2013 ZT Elite Owner/Parts Manual
Contents
1. st DS K 2552 Doce Lea prep T 263 in Si w TIL SUE Em LEE 84 e j E p ZEN FING GIUM SE3 WO YOR Can PAGE 17 SECTION 5 FRAME For non suspension models torque front fork nut to 40 ft Ibs Be sure to spin the fork while torquing the nut to ensure that no bearing damage is done Torque rear wheel lugs to 65 75 ft lbs Re torque at every oil change There is one grease fitting on each of the actuator bar pillow blocks located under the fuel tanks Grease twice a season PAGE 18 The pump belt tensioner is located under the engine and has a grease fitting at its pivot point Grease at every engine oil change The deck belt tensioner is located at the rear of the deck and has a grease fitting on its pivot point Grease at every engine oil change The control arm blocks have grease fittings located on the top and bottom of each block Grease one time a year SECTION 6 CUTTING DECK To remove the deck belt lift up on the belt while rotating the pulley to roll the belt up and off of the pulley be sure not to get your fingers between belt and pulley To check the level of the deck start on a flat surface and set the air pressure in all four tires Raise the deck up and measure all four corners of the deck to see if it is level from2. ELITE DES ZERO MOWER OWNER S SERVICE 8 MANUAL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 8 0 698 0090 92013 11 12 TABLE CONTENTS pi llillu O A section 1 pages 4 5 Bad Boy Safety Guidelines a section 2 pages 5 6 no section 3 pages 6 7 WE A section 4 7 Storage and Transportation ENEE section 5 page 8 Troubleshooting and section 6 pages 8 9 PP Section 7 page 9 Moving Inoperable MoWer mnn oection 8 page 10 II ERU section 9 10 Vekene section 10 11 E RIS RR oection 11 pages 11 How to choose the right blade Page 12 vum gu m Page 21 SERVICE SECTION BEGINS ON PAGE 13 PARTS SECTION BEGINS ON PAGE 22 LIMITED WARRANTY PAGE 42 PAGE 2 This manual applies to the following equipment Bad Boy ZT Elite Series ZT Elite 4800 48727 hp Briggs ELS ZT Elite 4800 48727 hp Kohler ZT Elite 6000 60 27 hp Kohler ZT Elite 4800 48 726cc Kawasaki ZT Elite 6000 60 726cc Kawasaki COMMONLY USED ITEMS AND PART NUMBERS 60 ZT Blade Hi Lift Fusion Gator Blade 038 6060 00 038 6003 00 48 ZT Blade Hi Lift Fusion Gator Blade 038 5350 00 038 5000 00 Wave Blade 038 6015 00 Wave Blade 038 4825 00
3. 018 8059 00 5 16 x 1 3 4 Hex Bolt 086 0005 00 Starter to chassis cable 015 0027 00 27 Hp Briggs Exhaust 015 2751 00 Exhaust Gasket for 27 30 HP 063 8018 00 Oil Filter 063 6000 00 Universal inline Fuel Filter 063 4000 00 Air Filter W Cleaner 26 Int 015 2702 00 26 amp 27 Briggs Air Filter Cover 27HP PART NUMBER 5 16 Lock Washer 7 16 2 1 2 Hex Bolt 8 1 070 2000 00 Clutch Pigtal 9 1 033 5035 00 3 4 Motor Pulley x 10 4 018 1075 00 3 8x11 8bott 12 1 042 5020 00 1 4 2 Square key Stock 0 00 Exh E 15 5401 00 drain Valve 4 018 8067 00 5 16 18 x 3 4 Socket C S 63 8080 00 Filter Precleaner Kohler 41 6400 00 Filter 278 30 Kohler 15 2701 00 27 KO Courage Air Cleaner Cover 30 0050 00 5 16 Set Screw 22 086 0005 00 Starter to chassis cable 0 0 063 5400 00 0 0 PAGE 35 4 48 Deck 45 Spindle Assembly DETAIL B 15 Deck Idler Assembly DETAIL A PAGE 36 21 48 Deck DESCRIPTION 48 Deck Only Spindle Aluminum 2012 ZT 3 8 x 1 1 4 Hex Bolt 3 8 Hex Nut 3 8 Lock Washer ___6 3 0360300 8 0195500700 1 2 Lock Washer __ __9 3 _ 018 6019 00 _____ 1 2 20 x 1 1 2 Grade 5 Fine Thread Bolt 5 8 x 1 1 2 Grade 8 Bolt 15 6 037602300 Spindle Bering 1 2 x 5 1 2 Bolt 5 8 x 2 1 2
4. a H To bag or mulch Grass clippings do not contribute to thatch buildup or increase the chances of disease If you mow your lawn at the right height without removing any more than 1 3 of it s total height clippings will quickly breakdown without a trace These clippings contribute additional nitrogen and other nutrients to the soil and supply it with additional organic materials Clippings from a 1000 sq ft lawn can add as much as 1 2 pounds of nitrogen back into the soil If you have a compost pile then you may want to bag your clippings occasionally to add much needed green matter to the compost pile Make sure it is mixed thoroughly with brown matter to avoid a strong ammonia odor DO NOT COMPOST CLIPPINGS after applying any weed control or weed feed type product Before adding clippings to the compost pile wait at least 3 mowings after these products have been applied PAGE 21 Front Fork Assembly PARTS SECTION Parts List 2 1 013 8050 00 1 2 13 Nylon Flange Nut Orange 1 2 x 9 Bolt 4 1 022 2006 00 Tireandwheelassemby 5 1 025520200 Front Wheel Spanner 6 2 022700900 Wheel Bearing 7 1 014205000 RuberBearngCap 8 1 013 9004 00 1 Fine Thread 1 2 Nut 9 2 010 2000 00 Caster Bearing 2 2009 amp up 10 1 025 0004 00 2 2 Caster Bearing Spacer PAGE 22 DETAIL PAGE 23 1 60000
