BigDog® Mowers X Diablo General Service Manual ••••• 200 S.
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.
Table of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BigDog® Mower Service Program. . . . . . . . . . . . . . . . . . . . . . . . Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 BigDog® Mowers X Diablo Maintenance Locator Chart . . . . . . . 8-2 BigDog® Mowers X Diablo Maintenance Locator Chart . . . . . . . 8-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION BigDog® Mower Service Program This manual is part of a service package for the BigDog® X Diablo mowers. Use of this manual in conjunction with other BigDog® mower and component manuals will provide the information necessary to service and maintain BigDog® X Diablo mowers. This General 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.
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SAFETY This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER – denotes immediate hazards which WILL result in severe personal injury or death. WARNING – denotes a hazard or unsafe practice which COULD result in severe personal injury or death.
to uncomfortable or loud noises can cause impairment or loss of hearing. • Do not wear radios or music headphones while operating the machinery. Safe operation requires your full attention. Operation Precautions Avoid Fire Hazards Clean flammable material from machine. Prevent fires by keeping engine compartment, top of deck, exhaust area, battery, hydraulic lines, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris.
tape openings after adding the inhibitor. Keep container tightly closed when not in use. Inspect electrical wiring for worn or frayed insulation. Install new wiring if wires are damaged. 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.
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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 SIZE FT-LBS N-M #10 32.4 IN.-LBS. 3.6 M3 12 IN.-LBS. 1.3 .250 98.4 IN.-LBS. 11.1 M4 26.4 IN.-LBS. 3 .312 204 IN.-LBS. 23 M5 54 IN.-LBS. 6.1 .375 30 40 M6 92.4 IN.-LBS. 10.4 .438 48 65 M8 222 IN.-LBS. 25 .
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POWER UNIT MAINTENANCE Steering Adjustments Steering control lever neutral adjustment The 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, the steering control lever linkage can be adjusted. Before considering any adjustment, check the tire air pressure. Unequal tire pressure will cause the mower to drift to one side.
Control lever stops The steering control lever stops (see Figure 4-4) are designed to keep the pumps from bottoming out internally. Jam nut To keep the pumps from bottoming out internally use the following procedure: This adjustment is only required if the hydraulic pump(s) or pump linkage rod(s) have been replaced. WARNING Pump damage will occur if these stops are set incorrectly. Pump linkage rod Figure 4-3 8.
Steering control lever Jam nut Rear ball stud Steering damper spring housing Drive straight stop Figure 4-5 Figure 4-7 Steering damper The steering dampers are spring loaded to return the control levers to the neutral position from the reverse position. This gives the operator a sense of neutral during operation. To set the steering dampers in the correct operating position follow these steps: 1.
Align steering control lever ±.125” (3.175mm) Brake link Figure 4-9 Figure 4-10 Park Brake Adjustment WARNING This procedure will require that the unit be raised and blocked up off of the ground. It is necessary for the wheels to rotate without coming in contact with the floor or any object that would permit the unit to propel itself. Stay clear and exercise caution when rotating wheels to prevent injury.
the fibers of the belt covering. Keep oil and grease away from belts, and never use belt dressings. Any of these will destroy the belt composition in a very short time. Hydraulic Pump Belt Adjustment Control lever Park brake slot Outside edge 1/8” (3.175mm) Figure 4-12 12. Raise the rear of the mower and remove the jack stands. Lower the mower. 13. Reconnect the negative battery cable. 14. Lower and secure the seat platform.
Hydraulic System IMPORTANT: Never use hydraulic or automatic transmission fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system. WARNING Hydraulic fluid escaping under pressure may have sufficient force to penetrate skin and cause serious injury. Foreign fluid injected into the skin must be surgically removed within a few hours by a doctor, familiar with this form of injury, or gangrene may result.
wheel motor load. WARNING WARNING 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. The jack stands should not allow the machine to move when the engine is running and the drive wheels are rotating. Use only certified jack stands. Use only appropriate jack stands, with a minimum weight rating of 2000 pounds to block the unit up. Use in pairs only.
Test Example: PY (12) Pump RESTRICTION VALVE BI-DIRECTIONAL FLOW METER 300 psi (21 bar) reading 7 gpm (26 l/min) (1st reading) 1100 psi (76 bar) reading 3 gpm (11 l/min) (2nd reading) 7 gpm (26 l/min) -3 gpm (11 l/min) 4 gpm (15 l/min) (1st reading) (2nd reading) (the difference) CONNECTIONS TO THE FWD/RVS LINES DISCONNECTED FROM WHEEL MOTOR RESTRICTION VALVE BI-DIRECTIONAL FLOW METER CONNECTIONS TO THE FWD/RVS LINES DISCONNECTED FROM WHEEL MOTOR PK (12) 300 psi (21 bar) reading 1100 psi (76 bar
unit, the oil level will drop. 2. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 or 6 times). Check the oil level and add oil as required after stopping the engine. It may be necessary to repeat Steps 1 and 2 until all the air is completely purged from the system. When the pumps operate smoothly forward and reverse at normal speeds, purging is complete.
