BIGDOG® MOWER CO.

ALPHA® MP

Operator’s Manual

200 South Ridge Road

Hesston, Kansas
67062

605046 REV K
 WARNING
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.

NOTICE OF REQUIREMENT OF SPARK ARRESTER MUFFLER

This equipment may create sparks that can start fires around dry vegetation. California Public Resources Code
Section 4442.6 provides that it is unlawful to use or operate an internal combustion engine on any forest-covered,
brush-covered, or grass-covered land unless the engine is equipped with a spark arrester maintained in effective
working order. A spark arrester is a device constructed of nonflammable materials specifically for the purpose of
removing and retaining carbon and other 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 SHOULD CONTACT YOUR AUTHORIZED DEALER FOR THE PURCHASE OF
A SPARK ARRESTER.

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

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

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

Federal law and California State law prohibit the following acts or the causing thereof:
1. The removal or rendering inoperative by any person other than for purposes of maintenance,
repair, replacement, of any device or element of design incorporated into any equipment for the
purposes of emissions control prior to or after its sales or delivery to the ultimate purchaser or
while it is in use, or
2. The use of the equipment after such device or element of design has been removed or rendered
inoperative by any person.

REV K 605046
 TABLE OF CONTENTS

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

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

Using this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Literature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Safety and Instructions Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

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

Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Safety Start Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Moving the Mower with Stalled Engine . . . . . . . . . . . . . . . . . . . . . 3-4
Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deck Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Anti-Scalp Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

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

Service Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Flex Forks Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuel and Evaporative Emissions Control System . . . . . . . . . . . . . 4-2
Fuel Evaporation System Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

605046 toc-1 REV K

 Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Steering Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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

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

REV K toc-2 605046

 GENERAL INFORMATION

This manual applies to the following BigDog® Mowers Though current at the time of printing, photographs and
equipment lines: illustrations shown may vary slightly from your mower due to
subsequent production changes. BigDog® Mower Company
BigDog® Mowers Alpha® MP reserves the right to redesign and change the machine as
deemed necessary, without notification. If a change has been
To the New Owner made to your machine which is not reflected in this manual,
contact your BigDog® Mower Dealer for current information.
BigDog® mower owners and operators must read this Warranty Registration
manual carefully. It contains operation and maintenance
information that will help you achieve years of dependable
To activate your warranty policy the mower must be
service.
registered, by your Dealer, with the Manufacturer of BigDog®
The Engine Owner’s Manual, included in the owner’s mowers within ten (10) days following the date of purchase.
packet, contains engine information that will not be repeated It is recommended that you contact your Dealer to make sure
in this manual. the mower is registered.
The owner’s responsibilities include, but are not limited to, IMPORTANT: The mower and any attachment that
making certain that the operators and mechanics: displays a model and serial identification number plate must
• read and understand the engine owner’s manual be registered with Excel Industries, Inc., manufacturer of
before attempting to operate or repair the engine. BigDog® mowers (“Manufacturer”).
• read and understand the mower’s operator manual and IMPORTANT: Any unauthorized modification, alteration,
all decals before operating this machine. or use of non-approved attachments voids the warranty and
• are qualified and physically able individuals, properly releases Manufacturer from any liability arising from
trained in the operation and maintenance of this subsequent use of this equipment. Do not use or operate any
equipment. Before they are allowed to operate or attachment not approved by BigDog® Mower Company.
maintain this machine, they must be familiar with its IMPORTANT: Damage caused by unauthorized
safe operation, operator controls, and decals. replacement parts is not covered by this warranty.
• know they are responsible for their own safety as well Manufacturer expressly excludes liability for defects or
as the safety of other persons within the vicinity. damage caused by such 'unauthorized' articles or service.
Remember, the operator is responsible for accidents Model and Serial Number
or hazards occurring to other people or their property.
• who cannot read and understand English have this Mower model and serial numbers are found on the serial
material explained to them. identification plate, located on the left mower frame side rail.
IMPORTANT: As the owner/operator you can prevent These numbers are required when the unit is registered
accidents. You are responsible for accidents or injuries with BigDog® Mowers. They will also assure you of the
occurring to yourself, other people or property. correct service parts when replacement becomes necessary.
Never let children or untrained people operate or service Parts and Service
the equipment. Local regulations may restrict the age of the
operator.
Use original BigDog® Mower replacement parts, or parts
For more detailed maintenance and adjustment that are equivalent in overall performance, that are available
information refer to the proper General Service Manual for from your local BigDog® Mower Dealer. For prompt, efficient
your machine. Refer to the Product Literature section of this service, always provide the following information when
manual for information on how to obtain this manual. ordering parts:
Using this Manual 1. Correct part description.
2. Correct part number.
This manual contains general operation information as
3. Correct model number.
well as basic adjustment and maintenance information.
Since operating conditions vary considerably, all conditions 4. Correct serial number.
cannot be addressed individually. Through training and All arrangements for warranty repair and service must be
experience, operators should develop safe operating handled through an authorized BigDog® Mower Dealer.
practices suitable to most conditions.
Directions used in this manual, for example RIGHT or LEFT,
refer to directions when in the operator position and facing
forward, unless otherwise stated.

605046 1-1 REV K

Product Literature

If you would like to view or print a copy of the product

manuals (Operator’s Manual, Parts Manual, or General
Service Manual) for these mowers go online to
www.bigdogmowerco.com.
Contact your local BigDog® Mower dealer if you require
another engine manual.

REV K 1-2 605046

 SAFETY PRECAUTIONS

Incorrect usage of this equipment may result in severe injury

or death. Personnel operating and maintaining it should be
trained in its proper use. They should read this manual
completely and thoroughly before attempting to set-up,
operate, adjust, or service this equipment.

Safe Operating Practices

This safety alert symbol is used to call attention to a This product is capable of amputating hands and feet and
message intended to provide a reasonable degree of throwing objects. Always follow all safety instructions to
PERSONAL SAFETY for operators and other persons during avoid serious injury or death.
the normal operation and servicing of this equipment.  Never allow persons to operate this mower without
proper instruction or allow children to operate the
mower. Allow only responsible adults who are familiar
with these instructions to operate this mower.
DANGER

– denotes immediate hazards which WILL result in

severe personal injury or death. Safe Operation
 Evaluate the terrain to determine what accessories
and attachments are needed to properly and safely
perform the job. Only use accessories and
attachments approved by the manufacturer.
• Do not use any unauthorized attachment or
WARNING

modify the mower.

– denotes a hazard or unsafe practice which COULD
• Follow the manufacturer’s recommendation for
result in severe personal injury or death.
wheel weights or counterweights.
• If any attachment or additional weight is
mounted on the rear of the unit, any rapid
movement of the control levers in either direction
This manual uses two other words to highlight information:
could result in a reaction of the mower that can
A. IMPORTANT – calls attention to special mechanical cause serious injury.
information.
 Do not use a catcher on any mower equipped with Flex
B. NOTE – emphasizes general information worthy of Forks®.
special attention.
 Always be alert and inspect area to be mowed for
The owner’s responsibilities include, but are not limited to, hazards such as rocks, metal objects and other debris
• making certain that the operators and mechanics read which may be thrown or entangled by mower blades.
and understand this manual and all decals before Remove these objects before mowing. Watch out for
operating this machine. holes or deep depressions.

• making certain that before the operators and  Always operate mower in daylight or with adequate
mechanics are allowed to operate or maintain this working lights.
machine, they must be familiar with its safe operation,  Never operate the mower when there is a risk for
operator controls, and decals. lightning.
• ensuring that the operators and mechanics know they
are responsible for their own safety as well as the Personal Safety
safety of other persons within the vicinity. Remember,  Always wear long pants and safety shoes with slip-
the operator is responsible for accidents or hazards resistant soles when operating this mower.
occurring to other people or their property.
• Do not wear sandals, tennis shoes, sneakers,
Improper use, adjustment, or maintenance by the operator, shorts or any type of loose fitting clothing as they
mechanic or owner can result in injury or death. Reduce the may get tangled in moving parts.
potential for injuries by following these safety instructions.
• Do not wear a towel from the waist, or use a towel
Pay close attention to the safety alert symbol “” and the
as a headband or neck wrap.
instructions that follow it. Failure to comply with these
instructions may result in personal injury or death. • Long hair or jewelry may get tangled in moving
parts.

605046 2-1 REV K

  Always wear adequate ear protection, such as  Stop the engine before removing the grass catcher or
earplugs. Prolonged exposure to loud noise can cause unclogging the discharge chute. Never clear the
impairment or loss of hearing. discharge chute with the engine running. Turn off the
• Do not wear radios or music headphones while engine and be sure the blades have stopped before
operating this mower. Safe operation requires cleaning. Use a stick to clear a plugged discharge
your full attention. area. Never use your hand!

 Always wear safety goggles or safety glasses with side  Follow daily and weekly checklists, making sure hoses
shields when operating this mower. are tightly secured and bolts are tightened.

 Do not operate the mower if you are fatigued, sick or • Never operate a poorly maintained mower.
while under the influence of alcohol or drugs, if you are  Clean flammable material from mower. Prevent fires by
pregnant or under 18 years old. keeping the engine compartment, top of the deck,
 Poor posture or operating the mower for extended exhaust area, battery, fuel line, fuel tank and operator’s
periods of time may lead to fatigue or injury, resulting station clean of accumulated trash, grass clippings, and
in loss of mower control. Occasionally, stop the mower other debris. Always clean up spilled fuel and oil.
and get off the seat to stretch and relax.  Prevent fires by keeping the engine and exhaust areas
 Data indicates that operators aged 60 years and above clear of grass clippings and other debris. Do not back
are involved in a large percentage of riding mower- mower into flammable materials.
related injuries. These operators should evaluate their • Allow the mower, especially the engine, to cool in
ability to operate the mower safely enough to protect a well ventilated area before storing inside a
themselves and others from serious injury. building or other enclosure.
 Do not change the engine governor setting or over
Operation speed the engine. Operating the engine at excessive
 Never leave a running mower unattended. Before speed may increase the hazard of personal injury.
leaving the operator’s seat for any reason, including  Rapid movement of the steering control levers in either
emptying the catcher or unclogging the chute: direction could result in a reaction of the mower that
• Always stop on level ground. can cause serious injury.
• Disengage the deck clutch. • Never push forward suddenly on your steering
• Place the steering control levers in the park brake control levers while the mower is in rearward
position. motion because mower may tip backwards.

