Home

2014 Diesel Parts Manual

1. me av PART WONDER DESCRIPTION 1 1 7 1 ELE 2 5 osso 3 x1 Caras Gk 3 1 Orin Gene iting 47171 AA der Paley 37171 esso Pump 1 SP Ded 5 1 172 13 Wen Flange ut Orange 7 AR x3 a i foso MS M Speer a S Puey ely for 77 Dec Dia 39 1 0540 x U Colar Spacer orly for 72 Deck Desai m 2 BET i joo EETL 1 mor Fed Mou Rear Mount 3 1 fows7o1600 TEI IT 15 3 on osroo Ending Washer 15 1 93072 Lock Veer x AU Hes Na m 1 Jason 39 1 6865500 TIE Lok Washer 1 fossar 7I 52 34 Fra Thread ak a s fossor 6301 x 1 122 0 x 182 THK PER Washer 2 1 oea Deck Serra m i season NT Camage 2 2 370 33 Ron ak Gange 35 1 fosar U2 x 24 2 Tha Ses as 1 oss Desa PTO Engager Heder gt 2 msan Farge Nut as 1 osresoo Nabos eg 1 LAE II 3 1 eseso Pump Am a i Pump wh Fan and Cover Right 2 Die 3 1 oao Wa Wa 3 1 Bok 1 2 Ane na 3s 2 nssosran A Leck Visier 2 msn IEA UZ Hen ae 2 Oses Washer 38 2 ES EER 1 Jansen 30 Dogs iting VT x31 4501 8548 1 ness 50 Degree Fating 98x 916 400168 1 ores Fan Gard 7 Compact Deal Ory a a oso iro Fan Dee Ory L
2. DETAIL B PAGE 50 Pars er TEM qw PART NUMBER DESCRIPTION 1 1 00072012 72 Deck Shell Orly 2 1 269721000 72 Deck Adjustable Front eg 3 1 2210 727 Deck Adustable Front igh 1022100000 Deck Whee 5 FI 013 8050 00 12413 Nylon Flange Nut Orange 5 E 018200200 1 x 11 4 Camiage Bot T 1 208601700 Discharge Chute Hanger deck mounted 1 EE 60 Discharge Chute Upper Hanger E 1 210 6005 00 Rubber Dscharge Chute 10 1 EE Discharge Lower Bracket 2 019 6042 00 360 ID Plastic Washer 12 5 300100 5 16 Pange NA Zinc WiSerratons 2 00707 xi Bot m 3 GEEET Fange Nut 15 3 016 5250 00 38 Hex Bob 16 5 018470200 5 16 1 1j Carriage Bot 17 2 013 8045 00 5 16 Nylon Flange Nut 2 04720400 72 spinae Cover 19 90920 5 16 Knob 20 3 037 8000 00 Double Bearing Spindle Fi 2 037 8001 00 Double Bearing for spindle E 1 015 4807 00 SIE Lock Washer 1 ITI SE 1 172 Grade 8 Bot FI 1 018 6015 00 12720 x 1 1 2 Grade 5 Fine Tread at 25 1 01602000 1 2 Washer 26 4 ETE 376 15 Hex Nus Zine ar 4 EET 3 8 Lochwasher ne E 1 723000 72 Mich UI Fusion Bade 29 1 EET 7 Deck Paley 3 1 030 0050 00 5 16 Set Screw E 1 019 500700 1 27 Lock Washer 3 4 019501250 3
3. PAGE 54 Bad Boy Inc 102 Industrial Drive Batesville AR 72501 1 866 622 3269 www badboymowers com Technical Support James Russell Warranty Jack Vaughn Parts Tim Tosh Robert Patterson james russell badboymowers com jack vaughn badboymowers com tim tosh 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 State Zip SERIAL Purchase Date Telephone Purchased From certify that have been properly instructed on operating this machine For additional information please see us at 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 Place Stamp Here post orice WILL NOT DELIVER WITHOUT POSTAGE BAD BOY MOWERS 102 Industrial Drive Batesville AR 72501
4. 15 14 12 15 81 8 2 83 84 85 86 94 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 If it is necessary to move mower when the engine is inoperable the hydraulic drive pumps are equipped with bypass valves Before moving the mower turn the bypass valves counterclockwise one half to one revolution The valve stems on each pump are located near the top and are identified as a hex stud Your Bad Boy Mower Weighs DIESEL SERIES 1607 1935 Ibs 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 INSTRUMENTATION Electronic Hour Meter Registers Hour increments up to 9 999 9 total hours This meter records the cumulative time the engine is running PAGE 13 PAGE 14 104 10 2 10 3 104 10 5 10 6 10 7 111 112 113 114 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 gra
