BigDog Mower Hike Operator's Manual

BIGDOG® MOWER CO. HIKE

Operator’s Manual

122790 REV A

200 South Ridge Road

Hesston, Kansas

67062

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.

WARNINGWARNING

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 A 122790

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

Safe Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Safety and Instructions Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

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

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

Safety Start Interlock System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Stopping the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cold Weather Pump Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Moving the Mower with Stalled Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Deck Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Anti-scalp Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Stand-up Sulkies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

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

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

Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuel and Evaporative Emissions Control System. . . . . . . . . . . . . . . . . . 4-2

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

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

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

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

122790 toc-1 REV A

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

Mower Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

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

Product Literature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

REV A toc-2 122790

GENERAL INFORMATION

This manual applies to the following BigDog® Mowers prod-

uct lines:

Big Dog® Hike

To the New Owner

Big Dog® mower owners and operators must read this man­ual carefully. It contains operation and maintenance informa­tion that will help you achieve years of dependable service.

The Engine Owner’s Manual, included in the owner’s
packet, contains engine information that will not be repeated
in this manual.

The owner’s responsibilities include, but are not limited to,
making certain that the operators and mechanics:

• read and understand the engine owner’s manual
before attempting to operate or repair the engine.

• read and understand the mower’s operator manual and
all decals before operating this machine.

• are qualified and physically able individuals, properly
trained in the operation and maintenance of this
equipment. Before they are allowed to operate or
maintain this machine, they must be familiar with its
safe operation, operator controls, and decals.

• know 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.

• who cannot read and understand English have this
material explained to them.

IMPORTANT: As the owner/operator you can prevent acci­dents. You are responsible for accidents or injuries occurring
to yourself, 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 obtain this manual.

Using this Manual

This manual contains general operation information as
well as basic adjustment and maintenance information.
Since operating conditions vary considerably, all conditions
cannot be addressed individually. Through training and ex pe­rience, operators should develop safe operating practices
suitable to most conditions.

Directions used in this manual, for example RIGHT or LEFT,
refer to directions when in the operator position and facing
forward, unless otherwise stated.

Though current at the time of printing, photographs and
illustrations shown may vary slightly from your mower due to
subsequent production changes. Big Dog

®

Mower Company
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 manual,
contact your Big Dog

®

Mower Dealer for current information.

Warranty Registration

To activate your warranty policy the mower must be regis-

tered, by your Dealer, with the Manufacturer of Big Dog

®

mowers within ten (10) days following the date of purchase.
It is recommended that you contact your Dealer to make sure
the mower is registered.

IMPORTANT: The mower and any attachment that dis­plays a model and serial identification number plate must be
registered with Excel Industries, Inc., manufacturer of Big

®

Dog

mowers (“Manufacturer”).

IMPORTANT: Any unauthorized modification, alteration,
or use of non-approved attachments voids the warranty and
releases Manufacturer from any liability arising from sub se­quent use of this equipment. Do not use or operate any
attachment not approved by Big Dog

®

Mower Company.

IMPORTANT: Damage caused by unauthorized replace­ment parts is not covered by this warranty. Manufacturer
expressly excludes liability for defects or damage caused by
such 'unauthorized' articles or service.

Model and Serial Number

Mower model and serial numbers are found on the serial
identification plate, located on the left side of the frame
directly below the console support and behind the tire.

These numbers are required when the unit is registered
with BigDog

rect service parts when replacement bec omes necessa ry.

®

Mowers. They will also assure you of the cor-

Parts and Service

Use original Big Dog® Mower replacement parts, or parts
that are equivalent in overall performance, that are available
from your local Big Dog
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 arrangements for warranty repair and service must be
handled through an authorized Big Dog

®

Mower Dealer. For prompt, efficient

®

Mower Dealer.

122790 1-1 REV A

REV A 1-2 122790

SAFETY PRECAUTIONS

DANGER

WARNING

Incorrect usage of this equipment may result in severe injury.
Personnel operating and maintaining it should be trained in its
proper use. They should read this man ual completely and thor ­oughly before attempting to set-up, oper ate, adjust, or service
this equipment.

Safe Operating Practices

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.

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

This manual uses two other words to highlight information:

A. IMPORTANT – calls attention to special mechanical

information.

B. NOTE – emphasizes general information worthy of

special attention.

The owner’s responsibilities include, but are not limited to,

• making certain that the operators and mechanics read
and understand this manual and all decals before
operating this machine.

• making certain that before the operators and mechan­ics are allowed to operate or maintain this machine,
they must be familiar with its safe operation, operator
controls, and decals.

• ensuring that the operators and mechanics know 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.

Improper use, adjustment, or maintenance by the operator,
mechanic or owner can result in injury. Reduce the potential
for injuries by following these safety instructions. Pay close
attention to the safety alert symbol “” and the instructions
that follow it. Failure to comply with these instructions may

result in personal injury or death.

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

 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.

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.

• Do not use any unauthorized attachment or mod­ify the mower.

• 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 sudden
movement of the PowerBar handle could cause
the front of mower to come off of the ground
resulting in possible loss of control and ser ious
injury.

• The use of any other manufacturer’s attach­ments, including stand-up sulkies, increases the
risk of operator injury, therefore, extreme caution
must be exercised when using these devises.

 Always be alert and inspect area to be mowed for haz-

ards such as rocks, metal objects and other debris
which may be thrown or entangled by mower blades.
Remove these objects before mowing. Watch out for
holes or deep depressions.

 Always operate mower in daylight or with adequate

working lights.

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

ning.

Personal Safety

 Always wear long pants and safety shoes with slip-

resistant soles when operating this mower.

• Do not wear sandals, tennis shoes, sneakers,
shorts or any type of loose fitting clothing as they
may get tangled in moving parts.

• Do not wear a towel from the waist, or use a towel
as a headband or neck wrap.

122790 2-1 REV A

• Long hair or jewelry may get tangled in moving
parts.

 Always wear adequate ear protection, such as ear-

plugs. Prolonged exposure to loud noise can cause
impairment or loss of hearing.

• Do not wear radios or music headphones while
operating this mower. Safe operation requires
your full attention.

 Always wear safety goggles or safety glasses with side

shields when operating this mower.

 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 peri-

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

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

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

Operation

 If you lose steering control while operating the machine,

place the neutral lock/park brake lever in the park brake
position immediately. Inspect the machine and involve
your Big Dog
before continuing to operate.

