Bad Boy 2009 Mowers Service Mower Owner's Manual

SECTION 1: HYDROSTATIC SYSTEM

TO CHANGE HYDRO OIL ON COMMERCIAL MODELS, REMOVE OIL

RETURN LINES FROM TOP OF HYDRO TANK AND PLACE THEM IN

A DISPOSABLE OIL CONTAINER. START AND RUN MOWER

UNTIL OIL LEVEL IS REDUCED DOWN TO ABOUT 2” OF OIL

REMAINING IN THE TANK. DO NOT ALLOW AIR TO ENTER THE

OIL LINES IN THE BOTTOM OF THE TANK. KEEP IN MIND THAT

ONLY ABOUT 75% OF THE HYDRO OIL CAN BE CHANGED AT A

TIME. USE ONLY 20W50 MOTOR OIL IN THE HYDRO SYSTEM.

CHANGE HYDRO OIL FILTERS BY UNSCREWING THEM FROM THE

FILTER HEAD. FILL NEW FILTERS WITH 20W50 MOTOR OIL

BEFORE INSTALLING. USE ONLY BAD BOY REPLACEMENT

FILTERS. USING ANY OTHER FILTER WILL RESULT IN DAMAGE

TO THE HYDRO SYSTEM AND VOID THE WARRANTY.

ONCE THE SYSTEM IS REFILLED WITH OIL, LIFT REAR OF

MOWER UNTIL TIRES ARE OFF THE GROUND. START ENGINE,

RELEASE PARKING BRAKE, PUSH CONTROL ARMS FORWARD,

STAY CLEAR OF MOVING REAR TIRES, OPEN AND CLOSE THE

BYPASS VALVE ON EACH PUMP ABOUT 6-10 TIMES BY

LOOSENING AND TIGHTENING THE BOLT SHOWN IN THE ABOVE

PHOTO. THIS WILL PURGE THE AIR FROM THE SYSTEM.

(THE BYPASS BOLT HAS A HOLE DRILLED THROUGH THE SIDE

OF THE BOLT HEAD). THIS VALVE ALSO SERVES AS A NEUTRAL

FOR MOVING THE MOWER WITHOUT THE ENGINE RUNNING.

WHEN SERVICING A LIGHT DUTY COMMERCIAL 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 10MM BOLTS. NEXT, REMOVE THE FILTER. THE

FILTER ALSO SERVES AS THE OIL DRAIN. EACH TRANSAXLE

HOLDS ABOUT 2 QUARTS OF HYDRO OIL. REINSTALL NEW

FILTERS AND SKID PLATES. USE ONLY HYDRO-GEAR OR BAD

BOY HYDRO FILTERS. USE OF ANY OTHER TYPE OF FILTER

WILL RESULT IN DAMAGE TO THE HYDRO SYSTEM AND VOID

THE WARRANTY.

THE FILL PLUG IS LOCATED AT THE TOP CENTER OF THE

INSIDE CASE OF EACH TRANSAXLE. USE ONLY 20W50 MOTOR

OIL IN THE HYDRO SYSTEM.

ONCE THE SYSTEM IS FILLED WITH OIL, LIFT REAR OF MOWER

UNTIL REAR TIRES ARE OFF THE GROUND. START ENGINE,

RELEASE PARKING BRAKE, PUSH DRIVE HANDLES FORWARD,

STAY CLEAR OF MOVING REAR TIRES. NEXT, PULL THE

NEUTRAL BYPASS LEVERS (LOCATED AT THE REAR OF THE

FRAME, ON EITHER SIDE OF THE MUFFLER) IN AND OUT 6-10

TIMES TO PURGE THE SYSTEM OF ANY AIR. IT MAY BE

NECESSARY TO ADD MORE OIL TO THE OVERFLOW TANK AFTER

10-15 MINUTES OF RUNNING. THESE BYPASS LEVERS ALSO

SERVE AS A NEUTRAL FOR MOVING THE MOWER WITHOUT THE

ENGINE RUNNING.

THE HYDRO OVERFLOW TANK ON A ZT MODEL IS LOCATED

BEHIND THE SEAT. NOTICE THE “FULL COLD” LINE AT THE

BOTTOM OF THE TANK. USE ONLY 20W50 MOTOR OIL IN THIS

TANK.

SECTION 2: DRIVE BELT

SHOWN ABOVE IS THE AOS/DIESEL PUMP BELT TENSIONER.

TIGHTENING THE TWO ¾”JAM NUTS ON THE LEFT 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 BELOW.

SHOWN ABOVE IS A TYPICAL PUMP BELT TESIONER FOR PUP

AND LIGHTENING MODELS.

SHOWN ABOVE IS A TYPICAL PUMP BELT LAYOUT FOR MOST

COMMERCIAL MODELS.

SECTION 3: ENGINE

SHOWN ABOVE IS A KAWASAKI ENGINE WITH THE “QUICK

DRAIN” OIL DRAIN LOCATED ON THE LEFT SIDE OF THE ENGINE.

USE A FLAT SCREW DRIVER AS SHOWN TO LOOSEN THE DRAIN.

MOST MODELS HAVE A DRAIN HOSE INSTALLED ON THE ENGINE

FOR EASIER OIL CHANGES. ALL GAS ENGINES USED BY BAD

BOY HAVE AN OIL CAPACITY OF 2 QUARTS. BAD BOY

RECOMMENDS THAT THE OIL AND FILTER BE CHANGED EVERY

50-60 HOURS OF USAGE.

THE FUEL FILTER IS LOCATED IN THE FUEL LINE ABOUT 12”

FROM THE CARBURATOR ON THE SIDE OF THE ENGINE. NOTE

THE DIRECTION OF FLOW ON THE SIDE OF THE FILTER.