5. m 3 028 1000 00 Diesel Weight Bar Bracket 018 2005 00 3 8 x 4 1 2 Bolt 013 5041 00 3 8 Nylock Nut 088 2000 00 5810 Diesel Weight 070 5520 00 Diesel 4cyl 61 Frame Suspension eee ele eee eR 089 3050 00 2 X 3 ROPS Fits All 2012 Diesel Models PAGE 33 5 do D l Ys Diesel Seat Frame Diesel Seat Fame TEM qw PART NUMBER DESCRIPTION 1 1 Hand rake Assembly 2 2 oersorson iter Heed 3 2 oexemaoo Harau iter 4 3 024 5050 00 Piter Head rang 5 ENE D 2 5 16 x 1 3 4 Hox Bat 7 1 080700005 2007 Diesel Seat Fame s 1 Battery Diesel Models IST s 5 ors 6052 00 187 347 Hex Bot 10 5 o1e s008 00 3 8 Lock Washer 4 012 90002 00 5 16 ange Nut 12 2 025 0041 00 rich Block Pastic 1 oettoss oo Short Brake Cable m 4 1024 x Bol 15 1 067 201000 Auminum Hydra Tank 16 1 oss 8050 00 Hydraulic Tank 17 1 oeranss oo Long Brake cable 18 1 3I x 3I Hose m 05060 3 07 x9 1 4 Braided Hose 20 1 Tite Diese Fi 1 osssmazs Diesel GEE Or 22 2 Spring Cushion 2 17 Momentary
6. 10 17220x 1 1 2 Lug MN 5 2 26 x 12 00 12 Tire ord Orange Wheel Assembly 52 i 26x 1200 12 Tre E fomm 32 1105 Wheel AOS Rer 17 77 Suspension Wheel MEE 55 1 9 t3 1 1 4 Hex bolt On 607 Suspension Kit Wheel Nato 55 17 05160500 16 Hose Oy s 1 ose s0 0 Diesel Food Radiator Assembly A a Diesel Hydraulic Cooler 9 7 Hydraulic Cooler Only on 35hp CAT Diesel PAGE 41 PAGE 42 Radiator Assembly ITEM QTY PART NUMBER DESCRIPTION 1 1 061 5000 00 Radiator Diesel 2 1 094 5088 00 Radiator Screen Diesel 3 1 072 8090 00 Diesel Clamp 1 3 4 Vinyl 4 1 051 3000 00 Radiator Hose for Diesel 5 1 051 3001 00 Bottom Radiator Hose for Diesel 6 4 072 2003 00 1 1 8 Hose Clamp 7 1 013 8049 00 5 16 Nylock Flange Nut 8 1 018 6083 00 5 16 x 3 4 Hex Bolt 9 1 039 1015 00 Diesel Radiator Hose Clamp Bracket 10 1 015 0104 00 Radiator cap 11 2 019 5050 00 3 8 2 1 4 OD Fibre Washer 12 2 019 5037 00 3 8 Lock Washer 13 2 019 5029 00 3 8 Flat Washer 14 2 013 6014 00 3 8 Hex Nut 15 2 084 4015 00 Rubber Trim 16 1 015 0111 00 overflow Reservoir 28 35Hp Diesel 17 1 051 8069 00 5 16 Clear Hose 18 1 066 8075 00 Reservoir Tank Cap Overflow 19 1 019 7040 00 1 4 Flat Washer
7. PAGE 44 28hp CAT Diesel Engine ITEM QTY PART NUMBER DESCRIPTION 1 015 0004 00 28hp CAT Diesel Engine 2 1 039 1010 00 Diesel Throttie Bracket 4 Tier 3 1 017 3000 00 Stub Shaft 6 019 4008 00 1 4 Lock Washer 5 1 201 8005 00 Air Cleaner Support Diesel 6 2 018 2001 00 x 1 25 x 25mm Hex Head Bolt T 2 018 5320 00 MS x 1 25 x 30mm Hex Head Bolt 8 10 019 8051 00 5 16 Lock Washer 9 6 019 8044 00 15 16 Flat Washer 10 1 201 8008 00 Diesel Motor Side Support Right 11 6 018 2000 00 mm x 20mm Bolt 12 1 086 7004 00 Pressure sender 2012 Gauge and up 13 1 072 8090 00 Diesel Clamp 1 3 4 Vinyl 14 1 039 1015 00 Diesel Radiator Hose Clamp Bracket 15 1 015 0010 00 28 35hp Caterpillar Muffler 16 1 043 1010 00 Diesel Muffler Guard 28hp 17 3 030 8000 00 1 4 x 3 4 Set Screw 18 8 019 5007 00 1 2 Lock Washer 19 8 018 6022 00 12mm Bolt Diesel 20 8 018 2007 00 15 16 x 1 Bolt 21 1 203 8000 00 Muffler Diesel 22 3 013 2050 00 1 4 20 Nylon Insert flange Nut 23 2 013 9002 00 5 16 Flange Nut 24 1 051 3001 00 Bottom Radiator Hose for Diesel 25 1 051 3000 00 Top Radiator Hose for Diesel 26 4 072 2003 00 1 1 8 Hose Clamp 27 1 201 8001 00 Hood Holder Diesel 28 2 032 4050 00 Rubber Isolator 29 2 018 7016 00 1 2 x 3 Hex Bolt 30 4 019 5010 00