 Never leave a running mower unattended for any rea-

son including emptying the catcher or unclogging the
discharge chute:

• Always stop on level ground.

• Disengage the deck clutch.

• Place the PowerBar steering in the neutral posi-

tion.

• Move the neutral lock/park brake lever to the
park brake position.

• Stop the engine.

• Remove the ignition key.

• Wait for the engine and all moving parts to come

to a complete stop.

 Always inspect mower for damage after striking a for-

eign object. If damage is found, repair mower immedi­ately.

 Turn off the mower blades when not mowing.
 Always keep safety shields and covers in place, except

for servicing.

 Never operate the mower deck with the discharge

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

®

Mower dealer to resolve the problem

 Always keep clear of the mower blades and attach-

ments during their operation.

• Never put hands or feet under any part of the
mower while it is running.

 Stop the engine before removing the grass catcher or

unclogging the discharge chute. Never clear the dis­charge chute with the engine running. Disconnect the
spark plug wires from the spark plugs before cleaning,
being careful not to touch the hot engine or muffler.
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!

 Follow daily and weekly checklists, making sure hoses

are tightly secured and bolts are tightened.

 Clean flammable material from mower. Prevent fires by

keeping the engine compartment, top of the deck,
exhaust area, battery (if applicable), fuel line, fuel tank
and operator’s station clean of accumu lated 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.

• Allow the mower, especially the engine, to cool

before storing inside a building.

• Never cover the machine with a tarp or cover of
some type until the engine and muffler have
cooled.

 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.

 When traveling in reverse, rotate handle forward gently

and avoid sudden movement. Rapid movement of the
handle in either direction could result in a reaction of
the mower that can cause serious injury.

• Never rotate forward suddenly on PowerBar han­dle while the machine is in rearward motion.

 Always be aware of what is behind the machine before

backing up.

 Slow down before turning.
 Never attempt high speed maneuvering, especially in

crowded or congested areas.

 Always maintain a safe distance from people and pets

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

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

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

 Always observe traffic laws while driving mower from

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

REV A 2-2 122790

• Use care when approaching blind corners,
shrubs, trees, or other objects that may obscure
your vision.

Using A Ramp

 Exercise 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 ac ci­dents, 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 machine could slip or
tip.

• Do not operate the BigDog
slopes when using a stand-up sulky.

• Turn slowly.

 To check a slope, attempt to back up it. If the unit can

back up the slope without the operator and drive
wheels slipping, reduce ground speed and proceed
with caution.

 Always be sure of your footing. Keep a firm hold on the

PowerBar handle and walk - never run.

 Block or chock the machine when parked on a slope or

when trailering.

 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 slope. If tires lose

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

 Never operate the machine on a slope from a position

below the mower.

 Do not mow on wet grass. Slippery conditions reduce

traction which could cause sliding and loss of control.

®

Hike mower on

 Avoid starting and stopping on a slope. If tires lose

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

 The Big Dog

®

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 slowly, 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.

Terrain conditions can affect traction resulting in pos­sible loss of control of the mower. Some of the condi­tions to be aware of are:

• Wet terrain

• Depressions in the ground; i.e. holes, ruts, wash-

outs

• Mounds of dirt

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

• Grass type, density, and height

• Extremely dry conditions of grass

• Tire pressure

Any attachments mounted to the mower will also
affect the way it handles on a slope. Be aware that
each attachment’s characteristic s 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:

• Water; i.e. lake, river

• Cliffs, retaining walls

• Roads, highways

• Buildings

• 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 remember to always exercise extreme caution
when operating on any slope.

Children

Tragic accidents can occur if the operator is not alert to the
presence of children. Children are of ten attracted to the mower
and the mowing activity. Never assume that children will remain
where you last saw them.

122790 2-3 REV A

 Never leave the mower unattended with the ignition

key in the switch, especially with children present.

 Children or bystanders may be injured if they attempt

to move or to operate the mower while it is unat­tended.

• Always stop on level ground.

• Disengage the deck clutch.

• Place the PowerBar steering in the neutral posi-

tion.

• Move the neutral lock/park brake lever to the
park brake position.

• Stop the engine.

• Remove the ignition key.

• Wait for the engine and all moving parts to come

to a complete stop.

 Keep children out of the mowing area and under the

watchful care of a responsible adult other than the
operator.

 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.

Service Precautions

 Unless specifically required, DO NOT have the engine

running when servicing or making adjustments to the
mower.

• Park the mower on level ground.

• Disengage the deck clutch.

• Place the PowerBar steering in neutral.

• Place the neutral lock/park brake lever in park

brake position,

• Lower the deck.

• Stop the engine.

• Remove the ignition key.

• Remove the spark plug wires from the spark

plugs, or, if applicable, disconnect the negative
battery cable.

• Wait for all movement to stop before adjusting,
cleaning or repairing.

• Repairs or maintenance requiring engine power
should be performed by trained maintenance per­sonnel only.

• To prevent carbon monoxide poisoning, operate
the engine in a well ventilated area only.

• Read and observe all safety warnings in this man­ual.

 Before working on or under the deck, make certain the

engine cannot be accidentally started.

 Except when changing or checking belt, always keep

belt covers on mower deck for safety as well as for
cleanliness except when changing or checking the
belt.

 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.

 Always wear adequate eye protection when:

• servicing the hydraulic system.

• servicing the battery.

• grinding mower blades and removing accumu-

lated debris.

 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 appropri­ate 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 jack

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. Be careful of hot

muffler. Allow engine to cool before servicing.

 Keep nuts and bolts tight, especially the blade attach-

ment bolts. Keep equipment in good working condi­tion.

 Never tamper with safety devices. Check their proper

operation regularly.

 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
recommended parts, when necessary.

REV A 2-4 122790

 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 original Big Dog

®

Mower replacement parts, or
parts that are equivalent in overall performance, that
are available from your local Big Dog

®

Mower Dealer.

• The mower may not comply with the appropriate

safety standards if aftermarket parts, accesso­ries, or attachments are used.

Mower Blade Maintenance Precautions

 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 wear adequate eye protection when grinding

mower blades.

 Mower blades are sharp and can cut. Wrap the

blade(s) or wear gloves and use extra caution when
servicing them.

Battery Service Precautions

 Battery posts, terminals, and related accessories con-

tain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive
harm. Wash hands after handling.

