1 Table of Contents Basic Information
Contents
1. LC o 7200 AOS 27 hp Kawasaki LC o 6000 AOS 35 hp Vanguard o 7200 AOS 35 hp Vanguard Bad Boy Diesel Series o 6000 AOS 28 hp Caterpillar Diesel LC o 7200 AOS 28 hp Caterpillar Diesel LC o 6000 AOS 35 hp Caterpillar Diesel LC o 7200 AOS 35 hp Caterpillar Diesel LC Bad Boy Team Series o 5200 Lightning 26 hp Kawasaki LC o 6000 Lightning 26 hp Kawasaki LC To The New Bad Boy Owner Congratulations on the purchase of your new Bad Boy Mower The purpose of this manual is to assist operators in maintaining and operating their Bad Boy Mower The information and instructions in this manual can help you attain years of performance from your new Bad Boy Remember All Bad Boy engines use 10W30 engine oil 4 All Bad Boy hydraulic systems use 20W50 engine oil 4 All Bad Boy Mowers use hi temp multi purpose grease NLGI No 2 for the grease fittings 4 ZT models have 12 psi in both front and rear tires 4 Pups AOS and Diesel models have 12 psi in front tires and 10 psi rear tires Warranty Registration The Warranty Registration form must be completed and signed to validate your warranty As the new equipment owner you are expected to see that the form is completed and forwarded to Bad Boy Inc at time of delivery Model Serial Number Lightning Pup AOS Diesel model serial numbers are found on the SIN plate located underneath the floor panel ZT model serial numbers are foun2. Pivot Idler Arm Isolator Pivot Arm 12
3. or when needed make sure blades are tightened properly check spring and belt tension check the underside of the deck to ensure the mower deck is free of grass build up and debris make sure your machine is at full throttle and vary your mowing pattern each time you cut your grass Q What should I do if my mower won t start A Check battery charge and connection check your fuel make sure fuel is less than 30 days old and contains no water make sure your spark plug is in good condition and spark plug wire is attached and make sure air filter is clean a dirty filter makes it more difficult for the engine to draw air Q What should I do if the blades won t engage A Make sure the safety switch is plugged in on the bottom of seat Check the underside of the PTO engager to ensure the plug is secure at switch Q What should I do if mower arms are in neutral position and mower still creeps Contact authorized Bad Boy Mower Dealer Controls 4 Ignition Switch Bad Boy Mowers have a three position ignition switch off run and start With key inserted rotate it clockwise to START position and release key when engine starts and switch will automatically return to the RUN position Throttle Control A cable is connected to the engine throttle for controlling engine speed Move lever forward to increase engine rpm move lever backward to decrease engine rpm Choke Control A cable i
4. that is not recommended unless grass is sparse or it is late fall when grass grows slowly Alternate mowing direction to keep grass standing straight This also helps disperse clippings which enhance decomposition and fertilization 4 Mow in intervals Usually you should mow every four days However grass grows at different rates at different times of the year Maintain the same cutting height and mow often in early spring As grass growth slows in the summer mow less frequently Greasing the Bearings Grease Type NGLI grade 2 multi purpose gun grease Grease the front caster pivots and wheels 4 Park the machine on a level surface and disengage the blade control switch 4 Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Clean the grease fittings with a cloth Make sure to scrape ant paint off of the front of fitting s Connect a grease gun to each fitting Pump grease in fittings until greases begins to seep out of the bearings Wipe up excess grease The pictures on the following pages show suggested grease points general location Front Fork Front Fork Housing Housing Front Tire mes b Y Front Tire Steering Arm Steering Housing Arm Housing Actuator Bar Block Actuator Bar Block Pump Idler 11 Isolator
5. Table of Contents Basic InfotinatiOt qse ines cesar ss wees yox vea UR va wba VEO ERR REUS das ati Bad Boy Safety Guidelines zera i eoo ro Ot A Se Y RN SE ETO o is eor ev Eo SS STA cR VR AN ad Ms Malte HH CC d omar aoi TD EE Pd MIS E ME cdta Storage and Transportation cm eerte terr epe AER ERR sen REA tr E er ees AA JUS ENS concessa voe bore nma e bare cd c ur ec VE a eds Troubleshooting and FAQ upa on pre esr nep eo E Leda SP Ee E Controls esa reda erat ease ad neat Ta DE AS TOM DPA E ed a bua EN Moving Inoperable MoOWeT ocooccoccccconcconccnconccnc e he he he he hehehe nnn Instrumentat ON vee ARAS oki rae duo One pu avr D a D Blade Maintenance and Cutting TipS ccc cee eee ees A A Pa RE BASIC INFORMATION This manual applies to the following equipment Bad Boy ZT Series o ZT 2600 36 26 hp Briggs ELS o ZT 2600 50 26 hp Briggs ELS o ZT 2600 60 26 hp Briggs ELS o ZT 2300 36 23 hp Vanguard o ZT 2300 50 23 hp Vanguard o ZT 2300 60 23 hp Vanguard Bad Boy Pup Series o 4800 Pup 23 hp Vanguard o 5200 Pup 23 hp Vanguard o 6000 Pup 23 hp Vanguard o 4800 Pup 30 hp Kohler o 5200 Pup 30 hp Kohler o 6000 Pup 30 hp Kohler o 7200 Pup 30 hp Kohler Bad Boy Lightning Z Series o 5200 Lightning 26 hp Kawasaki LC o 6000 Lightning 26 hp Kawasaki LC o 6000S Lightning 32 hp Vanguard o 7200S Lightning 32 hp Vanguard Bad Boy AOS Series o 6000 AOS 27 hp Kawasaki
