BigDog Diablo MP Operator's Manual

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BigDog® Mowers Diablo® MP

Operator Manual

605231 REV B

200 South Ridge Road Hesston, Kansas 67062

REV B 605231

Table of Contents

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

To The New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Warranty Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Model And Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Parts And Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety And Instruction Decals . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Safe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Using A Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Slope Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Safety Start Interlock System. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Moving Mower With Stalled Engine . . . . . . . . . . . . . . . . . . . . . . 3-6

ROPS (Roll Over Protective Structure) . . . . . . . . . . . . . . . . . . . 3-6

Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Air Flow Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Deck Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3-12

Anti-Scalp Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Maintenance & Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

605231 toc-1 REV A

Fuel And Evaporative Emissions Control System . . . . . . . . . . . .4-3

Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Engine Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Fuel Evaporation System Filter . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Mower Blade Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Mower Blade Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Steering Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . .4-9

Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Product Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

REV A toc-2 605231

GENERAL INFORMATION

This manual applies to the following BigDog® Mower lines:

BigDog® Mowers Diablo® MP

To The New Owner

The purpose of this manual is to assist owners and operators in maintaining and operating your BigDog it carefully; information and instructions furnished can help you achieve years of dependable performance.

A separate Engine Owner’s Manual is included with your owner’s packet which contains additional engine information that will not be repeated in this manual. It is the owner’s responsibility to make certain that the operators and mechanics read and understand the engine owner’s manual before attempting to operate or repair the engine.

The decals are designed to give the operator brief information needed in the daily operation and service of the machine. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable.

It is the owner’s responsibility to make certain that the operators and mechanics read and understand this manual and all decals before operating this machine. It is also the owner’s responsibility to make certain that the operators and mechanics are qualified and physically able individuals, properly trained in the operation of this equipment. All operators and mechanics must become familiar with the safe operation of the equipment, operator controls and decals.

IMPORTANT: The owner/user can prevent and is responsi-

ble for accidents or injuries occurring to themselves, other people or property.

Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

For more detailed maintenance and adjustment information refer to the proper General Service Manual for your machine. Refer to the “Product Literature” section of this manual for information on how to attain these manuals.

Mower. Please read

Using This Manual

General operation, adjustment and maintenance guidance is outlined for both the experienced and novice BigDog user. Operating conditions vary considerably and cannot all be addressed individually. Through experience, however, operators should find no difficulty in developing good operating skills suitable to most conditions.

Directions used in this manual, for example RIGHT or LEFT,

Mowers

refer to directions when in operator position and facing forward, unless otherwise stated.

Photographs and illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. BigDog

Mowers 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 operator’s manual, or the parts manual, see your BigDog

Mowers Dealer for current

information and parts.

Warranty Registration

Your BigDog® Mowers Dealer must register the unit on-line

within ten (10) days following date of purchase to validate your warranty protection. As the new equipment owner, you should confirm that your BigDog mower with BigDog

Mowers Dealer has registered your

Mowers.

Be sure to register the mower plus each attachment that displays a model and serial identification number plate with BigDog

Mowers.

IMPORTANT: Any unauthorized modification , alteration,

or use of non-approved attachments voids the warranty and releases BigDog

Mowers from any liability arising from subsequent use of this equipment. Do not use or operate any attachment not approved by BigDog® Mowers.

Model And Serial Number

Mower model and serial numbers are found on the serial identification plate, located on the frame directly below and to the left of the operator’s platform.

These numbers are required when the unit is registered with BigDog

Mowers. They will also assure you of the correct

service parts when replacement becomes necessary.

Parts And Service

Use original BigDog® Mower replacement parts only. These parts are available through your local BigDog To obtain prompt, efficient service, always provide the following information when ordering parts:

1. Correct part description.

2. Correct part number.

3. Correct model number.

4. Correct serial number.

All warranty repair and service must be handled through an authorized BigDog

Mower Dealer. Arrangements should be

made through your local service center.

Mower Dealer.

605231 1-1 REV B

The Engine Owner’s Manual provides information regarding the U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep Engine Owner’s Manual with your unit. Should the Engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered per the information found in the Product Information section of the owner’s manual.

Federal law and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element of design has been remo v ed or rendered inoperative by any person.

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. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of removing and retaining carbon and other flammabl e particles over 0.0232 of an inch in size from the exhaust flow of an internal combustion engine that uses hydrocarbon fuels or which is qualified and rated by the United States Forest Service. Other states or federal areas may have similar laws. The Operator Should Contact Local Fire Agencies For Laws or Regulations Relating to Fire Prevention Re quirements. THIS EQUIPMENT DOES NOT HAVE A SPARK ARRESTER AND YOU SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF A SPARK ARRESTER.

Inspect spark arrester daily; replace every 500 hours or as needed.

REV B 1-2 605231

SAFETY PRECAUTIONS

DANGER

WARNING

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.

– denotes immediate hazards which WILL result in severe personal injury or death.

• It is also the owner’s responsibility to make certain that

the operators and mechanics are qualified and physically able individuals, properly trained in the operation of this equipment.

• All operators and mechanics must become familiar with the safe operation of the equipment, operator controls and decals.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property.

• The owner should also ensure that the operators/mechanics know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator is responsible for accidents or hazards occurring to other people or their property.

– denotes a hazard or unsafe practice which COULD result in severe personal injury or death.

This manual uses two other words to highlight information.

IMPORTANT calls attention to sp ecial mechanical information and NOTE emphasizes general information worthy of special attention.

All operators and mechanics should read this manual, and be instructed about safe operating and maintenance procedures. If the operators or mechanics cannot read and understand English, it is the owner’s responsibility to explain this material to them.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol “”, which means DANGER or WARNING “personal safety instructions.” Failure to comply with the instructions may result in personal injury or death.

Incorrect usage of this mower may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this mower.

Safety And Instruction Decals

The decals are designed to give the operator brief information needed in the daily operation and service of the mower. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable.

• It is the owner’s responsibility to make certain that the

operators and mechanics read and understand this manual and all decals before operating this mower.

605231 2-1 REV B

Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable.

The following illustrations show the various safety decals that are located on the mower. A brief explanation, for those requiring one, is shown to help the operator understand the meanings of these decals.

• Read Operator’s Manual and Safety Warning Decals before

attempting to operate this machine.

• Do not smoke while refueling.

• Do not remove the fuel tank cap or fill tank with engine running

or while the engine is hot.

• Allow engine to cool before storing machine inside a building.

• Store away from open flame or spark if there is fuel in tank.

• Clean up any gasoline spills.

• Do not refuel while in enclosed trailer or other enclosed areas.

• Maximum of 10% ethanol (E10) in fuel. Fuels with greater than

10% ethanol, (such as E15, E20 and E85) voids warranty. Fuels

with greater than 10% ethanol are not approved for use and

such illegal use could cause equipment failure and pose a fire

hazard.

Part Number

602041

601837

If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and

involve your dealer to resolve the problem before continuing to operate.

If pump belt fails, steering control will be lost. Refer to owner’s manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.

600899

601967

779280

601968

601892

WARNING: Thrown objects!

• Always maintain a safe distance from

people and pets when mowing.

• Always stop machine if someone

enters the area.

• Inspect area to be mowed for hazards

such as rocks, metal objects and other debris which may be thrown or entan gled by mower blades. Remove these objects before mowing.

WARNING: Fire!

• Clean flammable material from

machine. Prevent fires by keeping engine compartment, top of deck,

Part Number 601967

exhaust area, battery, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

Part Number 779280

WARNING: Hot surface!

• Keep a safe distance from the machine.

Part Number 602041

DANGER: Rotating blades, pulleys & belts

• Keep shields and covers in

place while machine is in opera tion

Part Number 601837

• Keep hands, feet and clothing

away from rotating pulleys and belts.

Part Number 600899

• If you lose steering control while operating the machine, place

the steering control levers in the park brake position immedi ately. Inspect the machine and involve your dealer to resolve the problem before continuing to operate.

• If pump belt fails, steering control will be lost. Refer to owner’ s

manual for inspection and replacement intervals and refer to above paragraph for emergency procedures.

WARNING: Thrown objects!

Part Number 601624

• Never operate the mower deck with side

deflector damaged, altered , removed or in raised position, except when the entire grass catcher attachment or mulching system is being used.

WARNING: Hot surface!

• Avoid skin contact with hot surface

Part Number 601968

WARNING: Fluid

under pressure!

• Avoid hydraulic fluid escaping under pressure

• Hydraulic fluid escaping under pressure can pene-

trate skin.

• 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.

• Before applying pressure to hydraulic system,

make sure all connections are tight and all hoses and lines are in good condition.

• Relieve all pressure in the system before discon-

necting or working on hydraulic lines.

• To find a leak under pressure, use a piece of card-

board or wood – never use your hands.

• To relieve all pressure in system, lower attach-

ment and turn engine off.

REV B 2-2 605231

WARNING:Thrown objects!

604222

604221

DANGER: Rotating blades, pulleys & belts

• Always maintain a safe distance from

people and pets when mowing.

• Always stop machine if someone enters

the area.

• Inspect area to be mowed for hazards

such as rocks, metal objects and other debris which may be thrown or entan gled by mower blades. Remove these objects before mowing.

WARNING:Thrown objects!

• Never operate the mower deck with side

deflector damaged, altered, removed or in raised position, except when the entire grass catcher attachment or mulching system is being used.

Part Number 604222

Part Number 604221

• Keep shields and covers in

place while machine is in oper ation

• Keep hands, feet and clothing

away from rotating pulleys and belts.

DANGER: Rotating blades, pulleys & belts

• Keep shields and covers in

place while machine is in oper ation

• Keep hands, feet and clothing

away from rotating pulleys and belts.

605231 2-3 REV B

601815

• Avoid skin contact

with battery acid

• Do not allow open flame near the bat-

tery when charging.

• Hydrogen gas forms inside the bat-

tery. This gas is both toxic and flammable and may cause an explosion if exposed to flame. Always remove the negative ground first and replace it last.

• Do not overfill battery.

