Bad Boy PUP User manual

PUP or LIGHTNING MODEL MOWER

OWNER’S & PARTS MANUAL

2010 Edition

For additional information, please see us at

www.badboymowers.com

Bad Boy, Inc.

102 Industrial Drive

Batesville, Arkansas 72501

(870) 698-0090

PAGE 1

TABLE OF CONTENTS

Basic Information ........................................................................................... Section 1 (pages 3, 4)

Bad Boy Safety Guidelines ............................................................................. Section 2 (pages 5, 6)

Operation ....................................................................................................... Section 3 (pages 6, 7)

Maintenance ........................................................................................................ Section 4 (page 7)

Storage and Transportation ................................................................................. Section 5 (page 8)

Adjustments ................................................................................................... Section 6 (pages 8, 9)

Troubleshooting and FAQ ..............................................................................Section 7 (pages 9, 10)

Controls ...................................................................................................... Section 8 (pages 10, 11)

Moving Inoperable Mower ................................................................................ Section 9 (page 12)

Instrumentation ................................................................................................Section 10 (page 13)

Blade Maintenance and Cutting Tips .................................................................Section 11 (page 14)

Greasing Bearings ..................................................................................... Section 12 (pages 14, 15)

PARTS MANUAL BEGINS ON PAGE 16

PAGE 2

This manual applies to the following equipment:

Bad Boy Pup Series

4800 Pup 23 hp Vanguard

5200 Pup 23 hp Vanguard

6000 Pup 23 hp Vanguard

4800 Pup 30 hp Kohler

5200 Pup 30 hp Kohler

6000 Pup 30 hp Kohler

5200 Pup 31 hp Kawasaki

6000 Pup 31 hp Kawasaki

Bad Boy Lightning Z Series

5200 Lightning 26 hp Kawasaki LC

6000 Lightning 26 hp Kawasaki LC

5200 Lightning 31 hp Kawasaki

6000 Lightning 31 hp Kawasaki

7200 Lightning 31 hp Kawasaki

6000 Lightning 32 hp Vanguard

7200 Lightning 32 hp Vanguard

ALL INFORMATION IN THIS MANUAL

MAY NOT APPLY TO YOUR MOWER!

PAGE 3

SECTION 1: BASIC INFORMATION

Congratulations on the purchase of your new Bad Boy Mower! The purpose of this manual is to 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.

1.1 All Bad Boy engines use 10W30 engine oil.

1.2 All Bad Boy hydraulic systems use 20W50 engine oil.

1.3 All Bad Boy Mowers use hi-temp multi-purpose grease. NLGI No. 2 for the grease ﬁttings.

1.4 ZT models have 12 psi in both front and rear tires.

1.5 Pups, AOS, and Diesel models have 12 psi in front tires and 10 psi rear tires.

1.6 Most Briggs, Kohler, Kawasaki, and Vanguard engines hold one (1) quart of motor oil.

1.7 3 Cylinder Caterpillar engines hold four (4) quarts of motor oil and 4 Cylinder Caterpillar Engines

Hold ﬁve (5) quarts.

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 found 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.

PAGE 4

SECTION 2: MOWER OPERATION

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.

2.5 Always operate machine in daylight or with adequate working lights.

2.6 Be alert of surroundings. Watch for rocks, stumps, and mounds or depressions while mowing.

2.7 Always wear eye protection while mowing and servicing.

2.8 Always wear ear protection, such as earplugs, while mowing.

2.9 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.

2.10 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.

2.13 Always buckle seat belt, if provided one.

2.14 Never attempt high speed maneuvering, especially around people or property.

2.15 Never put hands or feet under the machine while ignition is on.

2.16 Never refuel machine when engine is running.

2.17 Never leave key in ignition, especially around children.

2.18 Never run engine in enclosed area.

2.19 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 Be aware 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 followed.

2.24 Never operate the mower with the discharge chute open.

2.25 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.

2.26 Do not store machine near open ﬂame or source of ignition, such as a water heater or

furnace.

2.27 Do not attempt to mount a tire without the proper equipment and experience to perform the

job.

2.28 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.

Understand service procedure before doing work.

SECTION 3: 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 the discharge chute open. Do not cross

terrain, other than grass, with blades turning. This could cause damage to property or

bystanders.

3.1 Place parking brake in up position

3.2 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.

3.3 Put PTO switch in the OFF position.

3.4 If your machine has been equipped with a ROPS (Roll Over Protection System) then you

must fasten seatbelt.

3.5 If machine has not been started recently, engage the choke.

3.6 Make sure nothing is under or around machine.

3.7 Place key in ignition and turn.

3.8 Once machine is started, disengage the choke.

PAGE 6

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 will decrease.