 Charge batteries in a well-ventilated open area, away

from sparks and flames. Unplug charger before connect­ing 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 a 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
explosion if exposed to flame. Always disconnect
the negative (black) battery cable(s) before dis­connecting the positive (red) cable(s). Always
connect the positive (red) battery cable(s) befor e
connecting the negative (black) cable(s).

• Do not overfill the battery.

• Electrolyte may overflow and damage paint, wir-

ing or structure. When cleaning the battery, use
soap and water. Be careful not to get soap and
water into the battery. Clean the battery termi-

nals with a solution of four parts water and one
part baking soda when they become corroded.

 Shorts caused by battery terminals or metal tools

touching metal mower components can cause sparks.
Sparks can cause a battery gas explosion which will
result in personal 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

the mower and battery cables. This can cause sparks
which can cause a battery gas explosion which will
result in personal 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).

Fuel Handling Precautions

 To avoid personal injury or property damage, use

extreme care when handling gasoline. Gasoline is
extremely flammable and th e vapors are explosive.

• A fire or explosion from gasoline can burn you

and others and can damage property.

 Observe the usual gasoline 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 gasoline

spills.

• If gasoline is spilled, do not attempt to start the
engine but move the machine away from the area
of spillage and avoid creating any source of igni­tion until gasoline vapors have dissipated.

• Keep gasoline 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.

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

• Never attempt to start the engine when there is a
strong odor of gasoline fumes present. Locate
and correct the cause.

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

• 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 gasoline contain­ers on the ground away from your vehicle before
filling.

122790 2-5 REV A

• When practical, remove the machine from the

WARNING

M

A

X

O

F

1

0

%

E

T

H

A

N

O

L

I

N

F

U

E

L

I

G

H

E

R

T

H

A

N

E

1

0

F

U

E

L

V

O

I

D

S

W

A

R

R

A

N

T

Y

H

601931

601967

601796

truck or trailer and refuel the machine with its
wheels on the ground. If this is not possible , then
refuel such machine 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.

 Gasoline is harmful or fatal if swallowed.
 Avoid prolonged breathing of vapors.

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

 Keep gasoline away from eyes and skin.

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

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

Safety and Instructions Decals

The decals are designed to give the operator and mechanic
brief daily operational and service information. Use these
decals as an extension of this manual. Do not remove or
obliterate the decals. Replace unreadable or missing decals.

It is the owner’s responsibility to make certain that the
operators and mechanics read and understand all decals
before operating 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 601931

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 entangled
by mower blades. Remove these objects
before mowing.

Specific safety warning decals are located on the
equipment near the immediate areas of potential
hazards. Do not remove or obliterate these decals.
Replace them if they become non-readable.

The following illustrations show the safety decals that are
located on the mower. A brief explanation is shown to help
the operator understand the decal’s meaning.

• Read Operator’s Manual and Safety Warning Decals before

attempting to operate this machine.

REV A 2-6 122790

WARNING: Fire!

Part Number 601967

WARNING:
Thrown objects

Part Number 601796

• Clean flammable material from

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

• 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 602041

602041

601787

Part Number 601787

DANGER:

Rotating blades, pulleys & belts!

601815

• 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.

• Avoid skin con-

tact with battery
acid

• Do not allow open flame near the

battery 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.

WARNING:

Hot surface!

• Keep a safe distance from the machine.

• Keep shields and covers in place while machine is in operation

• Keep hands, feet and clothing away from rotating pulleys, belts and

blades.

DANGER: Battery Hazards!

Part Number 601815

122790 2-7 REV A

601935

B

A

B

M

D

F

E

J

I

H

C

L

K

O

Part Number 601935
(electric start)

• Go across slopes, not up and

down.

• Never operate the machine on a

slope from a position below the
mower.

• Before and while backing, look

behind and down for small children
and obstacles.

WARNING: Falling!

N

G

A. Fast
B. Slow
C. Choke
D. Mower blade engage/disengage switch

E. Ignition switch - insert key

F. OFF
G. ON
H. Neutral lock lever locked/park brake engaged

I. Wear ear protection, eye protection and safety shoes with

slip resistant soles when operating this equipment.

J. Read Operator’s Manual before attempting to operate this

machine. Read Operator’s Manual before attempting to
service this machine.

K. Before starting the engine:

• Read Operator’s Manual

• Disengage mower blades

• Place neutral lock lever in locked position

L. Disconnect spark plug before servicing

M. Neutral lock lever unlocked

N. Engine start position

O. If warning light comes on, check engine oil

REV A 2-8 122790

A

B

M

D

F

G

E

J

I

H

C

L

K

WARNING: Falling!

• Go across slopes, not up and

down.

• Never operate the machine on a

slope from a position below the
mower.

• Before and while backing, look

behind and down for small children
and obstacles.

Part Number 601934
(recoil start)

601934

B 601934

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

G. ON

H. Neutral lock lever locked/park brake engaged

I. Wear ear protection, eye protection and safety shoes with

slip resistant soles when operating this equipment.

J. Read Operator’s Manual before attempting to operate this

machine. Read Operator’s Manual before attempting to
service this machine.

K. Before starting the engine:

• Read Operator’s Manual

• Disengage mower blades

• Place neutral lock lever in locked position

L. Disconnect spark plug before servicing

M. Neutral lock lever unlocked

122790 2-9 REV A

REV A 2-10 122790

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 es timation of the gr ound 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.

122790 2-11 REV A

REV A 2-12 122790

OPERATION

D

C

F

E

A

B

D

C

F

G

E

A

B

H

I

H

Safe Operating Practices

Refer to the Safety section of this manual for detailed opera­tional and personal safety information.

Control Panel

Recoil start mowers

A. Deck clutch switch
B. Ignition switch
C. Throttle
D. Choke

Electric start mowers

A. Deck clutch switch
B. Ignition switch
C. Throttle
D. Choke

A. Deck clutch switch (Figure 1-1 & Figure 1-2) — this

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

For additional clutch information refer to the Mower
Deck Operation section of this manual.

E. Hour meter
F. Neutral lock/park brake

lever

Figure 3-1

E. Hour meter
F. Neutral lock/park brake

lever

G. Oil pressure light

Figure 3-2

H. Operator presence control levers
I. PowerBar handle

Figure 3-3

B. Ignition switch (Figure 1-1 & Figure 1-2) —

(Recoil start) a two position switch: off and run. With

key inserted, rotate it cl ockwise t o RUN pos ition.
(Electric start) a three position switch: “OFF”, “RUN”,

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

C. Throttle control (Figur e 1-1 & Figure 1-2) — a cable is

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

D. Choke control (Figure 1-1 & Figure 1-2) — a cable is

linked to manually operate the engine choke. When the
lever is in the down position, the choke is in the “OFF”
(run) position. When the knob is pulled up, the choke is
in the “ON” (start) position. Do not operate the machine
in the “ON” (start) position.