• Electrolyte may overflow and damage

paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Use soda mixed in water to clean corrosion off the terminals.

• Always wear eye protection when check-

ing the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing.

601635

Part Number 601635 WARNING: Read Operator’s Manual and decals before attempting to operate this machine.

WARNING: This structure’s protective capability may be impaired by structural damage,

overturn, or alteration. If any of these conditions occur, this structure must be replaced.

WARNING: Roll over!

• Never operate machine on a slope with the ROPS folded down (lowered position).

• There is no roll over protection when the ROPS is in the lowered position.

• Lower the ROPS only when absolutely necessary. Drive slowly and carefully. Raise the

ROPS as soon as clearance permits.

• Read and follow slopes operation instructions and warnings.

• Do not wear seat belt when the ROPS is in the lowered position.

WARNING: Ejection!

• Avoid crushing, use seat belt.

• Do not jump if machine tips.

• To minimize chance of injury or death from rollover; keep ROPS in the raised and locked

position and use the seat belt.

• Do not remove ROPS

• Always pull from the mower hitch.

• Do not attach chains or ropes to the ROPS for pulling purposes, as the machine can tip

backwards.

Part Number 601815

DANGER: Battery Hazards!

REV B 2-4 605231

603056

Part Number 603056

A. Fast B. Slow C. Choke D. Mower blade engage/disengage switch E. Ignition switch - insert key

F. OFF G. ON H. Engine start position

I. Before starting the engine:

• Read Operator’s Manual

• Disengage mower blades

• Place control levers in park brake position

J. Read Operator’s Manual before attempting to operate this machine. K. Wear ear protection, eye protection and safety shoes when operating this equipment.

L. If warning light comes on, check engine oil

M. For maximum electric clutch life engage at 1/2 - 3/4 throttle position.

N. For maximum electric clutch life disengage at low throttle position.

605231 2-5 REV B

Part Number 601993

WARNING: Read Operator’s Manual and decals before attempting

to operate this machine.

WARNING: Roll over!

• Mow a safe distance (minimum of 10 feet) away from drop-offs,

retaining walls, drainage ditches, embankments, water, and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away.

WARNING: Back over!

• Always be aware of what is behind the machine before backing

up. Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing up.

• Do not carry passengers.

• Always stop machine if someone enters the area.

WARNING: Roll over!

• Slow down before turning.

• Do not operate on slopes greater than 15 degrees.

• Keep all movement on slopes slow and gradual. Never make

sudden changes in speed and direction.

• Do not mow on slopes above a retaining wall or drop-off.

WARNING: Ejection!

• Do not operate on slopes greater than 15 degrees.

• Keep all movement slow and gradual when going up or down

slopes.

• Do not remove or modify stabilizer wheels or injury can result.

WARNING: Loss of traction/control on slopes!

• Shut off blades.

• Back slowly down the slope when loss of traction occurs.

REV B 2-6 605231

1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal.

2. Align Line B with a vertical surface such as pole, tree or building.

3. Fold the paper along the slope guide lines (C, D or E).

4. Align the closest slope guide line with the ground slope. This will give you a close estimation of the ground slope to be

mowed.

Slope Guide Lines

Line B

D (10o)

C (5o)

E (15o)

Line A

Slope Guide

Use this diagram when determining the degree of slope to be mowed.

605231 2-7 REV B

REV B 2-8 605231

OPERATION

Safe Operating Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Safe Operation

 Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

 Never leave a running mower unattended. Always stop

on level ground, disengage the deck clutch, place the steering control levers in the park brake position, stop the engine, and remove the ignition key before leaving the operator’s seat for any reason. Wait for the engine and all moving parts to come to a complete stop before leaving the mower for any reason including emptying the catcher or unclogging the chute.

 Do not change the engine governor setting or over speed

the engine. Operating the engine at excessive speed may increase the hazard of personal injury.

 Always remain seated while operating the mower.  Always keep safety shields and covers in place, except

for servicing.

 Always maintain a safe distance from people and pets

when mowing. Always stop mower if someone enters the area.

 Always operate mower in daylight or with adequate

working lights.

 Follow daily and weekly checklists, making su re hoses

are tightly secured and bolts are tightened.

 Always observe traffic laws while driving mower from

one location to another. Watch for traffic when operating near or crossing roadways.

 Always be alert for hazards such as rocks, metal objects

and other debris which may be thrown or entangled by mower blades. Watch out for holes or deep depressions.

 Never operate the mower when there is a risk for light-

ning.

 Inspect area to be mowed for hazards such as rocks,

metal objects and other debris which may be thrown or entangled by mower blades. Remove these objects before mowing.

 Always inspect mower for damage after striking a foreign

object. If damage is found, repair mower immediately. Be sure to stop on level ground, disengage the deck clutch, set the park brake, stop the engine, and remove the igni tion switch key when leaving the operator’s seat to inspect damage.

 Always wear adequate ear protection, such as earplugs,

when operating this equipment as prolonged exposure 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.

 Do not operate the equipment while wearing sandals, ten-

nis shoes, sneakers, shorts or any type of loose fitting clothing. Do not use a towel as a headband or neck wrap and do not hang a towel from the waist. Long hair, loose clothing or jewelry may get tangled in moving parts. Always wear long pants, safety glasses, ear protection and safety shoes with slip-resistant soles when operating this mower.

 Always be aware of what is behind the mower before

backing up. Never mow in reverse. Always look down and behind before and while backing up.

 Never push forward suddenly on your steering control

levers while the mower is in rearward motion because mower may tip backwards.

 Never pull back suddenly on your steering control levers

while the mower is in forward motion.

 If mowing in reverse is unavoidable, push forward slowly

on the steering control levers and avoid sudden move ment. Rapid movement of the steering control levers in either direction could result in a reaction of the mower that can cause serious injury.

 Never operate a poorly maintained mower.  Never attempt high speed maneuvering, especially in

crowded or congested areas.

 Never allow persons to operate this mower without

proper instruction or allow children to operate the mower. Allow only responsible adults who are familiar with these instructions to operate this mower.

 Never put hands or feet under any part of the mower

while it is running.

 Never carry passengers.  Never direct discharged material toward anyone. Avoid

discharging material against a wall or obstruction. Mate rial may ricochet back toward the operator. Always disengage the mower blades and wait for them to stop before crossing gravel drives, walks or roads.

 Never operate the machine with the floor plate pulley

cover removed.

 Always keep clear of the mower blades and attachments

during their operation.

 Do not use any unauthorized attachment or modify the

mower.

 Turn off the mower blades when not mowing.  Slow down before turning.  Stop the engine before removing the grass catcher or

unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be

sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area. Never use your hand!

 Do not operate the mower if you are fatigued, sick or

while under the influence of alcohol or drugs, if you are pregnant or under 18 years old.

 Poor posture or operating the mower for extended periods

of time may lead to fatigue or injury, resulting in loss of mower control. Occasionally, stop the mower and get off the seat to stretch and relax.

605231 3-1 REV B

 Exercise extreme caution when loading or unloading the

mower onto a trailer or truck.

 Always wear safety goggles or safety glasses with side

shields when operating the mower.

 Data indicates that operators, age 60 years and above, are

involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the mower safely enough to protect themselves and others from serious injury.

 Follow the manufacturer’s recommendation for wheel

weights or counterweights.

 If any attachment or additional weight is mounted on the

rear of the unit, any rapid movement of the control levers in either direction could result in a reaction of the mower that can cause serious injury.

 Clean flammable material from mower. Prevent fires

by keeping the engine compartment, top of the deck, exhaust area, battery, fuel line, fuel tank and opera tor’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

 Prevent fires by keeping the engine and exhaust areas

clear of grass clippings and other debris. Do not back mower into flammable materials.

 Always secure the ROPS in the raised position and

buckle the seat belt before starting mower.

Using A Ramp

 Use extreme caution when loading and unloading a

mower onto a truck or trailer with a ramp.

 Use only a single, full width ramp; do not use individual

ramps for each side of the unit. Having a full width ramp provides a surface for the mower frame to contact if the unit starts to tip backwards. It also reduces the risk of a wheel going off and the mower tipping over.

 Do not exceed a 15 degree angle between the ramp and

the ground or between the ramp and the trailer or truck.

 Avoid sudden acceleration when on a ramp.

Slope Operation

Slopes are a major factor in loss-of-control and tip-over

accidents, which can result in severe injury or death. All slopes require extra caution. If you cannot back the mower up the slope or if you feel uneasy on the slope; do not mow it. REMINDER: Only operate on slopes of 15 degrees or less.

 Use extreme caution when operating on slopes.

• Be extremely careful changing directions on a slope. Slow down.

• Do not operate where the mower could slip or tip.

• Turn slowly.

• Turn on the most level part of the slope.

• To maximize traction, it is better to turn the front of the mower uphill, rather than downhill. If drive

tires lose traction, steering control is lost which could cause serious injury or death.

• If it becomes necessary to turn downhill, turn slowly and gradually, if possible.

 Do not remove or modify the stabilizer wheels.

 Watch for holes, ruts, bumps, rocks or other hidden

objects. Uneven terrain could overturn the mower. Tall grass can hide obstacles.

 Remove obstacles such as rocks, tree limbs, etc.  Keep all movement on slopes slow and gradual. Do not

make sudden changes in speed or direction.

 Avoid starting and stopping on a slop e. If tires lose trac-

tion, disengage the mower blades and proceed slowly straight down the slope.

 Mow a safe distance (minimum of 10 feet) away from

drop-offs, retaining walls, drainage ditches, embank ments, water, and other types of hazards to avoid a wheel dropping over the edge or to avoid the ground from breaking away. This will reduce the risk of the mower suddenly rolling over causing serious injury or death.

 Use a walk-behind, push mower or hand-held trimmer on

slopes and near drop-offs, retaining walls, drainage

ditches, embankments and water to avoid mower rollover and serious injury or death.

 Do not mow on wet grass. Slippery conditions reduce

traction which could cause sliding and loss of control.

 Do not tow on slopes. The weight of the towed equip-

ment may cause loss of traction and loss of control.