5. 4 LIMITATION THERE 15 NO OTHER EXPRESS WARRANTY ANY WARRANTY THAT MAY BE IMPLIED FROM THIS PURCHASE INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IS HEREBY LIMITED TO THE DURATION OF THIS WARRANTY AND TO THE EXTENT PERMITTED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you B BAD BOY INC WILL NOT BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES AND OR EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THE MOWER Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation s or exclusion s may not apply to you C Only the warranty expressed in this limited warranty shall apply and no dealer distributor or individual is authorized to amend modify or extend this warranty in any way Accordingly additional statements such as dealer advertising or presentations whether oral or written do not constitute warranties by Bad boy Inc and should not be relied on D This warranty extends only to turf equipment operated under normal conditions and properly serviced and maintained The warranty expressly does not cover i any defects damage or deterioration due to normal use wear and tear or exposure ii normal maintenance services such as oil change cleaning lubrication adjustment iii replacement of services items
6. blades Bear in mind that the re circulating airflow design of 3 1 blades makes them less efficient at discharging grass clippings than a standard 2 1 blade As with most all purpose tools there is some give and take as opposed to using a tool designed for a more specific purpose If you re experiencing less than desired cutting or discharging performance with a 3 1 blade you may want to check into using a 2 1 blade Conversely if you re using a 2 1 blade and want to mulch clippings you should see about the availability of mulching blades or a mulching kit The type of blade installed on a new mower is a decision the retailer makes for each model of mower based on the expected needs of most customers If you re unsure of which blade is on a particular model inspect the blade Blades have part numbers stamped into them Then compare these part numbers with the unit s Operator s Manual or Parts List It is true there are many other styles of blades available But since we don t manufacture or recommend using these other aftermarket styles we will leave them out of this discussion Should you want more information on special application or aftermarket blades you should contact the companies that make these products NOTE Customers using non OEM blades do so at their own risk The use of unapproved non OEM blades may void any or all of the mower and engine factory warranties MULCHING KITS These generally consist of mulching blad
7. 2013ZT ZT Rear Gaeren 6 09550 5 16 x 1 Carriage Bot 4 CH 03805 5 1618 Nylon Fange NE s 6 88000 1 4 x 3 4 Carriage Bol 5 0196020 3s0IDPasicWaser 3 6 peeso 8 rap 9 0820060 nek _ s oe i vmidamp ee Jaen amo _ LI Bi Ww nN PAGE 24 ZI Drive Arm Assemblies Items Per Side PAGE 25 ZT Drive Arm Assemblies 1 6 2 018 401 00 _______ 1 2 Nylcock Nut 2 Jam BLL 077 8073 00 Safety Switch 0 9 2 0181000 12 24x1 2HwHBot 3 8 x 1 1 4 Hex Bolt PAGE 26 e DETAIL A a A y 4 e SN OE NMA PAGE 27 PAGE 28 Frame Top Assemblies PART NUMBER 1 070 5410 00 1 014 3420 00 1 079 3420 00 18 8065 00 13 8049 00 1 054 8017 00 1 081 2010 00 40 6080 00 atchet Fastener 18 8040 00 4 x 3 4 Carriage Bolt 19 6042 00 360 ID Plastic Washer 13 8073 00 4 Nylock Nut 30 7042 00 16 x 3 4 washer head type F screw 18 5043 00 8 x 1 1 4 Carriage Bolt 13 6014 00 8 Hex Nut 18 8066 00 16 x 7 8 Carriage Bolt 13 9002 00 16 Flange Nut 34 8045 00 eat Spring 18 5040 00 8 x 1 1 4 Hex Bolt 19 5029 00 8 Flat Washer 19 5037 00 8 Lock Washer 44 4000 00 eat Braket Pin 13 5300 00 2 Flange Nut al 20 LA 14 8
8. 21 Hydro Filters 60 ZT Deck Belt 48 ZT Deck Belt 21 Pump Belt Oil Filter Air Filter Motor Oil Hydro Oil 063 1050 00 041 1650 00 041 1470 00 041 6400 00 Briggs Engine 063 2004 00 Briggs Engine 063 4000 00 10w30 2 quarts 20w50 4 quarts Kohler Engine 063 5400 00 Kohler Engine 063 8080 00 BASIC INFORMATION Congratulations on the purchase of your new Bad Boy Mower The purpose of this manual 15 10 assist operators in maintaining and operating their machine The information and instructions in this manual can help you attain years of performance from your new Bad Boy Also check out our website to learn more about the Bad Boy family 15 All Bad Boy engines use 10W30 engine oil Conventional or Synthetic may be used 12 All Bad Boy hydraulic systems use 20W50 engine oil Conventional or Synthetic may be used 13 All Bad Boy Mowers use hi temp multi purpose grease NLGI No 2 for the grease fittings 14 ZT models have 12 psi in both front and rear tires 1 5 Most Briggs Kohler Kawasaki and Vanguard engines hold two 2 quarts of motor oil 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 Warranty is non transferable Model Serial Number Your ZT model serial numbers are found on the SIN plate underneath