• Stop the engine. • Never pull back suddenly on your steering control
levers while the mower is in forward motion.
• Remove the ignition key.
 Always be aware of what is behind the mower before
• Wait for the engine and all moving parts to come backing up. Never mow in reverse. Always look down
to a complete stop. and behind before and while backing up.
 Always inspect mower for damage after striking a • If mowing in reverse is unavoidable, push forward
foreign object. If damage is found, repair mower slowly on the steering control levers and avoid
immediately. sudden movement.
 Always remain seated while operating the mower. Only  Slow down before turning.
start the engine from the operator’s position.
 Never attempt high speed maneuvering, especially in
 Turn off the mower blades when not mowing. crowded or congested areas.
 Always keep safety shields and covers in place, except  Always maintain a safe distance from people and pets
for servicing. when mowing. Always stop mower if someone enters
• Never operate the machine with the floor plate the area.
pulley cover removed.  Never carry passengers.
 Never operate the mower deck with the discharge  Never direct discharged material toward anyone. Avoid
chute damaged, altered, removed, or in the raised discharging material against a wall or obstruction.
position, except when the entire grass catcher Material may ricochet back toward the operator.
attachment or mulching system is being used. Always disengage the mower blades and wait for them
 Always keep clear of the mower blades and to stop before crossing gravel drives, walks or roads.
attachments during their operation.  Always observe traffic laws while driving mower from
• Never put hands or feet under any part of the one location to another. Watch for traffic when
mower while it is running. operating near or crossing roadways.

REV K 2-2 605046

 • Use care when approaching blind corners,  Operate a safe distance (minimum of 10 feet) away
shrubs, trees, or other objects that may obscure from drop-offs, retaining walls, drainage ditches,
your vision. embankments, water, and other types of hazards to
 Do not tow the machine. Move it by hand or use a avoid a wheel dropping over the edge or to avoid the
winch to load on a trailer for transporting. When ground from breaking away. This will reduce the risk of
transporting on another vehicle, the mower should be the mower suddenly rolling over causing serious injury
facing forward and it must be secured. or death.

 Secure frame to transport vehicle with at least two  Use a walk behind, push mower or hand-held trimmer
straps, chains, cables, or ropes. Never secure unit on slopes and near drop-offs, retaining walls, drainage
from rods or linkages to vehicle, otherwise damage ditches, embankments and water to avoid mower
could occur. rollover and serious injury or death.
 Do not mow on wet grass. Slippery conditions reduce
Using a Ramp traction which could cause sliding and loss of steering
control.
 Exercise extreme caution when loading and unloading
a mower onto a truck or trailer with a ramp.  Do not tow on slopes. The weight of the towed
equipment may cause loss of traction and loss of
 Use only a single, full width ramp; do not use individual
steering control.
ramps for each side of the unit. Having a full width
ramp provides a surface for the mower frame to  Do not try to stabilize the mower by putting your foot
contact if the unit starts to tip backwards. It also on the ground.
reduces the risk of a wheel going off and the mower  If the mower’s tires lose traction when operating on
tipping over. slopes, disengage the blades, place the control levers
 Do not exceed a 15 degree angle between the ramp in the park brake position, stop the engine, remove
and the ground or between the ramp and the trailer or ignition switch key, and get help.
truck.  Never make sudden starts, stops, turns, or reverse
 Avoid sudden acceleration when on a ramp. direction, especially when maneuvering on slopes. The
steering is designed for sensitive response. Rapid
Slope Operation movement of the control levers in either direction
could result in a reaction of the mower that can cause
Slopes are a major factor in loss-of-control and tip-over
serious injury.
accidents, which can result in severe injury or death. All slopes
require extra caution. If you cannot back the mower up the  Never stop suddenly while backing down slopes. This
slope or if you feel uneasy on the slope; do not mow it. action may result in a reaction of the mower that can
REMINDER: Only operate on slopes of 15 degrees or less. cause serious physical injury.

 Use extreme caution when operating on slopes.  The BigDog® mower is capable of operating
horizontally (traverse) on moderately steep slopes.
• Be extremely careful changing directions on a
When operating on slopes up to 15 degrees, be aware
slope. Slow down.
of any conditions that may cause the mower drive tires
• Do not operate where the mower could slip or tip. to lose traction resulting in a possible loss of control
• Turn slowly of the mower. An operator should not operate on a
slope until he is thoroughly familiar with the
• Turn on the most level part of the slope
equipment.
• To maximize traction, it is better to turn the front
Do not operate on slopes greater than 15 degrees.
of the mower uphill, rather than downhill. If drive
tires lose traction, steering control is lost which Refer to the Slope Guide, when determining the degree
could cause serious injury or death. of slope to be mowed.
• If it becomes necessary to turn downhill, turn It is strongly recommended that the operator drive the
slowly and gradually, if possible. mower off of the slope, using extreme caution, if any
sign of loss of traction is detected. Wait until the
 Watch for holes, ruts, bumps, rocks or other hidden
condition that caused the problem is resolved before
objects. Uneven terrain could overturn the mower. Tall
attempting to operate on the slope again.
grass can hide obstacles.
Terrain conditions can affect traction resulting in
 Remove obstacles such as rocks, tree limbs, etc.
possible loss of control of the mower. Some of the
 Keep all movement on slopes slow and gradual. Do not conditions to be aware of are:
make sudden changes in speed or direction.
• Wet terrain
 Avoid starting and stopping on a slope. If tires lose
• Depressions in the ground; i.e. holes, ruts,
traction, disengage the mower blades and proceed
washouts
slowly straight down the slope.
• Mounds of dirt

605046 2-3 REV K

 • Soil type; i.e. sand, loose dirt, gravel, clay  Use care when approaching blind corners, shrubs,
• Grass type, density, and height trees, the end of a fence or other objects that may
obscure vision.
• Extremely dry conditions of grass
Service Precautions
• Tire pressure
The attachments mounted to the mower will also  Unless specifically required, DO NOT have the engine
affect the way it handles on a slope. Be aware that running when servicing or making adjustments to the
each attachment’s characteristics vary. mower.
Another consideration to safe mowing on slopes is to • Park the mower on level ground.
be aware of what is located at the bottom of the slope.
Extreme caution should be used when there is a • Disengage the deck clutch.
hazard located at the bottom of the slope. Some • Place the steering control levers in the park brake
examples are: position.
• Water; i.e. lake, river • Lower the deck.
• Cliffs, retaining walls • Stop the engine.
• Roads, highways • Remove the ignition key.
• Buildings • Disconnect the negative battery cable.
• Rocks • Wait for all movement to stop before adjusting,
These are just a few examples of situations when cleaning or repairing.
caution must be used when operating on a slope. • Repairs or maintenance requiring engine power
There are many other possibilities too numerous to should be performed by trained maintenance
mention. Just remember to always exercise extreme personnel only.
caution when operating on any slope. • To prevent carbon monoxide poisoning, operate
the engine in a well ventilated area only.
Children
• Read and observe all safety warnings in this
Tragic accidents can occur if the operator is not alert to the manual.
presence of children. Children are often attracted to the mower
 Before working on or under the deck, make certain the
and the mowing activity. Never assume that children will remain
engine cannot be accidentally started.
where you last saw them.
 Always keep belt covers on mower deck for safety as
 Never leave the mower unattended with the ignition
well as for cleanliness except when changing or
key in the switch, especially with children present.
checking the belt.
 Children or bystanders may be injured if they attempt
 Use a stick or similar instrument to clean under the
to move or to operate the mower while it is
mower making sure that no part of the body, especially
unattended. Always disengage the deck clutch, place
arms and hands are under the mower.
the control levers in park brake position, stop the
engine, and remove the ignition key when leaving the  Always wear adequate eye protection when:
operator’s seat. • servicing the hydraulic system.
 Keep children out of the mowing area and under the • servicing the battery.
watchful care of a responsible adult other than the
• grinding mower blades and removing
operator.
accumulated debris.
 Be alert and turn the mower off if children enter the
 Never attempt to make any adjustments or repairs to
area.
the mower drive system, mower deck or any
 Before and while backing, look behind and down for attachment while the mower engine is running or deck
small children. clutch is engaged. Repairs or maintenance requiring
 Never carry children, even with the blades off. They engine power should be performed by trained
may fall off and be seriously injured or interfere with maintenance personnel only.
safe mower operation. Children who have been given  Never work under the machine or attachment unless it
rides in the past may suddenly appear in the mowing is safely supported with jack stands.
area for another ride and be run over or backed over by
• Make certain machine is secure when it is raised
the mower.
and placed on the jack stands.
 Never allow children to operate the mower.
• The jack stands should not allow the machine to
 Never allow children or others in or on towed move when the engine is running and the drive
equipment. wheels are rotating.