 Do not try to stabilize the mower by putting your foot on

the ground.

 If the mower’s tires lose traction when operating on

slopes, disengage the blades, place the control levers in the park brake position, stop the engine, remove the igni tion switch key, and get help.

 Never make sudden starts, stops, turns, or reversals of

direction, especially when maneuvering on slopes. The steering is designed for sensitive response. Rapid move ment of the control levers in either direction could result in a reaction of the mower that can cause serious injury.

 Never stop suddenly while backing down slopes. This

action may result in a reaction of the mower that can cause serious physical injury.

 The BigDog® mower is capable of operating horizontally

(traverse) on moderately steep slopes. When operating on slopes up to 15 degrees, be aware of any conditions that may cause the mower drive tires to lose traction resulting in a possible loss of control of the mower. An operator should not operate on a slope until he is thoroughly familiar with the equipment.

Do not operate on slopes greater than 15 degrees.

Refer to the Slope Guide, when determining the degree of slope to be mowed. It is strongly recommended that the operator drive the mower off of the slope, using extreme caution, if any sign of loss of traction is detected. Wait until the condition that caused the problem is resolved before attempting to operate on the slope again. T errain conditions can affect traction resulting in possible loss of control of the mower. Some of the conditions to be aware of are:

1.Wet terrain

2.Depressions in the ground; i.e. holes, ruts, washouts

3.Mounds of dirt

4.Soil type; i.e. sand, loose dirt, gravel, clay

5.Grass type, density, and height

REV B 3-2 605231

6.Extremely dry conditions of grass

7.Tire pressure Any attachments mounted to the mower will also affect the way it handles on a slope. Be aware that each attach ment’s characteristics vary. Another consideration for safe mowing on slopes is to be aware of what is located at the bottom of the slope. Extreme caution should be used when there is a hazard located at the bottom of the slope. Some examples are:

1.Water; i.e. lake, river

2.Cliffs, retaining walls

3.Roads, highways

4.Buildings

5.Rocks These are just a few examples of situations when caution must be used when operating on a slope. There are many other possibilities too numerous to mention. Just reme m ber to always exercise extreme caution when operating on any slope.

 The ROPS may minimize chance of injury or death from

rollover. Seat belt must be fastened while operating a machine equipped with ROPS in the raised and secured

position. Both retaining pins and hair pins must be installed. Failure to use seat belt with ROPS will result in

serious injury in the event of a roll over.

Children

the presence of children. Children are often attracted to the mower and the mowing activity. Never assume that children will remain where you last saw them.

 Never leave the mower unattended with the ignition key

in switch, especially with children present.

 Children or bystanders may be injured if they move or

attempt to operate the mower while it is unattended. Always disengage the deck clutch, place the control levers in park brake position, stop the engine, and remove the ignition key when leaving operator’s seat.

 Keep children out of the mowing area and under the

watchful care of a responsible adult other than the opera tor.

 Be alert and turn the mower off if children enter the area.  Before and while backing, look behind and down for

small children.

 Never carry children, even with the blades off. They may

fall off and be seriously injured or interfere with safe mower operation. Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the mower.

 Never allow children to operate the mower.  Never allow children or others in or on towed equipment.  Use care when approaching blind corners, shrubs, trees,

the end of a fence or other objects that may obscure vision.

Tragic accidents can occur if the operator is not alert to

605231 3-3 REV B

Control Panel

WARNING

Shown with steering control

levers in neutral position

Steering control lever

A. Throttle B. Choke C. Deck clutch switch D. Ig nition switch

Figure 3-1

IMPORTANT: When access is required under the seat plat-

form and the seat is equipped with the optional arm rests, make certain to place the control arms in the park brake position and pivot the arm rests upward before placing the seat platform in the full forward position to prevent arm rest damage.

A. Throttle control (Figure 3-1) — a cable is linked to

engine throttle for controlling engine speed. Move lev er forward to increase engine rpm, move lever rearward to decrease engine rpm.

B. Choke control (Figure 3-1) — a cable is linked to

manually operate the engine choke. When the control knob is in the down position, the choke is in the off (run) position. When the control knob is pulled up, the choke is in the on (start) position. Do not operate the machine in the on (start) position.

C. Deck clutch switch (Figure 3-1) — this switch engages

the deck. Pull the switch up to engage and push switch down to disengage the clutch.

IMPORTANT: For additional clutch information refer to the Mower deck operation section of this manual.

D. Ignition switch (Figure 3-1) — a three position switch:

off, run, and start. With key inserted, rotate it clockwise to START position; release key when engine starts, and switch will automatically return to the RUN position.

E. 10 amp fuse (Figure 3-1) — Main - 10 amp, blade-type F. 20 amp fuse (Figure 3-1) — Clutch/Aux - 20 amp,

blade-type.

G. Electronic hour meter (Figure 3-1) — registers 1/10

hour increments up to 9,999.9 total hours. Connected to the ignition switch, the meter records the accumulative time while the ignition key is switch to the RUN position.

H. Oil pressure light (Figure 3-1) — this light comes on

when the ignition switch is placed in the RUN position and stays lit until the engine is running and a safe oil

E. Oil pressure light F. Hour meter G. 10 amp fuse H. 20 amp fuse

pressure is developed. If light comes on during operation, shut engine off immediately and locate and correct the problem.

Controls

A. Steering control levers (Figure 3-2 & Figure 3-3) —

these levers control the mower’s speed, direction, stopping, and park brake. These levers are used to steer, accelerate, decelerate and change direction. When the steering control levers are in the park brake position the mower will not move when the engine is on and the drive pumps are operating.

The parking brake may not hold the mower if parked on a slope. Block or chock the machine when parked on a slope.

B. Deck lift pedal (Figure 3-4) — the deck lift pedal is used

to raise or lower the deck. Push on the pedal to raise the deck and then place the deck height locking pin into the desired cutting height hole. Push the deck lift pedal to raise the deck when going over obstructions.

Figure 3-2

REV B 3-4 605231

Shown with steering control levers in park brake position

Deck lift pedal

Figure 3-5

WARNING

Lights

Figure 3-3

Figure 3-4

the engine when the operator is unseated for any reason while the mower is operating. This is a safety feature designed to prevent runaway or accidental entanglement. To inspect the system:

1. The operator must be on the seat when testing the seat

switch.

2. Set both steering control levers in the park brake position.

3. Start the engine and allow it to warm up to operating

temperature.

4. With the deck clutch switch down and the steering

control levers in the park brake position, slowly raise off of the seat. The engine should continue to run.

5. With the deck clutch switch up and/or the steering control

levers in the neutral position, slowly raise off of the seat.

The engine should stop.

6. If the engine fails to stop when the deck clutch switch is

up or one or both of the steering control levers is up and the operator is off the seat, check the function of the seat switch. If the seat switch is not operating properly (is not opening or closing) and if the cause can not be determined, replace the seat switch. If the problem cannot be located, contact your BigDog

Mowers Dealer.

The BigDog® Diablo® MP mower comes equipped with operating lights mounted in the front of the mower frame. There is no dedicated “ON/OFF” switch for these lights. These lights come on when the ignition switch is in the “RUN” position and go off when the ignition switch is in the “OFF” position. 3-5

Safety Start Interlock System

The mower is equipped with a safety start interlock sys tem consisting of the park brake switches, seat switch, and deck clutch switch.

Check the mower’s safety start interlock system daily, prior to operation. This system is an important mower safety

feature. It should be repaired immediately if it malfunctions. The machine incorporates a separate seat switch which will stop

605231 3-5 REV B

Figure

The safety interlock system should always function per steps 4 and 5. If it does not function properly, it should be corrected immediately. Do not operate machine without a properly functioning seat safety switch.

Engine Starting

The mower’s safety start interlock system is also designed to protect the operator and others from accidental injury due to unintentional engine starting. The engine starting motor wil l not engage until:

1. Steering control levers are in the park brake position.

2. Deck clutch switch is in the down (OFF) position.

WARNING

Bypass valve

The safety interlock system must not be disconnected or bypassed. Doing so could cause the machine to operate unexpectedly resulting in personal injury.

NOTE: The operator’s seat is equipped with a separate

safety switch. If for any reason the operator should become unseated when the steering control levers are not in the park brake position (park brake switches are disengaged) or the deck clutch switch is engaged the engine will stop.

The following steps are the correct procedures for starting the engine. If difficulty is encountered, contact the BigDog Mowers Dealer in your area.

1. Before starting mower each day, perform daily pre-

operation checking. (See Safety Start Interlock System section.)

2. Make sure the steering control levers are in the park

brake position and the deck clutch switch is disengaged. Only start the engine from the operator’s position.

3. Use choke when engine is cold, or if warm engine fails to

start within 5 seconds of cranking. Avoid flooding by operating engine without choking as soon as possible.

4. Set throttle at approximately 1/2 open position.

5. Insert key in ignition switch and rotate full clockwise to

engage starting motor. Release key when engine starts. IMPORTANT: The engine starter should not be operated for periods longer than 30 seconds at a time. An interval of at least two minutes should be allowed between such cranking periods to protect the starter from overheating and burning-out.

6. Perform a test to make sure the safety start interlock

system is operating properly. Refer to Safety start interlock system section.

7. As soon as the engine begins to run, check to make

certain all engine warning lights are off. If not, stop the engine immediately and check for the cause.

8. Allow the engine to idle a few minutes before advancing

the throttle and/or engaging the deck clutch.

Stopping The Engine

Use the following procedure to shut off the engine after operating the equipment.

1. Place the steering control levers in the park brake

position.

2. Throttle the engine back to low idle, then disengage the

deck clutch. Refer to Mower deck operation section for more details.

3. Let the engine run at low idle for a couple of minutes.

4. Rotate the ignition key counter-clockwise to the “OFF”

position. Remove the key from switch before leaving the

mower.