REPLACE ONCE A YEAR.

MOST ALL MODELS HAVE A VACUUM OPERATED FUEL PUMP

BOLTED TO THE SIDE OR TOP OF THE ENGINE. THE PUMP HAS

A “FUEL IN”, A “FUEL OUT”, AND A VACUUM LINE COMING FROM

THE ENGINE BLOCK. FUEL FLOW CAN BE CHECKED HERE IF

THE PUMP IS SUSPECTED TO BE DEFECTIVE.

WHEN SERVICING THE FUEL SYSTEM ON THE CAT DIESEL, IT IS

NECESSARY TO PURGE THE AIR FROM THE SYSTEM BY

LOOSENING THE 9/16” BOLT ON TOP OF THE FUEL FILTER AND

PUMPING THE FUEL BULB UNTIL AIR BUBBLES ARE NO LONGER

VISIBLE.

REMOVE AND INSPECT AIR CLEANER WEEKLY. (MORE OFTEN IN

DUSTY CONDITIONS). DO NOT BLOW FILTER OUT WITH AIR

PRESSURE, THIS WILL 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. LBS. ON ALL MODELS.

RETORQUE AT EVERY OIL CHANGE.

KEEP RADIATOR SCREEN CLEAN AND FREE OF DEBRIS ON

LIQUID COOLED MODELS. CHECK SCREEN HOURLY DURING

DRY CONDITIONS. SLIDE RADIATOR SCREEN UP TO REMOVE.

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.

ON SMALLER COMMERCIAL AND LIGHT DUTY COMMERCIAL

MOWERS, THE 25 AMP MAIN FUSE IS LOCATED JUST BEHIND

THE BATTERY CONNECTED TO THE STARTER SOLINOID.

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.

ON MOST MODELS, THE RED WIRE COMING OUT OF THE ENGINE

IS THE CHARGING WIRE FROM THE ALTERNATOR. CHECK FOR

13.6 - 14.2 VOLTS DC AT THIS WIRE WITH ENGINE AT FULL

THROTTLE.

SECTION 5: FRAME

TORQUE FRONT FORK CASTLE NUT TO 40 FT.LBS. BE SURE TO

SPIN THE FORK WHILE TORQUING THE NUT TO ENSURE THAT

NO BEARING DAMAGE IS DONE.

BE SURE TO REINSTALL THE COTTER PIN INTO THE CASTLE

NUT. ALWAYS TRY TO GO TIGHTER ON THE NUT TO FIND A

CASTLATION FOR THE PIN TO FIT IN. NEVER BACK THE

BEARING TENSION OFF AFTER TORQUING THE NUT, THIS WILL

“SPRING” THE BEARING CAGE.

TORQUE REAR WHEEL LUGS TO 65-75 FT.LBS. RETORQUE AT

EVERY OIL CHANGE.

THERE IS ONE GREASE FITTING IN EACH FRONT WHEEL AND

ONE IN EACH FRONT CASTER BEARING HOUSING. GREASE AT

EVERY ENGINE OIL CHANGE.

THERE IS ONE GREASE FITTING ON EACH OF THE ACTUATOR

BAR PILLOW BLOCKS LOCATED UNDER THE FUEL TANKS.

GREASE TWICE A SEASON.

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.

WHEN ADJUSTING THE TRACKING ON THE MOWER, THE

LENGTH OF THE PUSHRODS CAN BE CHANGED BY SCREWING

THE SWIVEL JOINT IN OR OUT ON THE ENDS OF THE RODS.

SHORTENING THE OVERALL LENGTH OF THE ROD SLOWS THE

PUMP DOWN. LENGTHENING THE ROD WILL INCREASE THE

SPEED OF THE PUMP.

ON COMMERCIAL MODELS, THE REACTION OF THE HYDRO

PUMPS AND THE RESISTANCE FELT IN THE CONTROL ARMS

CAN BE ADJUSTED BY MOVING THE PUSHRODS OR THE

DAMPENERS UP OR DOWN IN THE MOUNTING HOLES.

MOVING DAMPENERS UP, LESS RESISTANCE.

DAMPENERS DOWN, MORE RESISTANCE.

MOVING PUSHRODS UP, SLOWER REACTION.

PUSHRODS DOWN, FASTER REACTION.

TO SERVICE THE PARKING BRAKE SYSTEM, THE REAR BRAKE

ASSEMBLY REQUIRES A HUB PULLER TO REMOVE THE BRAKE

DRUM AS SHOWN ABOVE. THE AXLE NUT MUST BE REPLACED

AND TORQUED TO 200 FT.LBS. BE SURE TO REINSTALL THE

COTTER PIN.

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 FROM LEFT TO RIGHT AND

FRONT TO BACK. ALL DECKS SHOULD BE LEVEL FROM LEFT TO

RIGHT AND HAVE A ¼” PITCH DOWN IN THE FRONT.

IF DECK ADJUSTMENTS ARE NECESSARY, START WITH THE

CHAIN LENGTH ADJUSTERS. THESE ADJUSTERS AFFECT THE

OVERALL HIEGHT OF THE DECK AND THE LEVEL FROM LEFT TO

RIGHT.

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 BUSINESS CARD). SPRING TENSION

ADJUSTMENTS CAN BE MADE BY SLIDING THE BOLT SHOWN

ABOVE FORWARD OR BACKWARD IN THE SLOT OF THE DECK.

ON AN AOS/DIESEL MODEL, DECK BELT ADJUSTMENTS CAN BE

MADE BY SLIDING THE REAR “V” IDLER PULLEYS UP OR DOWN

IN THEIR SLOTS.

THE CONDITION OF THE BLADES CAN DRASTICLY 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. RETORQUE THE BLADE BOLTS TO 90 - 110

FT.LBS.

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.