Excel Big Dog X Series Owner's Manual

GENERAL INFORMATION

This manual applies to the following BigDog™ Mowers:

BigDog™ Mowers X Series

To the new owner

The purpose of this manual is to assist owners and operators
in maintaining and operating the BigDog™ Mowers. Please
read 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. You are urged to read it
before attempting any operation or repair of 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 safety signs.

IMPORTANT: For more detailed maintenance and adjust-

ment information refer to the proper parts manual for your
machine. Refer to the “Produ ct L iterat ure” section of th is man­ual for ordering information.

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.

Using this manual

General operation, adjustment and maintenance guidance is
outlined for both the experienced and novice BigDog™ Mowers
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,
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 owner ’s manual, or the
parts manual, see your BigDog™ Mowers dealer for current
information and parts.

Warranty registration

The Delivery and Warranty Registration form must be com­pleted and signed to validate your warranty protection. As the
new equipment owner, you are expected to see that the form is
completed and forwarded to BigDog™ Mowers at time of deliv­ery.

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 on the Warranty Registration
form. They will also assure you of the correct service parts when
replacement becomes necessary.

Parts and service

Use original BigDog™ Mowers replacement parts only.
These parts are available through your local BigDog™ Mowers
dealer. 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™ Mowers dealer. Arrangements should be
made through your local service center.

602471_1009 1-1

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 provi des that it is unlawful to use or operat e an in ternal 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 flammable 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 Requirements. THIS EQUIPMENT DOES NOT HAVE A
SPARK ARRESTER AND YOU SH OULD CONTACT Y OUR AUTHORIZED DEAL ER FOR TH E PURCHASE OF A
SPARK AR REST ER.

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

The En g ine O wner’s Manual provi des inform ation regar ding the U.S. Environmental Protecti on Agency
(EPA ) and th e Cali fornia Emis sion Control Reg ulation of e mission systems, m aintenance and w arra nty.

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 th e information found in the Product Informa­tion section of the owner’s m anual .

The engine exhaust from this product

contai ns che mic al s kno wn to the State

of California to cause cancer , birth

defects or other reproductive harm.

WARNING:

1-2 602471_1009

BigDog™ MOWERS X SERIES

TWO YEAR (1200 HOURS) LIMITED WARRANTY

OR

FOUR YEAR (500 HOURS) LIMITED WARRANTY

OR

90 DAYS LIMITED WARRANTY IN RENTAL APPLICATIONS

OPTIONAL WARRANTY POLICIES

The purchaser must choose one of the following warranty poli­cies upon purchasing the machine:

a. Two (2) Year (1200 Hours) Limited Warranty
b. Four (4) Year (500 Hours) Limited Warranty
c. Rental Units (90 days) Limited Warranty

WHAT IS COVERED BY THIS WARRANTY

BigDog™ Mowers, makes the following warranty to the origi­nal purchaser only:

a. Two (2) Year (1200 Hours) Limited Warranty:

BigDog™ Mowers are warranted for two (2) years or
1200 hours, whichever comes first from date of
delivery, on all materials and workmanship.

If the Purchaser discovers within this warranty period
such a defect:

O He must promptly notify BigDog™ Mowers, or an

authorized dealer, in writing of the defect. In no event
shall such notification be received by BigDog™
Mowers, or an authorized dealer later than 30 days
after expiration of warranty.

O Within a reasonable time after such notification, Big-

Dog™ Mowers, will correct any defect in material or
workmanship on the BigDog™ Mowers, by repairing
or replacing part(s) with either new or used replace­ment parts.

O Such repair, including parts and labor shall be at the

expense of BigDog™ Mowers, and,

b. Four (4) Year (500 Hours) Limited Warranty:

BigDog™ Mowers are warranted for four (4) years or
500 hours, whichever comes first from date of
delivery, on all materials and workmanship.

If the Purchaser discovers within this warranty period
such a defect:

O He must promptly notify BigDog™ Mowers, or an

authorized dealer, in writing of the defect. In no event
shall such notification be received by BigDog™
Mowers, or an authorized dealer later than 30 days
after expiration of warranty.

O Within a reasonable time after such notification, Big-

Dog™ Mowers, will correct any defect in material or
workmanship on the BigDog™ Mowers, by repairing
or replacing part(s) with either new or used replace­ment parts.

O Such repair, including parts and labor shall be at the

expense of BigDog™ Mowers, and,

c. Rental Un its (90 days) Limited Warranty: Within 90

days of date of delivery BigDog™ Mowers, provides a
limited warranty on all materials and workmanship for
units used for rental purposes.
If the Purchaser discovers within this warranty period
such a defect:

O He must promptly notify BigDog™ Mowers, or an

authorized dealer, in writing of the defect. In no event
shall such notification be received by BigDog™
Mowers, or an authorized dealer later than 30 days
after expiration of warranty.

O Within a reasonable time after such notification, Big-

Dog™ Mowers, will correct any defect in material or
workmanship on the BigDog™ Mowers, by repairing
or replacing part(s) with either new or used replace­ment parts.

O Such repair, including parts and labor shall be at the

expense of BigDog™ Mowers, and,

d. The engine warranty is covered by the engine

manufacturer, to the original owner only, and,

e. The battery is covered by a one (1) year limited

warranty to the original owner only.

WHO MUST PERFORM THE WARRANTY SERVICE

All warranty service will be performed by dealers authorized by
BigDog™ Mowers. Service calls and/or transportation
expense of the product to and from the authorized dealer, for
warranty work, will be paid by the owner of the product. For
warranty service contact an authorized dealer.