SECTION 4: MOWER MAINTENANCE

**Check each and provide maintenance when needed.

DAILY

4.1 Check Engine Oil

4.2 Check Engine Air Filter

4.3 Tire Pressure

4.4 Radiator Screen (Screen should be cleaned frequently during heavy use)

4.5 Radiator Anti-Freeze

4.6 Inspect Blades

EVERY 30 HOURS OF USAGE

4.7 Grease Machine

EVERY 100 HOURS OF USAGE

4.8 Check All Filters

Check ﬁlters once a year if under 100 hours

Check air and fuel ﬁlters more often in dry, dusty conditions

EVERY 100 HOURS OF USAGE

4.9 Change Hydraulic Fluid

4.10 Refer to manufacturer manual for speciﬁc information on maintenance schedules.

PAGE 7

SECTION 5: MOWER STORAGE

5.1 Keep machine from collecting debris by storing in a covered area while not in use.

5.2 Fuel can harm your machine if left for more than 30 days without changing.

5.3 Disconnect the negative battery cable when machine will be stored for more than 30 days.

5.4 Always secure machine properly when transporting machine.

5.5 Do not load machine on trailer with blades engaged.

5.6 Do not use ramps to load the machine.

5.7 Make sure Parking Brake is in “up” position.

5.8 In wet conditions tires may spin while loading / unloading. If necessary, wait for dry

conditions before loading / unloading.

5.9 Make sure mode of transportation is suitable to bear the weight of mower.

5.10 Deck height should be set at maximum before attempting to load.

5.11 Secure mower with at least two straps capable of securing weight of mower.

SECTION 6: MAINTAINING YOUR MOWER

DECK LEVELING

6.1 Put mower on ﬂat, level surface

6.2 Check tire air pressure

6.3 Put deck on highest setting

6.4 Measure all four corners of the deck. Deck level should be the same from front left to right.

6.5 Set front corners to 1/8˝ lower than rear corners. (This is the distance from the bottom of

mower deck to the ground).

6.6 Use the deck hanger chains to raise or lower entire deck.

6.7 Use turnbuckles for raising and lowering the front of the deck.

BRAKE ADJUSTMENT

6.8 Locate set screw on top of brake handle knob

6.9 Turn knob on top of brake lever clockwise to loosen brake cable.

6.10 DO NOT OVER ADJUST – CABLE BREAKAGE MAY OCCUR.

DRIVE ARM ADJUSTMENT

6.11 Due to the sensitive nature of drive arm adjustments visit an Authorized Bad Boy Dealer and

they’ll be happy to help you with this.

PAGE 8

STANDARD HYDRAULIC/ OIL/FILTER SERVICING PROCEDURE

6.12 On all Bad Boy ZT Models, the hydraulic oil ﬁlters need to be initially changed when the

mower has reached 50 hours of usage. Each subsequent changing of the hydraulic oil and

ﬁlters needs to occur every 250 hours or once a year. The required hydraulic oil is 20W50

motor oil On all Bad Boy commercial models, the hydraulic oil and ﬁlters need to be initially

changed when mower has reached 50 hours of usage. Each subsequent changing of the

hydraulic oil and ﬁlters needs to occur 500 hours or once a year. The required hydraulic oil is

20W50 motor oil.

SECTION 7: TROUBLESHOOTING

7.1 Q: How do I sharpen my blades?

7.1 A: We recommend that sharpening be done by an authorized Bad Boy dealer.

7.2 Q: How should I prepare my Bad Boy Mower for the off season?

7.2 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.

7.3 Q: How do I prevent an uneven cutting pattern and increase the quality of cut?

7.3 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.

7.4 Q: What should I do if my mower won’t start?

7.4 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.

7.5 Q: What should I do if the blades won’t engage?

7.5 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.

7.6 Q: What should I do if mower arms are in neutral position and mower still creeps?

7.6 A: Contact authorized Bad Boy Mower Dealer.

PAGE 9

7.7 Q: What is the difference between a liquid-cooled engine and an air cooled-engine?

7.7 A: A liquid-cooled engine gives you a constant operating temperature which will increase

fuel economy, decrease oil breakdown, and may last up to 50% longer. In addition, a cooler

engine also means a cooler operator because the cooling fan draws hot air through the

radiator, past the engine and away from the operator. An air-cooled engine is much simpler

with fewer working parts which means a lower purchase price and less maintenance

7.8 Q: What type of fuel is recommended for my mower?

7.8 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.

7.9 Q: Does the Bad Boy warranty cover multiple owners?

7.9 A: The warranty applies only the original registered owner and is non-transferable.

7.10 Q: Do you offer touch-up paint for your mowers?

7.10 A: Touch-up paint is available. Contact your local dealer for more information.

7.11 Q: On average, how long should a Bad Boy mower last?

7.11 A: Maintenance, mowing conditions, temperature, and hours of operations play a huge role

in the life of a mower. However, Bad Boy Mowers are without a doubt the strongest, most

durable zero-turn mower available. With proper care, your Bad Boy will deliver many years

of reliability, productivity, and comfort.

7.12 Q: How durable is the electric deck lift?

7.12 A: The actuator which controls the deck height is designed for moving loads of up to 1000

pounds and has a static holding capability which exceeds 3,000 pounds. Our ¼˝ deck weighs

approximately 250 pounds which is only 25% of working capability.

SECTION 8: CONTROLS

8.1 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.

8.2 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.

PAGE 10

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