Moving Mower With Stalled Engine

If it becomes necessary to move the machine when the engine is inoperative, the hydraulic pumps are equipped with bypass valves. Before moving the unit, turn bypass valves counter clockwise one-half to one revolution. The valve stems on each hydraulic pump are located near the top and are identified as a hex stud. The valve is located per

Figure 3-6

The steering control levers must be placed in the neutral position, to release the park brakes, so that the mower can be moved.

Do not tow the machine. Move it by hand or use a winch to load on a trailer for transporting.

When transporting on another vehicle, the mower should be facing forward and it must be secured.

IMPORTANT: Always make certain the two byp ass valves

are returned to their operating position before running the mower following repairs.

Figure 3-6.

ROPS (Roll Over Protective Structure)

A ROPS may minimize the chance of injury or death from rollover.

A ROPS, when used with a seat belt, is effective in reducing injuries during unit overturn accidents. Overturning the unit without a ROPS or without ROPS locked in the raised position can result in serious injury or death.

The two-post ROPS can be pivoted down by removing the right and left retaining rings ( clevis pins so that the machine can operate under low hanging tree limbs or other obstructions. Do not wear the seat belt when the ROPS is in the lowered position. Use the ROPS in the

Figure 3-7

Figure 3-7), and pulling out on the

REV B 3-6 605231

Figure 3-7

WARNING

ROPS

Retaining ring

Clevis

WARNING

“folded” position only when absolutely necessary.

Do not operate the mower with the ROPS folded (low-

ered position) as a standard operating mode. A folded ROPS does not provide rollover protection.

Always wear your seat belt unless the mower is not equipped with a ROPS or if the ROPS is folded down. In this case, the seat belt should never be worn.

Always pull from the mower hitch. Do not attach chains or ropes to the ROPS for pulling purposes, as the machine can tip backwards.

Always fasten seat belt during operation of the machine

(mower equipped with ROPS in “raised/up” position).

Inspect the area prior to mowing for proper overhead

clearance (tree limbs, guy wires, doorways, etc).

Do not contact any overhead object with the ROPS.

Seat belt maintenance

Inspect the seat belt system (all seat, seat belt parts, seat pan and seat pan latch) daily prior to mowing for signs of any damage. These parts should be replaced if any parts indicate signs of:

• cuts

•fraying

• extreme or unusual wear

• significant discoloration due to UV exposure

• dirt or stiffness

• abrasion to the seat belt webbing

• damage to the buckle, latch plate or hardware.

• any other problem

If the seat belt is to be cleaned, use soap and water. Do not use carbon tetrachloride, naphtha, or other chemical cleaning agents, as these will weaken the webbing. For the same reason, do not bleach or dye the webbing. Replace the seat belt if worn or damaged.

Possible damage to ROPS

If the unit has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), the ROPS must be replaced to retain the best protection.

Following an accident, check the ROPS, the operator’s seat, the seat belt, seat belt mountings and seat latch for possible damage. Before operating the machine, replace all damaged parts.

IMPORTANT: Do not attempt to weld or straighten the

ROPS.

To minimize chance of injury or death from rollover:

• Keep ROPS in the raised and locked position and use the seat belt.

• Never operate machine on a slope with the ROPS folded down (lowered position).

• There is no roll over protection when the ROPS is in the lowered position.

• Lower the ROPS only when absolutely necessary. Drive slowly and carefully. Raise the ROPS as soon as clearance permits. Read and follow slope operation instructions and warnings.

• Do not wear seat belt when the ROPS is in the lowered position.

605231 3-7 REV B

The ROPS structure’s protective capability may be impaired by structural damage, overturn or altera tion. Do not remove or alter any of the ROPS parts. Do

not attempt to weld or straighten ROPS. Failure to adhere to these instructions could result in severe injury or death. If the ROPS or cab is replaced, make sure that the proper hardware is used and the recommended torque values are applied to the attaching bolts.

ROPS Inspection

Inspect the ROPS after the first 20 hours of operation. Following the initial inspection, check the ROPS after every 500 hours of operation or every six months, whichever comes first.

1. Check the torque of the ROPS mounting bolts. Tighten

WARNING

ROPS

mounting

bolts

ROPS post

DANGER

the bolts to the correct torques as shown below if necessary.

2. Inspect the operator’s seat and the mounting parts for the

seat belt. Tighten the bolts to the correct torque as shown below if necessary and replace parts that show wear or damage.

3. Check the seat latch to make sure it is secured and

functioning properly. Adjust or repair it as necessary.

Figure 3-8

Mower Operation

Driving the mower

Never make sudden stops or reverse direction, especially when maneuvering on a slope. The steering is designed for sensitive response. Rapid movement of the control levers in either direction could result in a reaction of the mower that can cause serious injury.

Never operate the mower with the seat latch un-installed and improperly secured. The seat platform must be securely latched to prevent seat from moving/tilting in the event of mower tipping or rollover.

Torque values are given below:

Ft-lbs. N-m

ROPS mounting bolts . . . . . . . . . . . . . . . . . . . . . .73. . . . 99

Seat belt mounting hardware. . . . . . . . . . . . . . . . .48. . . . 65

After starting engine, engage the steering control levers and

steer as follows:

To go forward, push steering control levers forw ard an equal

distance (

equal distance (

forward from neutral than the left steering control lever.

forward from neutral than the right steering control lever. (

Figure 3-9)

and the other steering control lever back of neutral. This will allow the drive wheels to counter-rotate. (

neutral. When going forward pull back gently on steering control levers. When going in reverse push forward gently on steering control levers.

place the steering control levers in the park brake position immediately.

Figure 3-9).

To go in reverse, pull steering control levers rearward an

Figure 3-9).

To turn left, move the right steering control lever farther

To turn right, move the left steering control lever farther

Zero radius turn, move one steering control lever forward

Figure 3-9)

To stop or decrease speed, move steering control levers to

For emergency stop, when traveling forward or rearward,

Figure 3-8

REV B 3-8 605231

When moving in the rearward direction push forward gently on steering control levers and avoid sudden move ment. Any sudden movement could cause the front of the mower to come off of the ground resulting in possible loss of control, causing serious injury or death.

To make a three point turn to the right, move the left

steering control lever farther forward from neutral than the right steering control lever and start the turn. Next, pull back on the steering control levers until they are past neutral and the machine starts to go rearward. Pull the right steering control lever farther rearward from neutral than th e left steerin g control lever until the rear of the machine has pivoted around. Then, push the steering control levers forward until they are both past neutral and the machine starts to go forward. Push the left steering control lever farther forward from neutral than the right

steering control lever and finish the turn. (Figure 3-10)

WARNING

FORWARD TRAVEL

FRONT OF MOWER FACES THIS DIRECTION

ZERO RADIUS TURN

FORWARD TRA VEL

RIGHT TURN

REVERSE TRAVEL

RIGHT TURN

REVERSE TRA VEL

N = NEUTRAL POSITION Direction of arrows indicate direction of mower

movement

Always be aware of what is behind the machine before backing up. Do not mow in reverse unless absolutely nec essary. Always look down and behin d before and while backing up.

IMPORTANT: Rapid movement of steering cont rol levers

is not recommended as damage to the hydraulic system compo nents may occur.

To increase speed, increase steering control lever’s distance

from neutral. The farther forward steering control levers are from neutral, the faster the mower will travel forward. The farther back steering control levers are from neutral, the faster the mower will go in reverse.

605231 3-9 REV B

Figure 3-9

Step 1

THREE POINT TURN

Step 2

Step 3

Neutral

Left control leverRight control lever

DANGER

WARNING

Operating suggestions

Prior to operating the mower the operator should be thoroughly familiar with the proper use and operation of the equipment, should read the manual completely and thor

oughly, and should have attempted slow moving maneuvers to become familiar with the operation of the equipment before attempting normal speed operation. An inexperienced operator should not mow on slopes or on uneven terrain.

If you lose steering control while operating the machine, place the steering control levers in the park brake position immediately. Inspect the machine and involve your BigDog

Mower Dealer to resolve the

problem before continuing to operate.

Figure 3-10

The unit’s steering control levers are very responsive: Easy does it! For smooth operation, move the levers slowly, avoiding sudden movement. Skill and ease of operation come with practice and experience. The machine can spin very rapidly. Use caution when making turns and slow down before making sharp turns.

Inexperienced operators may have a tendency to oversteer and lose control. Slow-moving (low engine rpm - idle) practice maneuvers on a flat open area are recommended to become familiar with these characteristics before attempting normal speed operation.

Sharp depressions or raised obstacles (such as gutters or curbs) should not be directly approached at high speed in an attempt to “jump” them as the operator could be thrown from the equipment. Approach at a slow speed and angle one drive wheel at the obstruction. Continue at an angle until the wheel clears and then pivot the opposite wheel around.

When turning on soft wet turf, keep both wheels rolling either forward or backward. Pivoting on one stopped wheel can damage turf. This is especially important when mowing.

Mower performance is at maximum when the throttle is set at full rpm. This gives maximum power to the drive wheels and deck when needed. Use the control levers to control ground speed rather than engine rpm.

Keep blades sharp. Many professional mowing companies

REV B 3-10 605231

DANGER

WARNING DANGER

WARNING

Discharge

chute

NOTE: Discharge chute may

vary from this illustration

have additional sets of blades and change blades twice a day: once in the morning and again at noon. Many problems with incorrect cutting patterns are due to dull blades or blades which have been sharpened incorrectly. Information on sharpening blades is listed in this manual’s maintenance section. In addition, most communities have individuals or companies which specialize in sharpening mower blades. Blade sharpness

should be checked daily.

Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place steering control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if the mower strikes a rock, branch or other foreign object during mow ing!

Use high blade speed. Your mower is designed to operate at

full throttle. The throttle setting directly controls blade speed. The highest blade speed generally gives the best cut.

Direct grass discharge to the right, away from the unmowed

area. Select a mowing pattern that directs grass discharge toward the outside, not toward the center, of the mowing area. Generally, this means using a pattern utilizing left turns because side discharge is to the right. In any case, avoid throwing grass discharge onto unmowed area because grass is then mowed “twice”. Mowing twice puts an unnecessary load on the unit and reduces mowing efficiency.