9. 2 x 2 1 2 Hex Bolt 1 2 13 Nylon Flange Nut Orange 1 2 x 1 2 Spacer All Thread pump Idler Tensioner QTY 1 m un Ke un x e 018 5043 00 3 2 2 Hex Nut 009 Deck Pump Idler Spring 3 4 Idler Pulley 360 ID Plastic Washer 8 x 1 1 4 Carriage Bolt 8 Hex Nut ctuator Bar Transaxle illow block 2bolt sealmaster 1 2 Lock Washer _ 1 2 x 1 1 2 Hex Bolt 2 Hex Nut eight Indicator Lever eight Indicator Bar 16 x 1 Bolt ctuator 2 x 1 2 Spacer 2 x 2 1 2 Hex Bolt 2 13 Nylon Flange Nut Orange ZT Neutral level rod 2011 ow Pin 3 8 Flat Washer kA t gt LO o un 18 5006 00 13 7018 00 31 7000 00 28 2502 00 18 2007 00 35 7033 00 25 7036 00 18 6036 00 13 8050 00 31 0060 00 44 2004 00 19 5029 00 4 013 7018 00 m eI n3 n3 mJ cn mJ J UJ GJ NA NJ t LA Kl mJ co UJ e 5 40 2008 00 Rod Clip 039 5944 98 030 0050 00 UJ UJ Idler Assembly Components 3 7 8 9 13 5 16 Set Screw PAGE 30 21 Transaxle Assembly DETAIL A O PAGE 31 21 Transaxle Assembly 3 8 x2 Hex Bolt ____5 2 1050 20750 Fam Pulleykie ____6 4 018 4701 00 5 16 x 3 Hex Bolt 0 ____7 8 1198040 5 16 FlatW
10. Hex Bolt 1 2 x 4 Bolt Grade 8 PAGE 37 ZT 48 Chute Assembly 21 48 Chute Assembly QTY PART NUMBER DESCRIPTION 1 Upper Hanger Discharge Lower Chute Bracket 210 6005 00 Rubber Discharge Chute Rubber Only 013 8049 00 15 16 Nylon Flange Nut 16 x 1 1 4 Carriage Bolt 206 6017 00 ischarge Chute Hanger deck mounted 018 2007 00 5 16 x 1 Bolt 019 6042 00 360 ID Plastic Washer 0 0 pa 13 8049 00 16 Nylon Flange Nut 18 5250 00 3 8 x 3 4 Hex Bolt 013 5201 00 3 8 Flange Nut 1 210 5218 00 48 Rubber Discharge Chute Assembly Components 1 2 3 4 5 LA UJ UJ kel PAGE 38 PAGE 39 PAGE 40 21 60 Deck 042 6030 00 1 4 x 1 Key 6 3 j0196020 00 ____ 1 2 Belleville Washer j 8 3 019 5007 00 1 2 Lock Washer 9 3 019480700 S 8 LockWashe_____________ 5 8 x 1 1 2 Grade 8 Bolt 3 8 x 1 1 4 Hex Bolt wo 6 ____ 037 6023 00 Spindle Bearing 16 6 1 060600500 60 ZT Deck Only 048 6056 00 047 6050 00 60 ZT Deck Belt 23 025 5203 00 3 4 OD x 1 2 ID x 3 4 Length 26 018 5311 00 013 8050 00 013 5301 00 60 Deck only Deck Idler Spring I 5 3 4 Deck Idler Pulley 032 5056 00 Flange Bushing For Deck Arm upper 025 5338 00 022 1000 00 40 41 018 5019 00 1 2 4 Bolt Grade 8 43 _____43 13 01
11. system PAGE 13 Once the system is filled with oil lift rear of mower until rear tires are off the ground Start engine release parking brake stay clear of moving rear tires Next pull the neutral bypass levers located at rear of the frame on either side of the muffler move the drive arms forward and backward 4 to 6 times slowly This relieves any air that may be trapped in the system It may be necessary to add more oil to the hydro overflow tank after 10 15 minutes of running These bypass levers also serve as a neutral for moving the mower without the engine running SECTION 2 DRIVE BELT shown on the right is a typical pump belt tensioner for your ZT model mower Tightening the two jam nuts on the right side will increase the belt tension on all models Factory setting is about 030 about the thickness of a credit card between coils as shown PAGE 14 SECTION 3 ENGINE Most models have a drain hose installed on the engine for easier oil changes All gas engines used by Bad Boy use 10w30 and have an oil capacity of 2 quarts Bad Boy recommends that the oil and filter be changed every 50 hours of usage The fuel filter is located in the fuel line about 12 from the carburetor on the side of the engine Note the direction of flow on the side of the filter Replace once a year Remove and inspect air cleaner weekly More often in dusty conditions Do not blow filter out with air pressure this w
12. will decrease Avoid operating your mower on side hills of over 5 degrees inclines of over 10 degrees and declines of over 15 degrees MOWER MAINTENANCE Check each and provide maintenance when needed DAILY 41 Check Engine Oil 4 2 Check Engine Air Filter 4 3 Tire Pressure 44 Inspect Blades Within FIRST five hours of usage change engine oil and filter EVERY 30 HOURS OF USAGE 45 Grease Machine EVERY 50 HOURS OF USAGE 4 6 Change Engine Oil and Filters Check fillers once a year if under 50 hours Check air and fuel filters more often in dry dusty conditions Within FIRST 50 hours of usage change hydraulic oil and filters EVERY 250 HOURS OF USAGE 4 Change Hydraulic Fluid and Filters 4 8 Refer to manufacturer manual for specific information on maintenance schedules PAGE 7 PAGE 8 9 1 9 2 9 3 9 4 9 0 9 0 5 7 9 0 9 9 9 10 9 11 6 1 6 1 6 2 6 2 6 3 6 3 6 4 6 4 MOWER STORAGE TRANSPORTATION Keep machine from collecting debris by storing in a covered area while not in use Fuel can harm your machine if left for more than 30 days without changing especially if the fuel contains ethanol Never use fuel with more than 10 ethanol by volume E 15 is not permitted Disconnect the negative battery cable when machine will be stored for more than 30 days Always secure machine properly when transporting machine Do not load machine on trailer with blades engaged Do not use ramps to