E. Electronic hour meter (Figure 1-1 & Figure 1-2) — regis-

ters 1/10 hour increments up to 9,999.9 total hours. It
is connected to the ignition switch. It records the
accumulative time while the ignition key is switched to
the “RUN” position.

F. Neutral lock/park brake lever (Figure 1-1 & Figure 1-2)

— when this lever is in the neutral lock/park brake
position, the transaxles are in neutral and the unit will
not move.

Moving the lever out of the neutral lock/park brake
position and forward engages the transaxles and
allows the PowerBar handle to be rotated.

G. Oil pressure light (Figure 1-2) — 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 pressure is developed. If the light comes on during
operation, shut the engine off immediately and locate
and correct the problem.

H. Operator presence control levers (Figure 1-3) —

engages the operator presence switches. If the switch

122790 3-1 REV A

is not engaged the unit will not operate. Refer to the

A

WARNING

Safety Interlock system for more information.

I. Powe r B ar han dle (Figure 1-3)

unit’s acceleration, speed, steering direction and
dynamic braking.

– this handle controls the

Controls

A. Deck lift lever (Figure 3-4) — the deck lift lever is used

to raise or lower the deck. Pull rearward on th e lever to
raise the deck and then place the deck height locking
pin into the desired cutting height hole.

Pull the deck lift lever to raise the deck when going
over obstructions.

one operator presence control lever is released, the unit will
continue to operate.

IMPORTANT: Repair this important safety feature immedi-

ately if it malfunctions.

This safety feature prevents mower runaway or accidental

entanglement during operation.

Check the mower’s safety start interlock system daily,

prior to operation.

To inspect the system:

1. Place the PowerBar lever in the neutral position,

2. Move neutral lock/park brake lever to the park brake

position.

3. Move deck clutch switch to the disengaged (down)
position.

4. Start the engine and allow it to warm up to operating
temperature.

5. With the neutral lock/park brake lever in the unlocked
position (Figure 1-2) and/or the deck clutch switch
engaged (up position), slowly release both operator
presence control levers. The engine should stop.

6. Place the neutral lock/park brake lever in the park
brake (locked) position (Figure 1-1) and the deck
clutch switch disengaged (down) position. The engine

should continue to run without the operator presence
control switches engaged.

7. If the engine fails to stop when:

• the deck clutch switch is up, or

• the neutral lock/park brake lever is unlocked, and

• both operator presence control levers are

released, then

• check the function of the operator presence con-

trol switches. If these switches are not operating
properly (are not opening or closing) and if the
cause can not be determined, contact your Big

®

Dog

Mower Dealer.

A. Deck lift lever

Figure 3-4

Safety Start Interlock System

The mower’s safety start interlock system consists of the
neutral lock switch, operator presence control switches, and
deck clutch switch.

The machine incorporates two operator presence control
switches which will stop the mower engine when the opera­tor releases both of the operator presence control levers for
any reason while the mower is operating. However, if only

REV A 3-2 122790

The safety interlock system should always func­tion per steps 5 and 6. If it does not function prop­erly, correct it immediately. Do not operate
machine without properly functioning operator
presence control switches.

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
will not engage until:

1. Neutral lock/park brake lever is in the park brake posi­tion.

Neutral lock/park brake lever in the locked position

A

A

WARNING

WARNING

neutral lock lever is unlocked or the deck clutch switch is
engaged (up position), the engine will stop.

On recoil start units only, the operator presence
lever/switches should never be engaged when
starting the unit. When the operator presence
switches are engaged, they override the neutral
lock lever and the deck clutch interlock system.
Severe personal injury could result when starting
the unit if the operator presence switches are
engaged.

A. Neutral lock/park brak e lever

Figure 3-5

Neutral lock/park brake lever in the unlocked position

A. Neutral lock/park brak e lever

Figure 3-6

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

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 machine is equipped with operator presence
control switches. If for any reason the operator should
release both of the operator presence control levers when the

Start the engine by following these steps. If you encounter

difficulty, contact your Big Dog

®

Mower Dealer.

1. Make sure the neutral lock/park brake lever is in the
locked position and deck clutch switch is disengaged
(down position).

2. Use the choke when the engine is cold, or if a warm
engine fails to start within 5 seconds of cranking.
Avoid flooding by operating the engine without chok­ing as soon as possible.

NOTE: If the ambient temperature is below 50°F (10°C),

disengage the cold weather pump clutch before attempt­ing to start the engine. Refer to the Cold weather pump
clutch section for more information.

3. Set the throttle at approximately the 1/2 open posi­tion.

4. Recoil start mowers only - Insert key in ignition switch
and rotate full clockwise. Pull engine recoil start rope.

Electric start mowers only - 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 then 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 burn-out.

5. 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.

6. Perform the test shown in the Safety Start Interlock Sy s-
tem section to make sure the safety start interlock sys-

tem operates properly.

7. Allow the engine to idle two minutes before advancing
the throttle and/or engaging the deck clutch. Press
operator’s presence control levers and rotate the Pow­erBar slowly forward.

Stopping the Engine

Use the following procedure to shut the engine off.

1. Place the PowerBar handle in the neutral position.

2. Place the neutral lock/park brake lever in the locked

position.

122790 3-3 REV A

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

WARNING

A

B

Spring Extension

5.4” – 6.4” (137mm – 163mm)

B

A

the deck clutch. Refer to the Mower Deck Operation sec­tion for more details.

4. Let the engine run at low idle for two minutes.

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

position. Remove the key from the switch before leav­ing the mower.

Never leave the machine unattended with key in
ignition switch.

Cold Weather Pump Clutch

This mower is equipped with a pump clutch that disen­gages the pump clutch belt. When the belt is disengaged, the
engine will start easier in colder temperatures.

To disengage the pump clutch, pull the chain until the ten­sion is released from the pump drive belt and latch in the
slot. Figure 3-7

To engage the pump clutch, with PowerBar locked in neu­tral, release the chain from the latching slot.