REV K 2-4 605046

 • Use only certified jack stands. Use only  Avoid skin and clothing contact with battery acid.
appropriate jack stands, with a minimum weight • Always wear eye protection when checking the
rating of 2000 pounds (907 kg) to block the unit battery. Acid can cause serious injury to skin and
up. eyes. If contact occurs, flush area with clean
• Use in pairs only. water and call a physician immediately. Acid will
• Follow the instructions supplied with the jack also damage clothing.
stands. • Do not drink the battery electrolyte.
 Exercise caution when releasing spring tension from • Do not allow open flame near the battery when
any of the belt idlers or when working with any of the charging.
deck lift components. • Hydrogen gas forms inside the battery. This gas
 Do not touch hot parts of machine. is both toxic and flammable and may cause an
 Keep nuts and bolts tight, especially the blade explosion if exposed to flame. Always disconnect
attachment bolts. Keep equipment in good working the negative (black) battery cable(s) before
condition. disconnecting the positive (red) cable(s). Always
connect the positive (red) battery cable(s) before
 Never tamper with safety devices. Check their proper connecting the negative (black) cable(s).
operation regularly.
• Do not overfill the battery.
 Grass collection system components are subject to
wear, damage and deterioration, which could expose • Electrolyte may overflow and damage paint,
moving parts or allow objects to be thrown. Frequently wiring or structure. When cleaning the battery,
check components and replace with manufacturer’s use soap and water. Be careful not to get soap
recommended parts, when necessary. and water into the battery. Clean the battery
terminals with a solution of four parts water and
 Exercise caution when working under the deck as the one part baking soda when they become
mower blades are extremely sharp. Wrap the blade(s) corroded.
or wear gloves and use extra caution when servicing
them.  Shorts caused by battery terminals or metal tools
touching metal mower components can cause sparks.
 Use original BigDog® Mower replacement parts, or Sparks can cause a battery gas explosion which will
parts that are equivalent in overall performance, that result in personal injury.
are available from your local BigDog® Mower Dealer.
• Prevent the battery terminals from touching any
• The mower may not comply with the appropriate metal mower parts when removing or installing
safety standards if aftermarket parts, the battery.
accessories, or attachments are used.
• Do not allow metal tools to short between the
battery terminals and metal mower parts.
Mower Blade Maintenance Precautions
 Incorrect battery cable routing could cause damage to
 Never attempt to straighten a bent blade by heating, or
the mower and battery cables. This can cause sparks
weld a cracked or broken blade as the blade may break
which can cause a battery gas explosion which will
and cause serious injury. Replace worn or damaged
result in personal injury.
blades.
• Always disconnect the negative (black) battery
 Never work with blades while engine is running or deck
cable(s) before disconnecting the positive (red)
clutch switch is engaged (on).
cable(s).
 Always wear adequate eye protection when grinding
• Always connect the positive (red) battery cable(s)
mower blades.
before connecting the negative (black) cable(s).
 Mower blades are sharp and can cut. Wrap the
blade(s) or wear gloves and use extra caution when Fuel Handling Precautions
servicing them.
 To avoid personal injury or property damage, use
extreme care when handling gasoline. Gasoline is
Battery Service Precautions
extremely flammable and the vapors are explosive.
 Battery posts, terminals, and related accessories
• A fire or explosion from gasoline can burn you
contain lead and lead compounds, chemicals known to
and others and can damage property.
the State of California to cause cancer and
reproductive harm. Wash hands after handling.  Observe the usual gasoline handling precautions:
 Charge batteries in a well-ventilated open area, away • Do not smoke while refueling. Extinguish all
from sparks and flames. Unplug charger before cigarettes, cigars, pipes and other sources of
connecting or disconnecting from battery. Wear ignition.
protective clothing and use insulated tools.

605046 2-5 REV K

 • Do not remove fuel cap or fill tank with engine It is the owner’s responsibility to make certain that the
running or while engine is hot. Clean up any operators and mechanics read and understand all decals
gasoline spills. before operating this machine.
• If gasoline is spilled, do not attempt to start the
engine but move the machine away from the area
of spillage and avoid creating any source of Specific safety warning decals are located on the

WARNING
ignition until gasoline vapors have dissipated. equipment near the immediate areas of potential
• Keep gasoline away from open flame or spark and hazards. Do not remove or obliterate these decals.
store machine away from open flame or spark or Replace them if they become non-readable.
pilot light such as on a water heater or
appliances.
• Refuel outdoors. Never refuel or drain the The following illustrations show the safety decals that are
gasoline from the machine indoors, or while in located on the mower. A brief explanation is shown to help
the operator understand the decal’s meaning.
an enclosed trailer or other enclosed area.
• Never attempt to start the engine when there is a
strong odor of gasoline fumes present. Locate
and correct the cause.
• Store gasoline in an approved container and keep
it out of the reach of children. Never buy more
than a 30-day supply of gasoline. • Read Operator’s Manual and Safety Warning Decals before
attempting to operate this machine.
• Do not fill fuel containers inside a vehicle or on a
truck or trailer bed with interior carpets or plastic
truck bed liners. Always place gasoline EL
0 F U V OI D

containers on the ground away from your vehicle

S E1

N
WA M A X O F

HI G H ER T H A
RR A NT Y
before filling.

IN F UEL
10
% E ANO

L
• When practical, remove the machine from the
TH

truck or trailer and refuel the machine with its

wheels on the ground. If this is not possible, then • Do not smoke while refueling.
refuel such machine on the truck or trailer using a • Do not remove the fuel tank cap or fill tank with engine running or
while the engine is hot.
portable container and not a fuel dispenser
• Allow the mower, especially the engine, to cool in a well ventilated
nozzle. If a fuel dispenser nozzle must be used,
area before storing inside a building or other enclosure.
keep the nozzle in contact with the rim of the fuel
• Store away from open flame or spark if there is fuel in tank.
tank or container opening at all times until
• Clean up any gasoline spills.
fueling is complete. Do not use a nozzle lock-
• Do not refuel while in enclosed trailer or other enclosed areas.
open device.
• Maximum of 10% ethanol (E10) in fuel. Fuels with greater than 10%
• Never use gasoline for cleaning parts. ethanol, (such as E15, E20 and E85) voids warranty. Fuels with
greater than 10% ethanol are not approved for use and such use
• Read and observe safety precautions elsewhere could cause equipment failure and pose a fire hazard.
in this manual.
 Gasoline is harmful or fatal if swallowed.
 Avoid prolonged breathing of vapors.
• Long-term exposure to vapors can cause serious
injury and illness. Part Number 602041
602041

WARNING: • Keep a safe distance from the machine.

 Keep gasoline away from eyes and skin. Hot surface!
• Keep face away from nozzle and fuel tank or fuel
container opening.
Part Number 600899
• If gasoline is spilled on clothing, change clothing
immediately.
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

Safety and Instructions Decals

inspection and replacement intervals and refer to above paragraph for
emergency procedures.
600899

• If you lose steering control while operating the machine, place the
The decals are designed to give the operator and mechanic steering control levers in the park brake position immediately.
Inspect the machine and involve your dealer to resolve the problem
brief daily operational and service information. Use these before continuing to operate.
decals as an extension of this manual. Do not remove or • If pump belt fails, steering control will be lost. Refer to owner’s
obliterate the decals. Replace unreadable or missing decals. manual for inspection and replacement intervals and refer to above
paragraph for emergency procedures.

REV K 2-6 605046

Part Number 785139 & 785220 Top of Deck Clutch Switch Shown
Park brake position Forward position Park brake position

A B

785139C E
785220C E

Reverse position
A. Deck clutch disengaged (OFF) position
B. Deck clutch engaged (ON) position

DANGER:
Rotating blades, pulleys & belts

• Keep shields and covers in place

while machine is in operation
601837 • Keep hands, feet and clothing
Part Number 601837 away from rotating pulleys and
belts.

DANGER: Battery Hazards!

Part Number 601815

601815

• Avoid skin con- • Do not overfill battery. • Do not allow open flame near the
tact with battery • Electrolyte may overflow and damage battery when charging.
acid paint, wiring or structure. When cleaning • Hydrogen gas forms inside the bat-
the battery, use soap and water. Be care- tery. This gas is both toxic and flam-
ful not to get soap and water into the mable and may cause an explosion if
battery. Use soda mixed in water to exposed to flame. Always remove
clean corrosion off the terminals. the negative ground first and replace
• Always wear eye protection when check- it last.
ing the battery, acid can cause serious
injury to skin and eyes. If contact occurs,
flush area with clean water and call phy-
sician immediately. Acid will also dam-
age clothing.

605046 2-7 REV K

 601967

WARNING: Fire! • Clean flammable material from

WARNING: • Never operate the mower deck with side
Thrown objects! deflector damaged, altered, removed or in
machine. Prevent fires by keeping
engine compartment, top of deck, raised position, except when the entire
Part Number 601967 Part Number 601624 grass catcher attachment or mulching sys-
exhaust area, battery, fuel line, fuel
tank and operator’s station clean of tem is being used.
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 position, except when the entire
grass catcher attachment or mulching
system is being used.
DANGER:
Rotating blades, pulleys & belts

• Keep shields and covers in place

while machine is in operation.
604221

• Keep hands, feet and clothing

Part Number 604221 away from rotating pulleys and
belts.

WARNING: Thrown objects! DANGER:

Rotating blades, pulleys & belts

• Always maintain a safe distance from • Keep shields and covers in place
people and pets when mowing. while machine is in operation.
• Always stop machine if someone enters 604222 • Keep hands, feet and clothing
the area. away from rotating pulleys and
• Inspect area to be mowed for hazards belts.
such as rocks, metal objects and other Part Number 604222
debris which may be thrown or entangled
by mower blades. Remove these objects
before mowing.

REV K 2-8 605046

 I
C

J
L D
F
A M
G

B
604889

K E
Part Number 604889

A. Fast J. Read Operator’s Manual before attempting to operate

B. Slow this machine.
C. Choke K. Before starting the engine:
D. Mower blade engage/disengage switch • Read Owner’s Manual
E. Ignition switch - insert key • Disengage mower blades
F. OFF • Place control levers in park brake position
G. ON L. For maximum electric clutch life engage at 1/2 - 3/4
H. Engine start position throttle position.
I. Wear ear protection, eye protection and safety shoes M. For maximum electric clutch life disengage at low
when operating this equipment. throttle position.

I
K C
E
A L
F

B
605996

J D
Part Number 605996

A. Fast I. Read Operator’s Manual before attempting to operate

B. Slow this machine.
C. Mower blade engage/disengage switch J. Before starting the engine:
D. Ignition switch—insert key • Read Owner’s Manual.
E. OFF • Disengage mower blades.
F. ON • Place control levers in park brake position.
G. Engine start position K. For maximum electric clutch life engage at 1/2–3/4
H. Wear ear protection, eye protection and safety shoes throttle position.
when operating this equipment. L. For maximum electric clutch life disengage at low
throttle position.