WHAT IS NOT COVERED BY THIS WARRANTY

BigDog™ Mowers, does not warranty:

O Some product components or parts not manufactured

by BigDog™ Mowers

O Repairs made by unauthorized persons
O Damage caused by use of the BigDog™ Mowers for

purposes other than those for which it was designed

O Damages caused by disasters such as fire, flood,

wind, and lightening

O Damages caused by neglect, abuse, abnormal use,

improper or unreasonable use, accident, negligence or
misuse

O Repairs or replacement resulting from the use of

unauthorized parts, accessories or attachments

O Damage caused by foam filled or solid filled tires.
O Repairs or replacement as the result if any alterations

or modifications, in the determination of BigDog™
Mowers, which adversely affects the operation, per­formance or durability of the equipment.

O A BigDog™ mower which has the serial number

removed or made illegible

O Depreciation or damage caused by normal wear, lack

of reasonable and proper maintenance, failure to fol­low the product’s owner’s manual operating, mainte­nance and adjustment instructions or other
operational instructions provided by BigDog™ Mow­ers.

O Normal maintenance parts and service including, but

not limited to, filters, fuel, lubricants, tune-up parts,

602471_1009 1-3

belts, blades, blade sharpening, bearings, brake or
steering adjustments

O Repairs necessary due to improper fuel, contaminates

in the fuel system, or failure to properly prepare the
fuel system prior to any period of non-use over three
months

DISCLAIMER OF WARRANTY

The foregoing warranties are in lieu of all other warranties,
expressed or implied, including but not limited to the im plied
warranties of merchantability and fitness for a particular pur­pose. However, if the Big Dog Mower is purchased as a con­sumer product, any implied warranty of merchantability or
fitness for a particular purpose is limited to the d uration of this
limited warranty. Some states do not allow limitations on how
long an implied warranty lasts, so the above limitation may not
apply to you. This warranty gives you specific legal rights, and
you may also have other rights which vary from state to state.

LIMITATION OF REMEDIES

In no case shall BigDog™ Mowers, be liable for any special,
incidental, or consequential damages based upon breach of war­ranty, breach of contract, negligence, strict liability in tort, or
any other legal theory.
Such damages include, but are not limited to:

O Loss of profits
O Loss of savings or revenue
O Loss of use of a BigDog™ mower or any associated

equipment

O Cost of capital
O Cost of any substitute equipment, facilities, services

or downtime

O The claims of third parties including customers, and

injury to property
Some states do not allow the exclusion or limitation of inciden­tal or consequential damages, so the above limitation or exclu­sion may not apply to you.

TIME LIMIT

a. Two (2) (1200 Hours) Year Limited Warranty

Any action for breach of warranty must be commenced
within 30 days following delivery of the goods in a non­rental application.

b. Four (4) Year (500 Hours) Limited Warranty

Any action for breach of warranty must be commenced

within 30 days following delivery of the goods in a
non-rental application.

c. Rental

Any action for breach of warranty must be commenced
within 30 days following delivery of the goods.

NO OTHER WARRANTIES

Unless modified in writing, signed by both parties, and
approved by the President of Excel Industries, Inc., this agree­ment is understood to be the complete and exclusive agreement
between the parties, superseding all prior agreements, oral or
written, and all other communications between the parties relat­ing to the subject matter of this agreement. No employee of
Excel Industries, Inc, or any other party is authorized to make
any warranty in addition to those made in this agreement.

ALLOCATION OF RISKS

This agreement allocates the risks of product failure between
BigDog™ Mowers, and the purchaser. This allocation is recog­nized by both parties and is reflected in the price of the goods.

OWNER'S RESPONSIBILITY

You must maintain your BigDog™ Mowers Product following
the maintenance procedures described in your owner's manual.
Such routine maintenance, whether performed by a dealer or by
you, is at your expense.

This machine like any other powered equipment is poten­tially dangerous unless properly operated. Any operator
must be cautious and keep safety in mind at all times. Any oper-

ator, prior to using the BigDog™ Mowers, should thoroughly
familiarize himself with the owne r's manual regarding operation
and safety of the machine, as well as all safety warnings on the
machine itself.

WARRANTY REGISTRATION

1. Dealers must register the unit on-line or by filling out

the Warranty registration form, provided in the owner ’s
packet. If using the Warranty registration form it MUST
be completed and signed by the authorized dealer and
original purchaser.

2. For validation, the completed Warranty registration form

MUST be forwarded to BigDog™ Mowers, within ten
(10) days following date of purchase.

3. The date of purchase constitutes delivery.

1-4 602471_1009

SAFETY PRECAUTIONS

This safety alert symbol is used to call attention to a message
intended to provide a reasonable degree of PERSONAL
SAFETY for operators and other persons during the normal
operation and servicing of this equipment.

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

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

This manual uses two other words to highlight informati on.
IMPORTANT calls attention to special 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 machine 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 machine.

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 safety signs.

• Never let children or untrained people operate of 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 operator/mechanic

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.

Safety and Instruction Decals

V 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 decals that are lo cated on the machine. A bri ef explanation, for those requiring one, is
shown to help the operator understand the meanings of these decals.

• Read Owner’s Manual and Safety Warning Decals before

attempting to operate this machine.

602471_1009 2-1

Part Number 779306

• Do not smoke while refueling.

• Do not remove the fuel tank cap or fill 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.

Part Number 600899

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

779280

601968

601837

601967

602041

Part Number
602041

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

steering control levers in the park brake position immediately.
Inspect the machine and involve your BigDog™ Mowers dealer to
resolve the problem before continuing to operate.

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

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

Part

Number

779280

WARNING: Hot surface!