NOTE: When engaged the spring should be extended to a

dimension of 5.4” – 6.4” (137mm – 163mm). Figure 3-8

IMPORTANT: Never operate the unit with the pump clutch
partially engaged. Make sure the clutch is completely
released and the chain has slack.

Figure 3-8

Moving the Mower with Stalled Engine

If it becomes necessary to move the unit when the engine
is inoperative, the transaxles are equipped with bypass
valves. Before moving the unit, pull out on the bypass valve
rods and slide them into the slot to lock in position.
Figure 3-9

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 unit must be tied
down to the transporting vehicle.

IMPORTANT: Always make certain the two bypass valves
are returned to their operating position before running the
unit following repairs.

Right transaxle shown

A. Chain B. Slot

Figure 3-7

REV A 3-4 122790

A. Bypass v alve rod (s hown in oper ating position)
B. Slot

Figure 3-9

Mower Operation

DANGER

PowerBar Steering

FRONT OF UNIT FACES THIS DIRECTION

DANGER

WARNING

WARNING

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 PowerBar handle in either direc­tion could result in a reaction of the mower that
can cause serious injury.

After starting engine, place the neutral lock/park brake

lever in the unlocked position and steer as follows:

To go forward, rotate the PowerBar handle forward.

Figure 3-10

To go in reverse, rotate the PowerBar handle to the ne utral
position. After achieving neutral, rotate lever rearward.
Figure 3-10

To turn left, rotate the PowerBar handle to the left and out

of the neutral position. Figure 3-10

To turn right, rotate the PowerBar handle to the right and

out of the neutral position. Figure 3-10

Zero radius turn, rotate the PowerBar handle the direction
desired with the handle in the neutral position. This will allow
the drive wheels to counter-rotate. Figure 3-10

To stop or decrease speed, move the PowerBar handle to
neutral. When going forward rotate handle rearward gently.
When going in reverse rotate handle forward. (Figure 3-10)
When traveling in reverse rotate handle rearward gently and
avoid sudden movement. Any sudden movement could cause
the front of the mower to come off of the ground resulting in
possible loss of control.

To increase speed, rotate the PowerBar handle’s distance
further from neutral. The farther the PowerBar handle is
rotated forward from neutral, the faster the unit will travel
forward. The farther the PowerBar handle is rotated rearward
from neutral, the faster the unit will go in reverse.

Operating Suggestions

An inexperienced operator should not mow on
slopes or on uneven terrain.

Before attempting normal speed operation an inex­perienced operator should:

• be thoroughly familiar with the proper use
and operation of the equipment.

• read the manual completely and thoroughly.

• have attempted slow moving maneuvers.

If you lose steering control while operating the
machine, place the neutral lock/park brake lever in
the park brake position immediately. Inspect the
machine and involve your Big Dog
to resolve the problem before continuing to oper­ate.

122790 3-5 REV A

®

Mower dealer

Figure 3-10

The unit’s PowerBar handle is 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.

Inexperienced operators may have a tendency to oversteer
and lose control. Practice slow maneuvers at low engine rpm
(idle) on a flat open area before attempting normal speed
operation.

WARNING

DANGER

WARNING

A

DANGER

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, especially when mowing.

Set the throttle at full rpm for maximum performance. This
gives maximum power to the drive wheels and deck when
needed. The throttle setting directly controls blade speed.
Use the PowerBar handle to control ground speed rather than
engine rpm.

When operating the BigDog

®

Hike mower on slopes, the
operator should mow traversing the slope. The operator
should stay more on the uphill side of the unit when mowing.

Keep blades sharp. 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. Blade sharpness

should be checked daily.

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 is
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.

• Never operate the mower deck with the dis­charge chute damaged, altered, removed, or
in the raised position, except when the entire
grass catcher attachment or mulching sys­tem is being used. Figure 3-11

Discharge chute may vary from this illustration

Never work with blades while the engine is running
or deck clutch switch is engaged (on).

Always place the deck clutch switch in the disen­gaged position, place the neutral lock/park brake
lever in the park brake position, turn the engine off
and disconnect the negative battery cable.

Block the mower up 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 mowing!

Direct grass discharge to the right, away from the
unmowed area. Generally, this means using a pattern of left
turns. Avoid throwing grass discharge onto unmowed area.
Mowing clippings 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
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.

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

A. Discha rge chute

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 the deck
housing. Fingers and toes can be cut off instantly.

REV A 3-6 122790

Deck Clutch Operation

WARNING

A

B

A

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 Big Dog

Follow these procedures to maximize clutch life.

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.

®

Mower Dealer.

Move the deck lift lever to the transport position slot when

the unit is in the transport mode. Figure 3-13.

A. Height adjus ting stop B. Heigh t adjusting bar

Figure 3-12

Deck Cutting Height Adjustment

Deck height is adjustable in 1/4” (6.4 mm) increments.

Figure 3-12

To adjust the cutting height, pull rearward on the deck lift
lever to raise the deck and then place the height adjusting
stop into the desired cutting height hole. Slowly release the
deck lift lever until the height adjusting stop is resting
against the bracket.

122790 3-7 REV A

A. Deck lift lever

Figure 3-13

Anti-scalp Wheels

A

B

Anti-scalp wheels are standard on some BigDog® Hike

mowers. These anti-scalp wheels are designed to minimize
scalping when mowing on rough, uneven terrain.

After setting the cutting height, adjust the 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 wheel position can be adjusted up or down
as needed from 3/4” to 1-3/4” (19.05 mm to 44.45 mm) below
the blade surface. Move the wheels up or down, in 1/2”
(12.70 mm) increments, using the different axle mount holes
in the wheel mount bracket. Figure 3-14

When adjusting the rear anti-scalp wheels, the wheel

should be in the same axle mount hole as the front anti-scalp
wheels.

Stand-up Sulkies

A. Adjusting hole B. An ti-scal p wheel

Figure 3-14

BigDog® Mowers does not warrant or accept liability for the

use of any attachments not manufac tured by BigDog

®

Mowers,

including the use of stand-up sulkies.

All manufacturer’s safety instructions issued with any

attachments including stand-up sulkies must be followed.

REV A 3-8 122790

MAINTENANCE & ADJUSTMENTS

WARNING

Safe Servicing Practices

Refer to the Safety section of this manual for more detailed
service safety information.

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 for more infor­mation.

Remain alert for unusual noises, which could signal a prob­lem. Visually inspect 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.