605046 2-9 REV K

 H

I
K C
E
A L
F M

B
606579

J D
Part Number 606579

A. Fast J. Before starting the engine:

B. Slow • Read Owner’s Manual.
C. Mower blade engage/disengage switch • Disengage mower blades.
D. Ignition switch—insert key • Place control levers in park brake position.
E. OFF K. For maximum electric clutch life engage at 1/2–3/4
F. ON throttle position.
G. Engine start position L. For maximum electric clutch life disengage at low
H. Wear ear protection, eye protection and safety shoes throttle position.
when operating this equipment. M. Seat fan switch
I. Read Operator’s Manual before attempting to operate
this machine.

REV K 2-10 605046

 Part Number 601981

WARNING: Read Operator’s Manual and decals before attempting to

operate this machine.

WARNING: Roll over!

• Operate 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 operate on slopes above a retaining wall or drop-off.

WARNING: Ejection!

• Do not operate on slopes greater than 15 degrees.

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

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

WARNING: Loss of traction/control on slopes!

1.

• Shut off blades.

2.

• Back slowly down the slope

601981when loss of traction occurs.

601981

605046 2-11 REV K

REV K 2-12 605046
 Slope Guide
Use this diagram when determining the degree of slope to be mowed.

E (15o) Slope Guide Lines

D (10o)

C (5o)
Line B

Line A

1. Hold this sheet of paper in front of you. Make sure that Line A is horizontal.
2. Align Line B with a vertical surface such as pole, tree or building.
3. Fold the paper along the slope guide lines (C, D or E).
4. Align the closest slope guide line with the ground slope. This will give you a close estimation of the ground slope to
be mowed.

605046 2-13 REV K

REV K 2-14 605046
 OPERATION

Safe Operating Practices

Mowers with seat fan switch

Refer to the Safety Precautions section of this manual for

A
operational and personal safety information. E
Control Panel

B F
Mowers with Kawasaki engines

A
D

C
E

B
A. Deck clutch switch D. N/A
C B. Ignition switch E. Hour meter
C. Throttle F. Seat fan switch

Figure 3-3
For additional clutch information refer to the Mower
A. Deck clutch switch D. Choke
Deck Operation section of this manual.
B. Ignition switch E. Hour meter
C. Throttle B. Ignition switch (Figure 3-1, Figure 3-2 & Figure 3-3) — a
three position switch: “OFF”, “RUN”, and “START”. With
Figure 3-1 the key inserted, rotate it clockwise to the “START”
position; release the key when the engine starts, and
Mowers with Kohler engines the switch will automatically return to the “RUN”
position
C. Throttle control (Figure 3-1, Figure 3-2 & Figure 3-3) — a
cable is linked to the engine throttle for controlling
engine speed. Move the lever forward to increase
A
engine rpm, move the lever rearward to decrease
engine rpm.
E
D. Choke control (if equipped) (Figure 3-1) — a cable is
C linked to manually operate the engine choke. When the
B lever is in the down position, the choke is in the “OFF”
(run) position. When the knob is pulled up, the choke is
in the “ON” (start) position. Do not operate the machine
in the “ON” (start) position.
E. Electronic hour meter (Figure 3-1, Figure 3-2 &
A. Deck clutch switch D. N/A Figure 3-3) — registers 1/10 hour increments up to
B. Ignition switch E. Hour meter 9,999.9 total hours. Connected to the ignition switch,
C. Throttle the meter records the accumulative time while the
ignition key is switched to the RUN position.
Figure 3-2
F. Seat fan switch (Figure 3-3) — this switch turns the
A. Deck clutch switch (Figure 3-1, Figure 3-2 & Figure 3-3) seat fan on or off.
— this switch engages the deck. Pull the switch up to
engage and push the switch down to disengage the
clutch.

605046 3-1 REV K

Controls
Shown with steering control levers in the park brake
position
A. Steering control levers (Figure 3-4 & Figure 3-5) —
these levers control the mower’s speed, direction,
stopping, and park brake.

A
WARNING

The parking brake may not hold the mower if

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

B. Deck lift pedal (Figure 3-6) — 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. A. Steering control lever

Shown with steering control levers in the neutral position Figure 3-5

Alpha© MP shown

A. Steering control lever

Figure 3-4
A. Deck lift pedal

Figure 3-6

REV K 3-2 605046

Lights • check the function of the seat switch. Replace
the seat switch if it is not operating properly (is
These mowers come equipped with operating lights not opening or closing) and if the cause can not
mounted in the front mower frame. There is no dedicated be determined.
“ON/OFF” switch for these lights. These lights come on when If you cannot locate the problem contact your BigDog®
the ignition switch is in the “RUN” position and go off when Mower Dealer.
the ignition switch is in the “OFF” position. Figure 3-7

The safety interlock system should always

WARNING
function per steps 4 and 5. If it does not function
properly, correct it immediately. Do not operate
machine without a properly functioning seat
safety switch.

Engine Starting

The mower’s safety start interlock system is also designed

A
to protect the operator and others from accidental injury due
to unintentional engine starting. The engine starting motor
will not engage until:
1. Steering control levers are in the park brake position.
A. Lights
2. Deck clutch switch is in the down (OFF) position.
Figure 3-7

Safety Start Interlock System

The safety interlock system must not be
WARNING

disconnected or bypassed. Doing so could cause

The mower’s safety start interlock system consists of the
the machine to operate unexpectedly resulting in
park brake switches, seat switch, and deck clutch switch.
personal injury.
IMPORTANT: Repair this important safety feature
immediately if it malfunctions.
This safety feature prevents mower runaway or accidental
NOTE: The operator’s seat is equipped with a separate
entanglement during operation.
safety switch. If for any reason the operator should become
Check the mower’s safety start interlock system daily, unseated when the steering control levers are not in the park
prior to operation. brake position (park brake switches are disengaged) or the
To inspect the system: deck clutch switch is engaged, the engine will stop.
1. Sit on the seat when testing the seat switch. The following steps are the correct procedures for starting
2. Set both steering control levers in the park brake the engine. If difficulty is encountered, contact the BigDog®
position. Mowers Dealer in your area.
1. Before starting mower each day, perform daily pre-
3. Start the engine and allow it to warm up to operating
operation checking. (See Safety Start Interlock System
temperature.
section.)
4. With the deck clutch switch down and the steering
2. Make sure the steering control levers are in the park
control levers in the park brake position, slowly rise off
brake position and deck clutch switch is disengaged.
of the seat. The engine should continue to run.
Only start the engine from the operator’s position.
5. With the deck clutch switch up and/or the steering
3. Use the choke, if the unit is equipped with one, when
control levers in the neutral position, slowly rise off of
engine is cold, or if warm engine fails to start within 5
the seat. The engine should stop.
seconds of cranking. Avoid flooding and operate
6. If the engine fails to stop when: engine without choking as soon as possible.
• the deck clutch switch is up, or 4. Set throttle at approximately 1/2 open position.
• one or both of the steering control levers is in the 5. Insert key in ignition switch and rotate full clockwise
up (out of neutral position), and to engage starting motor. Release key when engine
• the operator is off the seat, then starts.

605046 3-3 REV K

 IMPORTANT: The engine starter should not be
Bypass valve rod shown in operating position
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 B
system is operating properly. Refer to Safety Start
Interlock System section.
7. Allow the engine to idle a few minutes before
advancing the throttle and/or engaging the deck
clutch.

Stopping the Engine

Use the following procedure to shut the engine off. A

1. Place the steering control levers in the park brake

position.
2. Throttle the engine back to low idle, then disengage
the deck clutch. Refer to the Mower Deck Operation A. Bypass valve rod B. Slot
section for more details.
Figure 3-8
3. Let the engine run at low idle for two minutes.
4. Rotate the ignition key counter-clockwise to the “OFF” Mower Operation
position. Remove the key from the switch before
leaving the mower.
Driving the Mower
Moving the Mower with Stalled Engine
Never make sudden stops or reverse direction,
The bypass valves on the transaxles allow the mower to be especially when maneuvering on a slope. The
DANGER

moved if the engine quits working.

steering is designed for sensitive response. Rapid
movement of the control levers in either direction
could result in a reaction of the mower that can
Allow the engine exhaust manifold to cool before cause serious injury.
WARNING

engaging or disengaging the bypass valves. The

bypass valve rods are located close to the exhaust After starting the engine, engage the steering control
system. levers and steer as follows:
To go forward, push the steering control levers forward an
equal distance. Figure 3-9
Before moving the unit, pull out on the bypass valve rod To go in reverse, pull the steering control levers rearward
(Figure 3-8) until the notch in the rod hooks over the edge of an equal distance. Figure 3-9
the slot. This places the bypass valves in the disengaged
position. To turn left, move the right steering control lever farther
forward from neutral than the left steering control lever.
Place the steering control levers in the neutral position, to
release the park brakes, so that the mower can be moved. To turn right, move the left steering control lever farther
forward from neutral than the right steering control lever.
Do not tow the machine. Move it by hand or use a winch to Figure 3-9
load onto a trailer for transporting.
Zero radius turn, move one steering control lever forward
Secure the mower, facing forward, when transporting on and the other steering control lever back of neutral. This
another vehicle. Tie the mower down securely using straps, allows the drive wheels to counter-rotate. Figure 3-9
chains, cables, or ropes. Both front and rear straps should be
directed down and outward from the machine. To stop or decrease speed, move steering control levers to
neutral. When going forward pull back gently on steering
IMPORTANT: Always make certain the two bypass valves control levers. When going in reverse push forward gently on
are returned to their operating position before running the steering control levers.
mower following repairs.
For emergency stops, when traveling forward or rearward,
place the steering control levers in the park brake position
immediately.