• Avoid skin contact with hot surface

Part Number 601837

DANGER:
Rotating blades, pulleys & belts!

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

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

belts.

Part Number 601892

WARNING:
Thrown objects!

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 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.

• 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 attachment

and turn engine off.

WARNING: Fire!

Part Number 601967

• Always maintain a safe distance from peo-

ple 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.

• 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.

WARNING: Thrown objects!

• Never operate the mower deck

with side deflector damaged,
altered, removed or in raised

Part Number 601624

position, except when the entire
grass catcher attachment or
mulching system is being used.

WARNING: Hot surface!

• Keep a safe distance from machine

2-2 602471_1009

602233

A

Part Number 602233

K

L

H

D

C

F

G

E

I

B

J

• Do not overfill battery.

• Electrolyte may overflow and

damage paint, wiring or struc­ture. When cleaning the battery,
use soap and water into the bat­tery. 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 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.

DANGER: Battery Hazards!

• Avoid skin contact

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.

Part Number 601815

601815

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

F. OFF
G. ON
H. If warning light comes on, check engine oil

I. Engine start position

J. Before starting the engine:

Read Owner’s Manual
Disengage mower blades
Place control levers in park brake position

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

before attempting to service this manual.

602471_1009 2-3

601635

601635

Part Number 602233

Read Owner’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!

• Avoid crushing, use seat belt.

• Do not jump if machine tips.

• T o 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

• 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!

• Always pull from the mower’s hitch.

• Do not attach chains or ropes to the ROPS for pulling purposes,

as the machine can tip backwards.

2-4 602471_1009

Part Number 601981

WARNING: Read Owner’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!

• Do not carry passengers

• Always stop machine if someone enters the area.

• 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.

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 on 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.

602471_1009 2-5

• Back slowly down the slope when loss of traction

occurs.

INTERNATIONAL SYMBOLS

As a guide to the operation of your mower, various international symbols have been used on instruments and controls.

These symbols are depicted and described below.

Hours Recorded

Engine Water
Temperature

Air Filter

Engine Oil
Pressure

Full Time AWD

Auto AWD

Continuously
Variable

Neutral

Diesel Fuel

Glow

Engine Stop

Engine Oil

Engine Start

Parking Brake

Battery

Power Take-off
(ON)

Power Take-off
(OFF)

Slow

Fast

Control Lever
Hold

Attachment
(Raised)

Increase

Decrease

Fuel Level

High Range

Low Range

Lock

Release Lock

Differential Lock

Volume Empty

Attachment
(Lowered)

Remote Cylinder
(Retracted)

Remote Cylinder
(Extended)

Volume Full

2-6 602471_1009

SLOPE GUIDE

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

Line B

E (15o)

D (10o)

C (5o)

Slope Guide Lines

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 estimat ion of the ground slope to be

mowed.

602471_1009 2-7

Line A

2-8 602471_1009

OPERATION

Safe Operating Practices

Some of the following safety instructions are from ANSI
Standard B-71.4-2004 while others are specific to the BigDog™
Mowers.

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

Operation

V 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.

V Never leave a running machine unattended. Always stop

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

V Do not change the engine governor setting or overspeed

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

V Always remain seated while operating machine.
V Always keep safety shields and covers in place.
V Always maintain a safe distance from people and pets

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

V Always operate machine in daylight or with adequate

working lights.

V Follow daily and weekly checklists, making su re hoses

are tightly secured and bolts are tightened.

V Always observe traffic laws while driving machine from

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

V 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.

V 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.

V Always inspect machine for damage after striking a for-

eign object. If damage is found, repair machine immedi­ately. Be sure to stop on level ground, disengage deck
clutch, place steering control levers in park brake posi­tion, stop engine, and remove ignition key when leavin g
operator’s seat to inspect damage.

V 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.

V 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 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 when operating this machine.

V 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.

V Never push forward suddenly on your control levers

while the machine is in rearward motion because
machine may tip backwards.

V Never pull back suddenly on your control levers while

the machine is in forward motion.

V When moving in reverse, push forward slowly on control

levers and avoid sudden movement. Rapid movemen t of
the control levers in either direction could result in a
reaction of the machine that can cause serious injury .

V Never operate a poorly maintained machine.
V Never attempt high speed maneuvering, especially in

crowded or congested areas or on slopes.

V Never allow persons to operate this machine without

proper instruction or allow children to operate machine.
Allow only responsible adults who have read and under­stand these instructions to operate this machine.

V Never put hands or feet under any part of the machine

while it is running.

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

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

V Always keep clear of the mower blades and attachments

during their operation.

V Turn off blades when not mowing.
V Slow down before turning.
V

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!

V Always keep clear of the mower blades and attachments

during operation.

V Do not operate the machine if you are fatigued, sick or

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

V Exercise caution when loading or unloading the machine

onto a trailer or truck.

V Always wear safety goggles or safety glasses with side

shields when operating the mower.

V 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.

V Follow the manufacturer’s recommendation for wheel

weights or counterweights.

V If any attachment or additional weight is mounted on the

rear of the unit, any rapid movement of the control levers

602471_1009 3-1

in either direction could result in a reaction of the
machine that can cause serious injury.

V 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.

V Always secure the ROPS in the raised position and

buckle seat belt before starting mower.

Using a ramp

V Use extreme caution when loading and unloading a unit

onto a truck or trailer with a ramp.

V 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 machine tipping over.

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

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

V When on a ramp avoid sudden acceleration

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 up the slope
or if you feel uneasy on it; do not mow it. REMINDER: Only
operate on slopes of 15 degrees or less.

V 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.

• Turn slowly

• Turn on the most level part of the slope

• To maximize traction, it is better to turn the front of the
machine 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.