13. 047 00 08 5349 00 64 5300 00 03 5300 00 68 8049 00 1 064 5301 00 13 9001 00 43 8929 00 86 0005 00 18 8052 00 03 5400 00 1 069 1000 00 69 7000 00 77 8073 00 18 1080 00 19 2073 00 13 9003 00 26 1013 00 36 5300 00 30 3050 00 Z ubber Brake Grip cZT ZT 2013 afety Switch 2 24x 1 2 HWH Bolt 390 ID Plastic Washer 8 Nylock Jam Nut 1 2 Nut 013 ZT Seat Plate eat Switch Adapter 10 x 1 2 Self Taping Screw E n N N 29 4010 00 32 5053 00 1 019 6017 00 13 6051 00 3 8 Fine Threaded Jam Nut 40 6060 00 Seat latch pin 64 1000 00 64 3000 00 86 1201 00 86 3050 00 2 030 7040 00 2 013 9005 00 4 1 071 2020 00 2013 21 Seat 2 25 2 2 2 1 2 ISIS IG SS ISIS P 5 5 515 252 IIA y ins esl rl 0 e O N 00 5 N PAGE 29 Frame Bottom Assemblies PART NUMBER 70 5410 00 13 8049 00 39 5944 00 19 6017 00 18 5311 00 13 5301 00 18 6036 00 13 8050 00 25 7036 00 18 2004 00 13 7018 00 34 2009 00 33 6001 00 19 6042 00 18 5043 00 13 6014 00 28 4020 00 17 7008 00 19 5007 00 ITEM DESCRIPTION ZT cZT Frame 2013 Models 16 18 Nylon Flange Nut ump Idler Bracket 635 ID Plastic Washer 8 x 4 Hex Bolt 2 8 Nylock 1 2 Jam 1
14. 847000 3 8x1 1 2CariageBot j 018 1090 00 1 2 x 5 1 2 Bolt 013 8050 00 5 8 Std NC Nylock Nut 21 60 Chute Assembly ZT 60 Chute Assembly rrem QTY PART NUMBER DESCRIPTION 210 6005 00 Rubber Discharge Chute Rubber Only 013 8049 00 5 16 Nylon Flange Nut 018 4703 00 5 16 1 1 4 Carriage Bolt 206 6017 00 Discharge Chute Hanger deck mounted 5 2 018 2007 00 15 16 x 1 Bolt 019 6042 00 360 ID Plastic Washer 013 8049 00 5 16 Nylon Flange Nut 8 3 018 5250 00 3 8 x 3 4 Hex Bolt 013 5201 00 3 8 Flange Nut 039 4864 00 60 Upper Hanger Plate 039 4863 00 60 Lower Hanger 210 6004 00 60 Rubber Discharge Assembly Components 1 2 3 10 11 PAGE 41 037 6015 50 Spindle Aluminum 2012 ZT PART NUMBER 6 1 j037 9050 00 Collar Spacer Top of Spindle PAGE 42 091 0910 00 2013 ZT Back Panel Decal 27hp 091 0903 00 2013 cZT ZT 48 091 0905 00 2013 cZT ZT 60 TER 091 0911 00 2013 ZT Back Panel Decal 726cc ELITE 091 0900 00 2013 Elite Decal Grill 091 0901 00 2013 cZT ZT Instrument panel 091 0902 00 2013 cZT ZT Logo Decal Floorboard 091 0906 00 091 0905 00 2013 cZT ZT Steering Speed 2013 cZT ZT Brake Steering Control Decal Decal 091 3150 00 Outlaw Warning Decal 091 3017 00 Pump Belt Route Decal KEEP HANDS amp FEET AWAY DO NOT OPERATE MOWER UNLESS GUARD OR GRASS CATCHER
15. ING TIPS e Mow header strips at the ends of the lawn and around flower beds first Make them wide enough that you can turn the mower around in the already mown section Then mow back and forth between these header strips overlapping each lap by about 1 8 the width of the mower s deck e Don t cut your grass too short particular for cool season grasses Higher heights usually provide for a deeper root system looks better and is less likely to have weeds invading particularly crabgrass Don t remove any more than one third of the grass leaf at any one cutting If circumstances arise that a lawn gets too tall and you just have to lop off a bunch to get caught up bite the bullet and break it down into several mowings to get caught up with 3 or so days between cuttings NEVER SCALP YOUR LAWN Scalping severely damages the root system to such a degree that it may die Avoid mowing when the grass is wet or when it s dark Avoid throwing grass clippings into the street and driveway where they can be washed into the sewer system After mowing clean up driveway and walkways mowing remove only a third with each cutting except for the first mowing of the season when it s ok to remove more You can safely leave clippings that will quickly decompose and add nutrients back into the soil Contrary to popular opinion grass clippings do not add to thatch buildup Grass blades are made up of about 75 water Mow your lawn in a
16. IS ATTACHED 091 3012 00 Danger Decal Spindle Discharge 091 3309 00 48 Deck Belt Route Decal 091 1020 00 MZ Hydraulic Decal 091 3046 00 60 Deck Belt Route Decal PAGE 43 5 PAGE 44 NOTES PAGE 45 PAGE 46 2013 LIMITED WARRANTY FOR BAD BOY ZT ELITE SERIES 1 WHAT THIS WARRANTY COVERS AND FOR HOW LONG Bad Boy Inc will at its option repair or replace without charge any part covered by the warranty which 15 found to be defective in material and or workmanship within the lesser of two 2 years or 200 hours after the date of sale to the original retail purchaser unless Le product S ed for rental purposes in which warranty B used for commercial purpose in which Labor for all warranted parts will also be covered for 2 years from the date of sale to the original purchaser The leading edge of the deck shell will be warranted for the entire lifetime of the machine to the original purchaser against defects in materials and workmanship Labor required to repair or replace the leading edge of the deck shell will be covered by Bad Boy Inc for the first two years and at the unit owner s expense during the balance of the lifetime of the machine Belts are warranted for a period of ninety 90 days against materials or workmanship defects At Bad Boy Inc s request the customer will make the defective part available for inspection by Bad Boy Inc and or ret