REV K 3-4 605046

 FRONT OF MOWER FACES THIS DIRECTION

When moving in the rearward direction push

forward gently on steering control levers and avoid
DANGER

sudden movement. Any sudden movement could

cause the front of the mower to come off of the FORWARD TRAVEL
ground resulting in possible loss of control,
causing serious injury or death.
N N

To make a three point turn to the right:

1. Move the left steering control lever farther forward
from neutral than the right steering control lever and
start the turn. Figure 3-10 ZERO RADIUS TURN
2. Next, pull back on the steering control levers until they
pass neutral and the machine starts to go rearward.
Figure 3-10 N N
3. Pull the right steering control lever farther rearward
from neutral than the left steering control lever until
the rear of the machine pivots around. Figure 3-10
4. Then, push the steering control levers forward until
they both pass neutral and the machine starts to go
forward. Figure 3-10
FORWARD TRAVEL
5. Push the left steering control lever farther forward RIGHT TURN
from neutral than the right steering control lever and
finish the turn. Figure 3-10 N N

Always be aware of what is behind the machine

WARNING

before backing up. Do not mow in reverse unless

absolutely necessary. Always look down and
behind before and while backing up.
REVERSE TRAVEL
RIGHT TURN
N N

IMPORTANT: Damage to the hydraulic system

components may occur with rapid movement of the steering
controls.
To increase speed, increase the steering control lever’s
distance from neutral. The farther forward the steering
control levers are from neutral, the faster the mower will REVERSE TRAVEL
travel forward. The farther back the steering control levers
are from neutral, the faster the mower will go in reverse. N N

N = NEUTRAL POSITION

Direction of arrows indicate direction of mower

movement

Figure 3-9

605046 3-5 REV K

 Operating Suggestions
THREE POINT TURN
An inexperienced operator should not mow on
slopes or on uneven terrain.

DANGER
Before attempting normal speed operation an
inexperienced operator should:
• be thoroughly familiar with the proper use
and operation of the equipment.
• read the manual completely and thoroughly.
• have attempted slow moving maneuvers.

If you lose steering control while operating the

WARNING
machine, place the steering control levers in the park
brake position immediately. Inspect the machine and
Le trol
co ever

Step 1 involve your BigDog® Mower Dealer to resolve the

ft
n
l

problem before continuing to operate.

Ri ro
co ever

The unit’s steering control levers are very

gh l
nt
l

responsive: Easy does it! For smooth operation,

WARNING
move the levers slowly, avoiding sudden
movement. Skill and ease of operation come with
Ne

practice and experience. The machine can spin

ut

very rapidly. Use caution when making turns and

ra
l

slow down before making sharp turns.

Step 2
Inexperienced operators may have a tendency to oversteer
and lose control. Practice slow maneuvers at low engine rpm
(idle) on a flat open area before attempting normal speed
eut N
lev rol
co eft

operation.
n

ral
L
er
t

Sharp depressions or raised obstacles (such as

gutters or curbs) should not be directly
WARNING

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
lev rol
c ght

angle until the wheel clears and then pivot the

o
Ri
n
er
t

opposite wheel around.

When turning on soft wet turf, keep both wheels rolling

Step 3 either forward or backward. Pivoting on one stopped wheel
can damage turf, especially when mowing.
Set the throttle at full rpm for maximum performance. This
gives maximum power to the drive wheels and deck when
needed. The throttle setting directly controls blade speed.
Use the control levers to control ground speed rather than
engine rpm.
Keep blades sharp. Many problems with incorrect cutting
patterns are due to dull blades or blades which have been
sharpened incorrectly. Information on sharpening blades is
Neutral listed in this manual’s maintenance section. Blade sharpness
Right control lever Left control lever should be checked daily.

Figure 3-10

REV K 3-6 605046

 Never work with blades while the engine is running
Never attempt to make any adjustments to the
or deck clutch switch is engaged (on).

DANGER
mower deck while the engine is running or with the
DANGER

Always place the deck clutch switch in the deck drive clutch engaged. Mower blades cannot
disengaged position, place steering control levers be seen and are located very close to the deck
in the park brake position, turn the engine off and housing. Fingers and toes can be cut off instantly.
disconnect the negative battery cable.
Block the mower up when you must work under it.
Wear gloves when handling blades. Discharge chute may vary from this illustration

Always check for blade damage if the mower

strikes a rock, branch or other foreign object A
during mowing!

Direct grass discharge to the right, away from the

unmowed area. Generally, this means using a pattern of left
turns. Avoid throwing grass discharge onto unmowed area.
Mowing clippings puts an unnecessary load on the unit and
reduces mowing efficiency.
When mowing a lawn for the first time cut grass slightly
longer than normal to avoid scalping uneven terrain. When
cutting grass taller than six inches, you may want to mow the
lawn twice to achieve a better quality of cut.
During normal mowing cut only about 1/3 of the grass
blade.
Alternate the mowing direction to keep the grass growing
straight and for better dispersion of the clippings.
A. Discharge chute
Remember, grass grows at different rates at different
times of the year. Mow more often in the early spring to Figure 3-11
maintain the same cutting height. As the growth rate slows
in midsummer, mow less frequently. If you cannot mow at a
regular interval, mow at a high cutting height; then mow
Flex Forks
again two days later at a lower cutting height. New Flex Forks® require a brief break-in period. Refer to the
Raise the cutting height of the mower if the cutting width Maintenance and Adjustments section of this manual for more
of the mower is wider than the previous mower. This ensures details.
that uneven turf is not cut too short.
Deck Clutch Operation
Raise the cutting height of the mower if the grass is
slightly taller than normal or if it contains a high degree of Before beginning operation, check to make sure the deck
moisture. Then mow it again with the cutting height set clutch switch is engaging and disengaging the blades properly.
lower.
If the machine’s forward motion must be stopped while
mowing, a clump of grass clippings may drop onto your lawn.
WARNING

To avoid this, move onto a previously cut area with the Make sure that the area around and under the deck
blades engaged. is clear and that there are no bystanders in the
immediate area before proceeding.
Never direct the discharge of material from the
mower deck toward bystanders.
WARNING

• Never operate the mower deck with the

To check the deck clutch switch:
discharge chute damaged, altered, removed,
or in the raised position, except when the 1. Start the engine and engage the deck clutch.
entire grass catcher attachment or mulching 2. With the deck clutch switch up (clutch engaged) and
system is being used. Figure 3-11 the engine running, listen to confirm that the mower
blades are rotating.
3. Now, push the deck clutch switch down (clutch
disengaged), and with the engine running, listen to
confirm that the blades have stopped rotating.
4. If the mower blades continue to rotate with the deck
clutch switch down, discontinue operation
immediately and contact your BigDog® Mower Dealer.

605046 3-7 REV K

Follow these procedures to maximize clutch life. Anti-Scalp Wheels
1. Engage the clutch only when the throttle is set at
approximately 2/3 throttle and there is no load on the Anti-scalp wheels are standard on these mowers. These
blades. After clutch engagement, advance the engine wheels are designed to minimize scalping when mowing on
throttle to full rpm. rough uneven terrain. Figure 3-13

Engaging the deck clutch at high engine rpm or when Anti-scalp wheels can be installed in two positions. With
under heavy load (in tall grass, for example) can cause the wheel installed in the bottom hole, the wheel is located
belts and/or electric clutch to slip, resulting in premature 1.60” (40.6 mm) below the mower blades. This setting is
wear or possible damage. preferred when mowing at cutting heights of 2-1/2” (63.5
mm) or higher.
2. Disengage the clutch only when the throttle is set at
When the wheel is mounted in the top hole, it is located .70”
less than 1/2 throttle.
(17.8 mm) below the mower blades. This is the acceptable
Never disengage the clutch with the engine running at setting for mowing at cutting heights of 1-1/2” (38.1 mm) or
high rpm. Setting the throttle to less than 1/2 throttle higher.
when disengaging the clutch will help extend clutch life.
Warranty will not be allowed for deck clutches that fail due
to improper engagement and disengagement practices. A

Deck Cutting Height Adjustment

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

increments.
Step on the deck lift pedal and latch the transport lever in
the deck transport position. Pull the adjusting pin out of the
hole that it is in and insert it into the desired cutting height
hole. Step on the deck lift pedal to release the transport
lever. Figure 3-12
Step on the deck lift pedal and raise the deck to its highest B
position and latch the transport lever in place when
transporting the unit. Figure 3-12

A. Anti-scalp wheel B. Adjusting holes

A Figure 3-13

A. Transport lever C. Pin

B. Cutting height holes

Figure 3-12

REV K 3-8 605046

 MAINTENANCE & ADJUSTMENTS

Safe Servicing Practices Torque values are given below:

ft-lbs N•m
Refer to the Safety Precautions section of this manual for
Wheel (lug) nuts . . . . . . . . . . . . . . . . .70 . . . . . . . . . 95
more service safety information.
Blade spindle bolt top . . . . . . . . . . . . .73 . . . . . . . . . 99
Service Introduction
Blade spindle bolt bottom . . . . . . . . 118 . . . . . . . 160