Clear away heavy build-up of grease, oil and dirt, especially
in the engine and hydraulic component areas; minute dust
particles 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 build­up 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 which will probably result in 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 off from underneath.

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

Torque Values

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

®

Mower service center when assis-

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, refer to the engine owner’s man­ual.

Tires

It is important for level mowing that the tires have the
same 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 Big Dog
mower, the tire must be a Big Dog® Mower approved tire.
Warranty claims will be denied on any mower equipped with
unapproved non-pneumatic tires.

®

Lubrication

Use no more than 1 or 2 ounces (30–60 cc) of SAE multi­purpose grease, (1 to 2 pumps on an average grease gun). Do
not force lubricant in to grease zerks. Bearings are sealed
and do not require much lubricant.

After every 50 hours of normal operation, apply a SAE
multi-purpose grease to the other lubrication points shown
on the Maintenance Locator Chart found elsewhere in this
manual. When operating under extremely dirty conditions,
lubricate more frequently than every 50 hours.

To lubricate these points:

1. Wipe away all old grease and dirt from the lubrication
fittings to prevent dirt or foreign material from enter­ing as new grease is applied.

2. Use a high pressure grease gun to force in the new
grease. Apply pressure until clean grease oozes from
each lubrication point.

3. Wipe away any excess grease.

Electrical System

IMPORTANT: Refer to the Safety section of this manual fo r

detailed battery servicing safety information.

Torque values are given below:

ft-lbs N•m

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

Blade spindle bolt top . . . . . . . . . . . 118 . . . . . . . 160

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

122790 4-1 REV A

Electric start mowers only

The electrical system is a 12 volt, negative ground. The rec-

ommended battery size is:

Garden tractor BCI group U1R with a 225 or better
cranking AMP rating

A maintenance-free battery is recommended. Otherwise,

A

B

A

A

B

follow battery manufacturer’s maintenance, safety, storing
and charging specifications.

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 below the right front of the fuel tank.

Figure 4-1

saxle’s seals to prevent water intrusion and to ensure compo­nent performance.

A. Expans ion tank

A. Fuel tank B. Master fuse housing

Figure 4-1

Hydraulic System

This mower is equipped with two integrated hydrostatic
transmissions (transaxles).

IMPORTANT: Never use hydraulic or automatic transmis­sion fluid in this system; use only the specified motor oil.
Remember, dirt is the primary enemy of any hydraulic sys­tem.

The hydraulic expansion tank is located behind the left rear

corner of the engine. Figure 4-2

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

Fluid level should be at the “Full Cold” line on the expan­sion tank. Use only SAE 20W50 service motor oil.

Initial system oil and filter change must be after the first 75
hours of use or 1 year whichever comes first. Thereafter,
replace filter and oil in each transaxle every 2 years or 200
hours, whichever comes first. NOTE: The filter guard must be
removed to access the filter. Figure 4-3

Each transaxle’s filter is located per Figure 4-3. A standard
oil filter wrench is used to change filter, threads are right
handed. Use a Big Dog

IMPORTANT: When washing the mower, direct the spray

away (especially if using a power washer) from the tran-

®

Mowers approved filter element only.

Figure 4-2

A. Filter B. Filter gua rd

Figure 4-3

Refer to the BigDog

®

Hike General Service Manual (P/N

122793) for complete hydraulic oil and filter change proce­dures.

Fuel and Evaporative Emissions Control System

IMPORTANT: Refer to the Safety section of this manual for

fuel handling safety information.

®

Use only Big Dog
Your evaporative emission control system may include

parts such as:

• fuel tanks

Mower approved replacement parts.

REV A 4-2 122790

• fuel lines

WARNING

A

B

WARNING

A

• 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

• purge valves

• liquid/vapor separator

• other associated components

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

The 5.0 U.S. gallon (18.9 liter) fuel tank is located behind

the engine. Figure 4-4

Clean the area around the fuel cap before removing the

cap. 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.

IMPORTANT: Do not overfill the fuel tank. The fuel tank
should be filled no higher than to the top of the sight glass.
The fuel system is designed to leave room for the fuel to
expand with fuel temperature changes. Stop filling the tank
after the fuel nozzle automatically clicks off.

Overfilling the fuel tank 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 pose a fire hazard.

Refer to the Engine Owner’s Manual for additional fuel spec­ification requirements.

The fuel filter is installed in the fuel line between fuel tank
and engine fuel pump. Replace filter annually or after every
500 hours of operation, whichever occurs first. Figure 4-5

When replacing the fuel filter, check the fuel line hoses for
any cracks or leaks. Replace as needed.

A. Fuel tank B. Top of sight glass

Figure 4-4

Park the mower on level ground before filling the fuel tank.

122790 4-3 REV A

A. Fuel filter

Figure 4-5

Fuel Evaporation System Filter

A

WARNING

A

These mowers have a fuel evaporation system filter. This
filter must be checked and replaced every 300 hours or annu­ally whichever comes first. Figure 4-6

A. Fuel evap oration system filter

5. With the hose in position, use a 10 mm wrench or

socket and open the valve approximately 4 turns in the
counterclockwise direction. Allow 10 minutes for
engine oil to adequately drain.

6. After oil is drained, close the valve by turning it in the
clockwise direction until it is fully closed.

7. Once the valve is closed, carefully remove the oil drain
hose and clean up any spilled oil.

IMPORTANT: All oil drips or spills must be cleaned off
of the exhaust system before operating the machine.

8. Clean the oil drain hose and store it appropriately.

Figure 4-6

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.
Mower must be on a level surface when checking oil. Refer to
engine manual and maintenance schedule for oil recommen­dation and capacities.

Change the engine oil and filter after the first 5 hours of
operation and then per the engine manufacturer’s recommen­dations after that. If mower is being operated in extremely
dirty conditions, then it is recommended oil be changed more
frequently.

Draining the engine oil:

1. Locate the oil drain valve on the lower right side of the

engine. Figure 4-7

2. Locate the oil drain hose that was supplied with the
machine. Be sure to clean and clear it of debris that
might block the flow of the engine oil.

3. Attach one end of the hose onto the oil drain valve nip­ple. Make sure the hose is pushed all the way onto the
valve.

4. Position the loose end of the hose so that it can drain
into a suitable oil drain container.

A. Oil drai n valve

Figure 4-7

Engine Air Filter

Perform engine air filter maintenance per the Maintenance

Schedule shown elsewhere in this manual.

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.