When mowing a lawn for the first time cut grass slightly

longer than normal to avoid scalping uneven terrain. When possible, it is best to use the cutting height that was used in the past. When cutting grass taller than six inches, you may want to mow the lawn twice to achieve a better quality of cut.

During normal mowing cut only about 1/3 of the grass

blade. Cutting mo re than that is not recommended unless grass

is sparse or it is the end of the mowing season.

Alternate the mowing direction to keep the grass growing

straight and for better dispersion of the clippings.

Remember, grass grows at different rates at different times

of the year. Mow more often in the early spring to maintain the same cutting height. As the growth rate slows in midsummer, mow less frequently. If you cannot mow at a regular interval, mow at a high cutting height; then mow again two days later at a lower cutting height.

Raise the cutting height of the mower if the cutting width of

the mower is wider than the previous mower. This ensures that uneven turf is not cut too short.

Raise the cutting height of the mower if the grass if slightly

taller than normal or if it contains a high degree of moisture. Then mow it again with the cutting height set lower.

If the machine’s forward motion must be stopped while

mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.

Never direct the discharge of material from the mower deck toward bystanders. Do not operate the mower w ith out either the discharge chute or the entire grass collection system in place. Figure 3-11

Figure 3-11

Never attempt to make any adjustments to the mower deck while the engine is running or with the deck drive clutch engaged. Mower blades cannot be seen and are located very close to deck housing. Fingers and toes can be cut off instantly.

Deck clutch operation

Before beginning operation, check to make sure the deck clutch switch is engaging and disengaging the blades properly.

Make sure that the area around and under the deck is clear and that there are no bystanders in the immediate area before proceeding.

To check the deck clutch switch:

1. Start the engine and engage the deck clutch.

2. With the deck clutch switch up (clutch engaged) and the

engine running, listen to confirm that the mower blades are rotating.

3. Now, push the deck clutch switch down (clutch

disengaged), and with the engine running, listen to confirm that the blades have stopped rotating.

4. If the mower blades continue to rotate with the deck

clutch switch down, discontinue operation immediately and contact your BigDog

Mowers Dealer.

605231 3-11 REV B

Clutch life will be maximized if these procedures are

Baffles

60” Deck Shown

Slot

Transport lever

Cutting height holes

followed.

1. Engage the clutch only when the throttle is set at

approximately 2/3 throttle and there is no load on the blades. After clutch engagement, advance the engine throttle to full rpm. Engaging the deck clutch at high engine rpm or when under heavy load (in tall grass, for example) can cause belts and/or electric clutch to slip, resulting in premature wear or possible damage.

2. Disengage the clutch only when the throttle is set at less than 1/2 throttle.

Never disengage the clutch with the engine running at high rpm. Setting the throttle to less than 1/2 throttle when disengaging the clutch will help extend clutch life.

Warranty will not be allowed for deck clutches that fail due

to improper engagement and disengagement practices.

Air Flow Baffles

Some decks are equipped with front adjustable air flow baffles. These baffles can be adjusted up or down, depending upon the mowing conditions, to provide the best quality of cut. Figure 3-12

Setting Conditions

Bottom set of

holes

set of holes

Dry, sparse grass. Particularly useful when mowing at a height of cut of 3” (76.2mm) or higher. This setting provides the maximum vacuum and minimal blowout.

Manicured lawns. Provides the best vacuum for the best cut when removing weekly/bi-weekly growth.

Tall and stemmy grasses. The higher inner wall allows grasses to snap back up before contacting the blades to produce a cleaner cut.

NOTE: The air flow baffles are preset at the factory in the

“B” setting.

The 60” decks, that are equipped with these baffles, come with three sets of mounting hardware for each air flow baffle. The middle set of hardware does not need to be removed when changing the baffle setting. This is a slot and the hardware only needs to be loosened enough to allow the baffle to slide. The other hardware on the ends of the baffles will need to be removed. After the baffles have been adjusted, re-install and tighten the outer hardware and tighten the middle hardware.

Figure 3-12

Deck Cutting Height Adjustment

Deck cutting height is adjustable in 1/4” (6.4mm) increments. The holes in the height adjusting bar are spaced at 1/2” (12.7mm) intervals. By turning the height adjusting stop around, 1/4” (6.4mm) increments can be attained due to the 1/4” (6.4mm) plate that is part of the stop.

EXAMPLE: When the height adjusting stop is placed in the 3” (76.2mm) hole, with the 1/4” (6.4mm) plate facing to the front of the unit, the cutting height is at 3” (76.2mm). When the height adjusting stop is placed in the 3” (76.2mm) hole, with the 1/4” (6.4mm) plate on the operator’s side of the hole, the cutting height is at 3-1/4” (82.6mm).

The notch located at the rear of the height adjusting bar engages the stop handle when the deck lift pedal is fully depressed. This sets the deck in transport mode.

Figure 3-13

REV B 3-12 605231

Figure 3-13

Anti-Scalp Wheels

Anti-scalp wheel

Adjusting holes

Anti-scalp wheel kits are standard on BigDog® Mowers. These anti-scalp wheels are designed to minimize scalping when mowing on rough uneven terrain.

After setting the cutting height, adjust the front anti-scalp wheels so they extend below the deck but do not contact the ground. They should always be at least 1/4” to 3/4” (6.35mm to

19.05mm) below the deck. With the unit sitting on a flat level surface, the front wheel position can be adjusted up or down at either 3/4” or 1-3/4” (19.05mm or 44.45mm) below the blade surface. Move the front wheels up or down using the different axle mount holes in the wheel mount bracket.

NOTE: When the anti-scalp wheels are installed, the mini-

mum cutting height is 1” (25.4mm) with the anti-scalp wheels set at 3/4” (19.1mm).

Figure 3-14

605231 3-13 REV B

REV B 3-14 605231

MAINTENANCE & ADJUSTMENTS

Safe Servicing Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

Service Precautions

 Unless specifically required, DO NOT have engine run-

ning when servicing or making adjustments to mower. Park the machine on level ground. Place steering control levers in the park brake position, disengage deck clutch, lower deck, remove ignition switch key and disconnect negative battery cable before doing any maintenance. Wait for all movement to stop before adj usting, cleaning or repairing. Repairs or maintenance requiring engine power should be performed by trained maintenance per sonnel only. To prevent carbon monoxide poisoning, be sure proper ventilation is available when engine must be operated in an enclosed area. Read and observe safety warnings in front of manual.

 Before working on or under the deck, make certain

engine cannot be accidentally started. Shut engine off, remove ignition switch key and disconnect negative bat tery cable for maximum safety. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only.

 Except when changing or checking the belt, always keep

belt covers on mower deck for safety as well as for clean liness.

 Use a stick or similar instrument to clean under the

mower making sure that no part of the body, especially arms and hands are under the mower.

 Keep your machine clean and remove any deposits of

trash and clippings, which can cause engine fires and hydraulic overheating as well as excessive belt wear. Clean up oil or fuel spillage. Allow machine to cool before storing.

 Clean flammable material from machine. Prevent

fires by keeping the engine compartment, top of the deck, exhaust area, battery, fuel line, fuel tank and operator’s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil.

 Always wear adequate eye protection when servicing the

hydraulic system and battery, or when grinding mower blades and removing accumulated debris.

 Use extra caution when handling gasoline and other

fuels. They are flammable and vapors are explosive.

 Never attempt to start the engine when there is a strong

odor of gasoline fumes present. Locate and correct the cause.

 Never remove the fuel cap or refuel the mower while

engine is running or while engine is hot; never refuel near an open flame or near devices which can create a spark. Refuel outdoors. Never refuel or drain the fuel from the machine indoors.

 Never run the engine in an enclosed area unless exhaust

is vented to the outside. Exhaust gases contain carbon monoxide which is an odorless and deadly poison.

 Never attempt to make any adjustments or repairs to the

mower drive system, mower deck or any attachment while the mower engine is running or deck clutch is engaged. Repairs or maintenance requiring engine power should be performed by trained maintenance personnel only.

 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 appro

priate jack stands, with a minimum weight rating of 2000 pounds (907 kg) to block the unit up. Use in pairs only. Follow the instructions supplied with the vehicle stands.

 Exercise caution when releasing spring tension from any

of the belt idlers or when working with any of the deck lift components.

 Do not touch hot parts of machine.  Keep nuts and bolts tight, especially the blade attachment

bolts. Keep equipment in good working condition.

 Never tamper with safety devices. Check their proper

operation regularly.

 Stop the engine before removing the grass catcher or

unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a stick to clear a plugged discharge area. Never use your hand!

 Grass collection system components are subject to wear,

damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recom mended parts, when necessary.

 Exercise caution when working under the deck as the

mower blades are extremely sharp. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

 Use only genuine BigDog® Mowers replacement parts to

ensure that original standards are maintained.

Service Introduction

Regular maintenance is the best prevention for costly downtime or expensive, premature repair. The following pages contain suggested maintenance information and schedules which the operator should follow on a routine basis. For more detailed information order the correct Parts Manual and General Service Manual for your unit. Refer to the Product Literature section of this manual.

Remain alert for unusual noises, which could signal a problem. Visually inspe ct the machine for any abnormal wear or damage. A good time to detect potential problems is while performing scheduled maintenance service. Correcting the problem as quickly as possible is the best insurance.

605231 4-1 REV B

Clear away heavy build-up of grease, oil and dirt, especially

WARNING

in the engine and under the seat platform areas; minute dust particle are abrasive to close-tolerance engine and hydraulic assemblies.

Inspect mower daily for grass clippings and wire or string

tangles. The underside of the mower deck will collect a build-up of grass clippings and dirt, especially when grass is wet or has high moisture content. This build-up will harden, restricting blade and air movement and will probably show a poorer quality of cutting. Therefore it should be removed routinely.

To do this it will be necessary to raise and block the deck using jack stands or blocks in the full up position. Scrape the build-up from underneath.

Some repairs require the assistance of a trained service mechanic and should not be attempted by unskilled personnel. Consult your BigDog is needed.