Regular maintenance is the best prevention for costly Lug nuts only - It is recommended that these be checked
downtime or expensive, premature repair. The following after the first 2 hours of operation, initially, every 40 hours
pages contain suggested maintenance information and and following removal for repair or replacement.
schedules which the operator should follow on a routine For all other torques refer to the mower’s General Service
basis. For more detailed information order the correct Parts Manual for standard torque chart. See the Product Literature
Manual and General Service Manual for your unit. Refer to the section for ordering information.
Product Literature section of this manual. For engine torque values, refer to the engine owner’s
Remain alert for unusual noises, which could signal a manual.
problem. Visually inspect the machine for any abnormal wear
Tires
or damage. A good time to detect potential problems is while
performing scheduled maintenance service. Correcting the
It is important for level mowing that the tires have the
problem as quickly as possible is the best insurance.
same amount of air pressure. The recommended pressures
Clear away heavy build-up of grease, oil and dirt, especially are:
in the engine and under the seat platform areas; minute dust
particle are abrasive to close-tolerance engine and hydraulic Drive wheels . . . . . . . . . . . . . . . . . . 8–12 psi (55–83 KPa)
assemblies. Front wheels . . . . . . . . . . . . . . . . . . 8–12 psi (55–83 KPa)
Inspect mower daily for grass clippings and wire or string Only pneumatic tires are approved for use on this mower.
tangles. The underside of the mower deck will collect a build- Warranty claims will be denied on any mower equipped with
up of grass clippings and dirt, especially when grass is wet or non-pneumatic tires.
has high moisture content. This build-up will harden,
Flex Forks Break-In
restricting blade and air movement and will probably show a
poorer quality of cutting. Therefore it should be removed
Flex Forks® may raise the front of the mower
routinely.
approximately 1" (25.4 mm) when first installed. It is not
To do this it will be necessary to raise and block the deck necessary to re-level the deck at this time. Drive the mower
using jack stands or blocks in the full up position. Scrape the for approximately 20 minutes, stop the mower and check to
build-up from underneath. see if the deck is level. If adjustment is required, refer to the
IMPORTANT: Seat arm rests – Place the steering control mower’s General Service Manual for deck leveling
levers in the park brake position and pivot the arm rests procedures.
upward before lifting the seat platform to prevent arm rest
damage.
Never attempt to make any adjustments to the
Some repairs require the assistance of a trained service
DANGER

mower deck while the engine is running or with the

mechanic and should not be attempted by unskilled
deck drive clutch engaged. Mower blades cannot
personnel. Consult your BigDog® Mowers service center
be seen and are located very close to the deck
when assistance is needed.
housing. Fingers and toes can be cut off instantly.
Torque Values

Lubrication
Particular attention must be given to tightening
Use SAE multi-purpose grease.
WARNING

the drive wheel lug nuts and blade spindle bolts.

Failure to correctly torque these items may result Electrical System
in the loss of a wheel or blade, which can cause
serious damage or personal injury. IMPORTANT: Refer to the Safety section of this manual for
detailed battery servicing safety information.
The electrical system is a 12 volt, negative ground. The
recommended battery size is:

605046 4-1 REV K

 Garden tractor BCI group U1R with a 225 or better NOTE: The filter guard must be removed to access filter.
cranking AMP rating. Each transmission’s filter is located per Figure 4-3. A
A maintenance-free battery is recommended. Otherwise, standard oil filter wrench is used to change filter, threads are
follow battery manufacturer’s maintenance, safety, storing right handed.
and charging specifications.
Use a BigDog® Mowers approved filter element only.

Master in-line fuse IMPORTANT: Dirt is the primary enemy of any hydraulic
system.
These mowers have a master in-line fuse in the electrical
IMPORTANT: When washing the mower, direct the spray
system. This is the main fuse to protect the complete
away (especially if using a power washer) from the
electrical system. It is located under the seat platform and
transmission’s seals to prevent water intrusion and to ensure
next to the solenoid. Figure 4-1
component performance.

A. Expansion tank

A. Master fuse housing Figure 4-2

Figure 4-1

Hydraulic System

IMPORTANT: Refer to the General Service Manual (P/N

119295) for complete hydraulic oil and filter change
procedures.
This mower is equipped with two integrated hydrostatic
transmissions. Figure 4-3
IMPORTANT: Never use hydraulic or automatic
transmission fluid in this system; use only motor oil as
specified.
B
Use SAE 20W50 motor oil, 15W50 synthetic oil or 20W50 A
synthetic oil when changing the system oil and filter. The
hydraulic expansion tank is located in front of the engine and
under the operator’s platform. Figure 4-2 A. Transmission B. Filter

Check oil level in hydraulic system after every 40 hours of Figure 4-3
operation or weekly, whichever occurs first. Check more
often if system appears to be leaking or otherwise Fuel and Evaporative Emissions Control System
malfunctioning.
When the hydraulic system oil is cold, the fluid level should IMPORTANT: Refer to the Safety section of this manual for
be at the “Full Cold” line on the expansion tank. Use only the fuel handling safety information.
specified oil shown. IMPORTANT: Refer to the engine owner’s manual for
Initial system oil and filter change must be after the first 75 additional emissions control information.
hours of use or 1 year whichever comes first. Thereafter, The fuel and evaporative emissions control system for this
replace filter and oil in each transmission every 2 years or 200 mower is EPA compliant. Use only BigDog® Mower approved
hours, whichever comes first. replacement parts.

REV K 4-2 605046

 Your evaporative emission control system may include
parts such as:
• fuel tanks
A
• fuel lines
• fuel line fittings
• fuel caps
• carbon canisters
• canister mounting brackets
• carburetor purge port connection
• filters
• vapor hoses
• clamps, control valves
• control solenoids
• electronic controls
• vacuum control diaphragms
• purge valves A. Fuel cap
• liquid/vapor separator
Figure 4-4
• other associated components
IMPORTANT: Do not overfill the fuel tank. The fuel tank
Modifying or Tampering with the evaporative emissions
should be filled no higher than the bottom of the fill neck. The
control system or the fuel system is prohibited. Federal law
fuel system is designed to leave room for the fuel to expand
and California State law prohibit the following acts or the
with fuel temperature changes. Figure 4-5
causing thereof:
1. The removal or rendering inoperative by any person
other than for purposes of maintenance, repair,
WARNING

replacement, of any device or element of design incor- Overfilling the fuel tank may cause the following:
porated into any equipment for the purposes of emis- • Engine damage
sions control prior to or after its sales or delivery to the • Fire hazard!
ultimate purchaser or while it is in use, or
2. The use of the equipment after such device or element
of design has been removed or rendered inoperative by
any person. Fill to the bottom of the filler neck
A

Maximum
WARNING

Use of replacement parts not equivalent to the B

Do Not
original parts may result in system failure and
Overfill
pose a safety hazard.

A. Filler neck B. Fuel tank

The fuel tank is located under the seat platform with the
filler neck and fuel cap located in the left side fender. Figure 4-5
Figure 4-4
Use regular unleaded gasoline with an octane rating of 87
Park the mower on level ground before filling fuel tank. or higher. Maximum of 10% ethanol (E10) in fuel. Fuels with
Clean the area around the fuel cap before removing the greater than 10% ethanol (such as E15, E20 and E85) voids
cap. Remove the fuel cap slowly. warranty. Fuels with greater than 10% ethanol are not
approved for use and such illegal use could cause equipment
When threading the fuel cap onto the filler neck, tighten the
failure and pose a fire hazard.
cap until it begins to click, then, continue to turn it until at
least three clicks are heard. Refer to the Engine Owner’s Manual for additional fuel
specification requirements.

605046 4-3 REV K

Fuel Evaporation System Filter 3. Attach one end of the hose onto the oil drain valve nip-
ple. Make sure the hose is pushed all the way onto the
These mowers have a fuel evaporation system filter. This valve. Figure 4-7 & Figure 4-8
filter must be checked and replaced every 100 hours or 4. Position the loose end of the hose forward and down
annually whichever comes first. Figure 4-6 in front of the right side transmission so that it can
drain into a suitable oil drain container.
5. With the hose in position, use a 10 mm wrench or
socket and open the valve approximately 4 turns in the
counterclockwise direction. Allow 10 minutes for
engine oil to adequately drain.
6. After oil is drained, close the valve by turning it in the
clockwise direction until it is fully closed.
7. Once the valve is closed, carefully remove the oil drain
hose and clean up any spilled oil.
IMPORTANT: All oil drips or spills must be cleaned off
of the engine plate, muffler, and exhaust system
before operating the machine.
8. Clean the oil drain hose and store it appropriately.
Figure 4-7 & Figure 4-8
A
Kawasaki engines

A. Fuel evaporation system filter

A
Figure 4-6

Engine Oil and Filter

If the engine has been running and is up to operating

temperature, allow the engine to cool before
WARNING

changing the oil. Engine and engine oil will be very

hot, so be very careful when changing oil and wear
B
the appropriate protective gear to avoid being
burned or exposed to engine oil.

Check engine oil daily and after every 4 hours of operation. A. Oil drain hose B. Oil drain valve
Mower must be on a level surface when checking oil. Refer to
Figure 4-7
engine manual and maintenance schedule for oil capacities.
Change the engine oil and filter after the first 5 hours of Engine Air Filter
operation and then per the engine manufacturer’s
recommendations after that. If mower is being operated in These mowers come equipped with two different styles of
extremely dirty conditions, then it is recommended oil be air filters; integrated or canister. The required servicing for
changed more frequently. these two filter types is different from one to the other. Refer
IMPORTANT: After the new oil filter has been installed, to the following for the one appropriate for your mower.
clean up any oil which may have spilled onto the engine
plate, muffler, and exhaust system. Integrated Type
Perform engine air filter maintenance per the Maintenance
Kawasaki & Kohler Engines — Draining the engine oil: Schedule shown elsewhere in this manual. Figure 4-9,
1. Locate the oil drain valve on the lower right side of the Figure 4-10, & Figure 4-11
engine.
Canister Type
2. Locate the oil drain hose that was supplied with the
machine. Be sure to clean and clear it of debris that Perform engine air filter maintenance per the Maintenance
might block the flow of the engine oil. Figure 4-7 & Schedule shown elsewhere in this manual.
Figure 4-8

REV K 4-4 605046

 Kohler engines Kohler engine

A. Oil drain hose B. Oil drain valve A. Air filter cover

Figure 4-8 Figure 4-10

Kawasaki engine Briggs & Stratton engine

A. Air filter cover

A. Air filter cover Figure 4-11
Figure 4-9 3. Reinstall the top of the canister housing. Make sure it
seals all the way around the lower part of the housing,
A specially designed dry filter is standard equipment on
then tighten the clamps. Figure 4-12
these mowers and supplies clean combustion air to the
engine. Figure 4-12 4. Never operate the machine without an air filter
installed.
Recommended Service Procedure
1. Release clamps and remove element. Clean the air
Overservicing
cleaner canister with a damp cloth. Overservicing occurs when an air filter element is removed
for cleaning or replacement before it is necessary. Each time
2. Before installing a new element, inspect it by placing a
the filter is removed a small amount of dirt and dust could
bright light inside and rotating the element slowly,
fall in the intake system. This accumulated dirt can cause a
looking for any holes or tears in the paper. Also check
dusted engine. It only takes a few grams of ingested dirt over
gaskets for cuts or tears. Do not attempt to use a dam-
the normal service life of an engine to cause a dusted engine.
aged element which will allow abrasive particles to
enter the engine.

