Bad Boy BWK 3600 Owner'S Operator Service And Parts Manual Download Page 1

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ZERO-TURN MOWER

OWNER’S OPERATOR

SERVICE AND PARTS MANUAL

For additional information, please see us at

www.

badboymowers

.com

20 3-10

WALK-BEHIND

MODEL

Summary of Contents for BWK 3600

Page 1: ...ZERO TURN MOWER OWNER S OPERATOR SERVICE AND PARTS MANUAL For additional information please see us at www badboymowers com 2020 3 10 WALK BEHINDMODEL ...

Page 2: ...ation Section 5 Page 10 Troubleshooting and FAQ Section 6 Page 12 Controls Section 7 Page 13 Moving In operable Mower Section 8 Page 14 Instrumentation Section 9 Page 14 Mower Blade Maintenance Section 10 Page 15 Equipment Lubrication Section 11 Page 15 How To Choose the Right Blade Page 16 Mowing Tips Page 17 Service Section Page 18 Parts Section Page 32 Limited Warranty Page 46 ...

Page 3: ...ade 038 5350 00 038 5000 00 038 4825 00 54 WALK BEHIND Blade Hi Lift Fusion Gator Blade Wave Blade 038 0001 00 038 0003 00 038 5220 00 36 WALK BEHIND Deck Belt 041 8054 00 48 WALK BEHIND Deck Belt 041 8055 00 54 WALK BEHIND Deck Belt 041 6027 00 WALK BEHIND Pump Belt 041 8053 00 Fuel Filter 063 6000 00 Spark Plug 015 8001 00 Air Filter 063 2097 00 Oil Filter 063 8017 00 Motor Oil 10W 30 Motor Oil ...

Page 4: ...SERVICE Bad Boy recommends using Bad Boy replacement parts on your mower Replacement parts are available through your local Bad Boy Mowers 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 we...

Page 5: ...if anyone enters the area 2 7 Never carry passengers 2 8 Do not mow in reverse unless absolutely necessary Always look down and behind before and while backing 2 9 Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction as material may ricochet back toward the operator Stop the blades when crossing gravel surfaces 2 10 Never operate the machine witho...

Page 6: ...opes slow and gradual Sudden changes in speed or direction could cause the machine to roll over 2 30 Use extra care while operating machine with grass catchers or other attachments they can affect the stability of the machine Do not use on steep slopes 2 31 Do not try to stabilize the machine by putting your foot on the ground 2 32 Do not mow near drop offs ditches or embankments The machine could...

Page 7: ...iner rather than from a gasoline dispenser nozzle 2 53 Never fill gasoline containers inside a vehicle or on a truck or trailer bed with a plastic liner Always place containers on the ground away from your vehicle before filling 2 54 Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete Do not use a nozzle lock open device 2 55 If ...

Page 8: ... with a safety interlock system This system is designed to prevent serious injury or death to the operator and other people or property damage The system consists of an operator presence switch in the handlebar the parking brake speed control neutral position the mower deck PTO switch and the ignition switch These interlocks are vitally important and must be tested frequently Following are instruc...

Page 9: ... Once machine is started disengage the choke 3 8 Increase RPM by sliding the throttle to the fast position 3 9 Owners must become familiar with the controls before operating a zero turn radius vehicle 3 10 Start slowly and build your skill level Have ample practice before using the machine at full capabilities 3 11 Be comfortable with machine before engaging blades Know what each component control...

Page 10: ...y whichever comes first Check air and fuel filter more often in dusty conditions DealerGet maintenance performed at a registered dealership SECTION 5 MOWER STORAGE TRANSPORTATION 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 especially if the fuel contains ethanol Never use fuel wi...

Page 11: ...te Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed Date Hours Performed ...

Page 12: ... 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 Also check PTO fuse underneath operator console 10 amps 6 4 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 ...

Page 13: ...ll mower operation 7 5 PTO Switch This switch engages the blades Pull the switch up to engage the blades and push the switch down to disengage the blades 7 6 Choke Control A cable is 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 t...

Page 14: ...ation Your Bad Boy Mower Weighs OUTLAW WALK BEHIND SERIES 590 lbs Weights fluctuate with the addition of accessories 8 3 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 8 4 Hopefully you ll never need to use this section of the manual However if you do use extreme caution when moving machine SECTION...

Page 15: ...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 SECTION 11 EQUIPMENT LUBRICATION 11 1 Park the machine on a level surface and disengage the blade control switch 11 2 Move the motion control levers outward to the neutral position engage parking brake...

Page 16: ...ore 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...

Page 17: ...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...