V Do not remove or modify the stabilizer wheels.
V Watch for holes, ruts, bumps, rocks or other hidden

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

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

make sudden changes in speed or direction.

V Avoid starting and stopping on a slope. If t ires lose trac-

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

V 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. This will reduce the risk of the machine
suddenly rolling over causing serious injury or death.

V 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 machine roll ­over and serious injury or death.

V Do not mow on wet grass. Slippery conditions reduce

traction which could cause sliding and loss of control.

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

ment may cause loss of traction and loss of control.

V Do not try to stabilize the machine by putting your foot

on the ground.

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

slopes, disengage the blades, place the control levers in
the park brake position, turn the engine off and get help.

V Never make sudden starts, stops, turns, or reverse direc-

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

V Never stop suddenly while backing down slopes. This

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

V The BigDog™ mower is capable of operating horizon-

tally (traverse) on moderate 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 machine. 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, page 2-9, when determining the
degree of slope to be mowed.
It is strongly recommended that the operator drive the
machine 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 machine. 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

6. Extremely dry conditions of grass

7. Tire pressure
The attachments mounted to the mower will also affect
the way it handles on a slope. Be aware that each attach­ment’s characteristics vary.
Another consideration is to always 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 and always be
aware of what is located at the bottom of the slope. This
will reduce the risk of the machine suddenly rolling over
causing serious injury or death.
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

3-2 602471_1009

4. Buildings

D

G

H

C

E

A

B

F

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 m­ber to always exercise extreme caution when operating
on any slope.

V The ROPS will 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 will result in serious

injury in the event of a roll over.

Children

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

V Never leave machine unattended with ignition key in

switch, especially with children present.

V Children or bystanders may be injured if they move or

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

V Keep children out of the mowing area and under the

watchful care of a responsible adult other than the opera­tor.

V Be alert and turn the machine off if children enter the

area.

V Before and while backing, look behind and down for

small children.

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

fall off and be seriously injured or interfere with safe
machine 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
machine.

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

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

Control Panel

IMPORTANT: When access is required under the seat

platform 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 upwa rd b efo re pl ac­ing the seat platform in the full forward position to prevent
arm rest damage.

A. Throttle control (Fig. 3-1) — a cabl e is l inked to engi ne

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

B. Choke control (Fig. 3-1) — 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

602471_1009 3-3

A. Throttle

B. Choke
C. Deck clutch switch
D. Igntion switch

E. Oil pressure light

F. Hour meter

G. 10 amp fuse

H. 15 amp fuse

Fig. 3-1

lever 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 (Fig. 3-1) — this switch engages the

deck. Pull the switch up to engage and push switch down
to disengage the clutch.
IMPORTANT: Never engage clutch with engine running
at high rpm or when the deck is under load. Clutch, belts
or deck could be damaged.

D. Ignition switch (Fig. 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. Oil pressure light and alarm (Fig. 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 pressure is developed. If light comes on duri ng
operation, shut engine off immediately and locate and
correct the problem.

F. Electronic hour meter (Fig. 3-1 & Figure 3-5) —

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 switched to
the RUN position. NOTE: The hour meter is found in
various locations on different mowers.

G. 10 amp fuse (Fig. 3-1) — Ignition - 10 amp, blade-type
H. 15 amp fuse (Fig. 3-1) — Clutch - 15 amp, blade-type

Controls

A. Control levers (Figure 3-2 & Figure 3-3) — these

levers control the mower’s speed, direction, stopping,
and park brake. Levers are used to steer, accelerate,
decelerate and change direction. When the control levers
are in the park brake position (3-3) the mower will not
move when the engine is on and drive pumps are
operating.

WARNING: The parking brake may not hold the

Control levers

shown in neutral position

Control lever

shown in park brake position

Deck lift pedal

Hour meter

machine 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

Figure 3-3

Figure 3-5

Safety start interlock system

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

Check mower 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 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 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 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 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 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 can not be located, contact your BigDog™

Mowers Dealer.

Figure 3-4

WARNING: 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 properly functioning seat
safety switch.

3-4 602471_1009

Engine starting

Bypass valve

ROPS

Retaining rings

Clevis

pin

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:

A. Control levers are in the park brake position.

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

WARNING: 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 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 control levers are in the park brake

position and 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 and
operate 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 burn-out.

6. Perform test to make sure safety start interlock system is

operating properly. Refer to Safety start interlock system
section.

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

the oil warning light is off. If not, stop 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.

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 bypass valves

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

Figure 3-6

Stopping the engine

Use the following procedure to shut off the engine after

operating the equipment.

1. Place the control levers in the park brake position

2. Disengage the deck clutch

3. Throttle back to low idle for a couple of minutes

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

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

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

602471_1009 3-5

Figure 3-7

ROPS
(Roll Over Protective Structure)

A Roll Over Protective Structure (ROPS) and seat belt is

provided with the equipment. Do not remove the ROPS and seat

ROPS

mounting

bolts

ROPS post

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

NOTE: Inspect the ROPS after the first 20 hours of opera-

tion. Following the initial inspection, check the ROPS after
every 500 hours of operation or every six months, whichever
comes first. Figure 3-7

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

the bolts to the correct torques as shown below if
necessary. Figure 3-8

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.

Torque values are given below:

Ft-lbs. Nm

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

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

The two-post ROPS can be pivoted down by removing the
right and left retaining rings and pulling out on the 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 “folded”
position only when it is absolutely necessary. Figure 3-7

WARNING: Do not operate the mower with the
ROPS folded (lowered position) as a standard operat­ing mode. A folded ROPS does not provide rollover
protection.