17. STRUMENTATION Electronic Hour Meter Registers Hour increments up to 9 999 9 total hours This meter records the cumulative time the engine is running 10 1 10 2 10 3 10 4 10 5 10 6 10 7 114 11 2 11 3 11 4 11 5 11 6 MOWER BLADE MAINTENANCE Check mower blades after each use This is essential for maintaining well groomed turf Keep the 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 ALWAYS place deck clutch in DISENGAGE position while performing maintenance Use blocks when you MUST work under mower ALWAYS wear thick gloves when handling blades 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 GREASING THE BEARINGS Park the machine on a level surface and disengage the blade control switch 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
18. asher x 8 2 025 5340 00 31 W Spacer _ 9 2 1185350 5 16 x6 Bolt x 17 8 013 3000 00 fAcormLugNut 5 16 x 2 1 2 Bolt ____23 9 013 8049 00 ________ 5 16 Nylon Flange Nut 5 16 x 1 Bolt 21 Transaxle Hub 2 8 050 2012 00 _________ Wheel Studs ZT Transaxle Charge Plate With O Ring PAGE 32 Parts List m m k EM QTY R DESCRIPTION 0 1 4 x 1 Key 03 5400 00 19 8051 00 18 1075 00 15 5404 00 drain 86 0005 00 18 5321 00 15 0038 00 15 2709 00 13 0075 00 8 1 25 Zinc Nut 5 0090 0 13 8043 00 5 16 Nut 19 8051 00 16 Lock Washer 19 8053 00 7 16 Lock Washer 18 5300 00 17 16 x 2 1 2 Hex Bolt 70 1000 00 Clutch Assembly 18 5350 00 5 16 18 x 5 1 2 GR 5 Hex Bolt 70 2000 00 Clutch Pigtail 1 6400 00 2097 00 8017 00 6000 00 33 5035 00 4 3 4 Motor Pulley Oo 79 a 17 2 3 gt 5 m o o e eis 8 5 EIE ojo PAGE 33 27 HP Briggs PAGE 34 Briggs 27 Hp PART NUMBER DESCRIPTION 015 3051 00 27Hp Briggs Engine Pro Series 5 16 Lock Washer 6 1 070 1000 00 Clutch Assembly 018 5350 00 5 16 18 5 1 2 GR 5 Hex Bolt 8 1 070 2000 00 Clutch Pigtail 9 1 041 6400 00 Pump Belt 051 5401 00 Oil drain Hose 5 16 Nat 019 8051 00 5 16 Lock Washer
19. before leaving the operating position Grease Type NGLI grade 72 multi purpose gun grease Grease the front caster pivots Clean the grease fittings with a cloth Scrape any paint off the front of the fitting s Connect a grease gun to each fitting Pump grease in fittings until grease begins to seep out of the bearings Wipe up excess grease Refer to service manual section for grease fitting locations PAGE 11 HOW CHOOSE THE RIGHT BLADE Essentially there are only TWO basic styles of mowing blades used or approved for use on our current products 1 The standard style of mowing blade is essentially designed for cutting grass and effectively discharging the clippings out from the deck to fall onto the lawn or to be captured in a grass collection system Standard blades are also referred to as 2 in 1 discharging amp bagging or high lift blades because they are designed to create a higher lifting airflow 2 Mulching blades generally have a more curved style surface and frequently include extra cutting 66 3 surfaces along the blade edges These blades may also come in a design which is actually two individual blades arranged in a perpendicular fashion to enhance mulching The blades are usually found on older style mowers newer ones utilize blades with more advanced mulching technology Mulching blades may also be referred to as 3 in 1 mulching discharging amp bagging or all purpose
20. cure at switch Q What type of fuel is recommended for my mower A We recommend that you use a name brand fuel to ensure quality Use fuel with an octane rating near 87 Higher octane fuels offer no benefit Only fuels with an ethanol content of 10 or less may be used E 15 is not permitted 65 Do you offer touch up paint for your mowers 6 5 A Touch up paint is available Contact your local dealer for more information 66 How durable is the electric deck lift 6 6 The actuator which controls the deck height is designed for moving loads of up to 1000 1 2 7 3 7 4 9 1 0 1 2 1 1 pounds and has a static holding capability which exceeds 3 000 pounds Our deck weighs approximately 250 pounds which is only 25 of working capability CONTROLS 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 he 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 Not Pictured located on left side by hand brake 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 i
21. d PAGE 6 2 24 2 29 2 26 2221 2 28 Never operate the mower with the discharge chute open Prevent Fires Remove grass and debris from engine compartment and muffler area before and after operating machine especially after mowing or mulching in dry conditions Do not store machine near open flame or source of ignition such as a water heater or furnace Do not attempt to mount a tire without the proper equipment and experience to perform the job Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel 2 29 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect 2 30 Let engine cool before storing 2 31 Hydraulic hoses and lines can fail due to physical damage kinks age and exposure Check hoses and lines regularly Replace damaged hoses and lines 2 32 Park machine on level ground Never allow untrained personnel to service machine 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 9 Understand service procedure before doing work MOWER 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