Page 18: ...s the oil filter serves as the drain for the transaxle 4 After the oil has drained wipe the filter base surface off and apply a film of new oil to the gasket of the new replacement filter 5 Install the new filter by hand turn 3 4 to one full turn after the filter gasket contacts the filter base surface 6 Re install the filter guard with two 1 4 screws Torque screws to 65 in lbs 7 3 Nm each 7 Repea...

Page 19: ...luid reservoirs 14 To purge the air from the transaxles pull the neutral bypass rods located on each side of the muffler and pin them into place Lift the rear of the mower off the ground and start the engine 15 Release parking brake then slowly move the drive arms in the forward and reverse directions 5 to 6 times 16 Take note the muffler will be hot Push the neutral bypass levers back into place ...

Page 20: ...out and lock them into place using the cotter pin to activate the bypass When adjusting the tracking on the mower the length of the pushrods can be changed by screwing the heim 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 Neutral Bypass Cotter Pin Cotter Pin Lower Push Rod End Upper Push...

Page 21: ...g the two jam nuts will increase the belt tension The tension should be adjusted so that there is between 60 to 65 lbs of tension on the belt This can be checked with a belt tension gauge Part Number 041 9999 00 as shown to the right Pump Belt Spring Tension Adjustment Pump Belt Belt Tension Gauge ...

Page 22: ...l filter Place a container under the oil filter to capture any oil and remove filter Wipe off mounting surface and reinstall drain plug Torque to 10 ft lbs 3 Place new filter in shallow pan with open end up Fill with new oil until oil reaches the bottom of the threads Allow two minutes for oil to be absorbed by filter material 4 Apply a thin film of clean oil to rubber gasket on new filter 5 Refer...

Page 23: ...form maintenance outdoors or in a well ventilated area Do not smoke or allow any open flames in the vicinity of any maintenance activities CHANGING YOUR FUEL FILTER 1 Locate your fuel filter and mark the direction it is facing 2 Clamp each side of the fuel filter to minimize any gas spills 3 Remove the clips from each side of the fuel filter and remove the fuel filter 4 Place the new fuel filter i...

Page 24: ...environments Adhering to these practices will help prevent loss of power and premature engine failure CHANGING THE AIR CLEANER 1 Locate the air filter and remove the cover 2 Remove the paper element and pre cleaner If applicable 3 Replace or wash pre cleaner in warm water with detergent Rinse and allow to air dry If applicable 4 Lightly oil pre cleaner with new engine oil squeeze out excess oil If...

Page 25: ...heting wrench 2 Remove the wire on the spark plug and use an appropriate socket to remove the spark plug 3 Check the gap on the spark plug to verify that it is 0 03 by using a feeler gauge 4 If the spark plug is worn overheated wet or carbon fouled replace the spark plug 5 Install the plug into cylinder head and torque to engine manufacture specifications Be careful not to overtighten the spark pl...

Page 26: ...PAGE 26 SECTION 4 ELECTRICAL SYSTEM WIRING DIAGRAM For a larger version of the below diagram please visit badboymowers com and click the parts manuals section ...

Page 27: ... Once you have torqued the nuts to 40 ft lbs reapply the dust cap by gently tapping around its edges Do NOT hit center of cap Torque rear wheel lugs to 65 75ft lbs Re torque at every oil change and check every morning 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 th...

Page 28: ... belt tensioner to its weakest installed position 3 Take off both pulley covers and route the belt by following the belt route decal The easiest way to finish running the belt is routing the belt through the deck pulleys leaving it off the left deck pulley Slip it onto the clutch then carefully slip it onto the left deck pulley 4 Verify that the belt is routed properly as improper routing can dama...

Page 29: ... in the slot of the deck Belt tension should be 60 65 lbs with the deck at its lowest setting Use a belt tension gauge to ensure the proper tension Your dealer or service center will have a belt tension gauge or you can buy one Part Number 041 9999 00 BLADE SHARPENING The blade on the top see photo was utilized long after replacement was required In addition to a decline in cut quality failure to ...

Page 30: ...d height by using the handles located on each side of the deck 3 Once the desired deck height is achieved replace the pins back in the deck height adjustment rods making sure that all four pins have the same number of empty holes above and below 4 Verify that the deck is level A 1 4 pitch is built into the deck Deck Height Pins Deck Height Pins ...

Page 31: ... A 3 4 wrench can be used on the spindle shaft above the blade to keep the shaft from turning The bolt has right handed threads Re torque the blade bolts to 90 110 lbs upon re installation The blade spindles contain a sealed ball bearing inside the top and bottom of the spindle The bearings are replaceable for a more cost effective repair Factors such as water introduction into the bearing will ha...