WARNING: 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.

WARNING: 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.

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

Figure 3-8

Always fasten seat belt during operation of the machine

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

Inspect the area to be mowed for proper overhead clearance

(tree limbs, guy wires, doorways, etc)

Do not contact any overhead object with the ROPS.

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:

1. cuts

2. fraying

3. extreme or unusual wear

4. significant discoloration due to UV exposure

5. dirt or stiffness

6. abrasion to the seat belt webbing

7. damage to the buckle, latch plate or hardware.

8. or any other problem

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

Possible damage to the 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,
and the seat belt and seat belt mountings for possible damage,
Before operating the machine, replace all damaged parts.

3-6 602471_1009

IMPORTANT: Do not attempt to weld or straighten the

ROPS.

WARNING: If the ROPS or cab is removed or
replaced, make sure that the proper hardware is used
and the recommended torque values are applied to the
attaching bolts.

WARNING: The ROPS structure’s protective
capability may be impaired by structural damage,
overturn or alteration. 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.

Driving the mower

DANGER: 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 machine that can cause
serious injury.

After starting engine, engage the control levers and steer as

follows:

To go forward, push control levers forward an equal distance

(Figure 3-9).

To go in reverse, pull control levers rearward an equal

distance (Figure 3-9).

T o turn left, move the right control lever farther forward from

neutral than the left control lever.(Figure 3-9)

To turn right, move the left control lever farther forward

from neutral than the right control lever. (Figure 3-9)

Zero radius turn, move one control lever forward and the

other control lever back of neutral. This will allow the drive
wheels to counter-rotate. (Figure 3-9)

To stop or decrease speed, move control levers to neutral.

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

For emergency stop, when traveling forward or rearward,

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

DANGER: When moving in the rearward direction
push forward gently on steering control levers 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, causing
serious injury or death.

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

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

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

IMPORT ANT: Rapid movement of control levers is not rec-

ommended as damage to the hydraulic system components may
occur.

To increase speed, increase control lever’s distance from

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

Operating suggestions

DANGER: Prior to operating t he mower the operator

should be thoroughly familiar with the proper use and
operation of the equipment, should read the manual
completely and thoroughly, 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.

WARNING: 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™ Mowers
dealer to resolve the problem before continuing to
operate.

WARNING: The unit’s steering control levers are
very responsive: Easy does it! For smooth operation,
move lever slowly, avoid 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 practice maneuvers are
recommended to become familiar with these characteristics
before attempting normal speed operation.

WARNING: 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 maximum when the throttle is set at
full rpm. This gives maximum power to the drive w heels and
deck when needed. Use the control levers to control ground
speed rather than engine rpm.

Keep blades sharp. Many professional mowing companies
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

602471_1009 3-7

FRONT OF MOWER FACES THIS DIRECTION

NN

FORWARD TRAVEL ZERO RADIUS

TURN

FORWARD TRAVEL

RIGHT TURN

REVERSE TRAVEL

RIGHT TURN

REVERSE TRAVEL

N= NEUTRAL POSITION
Direction of arrows indicate direction of mower movement

Figure 3-9

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.

DANGER: 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 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, a branch or
another foreign object during mowing!

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 best cut.

Direct grass discharge to right, away from unmown area.

Select a mowing pattern that directs grass discharge towards the
outside, not towards center, of mowing area. Generally, this
means using a pattern utilizing left turns because side discharge
is to 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 mowing direction to keep the grass growing

straight and better dispersion of the clippings.

Remember, grass grows at different rates at different time

of the year. Mow more often in the early spring to maintain the
same cutting height. As the growth rate slows in mid sum mer,
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.

WARNING: Never direct discharge of material from
mower deck towards bystanders. Do not operate the
mower without either the discharge chute or the entire
grass collection system in place. Figure 3-11

Mower deck operation

DANGER: 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.

With the engine running, engage the deck clutch switch

(Fig. 3-1) and advance engine th rottle to full rpm.

NOTE: 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.

Deck cutting height adjustment

Deck height is adjustable from 1” to 5” (2.54 cm - 12.7 cm) in
1/4” (.64 cm) increments. The holes in the height adjusting bar
are spaced at 1/2” (1.27 cm) intervals. By turning the height
adjusting stop around, 1/4” (.64 cm) increments can be attai ned
due to the 1/4” (.64 cm) plate that is part of the stop. Figure 3­12

3-8 602471_1009

Step 1

Three point turn

Step 2

Step 3

R

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ve

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v

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N

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a

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R

i

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c

o

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v

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N

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Neutral

Left control leverRight control lever

Discharge

chute

Stop handle

Height adjusting stop

Figure 3-11

EXAMPLE: When the height adjusting stop is placed in the

1” (2.54 cm) hole, with the 1/4” (.64 cm) plate facing to the
front of the unit, the cutting height is at 1”. When the height
adjusting stop is placed in the 1” (2.54 cm) hole, with the 1/4”
(.64 cm) plate on the operator’s side of the hole, the cutting

height is at 1-1/4” (3.18 cm).

The notch located at the rear of the height adjusting bar is to

be used when the deck is placed in the transport mode.

Figure 3-10

602471_1009 3-9

Figure 3-12

Anti-scalp wheels

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 as
needed from 3/4” to 1-3/4” (19.05mm to 44.45mm) below the
blade surface. Move the front wheels up or down, in 1/2”
(12.70mm) increments, using the different axle mount holes in
the wheel mount bracket. Figure 3-13

When adjusting the rear anti-scalp wheels, the wheel should
be in the lower axle mount hole when the front anti-scalp wheels

are in the lower or middle axle mount holes. When the front

Anti-scalp wheel

Adjusting holes

wheels are in the upper axle mount hole, the rear wheels should
be in the upper axle mount hole as well.