22. different direction with each mowing especially with lawns of shorter grass types Altering the direction ensures a more even cut since grass blades will grow more erect and less likely to develop into a set pattern Keep your mower s blade sharp which means having it sharpened several times during the mowing season Keep several blades around so you ll always have a sharp one on hand Sharp blades cut the grass cleanly and help mulch clippings into small pieces which break down quickly Don t forget to change your mower s oil at least once during the mowing season For brand new mowers change the oil after about 5 hours of operation during the initial break in period At the end of the mowing season use a fuel stabilizer in the remaining gasoline n the spring don t use that old gas unless you properly used a fuel stabilizer it can cause a number of problems Better to use fresh gasoline to begin the new mowing season Leaf demonstrates what a leaf blade should look like Se RUD Ze EE after mowing with a sharp blade E e Leaf blade B demonstrates a leaf blade that was injured by a dull mower blade e Leaf blade C was cut by the mower but indicates that the mower blade is not sharp enough The shredded white tissue protruding from the leaf blades C and D is the vascular tissue of the plant Leaf blade D has been mown for quite some time with a dull mower blade a i D
23. es and a mulching plug which closes off the discharge opening to keep the clippings contained under the deck for re cutting plus any necessary hardware for installation Please check with your parts distributor regarding the contents of a particular mulching kit PAGE 12 SERVICE SECTION SECTION 1 HYDROSTATIC SYSTEM The hydro overflow tanks on a 21 are located on the sides of the rear cover Notice the full cold line at the bottom of the tank Use only 20w50 motor oil in this tank Conventional or synthetic oil may be used When servicing a mower with a sealed transaxle unit start by removing the filter skid plate on the bottom of each unit The skid is held on by three 10 bolts Next remove the filter The filter also serves as the oil drain Each transaxle holds about 2 quarts of hydro oil Re install new filters and skid plates Use only hydro gear filters Use of any other type of filter will result in damage to the hydro system and void the warranty Transaxle service recommended within the first 50 hours of usage and every 250 hours thereafter or once a year The check plug is located at top center of the inside case of each transaxle The transaxle can be filled with oil by removing these check plugs from both transaxles and pouring the oil in the hydro overflow tank located behind the seat Oil will begin to run out of the check plug holes when the transaxles are full Use only 20w50 motor oil in the hydro
24. his warranty customer shall have read the operator s manual and shall have returned to Bad Boy Inc within the prescribed time the enclosed warranty registration card E This warranty gives you specific legal rights and you may also have other rights which vary from state to state Bad Boy Inc 102 Industrial Drive Purchased From certify that have been properly instructed on operating this machine Batesville AR 72501 1 866 622 3269 www badboymowers com Technical Support Brad COVINGTON RR RR brad covington badboymowers com A TT taylor prince badboymowers com James TASS RR RR james russell badboymowers com Warranty Dustin Tiseierg n nasa dustin badboymowers com Parts CANIS 0 07 1 eee chris epperson badboymowers com robert patterson badboymowers com Cut and Mail or Fill Out Online under Owners at www badboymowers com WARRANTY REGISTRATION Full Name Address City otate Zip SERIAL Purchase Date Telephone For additional information please see us www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 870 698 0090 Cut and Mail or Fill Out Online under Owners at www badboymowers com BAD BOY MOWERS 102 Industrial Drive Batesville AR 72501 Place Stamp Here POST OFFICE WILL NOT DELIVER WITHOUT POSTAGE