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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 recommendations, bolt torques, etc. The engine warranty is backed by the manufacturer. Special attention should be paid to applicable data which will not be duplicated here.
the following table for more detailed information. Figure 5-4 BigDog® X Diablo mowers with a 9xxxxxAU or 9xxxxxEX (i.e. 922222AU or 922222EX) model number may or may not have a fuel evaporation system filter. Refer to the following table for more detailed information. Figure 5-4 This filter must be replaced every 500 hours or annually whichever comes first.
On mowers produced after s/n 12080000 the vapor line is connected to the front port of the fuel tank. It connects the fuel tank to the engine’s vapor port. Figure 5-8 Export (EX or AU) mowers Mowers that are produced prior to s/n 12100000 have both a fuel hose and a vapor line. These mowers will have the same configurations as the mowers shown under the above Domestic mowers section. Mowers produced after s/n 12100000 will have the fuel line only.
Fuel tank Fuel shutoff valve Fuel line Seat support Fuel tank Export (EX or AU) mowers built after s/n 12100000 Figure 5-9 REV C 5-4 115615
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. ENDING WITH: HIGH IDLE MODEL NO. WITHOUT EXTENSION MODEL NO. WITH EX EXTENSION MODEL NO. WITH AU EXTENSION 3600 RPM NOTE: Model numbers may or may not end with an extension after the number.
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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 to level deck. The recommended pressures are as follows: Drive wheels . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa) Gauge wheels . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa) WARNING from the lift block at approximately 1" (2.54cm) (left & right side). Figure 6-4 10. Jam both nuts against the block.
Figure 6-5 17. Tighten the adjuster bolt jam nut to prevent the adjuster bolt from moving. Figure 6-5 18. Tighten the hardware holding the chain and adjuster onto the deck lift arm. Figure 6-5 Lift block Nuts 1” Chains 1” Deck lift rod Figure 6-4 19. Go to the right rear of the mower. 20. Make sure that there is still slack in the chain. If not, loosen the two nuts on the block holding the threaded rod until there is slack in the deck lift chain. 21.
IMPORTANT: When mounting blades, rotate them after installation to ensure blade tips do not touch each other or sides of the mower. Replace any blade which is bent, cracked or broken. WARNING WARNING Never attempt to straighten a bent blade by heating, or weld a cracked or broken blade as the blade may break and cause serious injury. Replace worn or damaged blades. Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.
IMPORTANT: Do not over tension the spring to compensate for a badly worn belt or pulley. Cutting edge Twisted Blade Edge (replace) Cutting Plane Spring chain Spring chain anchor point Cutting edge Straight Blade Edge End view of blades, comparing twisted and straightened blades Figure 6-10 Idler spring Belts Inspect belts frequently for wear and serviceability. Replace a belt that shows signs of severe cuts, tears, separation, weather checking and cracking, or burns caused by slipping.
NOTE: The following notes are the same for the two different decks shown. 1. Spring length after tensioning new belt. Measured from outside of hook to outside of hook with deck set at 3¼” (8.26cm) cut height. 2. Route belt as shown. 60” & 72” Deck Belt Routing & Tensioning 9.3” – 10.3” (23.6 – 26.
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ELECTRICAL Electrical Schematic – Kawasaki 115615 7-1 REV C
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MAINTENANCE SCHEDULE BigDog® Mowers X Diablo Refer to Figure 8-1, Figure 8-2, Figure 8-3 & Figure 8-4 WEEKLY OR 40 HOURS SERVICE AT INTERVALS INDICATED MONTHLY OR 100 HOURS ANNUALLY OR 500 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 Check oil level, engine (1)(4) Prior to each use or every 4 hours Clean air intake screen (7) Prior to each use or every 4 hour
BigDog® Mowers X Diablo Maintenance Locator Chart 7 6 9 2 12 11 21 3 10 4 1 21 12 11 6 5 9 Figure 8-1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
BigDog® Mowers X Diablo Maintenance Locator Chart 19 18 16 19 17 18 18 16 19 Figure 8-3 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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TROUBLESHOOTING SYMPTOMS SYMPTOMS Starting motor does not crank The engine will not start, starts hard or fails to keep running Engine: Runs with continuous misfiring or engine runs unevenly or erratically PROBABLE CAUSES Steering control levers not in park brake position or switch not adjusted Place steering control levers in park brake position or re-adjust switch Deck clutch switch engaged Disengage clutch switch Weak or dead battery Recharge or replace Electrical connections are corroded or l
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INDEX PAGE PAGE Belts ..................................................................4-5, 6-4 Maintenance Precautions ...................................... 2-2 Blades ......................................................................6-2 Maintenance Schedule .......................................... 8-1 Control lever stops ..................................................4-2 Mower blade maintenance .................................... 6-2 Deck Belt adjustment ...............................