605046 4-5 REV K

 General Engine Maintenance
Kohler engine

A 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 engine manufacturer. Special attention should
be paid to applicable data which will not be duplicated here.
Belts
B

Inspect belts frequently for wear and serviceability.

Replace a belt that shows signs of:
• severe cuts
• tears
• separation
• weather checking
• cracking

A. Air cleaner canister B. Clamp • burns caused by slipping.

Slight raveling of belt covering does not indicate failure,
Figure 4-12 trim ravelings with a sharp knife.
Do not clean the element, but replace with a new element
only. Cleaning used air filter elements, through improper If the pump belt fails, loss of control will occur
cleaning procedures, can get dust on the inside of the filter especially when operating on a slope. If you lose
WARNING

causing dirt ingestion and engine failure. steering control while operating the machine, place
the steering control levers in the park brake position
It is important to note that whenever an air filter element is
immediately. Inspect the machine and involve your
cleaned by any method, the person or company performing
BigDog® Mower Dealer to resolve the problem before
the cleaning assumes responsibility for the integrity of the
continuing to operate.
filter from then on. The warranty for air filters expires upon
cleaning or servicing in any manner because the condition of
Inspect the belt pulley grooves and flanges for wear. A new
the filter after servicing is completely out of the filter
belt, or one in good condition, should never run against the
manufacturer’s control. Therefore, on a dust ingested engine
bottom of the groove. Replace the pulley when this is the
failure, there will be no warranty consideration if the air filter
case, otherwise the belt will lose power and slip excessively.
element has been cleaned or serviced in any manner.
Never pry a belt to get it on a pulley as this will cut or
A partially dirty air filter element works better than a new
damage the fibers of the belt covering.
element. Therefore, a dirty filter element is not bad for the
engine unless it is excessively restricting the air flow and Keep oil and grease away from belts, and never use belt
engine performance is affected. The reason is simple. The dressings. Any of these will destroy the belt composition in a
media in the filter must be porous to allow air to pass very short time.
through it. When dirty air passes through the filter, the dirt Mower Blades
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 Mower Blade Maintenance
filter more efficient at stopping dirt from entering the engine. IMPORTANT: Refer to the Safety section of this manual for
This is referred to as barrier filtration. blade handling safety information.
Of course, at some point the filter media becomes too Refer to the Mower Blade Replacement section for blade
clogged to allow air to pass. removal and installation.
The mowing conditions will determine the frequency of air
filter element changing.
WARNING

Mower blades are sharp and can cut. Wrap the

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

REV K 4-6 605046

 Check the mower blades daily, they are the key to power
Comparison of Warped and Straight Blades
efficiency and well groomed turf. Keep the blades sharp. A
dull blade will tear rather than cut the grass, leaving a brown
A
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.
B
Always check for blade damage: C

• if mower strikes a rock, branch or other

WARNING

foreign object during mowing!

• or if an abnormal vibration occurs while
operating.
A. Warped blade — replace
Make all necessary repairs before resuming
B. Straight blade
operation.
C. Cutting plane
Sharpen the blades following the pattern shown. Touch-up
Figure 4-14
sharpening can be done with a file. Figure 4-13
After grinding the blades, check for balance. Blade End view of blades, comparing twisted and straightened
balancing can be done by placing the blade on an inverted blades.
line punch or 5/8" bolt. A commercial balancing tool is also
available through most hardware supply stores. D

The blade should not lean or tilt. When spinning the blade
slowly it should not wobble. Balance the blade before
reinstalling. A
Lay the blade on a flat surface and check for distortion. C
Replace any distorted blade. Figure 4-14 & Figure 4-15 D

A A. Twisted blade edge — C. Cutting plane

replace blade D. Cutting edge
B. Straight blade edge

Figure 4-15

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

easier to get a straight cutting edge following
the re-sharpening pattern shown above. IMPORTANT: Refer to the Safety section of this manual for
blade handling safety information.
WARNING

Mower blades are sharp and can cut. Wrap the

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

A 15/16" wrench is required to remove the 5/8" cap screw

holding the blade to the spindle shaft. NOTE: A blade holding
tool (P/N 381442) is available from BigDog® Mower. It is
A. Re-sharpening pattern designed to prevent the blades from rotating when they are
B. Original edge being removed or installed on the spindle. Contact your
Figure 4-13 BigDog® Mower Dealer for more information.

605046 4-7 REV K

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

Failure to correctly torque the bolt may result in A

the loss of the blade which can cause serious
injury.

Properly compressed cup washers maintain the correct

compression load on the blades. Replace the cup washers if
they are cracked or flattened.
IMPORTANT: The blade sail (curved part) must be
pointing upward toward the inside of the deck to ensure A
proper cutting.
When mounting blades, rotate them after installation to
make sure blade tips do not touch each other or sides of the
mower.
Seat Adjustment

The seat on the BigDog® Alpha® MP mower can be adjusted

forward and rearward by pivoting the seat platform up and
forward. Then, loosen the four cap screws on the underneath A. Cap screws
side of the seat platform. Position the seat where you have
Figure 4-16
the best control of the machine and are the most
comfortable and then tighten the cap screws. Figure 4-16
Steering Control Lever Adjustment

The steering control levers can be adjusted for operator A

comfort.
A. To pivot the upper control levers forward or rearward,
loosen the cap screws that attach the upper control
lever to the lower lever. Then, pivot the upper control
lever. Tighten the cap screws. Figure 4-17
B. To lower and raise the control levers, remove the cap B
screws. Slide the upper control lever up or down and
align the holes in it with the holes in the lower lever. C
Re-install the cap screws and tighten.
The steering control levers should be adjusted so that they
align with each other when in the neutral position.

A. Upper control lever C. Lower control lever

B. Cap screws

Figure 4-17

REV K 4-8 605046

 Maintenance Schedule
Refer to Figure 4-18, Figure 4-19, Figure 4-20, Figure 4-21,
Figure 4-22, & Figure 4-23
WEEKLY * ANNUALLY
SERVICE AT
OR 40 OR 100
INTERVALS INDICATED
HOURS HOURS

Verify safety start interlock system Prior to each use

Visually inspect unit for loose hardware and/or damaged parts Prior to each use
Visually inspect tires Prior to each use
Check oil level, engine (1) Prior to each use or every 4 hours
Clean air intake screen (7) Prior to each use or every 4 hours
Check fuel level Prior to each use
Blades - sharpen & securely fastened Prior to each use
Discharge chute - securely in place & in lowest position Prior to each use
Check tire pressure with a gauge Prior to each use
Clean engine and transaxle compartment After each use
Change transaxle oil and filter (10) Every 200 hours or 2 years
Replace engine air cleaner element (4) (9) As needed
Change engine oil & filter (1) (3) X
Clean cylinder and head fins (9) X
Check battery connections X
Clean engine exterior (9) X
Tighten lug nuts on wheels (2) X
Clean & regap spark plugs (9) X
Check transaxle & deck belt tension and condition (5) X
Check fuel system (6) X
Check fuel tank grommet (6) X
Change fuel filter (6) X
Replace fuel evaporation system filter (7) X
Replace spark plugs (9) X

NOTES:
1. Initial engine 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. Change engine oil filter per the engine manufacturer’s recommendations. Refer to Engine Owner’s Manual for recommendations and other
maintenance items.
4. Service more often under dusty or dirty conditions. Use caution when servicing to prevent dust contamination in the engine. Do not clean filter
element. Replace with a new one.
5. Pump drive belt only - Inspect every month and replace if worn or cracking is noticed. Otherwise, replace every 2 years.
6. Check fuel system for any cracks or leaks including, but not limited to, fuel line hoses, fuel valve, vent line hoses, vent valve, vapor valve, carbon
canister, and grommets. Replace as needed.
7. More often under dusty or dirty conditions and during hot weather.
8. Do not over grease. Wipe off any excess grease.
9. Refer to engine owner’s manual for engine service information.
10. Initial transaxle oil and filter change must be after the first 75 hours of use or 1 year whichever comes first. Thereafter, replace filter and oil in
each transmission every 2 years or 200 hours, whichever comes first.

* After completing maintenance cycle (100 hours), repeat cycle.

605046 4-9 REV K

Maintenance Locator Chart

Mowers with Kawasaki engines Figure 4-18

9
2 16 6
5 8

11

12

1. Engine Oil Fill & Dipstick

2. Fuel Filter
3. Engine Air Cleaner
4. Engine Oil Drain Valve
4 5. Battery
8 6. Fuel Tank
13 7. Engine Oil Filter
7 1 8. Park Brake Switch (2)
9 9. Drive Tire
10. Pump Belt
11. Engine Air Intake Screen
Mowers with Kohler engines Figure 4-19 12. Front Wheel Tires
(integrated air cleaner)
13. Hydraulic Oil Expansion Tank
9 14. Deck Belt
6 15. Blades
16 5 8 16. Fuel Evaporation System Filter

11

12

4
8
13
7 2 1
9

REV K 4-10 605046

 Figure 4-20
Mowers with Kohler engines
(canister air cleaners)
1. Engine Oil Fill & Dipstick
2. Fuel Filter 6
9
3. Engine Air Cleaner 5 8
4. Engine Oil Drain Valve 16
5. Battery
6. Fuel Tank 11
7. Engine Oil Filter
8. Park Brake Switch (2) 3
9. Drive Tire
10. Pump Belt
11. Engine Air Intake Screen
12. Front Wheel Tires
13. Hydraulic Oil Expansion Tank 12
14. Deck Belt
15. Blades
16. Fuel Evaporation System Filter

4
8
9 13

7 2 1

Figure 4-21 Figure 4-22

48"/54"/60” Deck
15
15

10

14

Figure 4-23

36"/42" Deck
15

14 15

605046 4-11 REV K

Maintenance Record

Perform the initial hydraulic system oil and filter change after the first 75 hours of use or yearly whichever comes first.

