Move the steering control lever to where it is just Remember hydraulic oil resistance will prevent the tire inside (1/4") the park brake slot. Figure 4-13 from rotating freely even with the bypass valves open. There should be no resistance from the brakes at this point.
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Page 19: Belts
NOTE: When the steering control lever is against the c. Place the control lever in the neutral position. The tire outside edge of the slot, the brakes should not be should rotate freely. engaged. 9. Close the hydraulic pump’s bypass valve. Figure 4-12 Repeat steps 4 through 9 for the other side. -
Page 20: Hydraulic System
750 hours of mower operation, then replace filter and oil in reservoir every 500 hours thereafter. The following is a list of the oils that are approved for use in the BigDog Diablo hydraulic system. ® ® Parker HT-1000 (replace after every 750 hours) -
Page 21: Warner Clutch Re-Gap Adjustment Procedures
A. Dipstick cap C. Hydraulic filter B. Hydraulic reservoir Figure 4-17 Warner Clutch Re-gap Adjustment Procedures A. Brake fastener E. Armature B. Brake spacer F. Re-gap shim C. Field shell G. Rotor The air gap is only adjustable on clutches that have a D. - Page 22 2. Using needle-nose pliers, or by hand, take hold of the tab and remove the shim (do not discard the shim until proper clutch function been confirmed). Figure 4-21 A. Gap between the rotor and armature face must be greater than .070"prior to shim removal B.
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Page 23: Tires
Perform Safety Check: 8. Remove and retain the grease port plug. Observe deck operation from the operator’s seat. 1. Start the engine and the deck should not be engaged with the PTO switch “off” and clutch de-energized. Engage and disengage the PTO switch to ensure the proper function of the clutch. - Page 24 10. Install the upper bearing. Figure 4-26 A. Upper bearing B. Tapered roller bearing race A. Caster pocket B. Thin Figure 4-26 C. Thick D. Shoulder 11. Install the caster fork assembly, taking care not to E. Tapered roller bearing races damage the lower seal lip.
- Page 25 FULLY ASSEMBLED A. Top cap B. Plug Figure 4-28 123936 4-13 REV B...
- Page 26 REV B 4-14 123936...
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Page 27: 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 levels with quality viscosity recommendations, bolt torques, etc. The engine warranty is backed by the manufacturer. - Page 28 3. Reinstall the dust cap. Make sure it seals all the way A partially dirty air filter element works better than a new around the air cleaner canister, then tighten the element. Therefore, a dirty filter element is not bad for the clamps.
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Page 29: Fuel Evaporation System Filter
Fuel Evaporation System Filter Fuel & Evaporative System Line Routings There are two rubber hoses that are connected to the fuel BigDog Diablo mowers have a fuel evaporation system ® ® tanks. One is the fuel hose that is part of the fuel system. The filter. -
Page 30: 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 FX850 ENGINE SPEED MODEL NO. -
Page 31: Deck Adjustments
DECK ADJUSTMENTS Deck Leveling Leveling the deck must be done in the following manner and order: 1. Check tire pressures to make certain they are properly inflated before starting level deck. recommended pressures are as follows: Drive wheels ....8-12 psi (55-83 KPa) Front wheels . -
Page 32: Blades
Blades Mower Blade Maintenance IMPORTANT: Refer to the Safety section of this manual for blade handling safety information. Refer to the Mower Blade Replacement section for blade removal and installation. Mower blades are sharp and can cut. Wrap the Do not sharpen to original pattern (below). It is blade(s) or wear gloves and use extra caution easier to get a straight cutting edge following when servicing them. -
Page 33: Belts
Properly compressed cup washers maintain the correct End view of blades, comparing twisted and straightened compression load on the blades. Replace the cup washers if blades. they are cracked or flattened. IMPORTANT: The blade sail (curved part) must be pointing upward toward the inside of the deck to ensure proper cutting. - Page 34 IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley. A. Idler spring C. Spring chain B. Spring chain anchor point Figure 6-7 REV B 123936...
- Page 35 NOTE: The following notes are the same for the different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3.25" (82.6mm) cut height. 2. Route belt as shown. Deck Belt Routing &...
- Page 36 REV B 123936...
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Page 37: Electrical
ELECTRICAL Electrical Schematic – Kawasaki RED/BLK (18) IGNITION SWITCH RED (14) CLUTCH SWITCH BLK (18) ORG (18) ORG/RED (18) SEAT SWITCH ORG (18) TAN (18) NEUTRAL NEUTRAL SWITCH SWITCH ORG (18) TAN/RED (18) TAN/RED (18) OIL* PRESS ORG (18) J1-P J1-N J1-M J1-L... - Page 38 REV B 123936...
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Page 39: Maintenance Schedule
Maintenance Schedule Refer to Figure 8-1, Figure 8-2, & Figure 8-3 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 40 More often under dusty or dirty conditions and during hot weather. Inspect ROPS after the first 20 hours of operation and then after every 500 hours of operation or yearly whichever comes first. 10. Refer to engine owner’s manual for engine service information. 11.
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Page 41: Maintenance Locator Chart
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. Front Wheel Bearing Zerks (2) 10. - Page 42 REV B 123936...
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Page 43: Troubleshooting
TROUBLESHOOTING SUGGESTED SYMPTOMS PROBABLE CAUSES SUGGESTED REMEDIES 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 switch not adjusted position or re-adjust switch... - Page 44 REV B 123936...
- Page 45 INDEX PAGE PAGE Avoid Acid Burns ....... . . 2-4 Mower Blade Replacement .
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