Mowers service center when assistance

Torque Values

Particular attention must be given to tightening the drive wheel lug nuts and blade spindle bolts. Failure to cor rectly torque these items may result in the loss of a wheel or blade, which can cause serious damage or personal injury.

Torque values are given below:

Ft-lbs. N-m

Wheel (lug) nuts . . . . . . . . . . . . . . . . . 70 . . . . . . . . 95

Blade spindle bolt top . . . . . . . . . . . . . 70 . . . . . . . . 95

Blade spindle bolt bottom. . . . . . . . . .118. . . . . . . .160

Wheel motor nut . . . . . . . . . . . . . . . . .230. . . . . . . . 312

Lug nuts only - It is recommended that these be checked after the first 2 hours of operation, initially, every 50 hours and following removal for repair or replacement.

For all other torques refer to the mower’s General Service Manual for standard torque chart. See Product Literature section for ordering information.

For engine torque values, see engine owner’s manual.

Tires

It is important for level mowing that the tires have the sam e amount of air pressure. The recommended pressures are:

Drive wheels . . . . . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

Front wheels . . . . . . . . . . . . . . . . . . . . . 8-12 psi (55-83 KPa)

If you wish to use non-pneumatic tires on your BigDog mower the tires must be an approved tire purchased from BigDog mower equipped with unapproved non-pneumatic tires.

Mowers. Warranty claims will be denied on any

Electrical System

The electrical system for this mower is a 12 volt, negative

ground.

When a replacement battery is required refer to the existing battery and replace it with a battery with the same specifications. The battery specification is listed below:

BCI group 45 with 480 or better cranking AMP rating.

A maintenance-free battery is recommended. Otherwise, follow battery manufacturer ’s maintenance, safety, storing and charging specifications.

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Charge batteries in an open well ventilated area, away from sparks and flames. Unplug charger before connect ing or disconnecting from battery. Wear protective clothing and use insulated tools.

• Avoid skin and clothing contact with battery acid.

• Always wear eye protection when checking the battery, acid can cause serious injury to skin and eyes. If contact occurs, flush area with clean water and call physician immediately. Acid will also damage clothing.

• Do not drink the battery electrolyte.

• Do not allow open flame near the battery when charging.

• Hydrogen gas forms inside the battery. This gas is both toxic and flammable and may cause an explo sion if exposed to flame. Always remove the negative ground first and replace it last.

• Do not overfill battery.

• Electrolyte may overflow and damage paint, wiring or structure. When cleaning the battery, use soap and water. Be careful not to get soap and water into the battery. Clean the battery terminals with a solu tion of four parts water and one part baking soda when they become corroded.

Lubrication

Use SAE multi-purpose grease.

REV B 4-2 605231

WARNING

Shorts caused by battery terminals or metal tools touch-

WARNING

Master fuse

housing

WARNING

ing metal mower components can cause sparks. Sparks can cause a battery gas explosion which will result in per sonal injury.

• Prevent the battery terminals from touching any metal mower parts when removing or installing the battery.

• Do not allow metal tools to short between the battery terminals and metal mower parts.

Incorrect battery cable routing could cause damage to t he mower and battery cables. This can cause sparks which can cause a battery gas explosion which will result in per sonal injury.

•Always disconnect the negative (black) battery cable(s) before disconnecting the positive (red) cable(s).

•Always connect the positive (red) battery cable(s) before connecting the negative (black) cable(s).

Master in-line fuse

These mowers have a master in-line fuse in the electrical system. This is the main fuse to protect the complete electrical system. It is located next to the starter solenoid which is mounted on the left front of the engine.

Figure 4-1

Hydraulic System

IMPORTANT: Never use hydraulic or automatic transmis-

sion fluid in this system; use only motor oil as specified. Remember, dirt is the primary enemy of any hydraulic system.

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.

Before applying pressure to hydraulic system, make sure all connections are tight and all hoses and lines are in good condition. To find a leak under pressure, use a piece of cardboard or wood — never use your hands. Relieve all pressure in the system before dis connecting or working on hydraulic lines. To relieve pressure, lower all attachments and shut off engine.

Check oil level in hydraulic system after every 50 hours of operation or weekly, whichever occurs first. Check more often if system appears to be leaking or otherwise malfunctioning.

Fluid level should be 1” (2.54cm) from top of reservoir. (

Figure 4-2) Use only SAE 20W50 SL/SM service motor oil for

the BigDog® Diablo® MP mowers.

NOTE: The reservoir will require approximately 3.0 U.S.

gallons (11.35 liters) of SAE 20W50 SL/SM service motor oil when replacing the oil after an oil and filter change. Do not overfill the reservoir.

Change hydraulic system filter element and oil after first 50 hours of mower operation, then replace filter and oil in reservoir every 500 hours thereafter.

IMPORTANT: It is necessary to drain the system oil from

the hydraulic reservoir, using the reservoir drain plug, before removing the hydraulic filter. Replace the drain plug before add ing system oil.

Use a 15/16” socket for the hydraulic system filter. The threads are right hand.

The hydraulic system filter is located inside the hydraulic reservoir on the underneath side of the tank. Use a BigDog Mowers approved filter element only. Figure 4-3

Hydraulic oil heat exchanger

The BigDog® Diablo® MP mower is equipped with a hydraulic oil heat exchanger. The heat exchanger coils must be kept clean to insure that the hydraulic oil is operating within the cor rect temperature range.

Check and clean the heat exchanger daily and more often in dirty, dusty conditions.

Figure 4-3

Figure 4-4

605231 4-3 REV B

Fuel And Evaporative Emissions Control System

The fuel and evaporative emissions control system for this mower is EPA compliant. Use only Bi gDog replacement parts.

Mowers approved

Figure 4-2

Hydraulic

reservoir

Hydraulic filter

Hydraulic

reservoir

Heat exchanger

WARNING DANGER

WARNING

purge valves, liquid/vapor separator and other associated components.

Modifying or Tampering with the evaporative emissions

control system or the fuel system is prohibited. Federal law

and California State law prohibit the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other

than for purposes of maintenance, repair, replacement, of any device or element of design incorporated into any equipment for the purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or while it is in use, or

2. The use of the equipment after such device or element of

design has been removed or rendered inoperative by any person.

Use of replacement parts not equivalent to the original parts may result in system failure and pose a safety haz

ard.

Figure 4-3

Figure 4-4

Your evaporative emission control system may include parts such as: fuel tanks, fuel lines, fuel line fittings, fuel caps, carbon canisters, canister mounting brackets, carburetor purge port connection, filters, vapor hoses, clamps, control valves, control solenoids, electronic controls, vacuum control diaphragms,

To avoid personal injury or property damage, use extreme care in handling fuel. Fuel is extremely flam

mable and the vapors are explosive.

Observe usual fuel handling precautions

• Do not smoke while refueling. Extinguish all cigarettes, cigars, pipes and other sources of ignition.

• Do not remove fuel cap or fill tank with engine running or while engine is hot. Clean up any fuel spills.

• If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spill

age and avoid creating any source of ignition until fuel vapors have dissipated.

• 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 appliances.

• Use extreme care when handling gasoline and other fuels which are extremely flammable and vapors are explosive. A fire or explosion from fuel can burn you and others and can damage property.

• Refuel outdoors. Never refuel or drain the fuel from the machine indoors.

REV B 4-4 605231

• Never attempt to start the engine when there is a

WARNING

Right fuel tank

Left fuel tank

Closed

position

strong odor of gasoline fumes present. Locate and correct the cause.

• Store fuel in an approved container and keep it out of the reach of children. Never buy more than a 30 day supply of fuel.

• Do not fill fuel containers inside a vehicle or on a truck or trailer bed with interior carpets or plastic truck bed liners. Always place fuel containers on the ground away from your vehicle before filling.

• When practical, remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel such equipment on the truck or trailer using a portable container and not a fuel dispenser nozzle. If a fuel dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do not use a nozzle lock-open device.

• Never use gasoline for cleaning parts.

• Read and observe safety precautions elsewhere in this manual.

pose a fire hazard. Refer to the engine owner’s manual for fuel specification requirements.

A fuel shut-off valve is located on each mower. Close the fuel

valve to prevent fuel flow to the engine. The valve’s two other positions will allow fuel to be drawn from either one or the other fuel tank.

Figure 4-5

• Gasoline is harmful or fatal if swallowed.

• Long-term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapo rs.

• Keep face away from nozzle and gas tank or fuel container opening.

• Keep gas away from eyes and skin.

• If fuel is spilled on clothing, change clothing immediately.

The fuel tanks are located in the mower’s fenders. Remove the fuel cap slowly.

When threading the fuel cap onto the filler neck, tighten the cap until it begins to click, then, continue to turn it until at least three clicks are heard.

IMPORT ANT: Do not overfill the fuel tanks. The fuel tanks

should be filled no higher than the bottom of the fill neck. The fuel system is designed to leave room for the fuel to expand with fuel temperature changes.

Overfilling fuel tanks may cause the following:

• Engine damage

• Fire hazard!

Use regular unleaded gasoline with an octane rating of 87 or higher. Maximum of 10% ethanol (E10) in fuel. Fuels with greater than 10% ethanol, (such as E15, E20 and E85) voids warranty. Fuels with greater than 10% ethanol are not approved for use and such illegal use could cause equipment failure and

Figure 4-5

Engine Oil and Filter

If the engine has been running and is up to operating temperature, allow the engine to cool before changing the oil. Engine and engine oil will be very hot, so be very careful when changing oil and wear the appropriate protective gear to avoid being burned or exposed to engine oil.

Check engine oil daily and after every 4 hours of operation. Machine must be setting level when checking oil. Refer to engine manual and maintenance schedule for oil recommendation and capacities.

IMPORTANT: Change the engine oil and filter after the

first 5 hours of operation and per the engine manufacturer’s rec ommendations after that. If mower is being operated in extremely dirty conditions, then it is recommended oil be changed more frequently. IMPORTANT: When removing the oil filter take precautions to minimize oil spillage on the exhaust system.