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

mum cutting height is 1” (2.54 cm) with the anti-scalp wheels
set at 3/4” (1.91cm).

Figure 3-13

3-10 602471_1009

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

V Unless specifically required, DO NOT have engine run-

ning when servicing or making adjustments to machine.
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 adjusting, cleaning
or repairing. Repairs or maintenance requiring engine
power should be performed by trained maintenance per­sonnel only. To prevent carbon mono xide 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.

V Before working on or under the deck, make certain

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

V Except when changing or a checking belt, always keep

belt covers on mower deck for safety as well as cleanli­ness.

V 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 mower.

V 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.

V Clean flammable material from machine. Prevent

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

V Always wear adequate eye protection when servicing the

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

V Use extra caution when handling gasoline and other

fuels. They are flammable and vapors are explosive.

V Never attempt to start engine when there is a strong odor

of gasoline fumes present. Locate and correct cause.

V Never remove the fuel cap or refuel mower while engine

is running; 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.

V Never run the engine in an enclosed area unless exhaust

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

V Never attempt to make any adjustments or repairs to the

mower’s drive system, mower deck or any attachment

while the engine is running or deck clutch is engaged.
Repairs or maintenance requiring engine power should be
performed by trained maintenance personnel only.

V Never work under the machine or attachment unless it is

safely supported with jack stands. Make certain machine
is secure when it is raised and placed on the jack stands.
The jack stands should not allow the machine to move
when the engine is running and the drive wheels are
rotating. Use only certified jack stands. Use only appro­priate jack stands, with a minimum weight rating of 2000
pounds to block the unit up. Use in pairs only. Follow the
instructions supplied with the vehicle stands.

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

bolts. Keep equipment in good working condition.

V Never tamper with safety devices. Check their proper

operation regularly.

V 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!

V 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.

V Exercise caution when working under the deck as the

mower blades are extremely sharp. Wear gloves and use
extra caution when servicing them.

V Use only genuine BigDog™ Mowers replacement parts

to ensure that original standards are maintained

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. The
following pages contain suggested ma intenan ce inf ormation an d
schedules which the operator should follow on a routine basis.
For more detailed information order the correct parts manual for
your unit. Refer to the Product Literature section of this manual.

Remain alert for unusual noises, they could be signaling 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.

Clear away heavy build-up of grease, oil and dirt, especially
in the engine and under the seat platform areas; minute dust
particle are abrasive to close-tolerance engine and hydraulic
assemblies.

Daily inspect mower for grass clippings and wire and string
tangles. The underside of the mower deck may 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 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,

602471_1009 4-1

using jack stands or blocks, in the full up position and 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™ Mowers service center when assistance
is needed.

Torque values

WARNING: 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.

Torque values are given below:

Ft-lbs. Nm

Wheel (lug) nuts . . . . . . . . . . . . . . . 65-75. . . . . 88.14-101.7

Blade spindle bolt top . . . . . . . . . . . 65-75 . . . . . 88.14-101.7

Blade spindle bolt bottom. . . . . . . . .118. . . . . . . . .160.01

Wheel motor nut . . . . . . . . . . . . . . 200-210. . . . 271.2-284.7

WARNING: 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 explosion
if exposed to flame. Always remove the negative
ground connection 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 solution of
four parts water and one part baking soda when they
become corroded.

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 various mower parts manuals
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 pressure are:

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

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

Only pneumatic tires are approved for use on BigDog™
Mowers X Series mowers. Warranty claims will be denied on
any mower equipped with non-pneumatic tires.

Lubrication

Use SAE multi-purpose grease.

Electrical system

The electrical system is a 12 volt, negative ground.
Recommended battery size is a garden tractor BCI group U1R
with 225 or greater cranking AMP rating. A maintenance-free
battery is recommended. Otherwise, follow battery
manufacturer’s maintenance, safety, storing and charging
specifications.

The main circuit is controlled by an in-line 25 amp fuse.

WARNING: 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.

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

WARNING: Shorts caused by battery terminals or
metal tools touching metal components can cause
sparks. Sparks can cause a battery gas explosion
which may 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.

WARNING: 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).

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.

WARNING: Hydraulic fluid escaping under pressure
may have sufficient force to penetrate skin and cause
serious injury. Foreign fluid injected into the skin must
be surgically removed within a few hours by a doctor,
familiar with this form of injury, or gangrene may
result.
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 dis­connecting or working on hydraulic lines. To relieve
pressure, lower all attachments and shut off engine.

4-2 602471_1009

Check oil level in hydraulic system after every 50 hours of

Hydraulic filter

Hydraulic

reservoir

Fuel shutoff valve

Left fuel tank

Right fuel tank

Closed position

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. Use

only SAE 20W50 SL/SM service motor oil. Fig. 4-1

Change hydraulic system filter element after first 50 hours of
machine operation, then replace filter and oil in reservoir every
500 hours thereafter. Fig. 4-1

The system filter is located in front of the hydraulic reservoir.
A standard oil filter wrench is used to change filter, threads are
right handed. Use a BigDog™ Mowers approved filter

element only.

IMPORT ANT: Prefill the filter element with clean oil, before
installing, to prevent drawing air into the system pump.

Fig. 4-1

Fuel system

DANGER: To avoid personal injury or property dam-

age, use extreme care in handling fuel. Fuel is
extremely flammable and the vapors are explosive.

DANGER: 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.

• 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. They 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.