Page 32: ...EW GR 5 ZINC 72 2 022 8049 19 11x6 5 front tire wheel assembly Kenda 72 1 1 022 2013 00 Front wheel ITEM QTY PART NUMBER DESCRIPTION 72 2 1 022 2012 00 11x4 00 5 Tire Only 72 3 1 022 7009 00 Ball Bearing w Retainer 99502H NR 625 Bore x 1 375 OD x 4375 Width 73 2 023 0002 00 2017 MZ Front fork 75 2 025 0003 00 2016 Front Bearing Spacer 76 2 025 0008 00 Front Wheel Spanner 137 2 058 1000 00 Spacer 1...

Page 33: ... 8020 00 Throttle Lever Assembly 136 1 056 8058 00 PTO Engager ITEM QTY PART NUMBER DESCRIPTION 154 1 077 0001 00 Brake switch 4 prong 155 1 077 0002 00 safety Switch 156 1 077 0003 00 Ignition Switch 159 1 079 0035 00 2020 Walk Control Panel 162 1 083 4013 00 Tachometer 179 1 091 4055 00 2020 Walk Control Panel Decal 184 1 216 1000 17 2017 MZ ZT MAV Tach Wire Assy PARTS SECTION PAGE 33 CONTROL PA...

Page 34: ...88 1 028 0009 00 2017 Walk Behind Control Pivot Rod 89 1 028 0043 00 2020 Walk Rider Presence Weldment Parts List ITEM QTY PART NUMBER DESCRIPTION 94 1 031 0039 70 2020 Walk Handle Bar 95 1 031 0042 00 2020 Walk Behind Control Lever Assembly Left 96 1 031 0043 00 2020 Walk Behind Control Lever Assembly Right 97 1 031 0047 00 2020 Walk Behind Neutral Lever 106 1 035 0002 98 Walk Speed Control Linka...

Page 35: ...ASHER NYLON 93 1 031 0036 00 Speed Control Lever 105 1 034 8025 00 Drive Lever Spring 106 1 035 0002 98 Walk Speed Control Linkage ITEM QTY PART NUMBER DESCRIPTION 106 1 1 013 0016 00 3 8 Left Handed Fine Threaded Jam Nut 106 2 1 013 6051 00 3 8 Fine Threaded Jam Nut 106 3 1 035 0002 00 Walk Speed Control Rod 106 4 1 046 0001 00 Yoke Left Hand Thread 106 5 1 048 3000 00 Spherical Rod End Outlaw 13...

Page 36: ... 1 95 4 031 0043 00 Parts List DESCRIPTION PART NUMBER QTY ITEM 1 4 DRIVE TYPE STRAIGHT GREASE FITTING ZINC YELLOW 024 6034 00 1 96 1 2019 Drive Arm Bushing 031 0032 00 2 96 2 2020 Walk Behind Control Lever Weldment Right 031 0043 01 1 96 3 2019 Stand On Control Grip 069 2014 00 1 96 4 035 0007 98 Parts List DESCRIPTION PART NUMBER QTY ITEM 3 8 Left Handed Fine Threaded Jam Nut 013 0016 00 1 107 1...

Page 37: ... 4 HEX CAP SCREW GR 8 ZINC YELLOW ITEM QTY PART NUMBER DESCRIPTION 114 4 1 018 6036 00 1 2 13 X 2 3 4 HEX CAP SCREW GR 5 ZINC 114 5 2 019 6017 00 635 ID X 1 120 OD X 140 THICK FLAT WASHER NYLON 114 6 1 025 7036 00 1 2 SOLID SHAFT COLLAR W 1 SET SCREW ZINC 117 4 040 6060 00 Seat latch pin 133 1 051 8067 15 15 Revolt Fuel Line Assembly 133 1 1 25 051 8067 00 1 4 Fuel Line Hose 133 2 2 072 8069 00 1 ...

Page 38: ... 70 1 1 022 6002 00 8 Inch Wheel 70 2 1 022 6001 00 20X10 8 Turf Tire 71 2 022 8019 00 21 x 7 10 Walk Behind Rim and Tire 36 Only ITEM QTY PART NUMBER DESCRIPTION 71 1 1 022 8022 00 10 Wheel Only 36 Stand On 71 2 1 022 8023 00 Walk Behind 36 Tire Only 21 X 7 10 74 2 024 1200 00 ZT Fitting 3 8 x 3 8 45 Degree 4603 6 6 77 1 025 0018 00 2017 Transaxle Spacer Walker 79 2 025 0070 00 2017 Transaxle Spa...