Draining the engine oil:

1. Locate the oil drain valve on the engine. Figure 4-6

2. Position a suitable oil drain container under the machine

below the oil drain valve.

3. Twist the valve counterclockwise to open the valve.

Allow 10 minutes for engine oil to adequately drain.

4. After oil is drained, close the valve by twisting it

clockwise.

5. Once the valve is closed, clean up any spilled oil.

605231 4-5 REV B

IMPORTANT: All oil drips or spill s must be cleaned off

Oil drain valve

Pre-cleaner

Canister

Dust cap

Safety filter

of the exhaust system before operating the machine.

Figure 4-6

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

A specially designed dry filter is standard equipment on these mowers and supplies clean combustion air to the engine. 4-7

These mowers are equipped with a safety filter. The filter element slides over the safety filter.

The safety element does not require servicing unless it becomes contaminated with dirt or moisture.

Figure 4-7

Recommended service procedure

1. Release clamps and remove element. Clean the canister

with a damp cloth.

2. Before installing a new element, inspect it by placing a

bright light inside and rotating the element slowly,

REV B 4-6 605231

Figure 4-8

looking for any holes or tears in the paper. Also check gaskets for cuts or tears. Do not attempt to use a damaged element which will allow abrasive particles to enter the engine.

3. Reinstall the dust cap. Make sure it seals all the way

Figure

around the air cleaner body, then tighten the clamps. Figure 4-7

4. Check all fittings and clamps periodically for tightness

and inspect hoses for holes or cracks.

5. Periodically check the intake hose for signs of ingested

dust. Locate and repair the source of ingested dirt.

6. Never operate the machine without an air filter installed.

Overservicing

Overservicing occurs when an air filter element is removed for cleaning or replacement before it is necessary. Each time the filter is removed a small amount of dirt and dust could fall in the intake system. This accumulated dirt can cause a dusted engine. It only takes a few grams of ingested dirt over the normal service life of an engine to cause a dusted engine.

Do not clean the element, but replace with a new element only. Cleaning used air filter elements, through improper

cleaning procedures, can get dust on the inside of the filter causing dirt ingestion and engine failure.

It is important to note that whenever an air filter element is cleaned by any method, the person or company performing the cleaning assumes responsibility for the integrity of the filter from then on. The warranty for air filters expires upon

cleaning or servicing in any manner because the condition of the filter after servicing is completely out of the filter manufacturer’s control. Ther efor e, on a dust ingested engine failure, there will be no warranty consideration if the air filter element has been cleaned or serviced in any manner.

A partially dirty air filter element works better than a new element. Therefore, a dirty filter element is not bad for the engine unless it is excessively restricting the air flow and engine performance is affected. The reason is simple. The media in the filter must be porous to allow air to pass through it. When dirty air passes through the filter, the dirt plugs some of the holes in the media and actually acts as part of the filter media. When the

next round of dirt enters, the first dirt helps filter out even

Fuel evaporation

system filter

WARNING

smaller particles making the filter more efficient at stopping dirt from entering the engine. This is referred to as barrier filtration.

Of course, at some point the filter media becomes too clogged

to allow air to pass.

The mowing conditions will determine the frequency of air

filter element changing.

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.

Fuel Evaporation System Filter

Some BigDog® Diablo® MP mowers have a fuel evaporation system filter. This filter must be checked and replaced every 500 hours or annually whichever comes first.

Figure 4-9

raveling of belt covering does not indicate failure, trim ravelings with a sharp knife.

If the pump belt fails, loss of control will occur especially when operating on a slope. If you lose steering control

while operating the machine, place the steering con trol levers in the park brake position immediately. Inspect the machine and involve your BigDog ers Dealer to resolve the problem before continuing to operate.

Inspect the belt pulley grooves and flanges for wear. A new 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 damage 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.

Mow-

Mower Blade Maintenance

Figure 4-9

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. Slight

Check the mower blades daily, they are the key to power efficiency and well groomed turf. Keep the blades sharp. A dull blade will tear rather than cut the grass, leaving a brown ragged top on the grass within a few hours. A dull blade also requires more power from the engine.

Replace any blade which is bent, cracked or broken.

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.

Never work with blades while engine is running or deck clutch switch is engaged (on). Always place deck clutch switch in the disengaged position, place steering control levers in the park brake position and turn engine off and disconnect negative battery cable. Block up mower when you must work under it. Wear gloves when handling blades. Always check for blade damage if mower strikes a rock, branch or other foreign object during mow ing!

605231 4-7 REV B

WARNING

Always wear adequate eye protection when grinding

WARNING

Resharpening

pattern

Do not sharpen to original pattern (below). It is

easier to get a straight cutting edge following

the resharpening pattern shown above.

Original edge

Warped Blade (Replace)

Straight Blade

Cutting

plane

Comparison of Warped and Straight Blades

Cutting edge

Twisted Blade Edge

(replace)

Cutting edgeCutting Plane

Straight Blade Edge

End view of blades, comparing

twisted and straightened blades

mower blades.

Mower Blade Removal

Use a 15/16” wrench to remove the 5/8” cap screw holding

the blade to the spindle shaft from underneath. NOTE: A blade holding tool (part number 381442) is available from BigDog Mowers. It is designed to prevent the blades from rotating when they are being removed or installed on the spindle. Contact your BigDog

(

commercial balancing tool is available through most hardware supply stores, or balancing can be done by placing the blade on an inverted line punch or 5/8” bolt. Blade should not lean or tilt. Spin the blade slowly, blade should not wobble. If blade is out of balance, true it up before reinstalling.

(

undercut threads. Torque bolts on spindles to 118 foot-pounds (160.0 N-m) when reinstalling blades.

compression load on the blades. Replace the cup washers if they are cracked or flattened.

ing upward toward the inside of the deck to ensure proper cutting.

installation to ensure blade tips do not touch each other or sides of the mower.

Mowers dealer for more information.

Sharpen the blades on a grinder following pattern as shown

Figure 4-10). Touch-up sharpening can be done with a file

Check the blades for balance following grinding. A

Lay the blade on a flat surface and check for distortion

Figure 4-11 & Figure 4-12). Replace any distorted blade.

Do not re-use spindle bolts which have stripped, worn or

Properly compressed cup washers maintain the correct

IMPORTANT: The blade sail (curved part) must be po int-

IMPORTANT: When mounting blades, rotate them after

Figure 4-10

Figure 4-11

Failure to correctly torque the bolt may result in the loss of the blade which can cause serious injury.

Mower blades are sharp and can cut. Wrap the blade(s) or wear gloves and use extra caution when servicing them.

REV B 4-8 605231

Figure 4-12

Seat Adjustment

The seat on the mower can be adjusted forward and rearward

by sliding the seat release handle and moving the seat until a

comfortable operating position is attained. Figure 4-13

Forward/rearward

travel lever

Upper

control

lever

Lower

control

lever

Nuts

Figure 4-13

Steering Control Lever Adjustment

The steering control levers can be adjusted for operator comfort. By loosening the nuts that attach the upper control lever to the lower lever ( can be pivoted to fit the operator’s personal preference.

Figure 4-14), the upper control lever

The steering control levers can also be adjusted up and down. Remove the cap screws and nuts and slide the upper control lever up or down and align the holes in it with the holes in the lower lever. Re-install the cap screws and nuts and tighten.

The steering control levers should be adjusted so that they align with each other when in the neutral position.

Figure 4-14

605231 4-9 REV B

Maintenance Schedule

Refer to Figure 4-15, Figure 4-16, & Figure 4-17

SERVICE AT

INTERVALS INDICATED

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 hours Check fuel level Prior to each use Blades - sharpen & securely fastened Prior to each use Discharge chute - securely in place & in lowest position Prior to each use Clean engine and pump compartment Daily Grease deck pusher arms X Grease pump idler X Grease deck height pivots X Grease front wheel bearings X Check battery connections X Check tire pressure with a gauge X Check hydraulic oil level X Clean engine exterior (A) X Check pump and deck belt tension and condition (5) X Check fuel system (6)(7) X Check hydraulic lines X Tighten lug nuts on wheels (2) X Change fuel filter (6) X Clean or replace hydraulic fill cap X Change hydraulic filter & oil (3) X Grease deck spindle housings X Check ROPS mounting hardware (8) X Replace fuel evaporation system filter (6)(7) X

WEEKLY

OR 40

HOURS

MONTHLY

OR 100 HOURS

ANNUALLY

OR 500

HOURS

NOTES:

1. Initial oil change is after 5 hours of operation. Thereafter, change oil after every 40 hours operation. Change more often under dusty or dirty conditions and dur-

ing hot weather periods.

2. Torque initially and after first 2 hours of operation.

3. Perform initial hydraulic oil and filter change after 50 hours (one week) of operation.

4. Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other maintenance items.

5. Pump drive belt only - Inspect every 100 hou rs and replace if worn or cracking is noticed. Otherwise, replace every 400 hours or 2 years whichever comes

first.

6. Chec k fuel system for any cracks or leaks inc luding but not limited to fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon canister and

grommets. Replace as needed.

7. More often under dusty or dirty conditions and during hot weather.

8. Inspect ROPS after the first 20 hours of operatio n and then after every 500 hours of operation or yearly whichever comes first.

REFERENCES:

A. Refer to Engine Owner’s Manual

NOTE: Refer to engine owner’s manual for engi ne service information. NOTE: After completing maintenance cycle (500 hours), repeat cycle.

REV B 4-10 605231

Maintenance Locator Chart

Figure 4-15

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. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tire

14. Pump Idler Zerk (1)

15. Pump Belt

16. Deck Pusher Arm Zerks (2)

17. Deck Belt

18. Spindle Housing Zerk (3)

19. Blades

20. Fuel evaporation system filter

21. Front Wheel Tires

605231 4-11 REV B

Figure 4-16

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. Engine Oil Filter

11. Deck Height Pivot Zerks (4)

12. Park Brake Switch

13. Drive Tire

14. Pump Idler Zerk (1)

15. Pump Belt

16. Deck Pusher Arm Zerks (2)

17. Deck Belt

18. Spindle Housing Zerk (3)

19. Blades

20. Fuel evaporation system filter

21. Front Wheel Tires

Figure 4-17

REV B 4-12 605231

TROUBLESHOOTING

The majority of operating problems that occur with a system can be traced to improper adjustments or delayed service. A consistently applied preventative maintenance program, as outlined in the Maintenance section of this manual, will prevent many problems. The following chart is designed to help you locate a problem by suggesting probable causes and the recommended solutions.