8. 90 days The leading edge of the deck shell wil be warranted for the enire of the machine to the orignal purchaser against defects in matenals and workmanship Labor required to repair or replace the leading edge of the deck shell wal be covered by Bad Boy Inc for wo years and atthe unit owner s expense during the balance of the of the machine The Bad Boy ZT Series featuring the Integrated Zero Turn Transaxle used commercially wil the shorter of a one year 200 hour warranty parts only Labor on a Bad Bay ZT Series machine used commercially will nat be covered by Bad Boy Inc and wil be the unit owner s responsibility Belts are warranted for a period of ninety 90 days against materiais or workmanship defects Seats are warranted for a period of 6 months against material or workmanship defects At Bad Boy Inc s request customer wil make the defective part available for inspection by Bad Boy nc and or return 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 accidente improper maintenance improper use or abuse of the product alterations or falure to follow the instruction contained in the Owner s Manual for operation and maintenance The customer shall pay any charges for making service calls andlor for transporting the mower to and from the place wh
9. 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 EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT Federal Evaporative Emission Control Warranty Your Warranty Rights and Obligations The Environmental Protection Agency EPA and Bad Boy Inc are pleased to explain the evaporative emission control system s warranty on your 2014 equipment New equipment that uses spark ignition engines for off road use must be meet stringent anti smog standards The evaporative emission control system on your equipment is designed built and equipped so it conforms at the time of sale to the ultimate purchaser with the requirements of 40 CFR 1060 The evaporative emission control system is free from defects in materials and workmanship that may keep it from meeting said requirements Bad Boy Inc must warrant the evaporative emission control system on your equipment for two years provided there has been no abuse neg
10. 00 Flange 10 3 orsanzsao 3 4 Week Nut 37 0143010 0 58 Round Insert 2 27 o4e 2007 00 Sie 3 51618 Nylock Insert Locknut 1 esses 516 Knob 1s 1 SIS x 11 4 Camage Bat 16 4 omm 1 4 x LUZ Saf Tapora Scr 17 a osmon Fat Washer 18 2 029 7036 00 8 Rubber Bumper 9 1 SIS a0 Hex Bob Grades 2 1 Sie Week L2 Jam a 4 o19 s702 00 112 Washer Grede 8 2 4 Lock Washer 4 0620000 3 x 1 Hex Bot E 1 enorm 5 8 St NC Nut 1 sexo 6 Suspension kit Wheel Motor 2 2 E 072 1000 00 one anes 00 56 x Bat laers 5 16 Nan Flange Nut 3 1 ommno 38 1 pin c 17 oaa Woodruff Key 2 1 Castle Nu for Whed Motor 47 013 5300 00 107 Farge Nut 47 osem UF Hex Bot 17 5 1618 Insert x 17 ois4soo m 18cc Parker Wheel Motor Right s 024 2050 0 45 Degree Wheel Motor Fig 8802 1010 1 09270000 Right Brake Caliper 1 lesse Brake Disk 1 xi Hex Bot a 17 oisas m 18 Parker Wed Motor La a 1 DIOS Left Brake Caper 4 267 Hose Assembly mt Adaptors 2 te 6059 00 _ SEWE Heat _ mE 2 osma 5 8 Std Nylock Nut 2 033 7005 00 S Vider Puey BOVI Bt v 2 025 7020 00 SIS x Colar W One Set Screw 1 623000 Sed arp Cover taten 2 1024 X 5 8 85 05 18855 s
11. 00 13 8 Nylock Flange Nut 26 2 018 5043 00 3 8 x 1 1 4 Carriage Bolt 27 1 1073 2000 00 Brass fuel line T 28 1 073 8068 00 fuel line T 29 11 072 8069 00 1 4 fuel damp 30 1 051 8068 00 3 16 Fuel Line 31 1 051 8075 00 5 16 fuel line hose 32 4 051 8067 00 1 4 fuel line hose 33 1 1086 0035 00 Wiring Harness 35 amp 28 Diesel 34 2 086 7002 00 Pigtail 2 Faria Gauge 2012 amp up Used For the water and Oil Gauges PAGE 29 Outlaw Compact Diesel Frame PAGE 30 Outlaw Diesel Frame Actuator Floor Board and Height Indicator ITEM QTY PART NUMBER DESCRIPTION 1 1 070 5570 00 Outlaw Diesel Frame 2012 2 1 028 6020 00 Outlaw Actuator Bar Rear 3 1 028 6010 00 Outlaw Front Actuator Bar Assembly 4 4 017 7008 00 pillow block 2bolt sealmaster 5 8 018 5006 00 1 2 x 1 1 2 Hex Bolt 6 8 019 5007 00 1 2 Lock Washer 7 8 013 7018 00 1 2 Hex Nut 8 1 018 2050 00 10mm Damper Ball Stud Steering 9 1 013 9002 00 5 16 Flange Nut 10 3 013 8050 00 1 2 13 Nylon Flange Nut Orange 11 2 018 0008 00 1 2 x 1 1 2 Carriage Bolt 12 1 028 6055 00 Outiaw Susp Frame Linkage Bar 13 1 035 7033 00 Actuator 14 1 018 5049 00 1 2 13x2 GR 5 Hex Bolt 15 2 019 5702 00 1 2 Washer Grade 8 16 1 018 4010 00 1 2 Nylcock Nut 1