Page 39: ...75 00 3 8 16 X 1 1 8 HEX WASHER UNSLOT SERRATED TRI LOB TRS ZINC YELLOW 47 1 018 5450 00 7 16 20 X 1 1 2 HEX CAP SCREW GR 8 ZINC YELLOW 52 2 018 6049 00 3 8 16 X 1 GR 5 Hex Bolts Zinc 62 1 019 6020 00 1 2 BELLEVILLE WASHER 1 5 8 OD X 140 THK ZINC 81 1 025 5032 00 1 130 x 1 75 x 1 Spacer Countersunk Zinc 91 1 030 0050 00 5 16 24 X 1 4 SOCKET SET SCREW CUP PT PLAIN 98 1 033 5034 00 4 3 4 Motor Pulle...

Page 40: ...9 6017 00 635 ID X 1 120 OD X 140 THICK FLAT WASHER NYLON 62 2 019 6020 00 1 2 BELLEVILLE WASHER 1 5 8 OD X 140 THK ZINC ITEM QTY PART NUMBER DESCRIPTION 84 2 026 0025 00 Deck Spindle Support Plate 91 2 030 0050 00 5 16 24 X 1 4 SOCKET SET SCREW CUP PT PLAIN 92 4 031 0023 00 2017 Walk Behind Deck Hanger 100 2 033 6003 00 5 Spindle Deck Pulley 104 1 034 2020 00 Deck Idler Spring 109 2 037 6015 50 S...

Page 41: ... THICK FLAT WASHER NYLON 62 3 019 6020 00 1 2 BELLEVILLE WASHER 1 5 8 OD X 140 THK ZINC ITEM QTY PART NUMBER DESCRIPTION 64 4 019 6050 00 360 ID X 983 OD X 120 THICK FLAT WASHER NYLON BLACK 82 1 025 5338 00 502 ID X 750 OD X 1 500 Long Spacer 83 1 025 5339 00 1 3 4 Pulley Spacer 84 3 026 0025 00 Deck Spindle Support Plate 91 3 030 0050 00 5 16 24 X 1 4 SOCKET SET SCREW CUP PT PLAIN 92 4 031 0023 0...

Page 42: ...GR 8 ZINC YELLOW 61 2 019 6017 00 635 ID X 1 120 OD X 140 THICK FLAT WASHER NYLON 62 7 019 6020 00 1 2 BELLEVILLE WASHER 1 5 8 OD X 140 THK ZINC ITEM QTY PART NUMBER DESCRIPTION 64 4 019 6050 00 360 ID X 983 OD X 120 THICK FLAT WASHER NYLON BLACK 69 4 022 1000 00 Deck Wheel 82 1 025 5338 00 502 ID X 750 OD X 1 500 Long Spacer 83 1 025 5339 00 1 3 4 Pulley Spacer 84 3 026 0025 00 Deck Spindle Suppo...

Page 43: ...WASHER NYLON 019 6042 00 2 181 4 Discharge Upper Chute Bracket 039 4870 00 1 181 5 Discharge Lower Chute Bracket 039 4871 00 1 181 6 Discharge Chute Hanger deck mounted 206 6017 00 1 181 7 Rubber Discharge Chute 210 6005 00 1 181 8 210 6005 98 Parts List DESCRIPTION PART NUMBER QTY ITEM 5 16 18 NYLON INSERT FLANGE LOCKNUT ZINC 013 8049 00 7 182 1 5 16 18 X 1 HEX CAP SCREW GR 5 ZINC 018 2007 00 2 1...

Page 44: ...OARD LOGO DECAL 091 4055 00 CONTROL PANEL DECAL 091 0903 18 48 DECK DECAL 091 0412 18 603cc PODIUM DECAL 091 0418 00 36 DECK BELT ROUTE DECAL 091 3601 18 36 DECK DECAL 091 3012 00 DANGER DECAL 091 1020 00 CAUTION DECAL 091 3309 00 48 DECK BELT ROUTE DECAL 091 3150 00 CAUTION DANGER DECAL 091 0904 18 54 DECK DECAL ...

Page 45: ...PAGE 45 ...

Page 46: ...ty claims requiring parts returned will be settled upon return of parts to Bad Boy for inspection D All warranty issues must be handled through an authorized service center or dealership 4 WARRANTY LIMITATION A THERE IS 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 TH...

Page 47: ...ANTY REGISTRATION Ensure selling dealership has registered mower within 30 days of purchase to validate warranty Please record your serial number date of purchase and dealership information for your records Serial ________________________________________________________ Date of Purchase ________________________________________________ Dealer Information ____________________________________________...

Page 48: ...www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 ...

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