6. air pressure 4 Put deck on highest setting 4 Measure all Four corners of the deck Rear and front corners of the deck should be equal in height Set front corners to 1 8 lower than rear corners 4 Use the deck hanger chains for rear adjustments 4 Use turnbuckles for front adjustments Brake Adjustment Turn knob clockwise to tighten and counter clockwise to loosen brake cable Locate set screw on top of brake handle knob 4 DO NOT OVER ADJUST CABLE BREAKAGE MAY OCCUR Drive Arm Adjustment Visit Authorized Bad Boy Dealer Troubleshooting and Frequently Asked Questions 4 Q How do I sharpen my blades 4 A We recommend that sharpening be done by an authorized Bad Boy dealer Q How should I prepare my Bad Boy Mower for the off season 4 A When preparing for any down period of 90 days or more the most important thing is proper fuel preparation Use a fuel stabilizer in your final tank of fuel or run dry Choke and repeatedly crank engine until it will not start This will decrease the potential for varnish or gum deposits forming in your system Also make sure your machine has plenty of antifreeze You can get an antifreeze tester at your local hardware store to ensure your machine is ready for winter 4 Q How do I prevent an uneven cutting pattern and increase the quality of cut 4 A Check tire pressure check blade sharpness replace blades or sharpen at least once per year
7. d on the SIN plate underneath seat The serial numbers are necessary on the warranty registration form Also these numbers can assist you in the ordering of new parts when replacements become necessary Parts Service Only Bad Boy replacement parts are to be used on your mower Replacement parts are available through your local Bad Boy Mower Dealer Remember to always provide the following information when ordering parts 1 Correct part number 2 Correct serial number All warranty repair and service must be handled through your authorized Bad Boy Mowers dealer To locate the nearest dealer go to our website and click on Locate A Dealer Safety general Never allow untrained people to operate this machine It is the owner s responsibility to get training and see to it that anyone who has permission to use your machine receives the proper training Do not mow around people The factory discharge chute is designed to deflect debris downward but it could be possible for debris to be thrown in a way that can cause damage to people or property Seek additional training when possible to learn more about safety techniques and practices Safety Precautions 4 Always remain seated while operating machine 4 Always maintain a safe distance from people and pets while mowing 4 Always disengage blades place steering controls in neutral engage parking brake and remove ignition key when leaving operator
8. ilt up If light comes on identified as a hex stud during operation shut engine off immediately and Do not tow machine Move it locate problem or contact by hand or use a winch to authorized Bad Boy Mower load on a trailer for dealer transporting ATTENTION RETURN BYPASS VALVES TO Mower Blade OPERATING POSITION P BEFORE RUNNING Maintenance MOWER FOLLOWING REPAIRS Check mower blades after each use This is essential for maintaining well groomed turf Keep the Bypass Valve on Hydraulic Pump blades sharp If a dull blade is used for cutting the grass will tear rather than cut This could damage the grass leaving a brown frayed top on the grass within a few hours A dull blade will also require more power from the engine NEVER attempt to straighten a bent blade by heating NEVER attempt to weld a cracked blade The blades can break and cause serious injury or death NEVER work with blades while engine is running or deck clutch is engaged 9 ALWAYS place deck clutch in DISENGAGE position while performing maintenance 4 Use blocks when you MUST work under mower ALWAYS wear thick gloves when handling blades 4 ALWAYS check for blade damage if mower strikes rock branch or other objects that could potentially damage the blade REMEMBER NEVER CHECK BLADE WHILE ENGINE IS ON NEVER CHECK BLADES WHILE BLADES ARE ENGAGED Cutting 4 Cut 1 3 of Grass Blade 10 Cutting more than