Belts

Inspect belts frequently for wear and serviceability.
Replace a belt that shows signs of:

• severe cuts

• tears

• separation

• weather checking

• cracking

• burns caused by slipping.

REV A 4-4 122790

Slight raveling of belt covering does not indicate failure,

WARNING

WARNING

WARNING

Do not sharpen to original pattern (below). It
is easier to get a straight cutting edge follow-

ing the re-sharpening pattern shown above.

A

B

A

B

C

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 PowerBar steering lever in the
neutral position immediately and place the neutral
lock/park brake lever in the park brake position.
Inspect the machine and involve your Big Dog

®

Mower dealer to resolve the problem before con tinu­ing 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.

Mower Blade

After grinding the blades, check for balance. Blade balanc­ing can be done by placing the blade on an inverted line
punch or 5/8" bolt. A commercial balancing tool is also avail­able through most hardware supply stores.

The blade should not lean or tilt. When spinning the blade
slowly it should not wobble. Balance the blade before rein­stalling.

Lay the blade on a flat surface and check for distortion.
Replace any distorted blade. Figure 4-9 & Figure 4-10

Mower Blade Maintenance

IMPORTANT: Refer to the Safety section of this manual for

blade handling safety information.

Refer to the Mower Blade Replacement section for blade

removal and installation.

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

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.

Always check for blade damage:

Sharpen the blades following the pattern shown. Touch-up
sharpening can be done with a file. Figure 4-8

• if mower strikes a rock, branch or other for­eign object during mowing!

• or if an abnormal vibration occurs while oper­ating.

Make all necessary repairs before resuming opera­tion.

A. Re-shar pening pattern
B. Origina l edge

Figure 4-8

Comparison of Warped and Straight Blades

A. Warped blade — replace
B. Straight blade
C. Cutting plane

Figure 4-9

122790 4-5 REV A

End view of blades, comparing twisted and straightened blades.

A

C

D

D

B

WARNING

WARNING

A. Twisted bla de edge —

replace blade

C. Cutting plane
D. Cutting edge

B. Straight blade edge

A 15/16" wrench is required to remove the 5/8" cap screw
holding the blade to the spindle shaft. NOTE: A blade holding
tool (part number 381442) is available from Big Dog

®

Mower.
It is designed to prevent the blades from rotating when they
are being removed or installed on the spindle. Contact your
Big Dog

®

Mower Dealer for more information.

Do not re-use spindle bolts which have stripped, worn or
undercut threads. Torque bolts on spindles to 118 ft-lbs
(160.0 N•m) when reinstalling blades.

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

Figure 4-10

Mower Blade Replacement

IMPORTANT: Refer to the Safety section of this manual for

blade handling safety information.

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

Properly compressed cup washers maintain the correct
compression load on the blades. Replace the cup washers if
they are cracked or flattened.

IMPORTANT: The blade sail (curved part) must be point­ing upward toward the inside of the deck to ensure proper
cutting.

When mounting blades, rotate them after installation to
ensure blade tips do not touch each other or sides of the
mower.

REV A 4-6 122790

Maintenance Schedule

Figure 4-11, Figure 4-12, Figure 4-13, Figure 4-14, & Figure 4-15

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) Prior to each use or every 4 hours
Clean air intake screen (4) 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 transaxle compartment Daily
Replace engine air cleaner element (4)(9) As needed
Change transaxle oil & filter (7) Every 200 hours or 2 years
Grease deck height pivots X
Grease front wheel bearings X
Change engine oil & filter (1)(3) X
Clean cylinder & head fins (9) X
Check battery connections X
Check tire pressure with a gauge X
Check hydraulic oil level X
Clean engine exterior (9) X
Clean & regap spark plugs (9) X
Check pump & deck belt tension and condition (5) X
Check fuel system (6) X
Check fuel tank grommet (6) X
Check hydraulic lines X
Tighten lug nuts on wheels (2) X
Change fuel filter (6) X
Replace spark plugs (9) X
Replace fuel evaporation system filter (8) X

WEEKLY

OR 50

HOURS

MONTHLY

OR 100
HOURS

* ANNUALLY

OR 300
HOURS

NOTES:

1. Initial engine oil change is after 5 hours of operation. Thereafter, change oil after every 50 hours operation. Change more often under dusty or
dirty conditions and during hot weather periods.

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

3. Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other main-

tenance items.

4. Service more often under dusty or dirty conditions.

5. Pump drive belt only - Inspect every 6 months or 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 200 hours or 2

years whichever comes first. Refer to Cold weather pump clutch section for tensioning information.

6. Check fuel system for any crack or leaks including, but not limited to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon
canister, and grommets. Repair as needed.

7. Initial hydraulic system oil and filter change must be after the first 75 hours of use or 1 year whichever comes first. Thereafter, replace filter and
oil in each transaxle every 2 years or 200 hours, whichever comes first.

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

9. Refer to engine owner’s manual for engine service information.

* After completing maintenance cycle (300 hours), repeat cycle .