• Never attempt to start engine when there is a strong
odor of gasoline or diesel fuel fumes present. Locate
and correct 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 or diesel fuel 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 lock­open device.

• Never use gasoline for cleaning parts.

• Read and observe safety precautions elsewhere in
this manual.

WARNING: Gasoline and diesel fuel is harmful or
fatal if swallowed.
Long-term exposure to vapors can cause serious injury
and illness.
Avoid prolonged breathing of vapors.
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.
Use regular unleaded gasoline with an octane rating of 87 or

higher. IMPORTANT: Never use methanol, gasoline containing
methanol, or gasohol containing more than 10% ethanol because
the fuel system could be damaged. Do not mix oil with gasoline.

A fuel shut-off valve is located on each mower. The location

and operation of the fuel valve will vary depending upon the
unit. 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. Fig. 4-2

602471_1009 4-3

Fig. 4-2

Engine oil and filter

Oil drain valve

Oil drain hose

WARNING: 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.

Change the engine oil and filter after the first 5 hours of
operation and 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. IMPORTANT: When removing the oil filter take
precautions to minimize oil spillage on the exhaust system.

A. Draining the engin e oil (units equipped with oil d rain

valve as shown in Fig. 4-3).

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

engine. Fig. 4-3

2. Remove the dust cap.

3. 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.

4. Attach one end of the hose onto the oil drain valve

nipple. Make sure the hose is pushed all the way onto
the valve. Fig. 4-4

5. Position the loose end of the hose out to the left side

of the mower so that it can drain into a suitable oil
drain container.

6. With the hose in position, twist the valve counter-

clockwise and pull out to open the valve. Allow 10
minutes for engine oil to adequately drain.

7. After oil is drained, close the valve by pushing in o n

the valve body and twisting it clockwise.

8. 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.

9. Re-install the dust cap on the oil drain valve nipple.

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

B. Draining the engin e oil (units equipped with oil d rain

valve as shown in Fig. 4-5).

1. Locate the oil drain valve on the engine. Fig. 4-5,

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 out thru the slo t cu t

in the engine base plate so that it can drain into a suit­able oil drain container.

5. With the hose in position, twist the valve counter-

clockwise to open the valve. Allow 10 minutes for
engine oil to adequately drain.

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

clockwise.

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.

Fig. 4-3

Fig. 4-4

Engine air filter

Perform engine air filter maintenance per the Service Interval

chart shown elsewhere in this manual.

Cartridge type filter

A specially designed dry filter is standard equipment on some
BigDog™ Mowers X Series mowers which supplies clean
combustion air to the engine. An example of the air filter are
shown in Fig. 4-6.

Recommended service procedure

1. Release clamps and remove element. Clean the canister

4-4 602471_1009

Fig. 4-5

Oil drain valve

Pre-cleaner

Canister

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 their control.
Therefore, 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
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.

Fig. 4-6

with a damp cloth.

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

bright light inside and rotate the element slowly, 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 cup. Make sure it seals all the way

around the air cleaner body, then tighten the clamps.

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 a 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 element, 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.

Belts

BigDog™ Mowers X Series mowers have two 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 raveling of belt
covering does not indicate failure, trim ravelings with a sharp
knife.

WARNING: 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 control levers in the park brake
position immediately. Inspect the machine and
involve your BigDog™ Mowers 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 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 maintenance

Check the mower blades daily, they are the key to power

602471_1009 4-5

efficiency and well groomed turf. Keep them sharp, a dull blade

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

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.

WARNING: Never attempt to straighten a bent blade
by heating, or weld a cracked or broken blade as the
blade may break and cause serious injury. Replace
worn or damaged blades.

DANGER: 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 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 rock, branch or other
foreign object during mowing!

WARNING: Always wear adequate eye protection
when grinding 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™ Mowers dealer for more information.

Sharpen the blades on a grinder following pattern as shown
(Fig. 4-7). Touch-up sharpening can be done with a file. Check
the blades for balance following grinding. A 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 1/2” 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.

Lay the blade on a flat surface and check for distortion
(Fig. 4-8 & Fig. 4-9). Replace any distorted blade.

Do not re-use spindle bolts which have stripped, worn or
undercut threads. Torque bolts on spindles to 118 foot-pounds
(160.0 nm) when reinstalling blades.

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

WARNING: 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. Wear gloves and
use extra caution when servicing them.

Seat adjustment

The seat can be adjusted forward and rearward by sliding the
seat release handle and moving the seat until a comfortable
operating position is attained.

Fig. 4-7

Fig. 4-8

Fig. 4-9

Control lever adjustment

The steering control levers can be adjusted for operator
comfort. By loosening the cap screws that attaches the upper
control lever to the lower lever (Fig. 4-11), the upper control
lever can be pivoted to fit the operator’s personal preference.

4-6 602471_1009

Fig. 4-10

Forward/rearward

travel lever

Cap screws

Upper

control

lever

Lower

control

lever

The steering control levers should be adjusted so that they

align with each other when in the neutral position.

Fig. 4-11

602471_1009 4-7

BigDog™ Mowers X Series

Maintenance Schedule

Refer to Fig. 4-12 & Fig. 4-13

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 (8) 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 gauge 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 (6) X
Check fuel and hydraulic lines (7) X
Check fuel valve and grommet (7) X
Tighten lug nuts on wheels (2) X
Change fuel filter X
Clean or replace hydraulic fill cap X
Change hydraulic filter & oil (3) X
Grease deck spindle housings X
Check ROPS mounting hardware (9) 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 during hot weather periods.

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

3. Perform initial hydraulic 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. Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contaminati on in the engine. Do

not clean filter element. Replace with a new one.