9. omfortable with machine before engaging blades Know what each component controls before using machine Maintenance Recommendations Daily Check each and provide maintenance when needed 4 Engine Oil 4 Engine Air Filter Tire Pressure Radiator Screen It is important to check screen several times a day when mower is in use Radiator Anti Freeze 4 Inspect Blades Every 30 Hours of Usage 4 Grease Machine Every 100 Hours of Usage 4 All Filters Check filters once a year if under 100 hours Every 500 Hours of Usage 4 Change Hydraulic Fluid Engine 4 Refer to manufacturer for specific information on maintenance schedules Storage and Transportation 4 Keep machine from collecting debris by storing in a covered area while not in use 4 Fuel can harm your machine if left for more than 30 days without changing 4 Disconnect the negative battery cable when machine will be stored for more than 30 days Always secure machine properly when transporting machine 9 Do not load machine on trailer with blades engaged 4 Do not use ramps to load the machine 4 Your mower will perform differently on an incline decline Be cautious slow down and do not make any sudden jerking movements with control arms The machine could lose traction on a decline or tip backwards on an incline Adjustments Deck Leveling 4 Put mower on flat level surface 4 Remove drive Belt 4 Check tire
10. s O Roads and highways 4 Safety warning decals are located on the mower and should always be observed and followed Operation Never operate the machine with faulty equipment Always be alert of sudden changes in landscape as the mower will react differently on slopes or embankments than it will on flat surfaces Never operate the mower with the discharge chute open Do not cross terrain other than grass with blades turning This could cause damage to property or bystanders Starting Machine 4 Place parking brake in up position 4 Drive arms must be in the open position While sitting on the machine each arm is positioned away from the operator to the right and left Drive arms will lock into place and must be in this position to start machine 4 Put PTO switch in the OFF position If your machine has been equipped with a ROPS Roll Over Protection System then you must fasten seatbelt 4 If machine has not been started recently engage the choke 4 Make sure nothing is under or around machine Place key in ignition and turn 4 Once machine is started disengage the choke Increase RPM by sliding the throttle to fast position toward the rabbit Driving the Machine 4 Owners must become familiar with the controls before operating a zero turn radius vehicle Start slowly and build your skill level Have ample practice before using the machine at full capabilities 4 Be c
11. s linked to manually operate the engine choke When the lever is in the down position the choke is in the off run position When the lever is pulled up the choke is in the on start position Do not operate the machine in the on start position Control Levers These levers control the mower s speed direction and neutral lock These levers are used to steer accelerate decelerate and change direction 4 Blade Engage Switch This switch engages the blades Pull the switch up to engage the blades and push the switch down to disengage the blades Deck Lift Control The deck lift switch is used to a raise and lower the deck Pa Pull the switch backwards to raise the deck and push the switch forward to lower Instrumentation the deck Moving mower with 4 Electronic Hour Meter Registers Hour increments up to 9 999 9 total hours This meter records the Inoperable engine If it is necessary to move cumulative time the ignition mower when the engine is key is switched to the RUN stalled the hydraulic drive position pumps are equipped with bypass valves Before Oil Pressure Light This moving the mower turn the light comes on upon placing bypass valves counter the ignition switch in the clockwise one half to one RUN position and stays lit revolution The valve stems until the engine is running on each pump are located and a safe oil pressure is near the top and are bu
12. s seat 4 Always operate machine in daylight or with adequate working lights 4 Always keep machine clean removing dirt trash and other materials from machine 4 Be alert of surroundings 4 Watch for rocks stumps and mounds or depressions while mowing 4 Always wear eye protection while mowing and servicing 4 Always wear ear protection such as earplugs while mowing If you strike something with the mower turn the blades and mower off engage the parking brake and inspect the machine for damage before resuming 4 Be aware of low hanging limbs or objects that could potentially be hazardous while mowing 4 Never operate a poorly maintained machine 4 Never carry passengers 4 Always buckle seat belt if provided one 4 Never attempt high speed maneuvering especially around people or property 4 Never put hands or feet under the machine while ignition is on 4 Never refuel machine when engine is running Never leave key in ignition especially around children 4 Never run engine in enclosed area 4 Do not touch hot parts of machine Do not remove deck wheels Conditions that can affect traction resulting in the loss of control of machine O Wet terrain O Depressions in the ground O Mounds of dirt O Extremely dry grass O Soil type gravel sand clay O Tire pressure Be aware of what of what is located at the bottom of slopes For example O Rocks O Water O Cliff
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