122790 4-7 REV A

Maintenance Locator Chart

1

7

5

6

8

8

10

3

4

2

7

14

15

36” Side Discharge Deck

11

9

13

12

13

11

48”/54” Side Discharge Deck

9

9

Figure 4-11

Figure 4-12 Figure 4-13

1. Engine oil fill & dipstick

2. Fuel filter

3. Engine air cleaner

4. Engine oil drain

5. Fuel tank

Figure 4-14 Figure 4-15

6. Engine oil filter

7. Drive tire

8. Front wheel bearings

9. Blades

10. Discharge chute

11. Deck drive belt

12. Pump belt

13. Transaxle oil filter

14. Evaporative emission system fil-

ter

15. Battery

REV A 4-8 122790

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

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

Overheating Air intake screen or clean-

Low engine oil pressure Low oil level Add oil

High oil consumption Numerous Contact your Dealer

Mower jerky when start­ing or
operates in one direction
only

Mower creeps when Pow­erBar handle is in neutral

Deck clutch engaged Disengage deck clutch

No fuel or line plugged Fill tank or replace line

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 ON

Numerous See engine manual

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

Poor compression Contact your Dealer

Steering linkage needs
adjustment

Tow valve open Close tow valve

The traction drive belt is
worn, loose or broken

The traction drive belt is off
the pulley

For additional causes See engine manual

ing fins clogged

For additional causes See engine manual

Oil diluted or too light Change oil and check for

Steering control linkage
needs adjustment

Transaxle component
faulty

Steering linkage needs
adjustment

SUGGESTED

REMEDIES

Drain the tank and replace
the fuel with the proper
type

Contact your Deal er

Adjust linkage

Install a new traction drive
belt

Install the traction drive
belt and check for a reason

Clean screen and fins

source of contami nation

Adjust linkage

Contact your Deal er

Adjust linkage

SYMPTOMS PROBABLE CAUSES

Mower circles or veers in
one direction

There is abnormal vibra­tion

Uneven cutting height The blade(s) are not sharp Sharpen the blades

Blades do not rotate The deck drive belt is worn,

Steering linkage needs
adjustment

Tires improperly inflated Adjust air pressure to 8–12

Transxle component faulty Contact your Dealer

The engine mounting bolts
are loose

The engine pulley, idler pul­ley or blade pulley is loose

The engine 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

A cutting blade(s) is/are
bent

The deck is not level Level the deck per the Deck

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

loose or broken

The deck drive belt is off
the pulley

Electric clutch is not
engaging

SUGGESTED

REMEDIES

Adjust linkage

psi (55–83 KPa)

Tighten the engine mount­ing bolts

Tighten the appropriate
pulley

Contact your Dealer

Install new cutting blade(s)

Tighten the blade mount­ing bolt

Replace or tighten spindle
bearing

Install new cutting blade(s)

leveling section of the Gen­eral Service Manual

Adjust the height of the
anti-scalp wheel

Clean the underside of the
deck

psi (55–83 KPa)

Install a new deck drive
belt

Install the deck drive belt
and check for a reason

Check and/or replace 10
amp fuse. Contact your
dealer

122790 5-1 REV A

REV A 5-2 122790

STORAGE

WARNING

WARNING

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 cut-

ting 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.

2. Clean mower and deck and touch up all scrapes with
touch-up paint.

3. Install new air filter per Engine Owner’s Manual.

4. Check thoroughly for any worn or damaged parts that

need replacing and order them from your dealer.

5. Thoroughly lubricate machine, according to the Main­tenance section.

6. Block mower up so weight is off tires. Check tire pres­sure and inflate to proper operating pressure.

NOTE: Do not deflate tires.

7. Perform separate engine and battery preparation as
listed below.

8. Store mower in a clean, dry place.

Preparation of engine for storage

If the mower is to be unused for an extended period of time
(30 days or more), the engine will need to be prepared for
storage. Use the following procedures before storing the
mower.

IMPORTANT: Refer to the Fuel Handling Precautions sec-
tion of this manual for important safety information before
proceeding.

1. Add an Excel approved fuel stabilizer to the fuel sys­tem. Refer to the instructions shown on the fuel stabi­lizer bottle for proper usage. For detailed info rmation
consult with your Dealer.

2. Fill the fuel tank(s) with fresh fuel.

NOTE: Use non-ethanol fuel if possible.

3. Run the engine for a minimum of 10 minutes.

Allow the engine to cool before changing the
engine oil. Use caution when changing the engine
oil as it will be very hot. You should wear the
appropriate protective gear to avoid being burned
or exposed to engine oil.

4. Drain the oil from the crankcase while the engine is
still warm.

5. Replace the engine oil filter.

6. Refill with fresh oil of the proper viscosity.

7. Close the fuel shut-off valve (if equipped).

8. Check the oil filler cap and fuel tank cap(s) to make

certain they are securely in place.

9. Refer to the engine manual for more information.

Preparation of battery for storage (if applicable)

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. Install fully charged battery and attach the battery

cables (if applicable).

4. Fill fuel tank(s) with fresh fuel. Run machine at half
speed for 5 minutes, checking operation of the Power­Bar handle. Stop engine and check for oil leaks, loose
fittings and so forth.

To prevent carbon monoxide poisoning, operate the
engine in a well ventilated area only.

122790 6-1 REV A

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.

5. Tighten any bolts that have loosened and make sure
all hair pins, cotter pins and clevis pins are in place.

6. Install all safety shields and review safety precautio ns
listed in this manual.

7. Check and inflate tires to 8–12 psi (55–83 KPa).

8. Refer to engine manual for more information.

REV A 6-2 122790

PRODUCT LITERATURE

If you would like to view or print a copy of the product manuals (Operator’s Manual, Parts Manual, or General Service Manual) for

these mowers go online to www.bigdogmowerco.com and click on the MANUALS button.

Contact your local Big Dog

®

Mowers dealer if you require another engine manual.

122790 6-3 REV A

REV A 6-4 122790

INDEX

PAGE PAGE

Anti-scalp Wheels ......................................................3-8

Battery Service Precautions .......................................2-5

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

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

Cold Weather Pump Clutch .........................................3-4

Control Panel .............................................................3-1

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

Deck Clutch Operation ...............................................3-7

Deck Cutting Height Adjustment ................................3-7

Driving the Mower ......................................................3-5

Electrical System .......................................................4-1

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

Engine Starting ..........................................................3-2

Fuel and Evaporative Emissions Control System ........4-2

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

Fuel Handling Precautions .........................................2-5

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

Mower Blade Replacement ........................................ 4-6

Mower Operation ...................................................... 3-5

New Season Preparation ........................................... 6-1

Operating Suggestions .............................................. 3-5

Operation .................................................................. 2-2

Parts and Service ...................................................... 1-1

Personal Safety ........................................................ 2-1

Preparation of Battery for Storage ............................. 6-1

Preparation of Engine for Storage ............................. 6-1

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

Safe Operation .......................................................... 2-1

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

Safety and Instructions Decals .................................. 2-6

Safety Start Interlock System .................................... 3-2

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

Service Precautions .................................................. 2-4

Slope Guide ............................................................ 2-11

General Mower Preparation for Storage ......................6-1

Hydraulic System .......................................................4-2

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

Maintenance Locator Chart ........................................4-8

Maintenance Schedule ...............................................4-7

Master In-line Fuse ....................................................4-2

Model and Serial Number ...........................................1-1

Moving the Mower with Stalled Engine .......................3-4

Mower Blade ..............................................................4-5

Mower Blade Maintenance .........................................4-5

Mower Blade Maintenance Precautions ......................2-5

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

Stand-up Sulkies ....................................................... 3-8

Stopping the Engine .................................................. 3-3

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

To the New Owner ..................................................... 1-1

Torque Values ........................................................... 4-1

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

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

Using this Manual ..................................................... 1-1

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

122790 i-1 REV A