25. ill cause the filter to be filled with tiny holes that will allow dirt to enter Instead tap filter on side to remove any debris Replace at least once a year more often in dusty conditions Torque the clutch bolt to 50 ft 105 on all models Re torque at every oil change All Models PAGE 15 SECTION 4 ELECTRICAL SYSTEM On most larger commercial engines 27 hp and up the 25 amp main fuse is located about 3 from the starter on the engine shown in first image on right On smaller commercial and light duty commercial mowers the 25 amp main fuse is located just behind the battery connected to the starter solenoid Shown in second image on right Always check the condition of the wiring harness ground cable The ground is located just inside of the right side fuel tank on most models Ensure that the ground is connected clean and tight On some models this wire may be connected to the negative side of the battery Check the condition and connection of the relays located under the seat Ensure that they are clean and connected Make sure that wire terminal ends have not been pushed out of the relay block 8 E LE in a gt E On most models the red wire coming out of the engine 15 the charging wire from the alternator Check for 13 6 14 2 volts DC at this wire with engine at full throttle PAGE 16 ALT RELA DECK LIFT RELA BRAKE SVITO d l s A pae
26. left to right and front to back All decks should be level from left to right and have a 1 8 pitch down in the front If deck adjustments are necessary start with the chain length adjusters These adjusters affect the overall height of the deck and the level from left to right PAGE 19 The large turn buckles on the front of the deck only affect the pitch of the deck or the level from front to back The deck spring tension is critical If the tension is too much it will cause the spring to break If too loose the belt can jump off or slip on the pulleys and cause a cut quality issue With the deck up the spring coil gap should be about 025 030 about the thickness of a credit card Spring tension adjustments can be made by sliding the bolt shown above forward or backward in the slot of the deck The condition of the blades can drastically affect the cut quality of the mower deck Replace as necessary These blades were used considerably too long Resharpening is recommended by professionals only to determine when the blade needs to be replaced and because of the need for rebalancing To change blades it may be easier to use a piece of wood to keep the blade from turning so that the bolt can be loosened Re torque the blade bolts to 90 110 105 The blade spindles contain a sealed ball bearing in the top and bottom of the spindle The bearings are replaceable for a more cost effective repair PAGE 20 MOW
27. load the machine Make sure Parking Brake is in up position In wet conditions tires may spin while loading unloading If necessary wait for dry conditions before loading unloading Make sure mode of transportation is suitable to bear the weight of mower Deck height should be set at maximum before attempting to load secure mower with at least two straps capable of securing weight of mower TROUBLESHOOTING Q How do prevent an uneven cutting pattern and increase the quality of cut A Check tire pressure check blade sharpness replace blades or sharpen at least once per year 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 grounds 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 Check for broken wires or bad connections 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 se
28. machine in daylight or with adequate working lights 2 6 Bealert of surroundings Watch for rocks stumps and mounds or depressions while mowing 2 Always wear eye protection while mowing and servicing 2 0 Always wear ear protection such as earplugs while mowing 2 9 f you strike something with the mower turn the blades and mower off engage the parking brake and inspect the machine for damage before resuming 210 Be aware of low hanging limbs or objects that could potentially be hazardous while mowing 2 11 Never operate a poorly maintained machine 2 12 Never carry passengers 213 Always buckle seat belt if provided one 214 Never attempt high speed maneuvering especially around people or property 2 15 Never put hands or feet under the machine while ignition is on 216 Never refuel machine when engine is running 217 Never leave key in ignition especially around children 218 Never run engine in enclosed area 249 Do not touch hot parts of machine 2 20 Do not remove deck wheels 2 21 Conditions that can affect traction resulting in the loss of control of machine Wet terrain Hills or extreme angles Depressions in the ground Mounds of dirt Extremely dry grass Soil type gravel sand clay Tire pressure 2 22 Beaware of what is located at the bottom of slopes For example Rocks Water Cliffs Roads and Highways PAGE 5 2 23 Safety warning decals are located on the mower and should always be observed and followe