SYMPTOMS PROBABLE CAUSES

Steering control levers not in park brake position or switch not adjusted

Deck clutch switch

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

Loss of power or system will not operate in either direction

Air cooled engine overheating

engaged

Weak or dead battery Recharge or replace

Electrical connections are corroded or loose

For additional causes See engine manual

No fuel or line plugged Fill tank or replace line (See

Fuel valve is turned off Open the fuel valve

There is incorrect fuel in the fuel system

There is dirt in the fuel filter Replace the fuel filter

Dirt, water or stale fuel in the fuel system

The choke is not on Move the choke lever to

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

Hydraulic line blockage Contact your Dealer

Internal interference or leakage in wheel motor

Insufficient hydraulic oil supply

Poor compression Contact your Dealer

Steering linkage needs adjustment

Tow valve open Close tow valve

The traction drive belt is worn, loose or broken

Air in system Check filter and fittings

For additional causes See engine manual

Air intake screen or cleaning fins clogged

For additional causes See engine manual

SUGGESTED

REMEDIES

Place steering control levers in park brake position or re-adjust switch

Disengage clutch switch

Check the electrical connections

Fuel System section for more details)

Drain the tank and replace the fuel with the proper type

Contact your Dealer

Check level in reservoir

Have dealer check hydraulic pump

Adjust linkage

Install a new traction drive belt

Clean screen and fin

SYMPTOMS PROBABLE CAUSES

Low oil level Add oil

Low engine oil pressure

High oil consumption Numerous Contact your Dealer

Mower jerky when starting or operates in one direction only

Hydraulic system operates hot (oil in reservoir smells rancid)

Mower creeps when steering control levers are in neutral

Mower circles or v eers in one direction

Mower creeps when parking brake engaged

There is abnormal vibration

Blades do not rotate The deck drive belt is worn,

Oil diluted or too light Change oil and check for

Failed oil pump Contact your Dealer

Steering control linkage needs adjustment

Pump or wheel motors faulty

Tow valves not closed completely

Low hydraulic oil level Fill reservoir

Hydraulic pump faulty Contact your Dealer

Hydraulic oil cooler clogged Clean oil cooler core

Steering linkage needs adjustment

Wheel motors faulty Contact your Dealer

Tires improperly inflated Adjust air pressure to 8 - 12

Hydraulic pump faulty Contact your Dealer

Steering linkage out of adjustment

Brakes need adjustment Adjust parking brakes

The engine mounting bolts are loose

The engine pulley, idler pulley or blade pulley is loose

The engine is pulley is damaged

The cutting blade(s) is/are bent or unbalanced

A blade mounting bolt is loose

Spindle bearing is worn or loose

A blade spindle is bent Contact your Dealer

loose or broken

The deck drive belt is off the pulley

Electric clutch is not engaging

SUGGESTED

REMEDIES

source of contamination

Adjust linkage

Contact your Dealer

Close tow valves

Adjust linkage

psi (55-83 KPa)

Adjust steering linkage

Tighten the engine mounting bolts

Tighten the appropriate pulley

Contact your Dealer

Install new cutting blade(s)

Tighten the blade mounti ng bolt

Replace or tighten spindle bearing

Install a new deck drive belt

Install the deck drive belt and check for a reason

Check and/or replace 20 amp fuse. Contact your Dealer

605231 5-1 REV B

SYMPTOMS PROBABLE CAUSES

The blade(s) are not sharp Sharpen the blades

A cutting blade(s) is/are bent

The deck is not level Level the deck per the

Uneven cutting height

An anti-scalp wheel is not set correctly

The underside of the deck is dirty

Tires improperly inflated Adjust air pressure to 8 - 12

A blade spindle is bent Contact your Dealer

SUGGESTED

REMEDIES

Install new cutting blade(s)

Deck leveling and height adjustment section of the parts manual

Adjust the height of the anti-scalp wheel

Clean the underside of the deck

psi (55-83 KPa)

REV B 5-2 605231

STORAGE

WARNING

When storing the unit at the end of the mowing season, the mower, engine, and battery should have the following items serviced before storage.

If the mower has been stored for an extended period of time, follow the new season preparation steps before beginning operation.

General Mower Preparation For Storage

1. Remove all grass, dirt, and trash from mower and cutting

units. IMPORTANT: Wash the machine with a mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel and engine. Clean mower and deck and touch up all scrapes with touch-up paint.

2. Replace air filter element.

3. Check thoroughly for any worn or damaged parts that

need replacing and order them from your dealer.

4. Thoroughly lubricate machine, according to the

Maintenance section.

5. Block mower up so weight is off tires. Check tire

pressure and inflate to proper operating pressure. NOTE: Do not deflate tires.

6. Perform separate engine and battery preparation as listed

below.

7. Store mower in a clean, dry place.

Preparation Of Engine For Storage

When the engine is to be unused for long periods, proceed as follows:

1. Run the engine for a minimum of 15 minutes.

2. Drain the oil from the crankcase while the engine is still

warm.

3. Refill with fresh oil of the proper viscosity.

4. Drain the fuel tank and run the engine until it stops from

lack of fuel. Gasoline evaporates if left in the carburetor for long periods, forming gum and varnish deposits in the carburetor. These deposits will cause engine flooding and loss the previous 100 hours.

5. Remove the spark plugs and pour a tablespoon of engine

oil into each spark plug hole. Install plugs, but do not reconnect plug leads.

6. Crank the engine with the starter at least a dozen

revolutions to distribute oil over the cylinder walls and valve mechanism.

7. Clean the exterior surface of the engine. Spread a light

film of oil over any exposed metal surfaces of the engine that are subject to corrosion.

8. Clean dirt and chaff from the cylinders and fins, blower

housing and muffler.

9. Check the oil filler cap and fuel tank caps to make certain

they are securely in place.

10. Refer to the engine manual for more information.

Preparation Of Battery For Storage

When the machine is to be unused for long periods, it is best to disconnect the battery and remove it from the unit. At this time perform the following battery maintenance:

1. Remove the battery from machine.

2. Clean the battery, terminals, and cable connectors.

3. Charge the battery, if necessary.

4. Store the battery in a cool, dry place (do not expose to

freezing temperatures).

5. Always keep the battery fully charged. Especially

important to prevent battery damage when the temperature is below 32°F (0°C).

New Season Preparation

Before starting the mower following post season storage, the following service is required:

1. Clean mower, removing trash and dirt accumulation.

2. Check engine oil and hydraulic oil levels.

3. Fill fuel tanks with fresh fuel. Run machine at half speed

for 5 minutes, checking operation of steering control lever. Stop engine and check for oil leaks, lo ose fittings and so forth.

At start of new season always check that fresh oil has been added to machine. If oil is drained at season’s end and not replaced, engine damage will result.

4. Tighten any bolts that have loosened and make sure all

hair pins, cotter pins and clevis pins are in place.

5. Install all safety shields and review safety precautions

listed in this manual.

6. Check and inflate tires to 8-12 psi (55-83 KPa).

7. Install fully charged battery and attach the battery cables.

8. Refer to engine manual for more information.

605231 6-1 REV B

PRODUCT LITERATURE

If you would like to view or print a copy of the BigDog® Mowers Diablo® MP product manuals (Operator’s Manual, General

Service Manual, or Parts Manual) go online to www.bigdogmowers.com.

Contact your local BigDog® Mowers dealer if you require another engine owner’s manual.

REV B 6-2 605231

INDEX

PAGE PAGE

Air flow baffles .......................................................3-12

Anti-scalp wheels Belts

.........................................................................4-7

Control Panel Controls

...................................................................3-4

Deck clutch operation Deck cutting height adjustment Driving the mower Electrical system Engine air filter Engine oil & filter Engine starting Fuel and evaporative emissions control system Fuel evaporation system filter General engine maintenance

..................................................3-13

...........................................................3-4

...........................................3-11

............................3-12

...................................................3-8

.....................................................4-2

........................................................4-6

.....................................................4-5

........................................................3-5

...4-3

................................4-7

.................................4-7

New season preparation Operating suggestions Parts and service

................................................... 1-1

Possible damage to ROPS Preparation of battery for storage Preparation of engine for storage ROPS

...................................................................... 3-6

ROPS Inspection

.................................................... 3-7

Safe Operating Practices Safe Operation

....................................................... 3-1

Safe servicing practices Safety and Instruction Decals Safety start interlock system Seat adjustment

..................................................... 4-8

Seat belt maintenance

........................................ 6-1

......................................... 3-10

.................................... 3-7

......................... 6-1

.........................6-1

.......................................3-1

.........................................4-1

............................... 2-1

.................................3-5

...........................................3-7

General mower preparation for storage Hydraulic oil heat exchanger Hydraulic system Lights

.......................................................................3-5

Lubrication

.....................................................4-3

...............................................................4-2

Maintenance Locator Chart Maintenance Schedule Model and serial number Moving mower with stalled engine Mower blade maintenance Mower blade removal Mower operation

.............................................4-8

.....................................................3-8

..................................4-3

.........................4-11, 4-12

.........................................4-10

........................................1-1

.........................3-6

.....................................4-7

................6-1

Service introduction Service precautions Slope guide

............................................................. 2-7

Slope Operation Steering control lever adjustment Stopping the engine Tires

........................................................................4-2

To the new owner Torque values Using a Ramp Using this manual Warranty registration

............................................... 4-1

..................................................... 3-2

.........................4-9

...............................................3-6

................................................... 1-1

......................................................... 4-2

......................................................... 3-2

................................................... 1-1

.............................................1-1

605231 i-1 REV A

BigDog Diablo MP Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual