Bad Boy ZT 4800 Owner'S Service Manual Download Page 3

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This manual applies to the following equipment:

Bad Boy ZT Elite Series

ZT 4800 48˝ 725cc Kohler

ZT 5400 54˝ 747cc Kohler

ZT 6000 60˝ 747cc Kohler

ZT 4800 48˝ 726cc Kawasaki

ZT 5400 54˝ 726cc Kawasaki

ZT 6000 60˝ 726cc Kawasaki

COMMONLY USED ITEMS AND PART NUMBERS

60˝ ZT Blade

Hi-Lift Fusion

Gator Blade

Wave Blade

038-6060-00 038-6003-00 038-6016-00

54˝ ZT Blade

Hi-Lift Fusion

Gator Blade

Wave Blade

038-0001-00 038-0003-00 038-0005-00

48˝ ZT Blade

Hi-Lift Fusion

Gator Blade

Wave Blade

038-5350-00 038-5000-00 038-4825-00

ZT Hydro Filters

063-1050-00

60˝ ZT Deck Belt

041-1650-00

54˝ ZT Deck Belt

041-1560-00

48˝ ZT Deck Belt

041-1470-00

ZT Pump Belt

041-6400-00

Oil Filter

Kohler Engines

Kawasaki Engines

063-5004-00 063-8017-00

Air Filter

Kohler Engines

Kawasaki Engines

063-5002-00

Pre-cleaner

063-2097-00

063-5003-00

Element

Motor Oil

10W-30 Motor Oil –

Bad Boy Synthetic Blend Motor Oil Recommended

Hydro Oil

20W-50 Motor Oil – Bad Boy Hydrostatic Oil Recommended

(Approximately 2.5 quarts/transaxle)

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Summary of Contents for ZT 4800

Page 1: ...ZERO TURN MOWER OWNER S SERVICE PARTS MANUAL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 ZT ELITEMODELS 2014 11 1 ...

Page 2: ... 5 page 10 Troubleshooting and FAQ Section 6 page 11 Controls Section 7 page 12 Moving In operable Mower Section 8 page 13 Instrumentation Section 9 page 13 Mower Blade Maintenance Section 10 page 14 Greasing Bearings Section 11 pages 14 How to choose the right blade Page 15 Mowing Tips Page 16 SERVICE SECTION BEGINS ON PAGE 17 PARTS SECTION BEGINS ON PAGE 25 LIMITED WARRANTY PAGE 42 PAGE 2 ...

Page 3: ...0001 00 038 0003 00 038 0005 00 48 ZT Blade Hi Lift Fusion Gator Blade Wave Blade 038 5350 00 038 5000 00 038 4825 00 ZT Hydro Filters 063 1050 00 60 ZT Deck Belt 041 1650 00 54 ZT Deck Belt 041 1560 00 48 ZT Deck Belt 041 1470 00 ZT Pump Belt 041 6400 00 Oil Filter Kohler Engines Kawasaki Engines 063 5004 00 063 8017 00 Air Filter Kohler Engines Kawasaki Engines 063 5002 00 Pre cleaner 063 2097 0...

Page 4: ...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 clic...

Page 5: ...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 without the discharge chute grass catcher or other safety devices correctly in place and functioning properly 2 11 Slow down befo...

Page 6: ...pes For example rocks water cliffs and roadways CHILDREN Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity NEVER assume that children will remain where you last saw them 2 33 Keep children out of the mowing area and in the watchful care of a responsible adult other that the operator 2 34 Maintain ...

Page 7: ...SERVICE 2 56 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect 2 57 Keep all nuts and bolts tight to be sure the equipment is in safe working condition Never operate a poorly maintained machine 2 58 Do not touch hot areas of the machine 2 59 Never interfere with the intended function of a safety device or reduce the protection provided by a safety device Chec...

Page 8: ...d be in off position the engine should not start 2 73 Engage parking brake and leave lever arms in outward position put blade actuator in the on position then attempt to start the machine the engine should not start 2 74 Next start the engine as stated in the Mower Operation Section disengage parking brake and Very Slowly begin to rise from the seat the engine should stop If any of these tests fai...

Page 9: ...d 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 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 befo...

Page 10: ...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 with more than 10 ethanol by volume E 15 is not permitted 5 3 Disconnect the negative battery cable when machine will be stored for more than 30 days 5 4 Always secure machine properly when ...

Page 11: ...eck for any bare wires and or bad connections 6 3 Q What should I do if the blades won t engage 6 3 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 10amps 6 4 Q What type of fuel is recommended for my mower 6 4 A We recommend that you use a name brand fuel...

Page 12: ...ft 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 in the on start position 7 4 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 7 5 Blade Enga...

Page 13: ...on Return the arms to the forward position for normal operation 8 4 Your Bad Boy Mower Weighs ZT SERIES 800 850 lbs Weights fluctuate with the addition of accessories 8 5 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 6 Hopefully you ll never need to use this section of the manual However if you ...

Page 14: ...hick gloves when handling blades 10 7 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 SECTION 11 GREASING THE BEARINGS 11 1 Park the machine on a level surface and disengage the blade control switch 11 2 Move the motion control levers outward...

Page 15: ...ific 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 o...

Page 16: ...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 ...

Page 17: ...ansaxle holds about 2 quarts of hydro oil Install new filters and replace the 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 The check plug is located at the top center of the inside case of each transaxle The trans...

Page 18: ... 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 subsequent usage 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 incre...

Page 19: ...y fuel leakage Always use new hose clamps and ensure the security of the new filter by lightly pulling on each hose Always perform maintenance outdoors or in a well ventilated area Do not smoke or allow any open flames in the vicinity of any maintenance activities The air cleaner is the engine s only defense against damaging foreign particles It is very important that the air cleaner element is in...

Page 20: ...any way Doing so creates a significant fire hazard and can cause severe damage to the mower s electrical components If a fuse is repeatedly blowing contact your Bad Boy dealer 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 Check the condition and connectio...

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Page 22: ...nsure no damage is done to the bearing This operation is only necessary if a repair requires it Torque rear wheel lugs to 65 75 ft lbs Re torque at every oil change and check at every mowing There is one grease fitting on each of the actuator bar pillow blocks located under the fuel tanks Grease twice a season PAGE 22 ...

Page 23: ...k to its highest position 4 Remove either the right or left blade pulley cover 5 While lifting up on the belt as shown in the photograph rotate the pulley until the belt is free of the pulley Exercise caution while performing this step as fingers can easily become caught between the belt and pulley To check the level of the deck start on a flat surface and set the air pressure in all four tires Ra...

Page 24: ...orward or backward in the slot of the deck Belt tension should be 50 55 lbs with the deck at its highest setting The blade in the foreground see photo was utilized long after replacement was required In addition to a decline in cut quality failure to replace a worn or damaged blade creates a major safety hazard Bad Boy recommends that blade sharpening be performed by a professional To change blade...

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Page 46: ... 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 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 ab...

Page 47: ...ISTRATION 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 ...

Page 48: ...ZT ELITE MODEL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 ...

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