6. Pump drive belt only - Inspect every 100 hours and replace if worn or cracking is noticed. Otherwise, replace every 400

hours or 2 years whichever comes first.

7. Check fuel line hoses, fuel valve and grommet for any cracks or leaks.

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

9. Inspect ROPS after the first 20 hours of operation 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 engine service information.

NOTE: After completing maintenance cycle (500 hours), repeat cycle.

4-8 602471_1009

BigDog™ Mowers X Series

1

2

3

4b

5

6

4a

6

7

8

9

10

9

11

12

12

11

13

13

14

15

Maintenance Locator Chart

1. Engine Oil Fill & Dipstick

2. Fuel Filter

3. Engine Air Cleaner

4a. Engine Oil Drain Valve

(Briggs & Stratton)

4b. Engine Oil Drain Valve

(Kohler & Kawasaki)

5. Battery

6. Fuel Tanks

7. Hydraulic Oil Reservoir

8. Hydraulic Oil Filter

9. Gauge 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

602471_1009 4-9

Fig. 4-12

BigDog™ Mowers X Series

3

1

3

3

1

2

4

4

4

1. Deck Pusher Arm Zerks (2)

2. Deck Belt

3. Spindle Housing Zerk (3)

4. Blades

Maintenance Locator Chart

Fig. 4-13

4-10 602471_1009

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 o utlined 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

Low engine oil pressure

High oil consumption Numerous See your dealer

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 val ve

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

Numerous See engine manual

Restrictions in air cleaner Service air cleaner

Hydraulic line blockage See your dealer

Internal interference or
leakage in wheel motor

Insufficient hydraulic oil
supply

Poor compression See 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

Low oil level Add oil

Oil diluted or too light Change oil and check for

Failed oil pump See your dealer

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 BigDog™
Mowers Dealer

ON

See your dealer

Check level in reservoir

Have dealer check hydrau­lic pump

Adjust linkage

Install a new traction drive
belt

Clean screen and fin

source of contamination

SYMPTOMS PROBABLE CAUSES

Steering control linkage

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,

needs adjustment

Pump or wheel motors
faulty

Tow valves not closed com­pletely

Low hydraulic oil level Fill reservoir

Hydraulic pump faulty See your dealer

Hydraulic oil cooler clogged Clean oil cooler core

Steering linkage needs
adjustment

Steering linkage needs
adjustment

Wheel motors faulty See your dealer

Tires improperly inflated Adjust air pressure to 8 - 12

Hydraulic pump faulty See 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 BigDog™

loose or broken

The deck drive belt is off
the pulley

Electric clutch is not engag­ing

SUGGESTED

REMEDIES

Adjust linkage

See your dealer

Close tow valves

Adjust linkage

Adjust linkage

psi (55-83 KPa)

Adjust steering linkage

Tighten the engine mount­ing bolts

Tighten the appropriate pul­ley

Contact your BigDog™
Mowers Dealer

Install new cutting blade(s)

Tighten the blade mounti ng
bolt

Replace or tighten spindle
bearing

Mowers Dealer

Install a new deck drive belt

Install the deck drive belt
and check for a reason

Check and/or replace 15
amp fuse.
Contact your BigDog™
Mowers dealer

602471_1009 5-1

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 BigDog™

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)

Mowers Dealer

6. Clean exterior surface of engine. Spread a light film of oil

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

7. Check oil filler cap and fuel tank cap to make certain they

are securely in place.

Preparation of battery for storage

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

1. Remove the battery from machine

2. Clean battery , terminals and cable connectors

3. Charge the battery, if necessary

4. Store 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

o

F (0oC).)

STORAGE

When storing the unit at the end of the mowing season, the
following steps should be taken to ensure readiness for the next
mowing season.

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

mower and touch up all scrapes with touch-up paint.
IMPORTANT: Wash the machine with a mild detergent
and water. Do not pressure wash the machine. Avoid
excessive use of water

2. Replace air filter element.

3. Check thoroughly for any worn or damaged parts that

need replacing and order them from your dealer.

4. Block machine up so weight is off tires. Check tire

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

5. Perform separate engine and battery preparation as listed

below.

6. Store machine in a clean, dry place.

Preparation of engine for storage

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

1. Run engine for a minimum of 15 minutes.

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

3. Refill with fresh oil of proper viscosity.

4. Drain fuel tanks.

5. Remove and replace fuel filter.

New season preparation

Before starting the mower following post season storage, the

following servicing is required:

1. Clean mower, removing trash and dirt accumulation.

2. Check engine oil, hydraulic oil and coolant 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, loose fittings
and so forth.

WARNING: 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 batteries and attach the battery

cables.

PRODUCT LITERATURE

If you would like to view or print a copy of the BigDog™
Mowers product manuals go online to www.bigdogmowers.com
and click on the MANUALS button.

5-2 602471_1009

INDEX

PAGE PAGE

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

Children
Control lever adjustment
Control Panel
Controls
Deck cutting height adjustment
Driving the mower
Electrical system
Engine air filter
Engine oil and filter
Engine starting
Fuel system
General engine maintenance
Hydraulic system
International symbols
Lubrication
Maintenance & adjustment introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

. . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

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

New season preparation
Operating suggestions
Operation safety
Parts and service
Preparation of battery for storage
Preparation of engine for storage
ROPS

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

Safe Operating Practices
Safe Servicing Practices
Safety and Instruction Decals
Safety start interlock system
Seat adjustment
Service safety
Slope guide
Slope Operation
Stopping the engine
Tires

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

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

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

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . 5-2

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

. . . . . . . . . . . . . . 5-2

. . . . . . . . . . . . . . 5-2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

602471_1009 i-1