29. n 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 Drive Arms 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 raise and lower the deck Pull the switch backwards to raise the deck and push the switch forward to lower the deck 7 6 7 5 PAGE 9 PAGE 10 8 1 8 2 8 3 8 4 8 9 8 6 9 1 MOVING INOPERABLE MOWER Do not tow machine Use a winch to load on a trailer for transporting ATTENTION RETURN BYPASS VALVES TO OPERATING POSITION BEFORE RUNNING MOWER FOLLOWING REPAIRS 21 Models are equipped with two neutral engage disengage arms located at the rear of the mower protruding from the frame and under the muffler By pulling the arms out the mower can be put in a neutral position Return the arms to the forward position for normal operation Your Bad Boy Mower Weighs ZT SERIES 800 850 10 Weights fluctuate with the addition of accessories As you can see by the weights of the machines you shouldn t ever try to push or pull a Bad Boy Mower by hand This could cause serious bodily injury Hopefully you ll never need to use this section of the manual However if you do use extreme caution when moving machine IN
30. 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 PAGE 4 MOWER SAFETY GUIDELINES 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 2 2 Always remain seated while operating machine 2 3 Always maintain a safe distance from people and pets while mowing 2 4 Always disengage blades place steering controls in neutral engage parking brake and remove ignition key when leaving operators seat 25 Always operate
31. such as oil lubricants spark plugs belts rubber hoses or other items subject to normal service replacement iv damage or defects arising out of or relating to misuse neglect alteration negligence or accident v repair or replacement arising from operation of or use of the turf equipment which is not in accordance with operating instructions as specified in the operator s manual or other operational instructions provided by Bad Boy Inc vi repair or replacement arising as a result of any operation from turf equipment that has been altered or modified so as to indetermination of Bad Boy Inc adversely affect the operation performance or durability of the equipment or that has altered modified or affected the turf equipment so as to change the intended use of the product vii repair or replacement necessitated by use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Bad Boy Inc viii repairs or replacements resulting from parts or accessories which have adversely affected the operation performance or durability of the turf equipment or ix damage or defects due to or arising out of repair of turf equipment by person or persons other than an authorized Bad Boy Inc service dealer or the installation of parts other than genuine Bad Boy Inc recommended parts As a condition to t
32. the discharge chute open Do not cross terrain other than grass with blades turning This could cause damage to property or bystanders Place parking brake in up position 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 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 If machine has not been started recently engage the choke Make sure nothing is under or around machine Place key in ignition and turn Once machine is started disengage the choke 3 9 Increase RPM by sliding the throttle to fast position toward the rabbit 3 10 Owners must become familiar with the controls before operating a zero turn radius vehicle 3 11 Start slowly and build your skill level Have ample practice before using the machine at full capabilities 3 12 Be comfortable with machine before engaging blades Know what each component controls before using machine 3 13 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 3 14 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing time
33. urn the defective part to Bad Boy Inc transportation charges prepaid 2 WHAT THIS WARRANTY DOES NOT COVER A This warranty does not cover defects caused by depreciation or damage caused by normal wear accidents improper maintenance improper use or abuse of the product alterations or failure to follow the instruction contained in the Owner s Manual for operation and maintenance B The customer shall pay any charges for making service calls and or for transporting the mower to and from the place where the anaa Way work is performed Engines mm warranted separately by their r respective Song eren The avaliable warranties covering this item are furnished with each mower Bad Boy Inc does not assume any warranty obligation liability or modification for this item which is covered exclusively by the stated warranty of the respective manufacturers D Tires blades deck anti scalping wheels and hoses are considered to be consumable wear items and are therefore not warranted E Batteries are warranted for six months free replacement from the retail purchase date against materials or workmanship defects The battery warranty must be obtained through the battery manufacturer 3 HOW TO OBTAIN SERVICE UNDER THIS WARRANTY A Warranty service can be arranged by contacting the dealer where you purchased the mower or by contacting Bad Boy Inc Proof of the date of purchase may be required to verify warranty coverage
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