Date: Maintenance/Service Performed:

Date: Maintenance/Service Performed:
Dealer:
Dealer:

Hour Meter Reading:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Date: Maintenance/Service Performed:
Dealer:
Dealer:

Hour Meter Reading:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Date: Maintenance/Service Performed:
Dealer:
Dealer:

Hour Meter Reading:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Date: Maintenance/Service Performed:
Dealer:
Dealer:

Hour Meter Reading:

Hour Meter Reading:

Date: Maintenance/Service Performed:

Date: Maintenance/Service Performed:
Dealer:
Dealer:

Hour Meter Reading:

Hour Meter Reading:

REV K 4-12 605046

 TROUBLESHOOTING

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

SUGGESTED
SYMPTOMS PROBABLE CAUSES
SUGGESTED REMEDIES
SYMPTOMS PROBABLE CAUSES
REMEDIES
Mower creeps when Steering linkage needs Adjust linkage
steering control levers are adjustment
Starting motor does not Steering control levers not Place steering control
in neutral
crank in park brake position or levers in park brake posi-
switch not adjusted tion or re-adjust switch
Mower circles or veers in Steering linkage needs Adjust linkage
one direction adjustment
Deck clutch switch Disengage clutch switch
engaged
Loose steering linkage Tighten linkage
Weak or dead battery Recharge or replace
Tires improperly inflated Adjust air pressure to 8–12
psi (55–83 KPa)
Electrical connections are Check the electrical con-
corroded or loose nections
Transaxle component Contact your Dealer
faulty
15 amp fuse is blown Replace the 15 amp fuse

Mower creeps when park- Steering linkage out of Adjust steering linkage
For additional causes See engine manual
ing brake engaged adjustment

The engine will not start, No fuel or line plugged Fill tank or replace line
Brakes need adjustment Adjust parking brakes
starts hard or fails to (See Fuel System section
keep running for more details)
There is abnormal vibra- The engine mounting bolts Tighten the engine mount-
tion are loose ing bolts
There is incorrect fuel in Drain the tank and replace
the fuel system the fuel with the proper
type The engine pulley, idler pul- Tighten the appropriate
ley or blade pulley is loose pulley
There is dirt in the fuel filter Replace the fuel filter
The engine pulley is dam- Contact your Dealer
aged
Dirt, water or stale fuel in Contact your Dealer
the fuel system
The cutting blade(s) is/are Install new cutting blade(s)
bent or unbalanced
The choke is not on Move the choke lever to ON
(if equipped)
A blade mounting bolt is Tighten the blade mount-
loose ing bolt
Numerous See engine manual

Spindle bearing is worn or Replace or tighten spindle

Engine: Numerous See engine manual
loose bearing
Runs with continuous
misfiring or engine runs
unevenly or erratically A blade spindle is bent Contact your Dealer

Loss of power or system Restrictions in air cleaner Service air cleaner Blades do not rotate The deck drive belt is worn, Install a new deck drive
will not operate in either loose or broken belt
direction Poor compression Contact your Dealer
The deck drive belt is off Install the deck drive belt
the pulley and check for a reason
Steering linkage needs Adjust linkage
adjustment
Electric clutch is not Check and/or replace 15
engaging amp fuse.
Tow valve open Close tow valve
Contact your Dealer

The traction drive belt is Install a new traction drive

Uneven cutting height The blade(s) are not sharp Sharpen the blades
worn, loose or broken belt

A cutting blade(s) is/are Install new cutting blade(s)

For additional causes See engine manual
bent

Air cooled engine over- Air intake screen or cooling Clean screen and fins
The deck is not level Level the deck per the Deck
heating fins clogged
leveling section of the Gen-
eral Service Manual
For additional causes See engine manual
An anti-scalp wheel is not Adjust the height of the
Low engine oil pressure Low oil level Add oil set correctly anti-scalp wheel

Oil diluted or too light Change oil and check for The underside of the deck Clean the underside of the
source of contamination is dirty deck

Failed oil pump Contact your Dealer Tires improperly inflated Adjust air pressure to 8–12
psi (55–83 KPa)
High oil consumption Numerous Contact your Dealer
A blade spindle is bent Contact your Dealer
Mower jerky when start- Steering control linkage Adjust linkage
ing or operates in one needs adjustment After initial break-in period,
direction only Flex Forks® are installed
level the deck per the Deck
Loose steering linkage Tighten linkage Leveling section of the Gen-
eral Service Manual
Transaxle component Contact your Dealer
faulty

605046 5-1 REV K

REV K 5-2 605046
 STORAGE

When storing the unit at the end of the mowing season, the 3. Run the engine for a minimum of 10 minutes.
mower, engine, and battery should have the following items
serviced before storage.
If the mower has been stored for an extended period of Allow the engine to cool before changing the

WARNING
time, follow the new season preparation steps before engine oil. Use caution when changing the engine
beginning operation. oil as it will be very hot. You should wear the
appropriate protective gear to avoid being burned
General Mower Preparation for Storage or exposed to engine oil.

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

cutting units. 4. Drain the oil from the crankcase while the engine is
IMPORTANT: Wash the machine with a mild detergent still warm.
and water. Do not pressure wash the machine. Avoid 5. Replace the engine oil filter.
excessive use of water, especially near the control
6. Refill with fresh oil of the proper viscosity.
panel and engine.
7. Close the fuel shut-off valve (if equipped).
2. Clean mower and deck and touch up all scrapes with
touch-up paint. 8. Check the oil filler cap and fuel tank cap(s) to make
certain they are securely in place.
3. Install new air filter per Engine Owner’s Manual.
9. Refer to the engine manual for more information.
4. Check thoroughly for any worn or damaged parts that
need replacing and order them from your dealer.
Preparation of Battery for Storage
5. Thoroughly lubricate machine, according to the
When the machine is to be unused for long periods, it is
Maintenance section.
best to disconnect the battery and remove it from the unit. At
6. Block mower up so weight is off tires. Check tire this time perform the following battery maintenance:
pressure and inflate to proper operating pressure.
1. Remove the battery from machine.
NOTE: Do not deflate tires.
NOTE: Always disconnect the negative (black) battery
7. Perform separate engine and battery preparation as cable(s) before disconnecting the positive (red) cable(s).
listed below.
2. Clean the battery, terminals, and cable connectors.
8. Store mower in a clean, dry place.
3. Charge the battery, if necessary.
Preparation of Engine for Storage 4. Store the battery in a cool, dry place (do not expose to
If the mower is to be unused for an extended period of time freezing temperatures).
(30 days or more), the engine will need to be prepared for 5. Always keep the battery fully charged. Especially
storage. Use the following procedures before storing the important to prevent battery damage when the
mower. temperature is below 32°F (0°C).
IMPORTANT: Refer to the Fuel Handling Precautions
section of this manual for important safety information New Season Preparation
before proceeding. Before starting the mower following post season storage,
1. Add a BigDog® Mower approved fuel stabilizer to the the following service is required:
fuel system. Refer to the instructions shown on the 1. Clean mower, removing trash and dirt accumulation.
fuel stabilizer bottle for proper usage. For detailed
information consult with your Dealer. 2. Check engine oil and hydraulic oil levels.

2. Fill the fuel tank(s) with fresh fuel. 3. Install fully charged battery and attach the battery
cables.
NOTE: Use non-ethanol fuel if possible.
IMPORTANT: Always connect the positive (red) battery
cable(s) before connecting the negative (black)
cable(s).
WARNING

4. Fill fuel tank(s) with fresh fuel. Run machine at half

To prevent carbon monoxide poisoning, operate the
speed for 5 minutes, checking operation of steering
engine in a well ventilated area only.
control levers. Stop engine and check for oil leaks,
loose fittings and so forth.
5. Tighten any bolts that have loosened and make sure
all hair pins, cotter pins and clevis pins are in place.

605046 6-1 REV K

 6. Install all safety shields and review safety precautions
listed in this manual.
At start of new season always check that fresh oil
WARNING

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

has been added to machine. If oil is drained at sea-
8. Refer to engine manual for more information.
son’s end and not replaced, engine damage will
result.

REV K 6-2 605046

INDEX
PAGE PAGE
Anti-Scalp Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Mower Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Battery Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mower Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Mower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Children . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 New Season Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operating Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

Deck Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Parts and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Deck Cutting Height Adjustment . . . . . . . . . . . . . . . . . . . . 3-8 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Driving the Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Preparation of Battery for Storage . . . . . . . . . . . . . . . . . . . 6-1

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Preparation of Engine for Storage . . . . . . . . . . . . . . . . . . . 6-1

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Product Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . 2-1, 3-1

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Flex Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Safe Servicing Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Flex Forks Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Safety and Instructions Decals . . . . . . . . . . . . . . . . . . . . . . 2-6

Fuel & Evaporative Emissions Control System . . . . . . . . . 4-2 Safety Start Interlock System . . . . . . . . . . . . . . . . . . . . . . . 3-3

Fuel Evaporation System Filter . . . . . . . . . . . . . . . . . . . . . . 4-4 Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Service Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fuel Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

General Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . 4-6 Slope Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

General Mower Preparation for Storage . . . . . . . . . . . . . . 6-1 Slope Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Steering Control Lever Adjustment . . . . . . . . . . . . . . . . . . 4-8

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Maintenance Locator Chart . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 To the New Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Master In-Line Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Model and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Using a Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Moving the Mower with Stalled Engine . . . . . . . . . . . . . . . 3-4 Using this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Mower Blade Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

605046 i-1 REV K

INDEX
PAGE PAGE

REV K i-2 605046