12. 16 Flat Washer 10 1 2 800800 Diesel Motor Side Support Right 117176 ore 2000 00 mm x 20mm Bot 12 1 ne70000 Pressure Sender 2012 Gauge and Up 1 przsos oo Diesel Camp 13 4 Vivi 34 1 99101500 Diesel Radiator Hose Camp Bracket 15 1 045 001000 8 35 Cate Ver 16 i 0 10900 Diesel Muller Guard 250 17 1 4 x 3 4 Se Srew 18 amp 019500700 127 Lock Washer 19 6 ot6022 00 12mm Bot Diesel 20 e pis200700 56 x Bot 21 1 _ 203 8000 00 Puffer Brace Dies 22 3 0132050600 114 20 Nyon Insert fange Nut 23 72 _ 013 8002 00 5716 Flange Nut 24 1 051 300100 Bottom Radiator Hose for Diesel 2s 051 300000 Top Radiator Hose for Diesel 26 4 07220020 11 8 Hose Gang a7 1 20 400 00 Hood Holder Diesel 2 405040 Rubber Isolator 35 2 7010100 112 x3 Hex Boe 30 4 01 501000 1 2 Brass Washer 31 2 orsoo700 3I Lock Washer 32 2 orz0s00 112 Hex Nut 3 38 Hex Bot 34 3 01 502900 Fat Washer as 3 019 03740 30 Lock Washer 36 3 ois601400 307 Hex Nut 37 4 oteso2s00 Sie x 11 4 Hex Bot 38 3 0 9405 00 5 16 Lock Washer 39 4 jos 01400 5 167 Fat Washer 4 o13 8043 00 5 16 Nat 317176 ote 0016 00 5618 x Button Head 42 1 06050 Starter to Chasis Cable Desc Hp i 0500 Engine Fan Diesel aa 1_ oss201000 CAT Fiter as 1 201 800900 Diesel Side Motor Mount Lee 47171 o13 9003 00 We Jam
13. safety precautions Note the operator must be seated properly on the machine during these tests and the engine should have been previously allowed to warm to operating temperature 271 With the parking brake engaged bring lever arms to their inward position then attempt to start the machine the blade actuator should be in off position the engine should not start 2 72 Ona level surface disengage the parking brake and place lever arms to their outward position then attempt to start the machine the blade actuator should 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 274 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 fail to produce the results indicated and the problem cannot be identified contact your Bad Boy Mower dealer or the support contacts in the rear of this manual ROLL OVER PROTECTION STRUCTURES ROPS If your machine is equipped with ROPS it is of utmost importance they are used properly ROPS when used correctly dramatically decrease the fatality rate in instances when the machine overturns 2 75 Periodically ensure the bolts that attach the ROPS to the machine are securely fastened 2 76 Always operated the machin
14. traction disengage the blades and proceed slowly straight down the slope Keep all movement on slopes slow and gradual Sudden changes in speed or direction could cause the machine to roll over 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 Do not try to stabilize the machine by putting your foot on the ground Do not mow near drop offs ditches or embankments The machine could suddenly roll over if a wheel goes over the edge or the edge caves in Be aware of what is located at the bottom of slopes 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 alertness and turn machine off if a child enters the area 2 35 Before and while backing look behind and down for small children 2 36 Never carry children even with the blades shut off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the machine 2 37 Never allow child
15. 0 Collar Spacer Top of Spindle 037 6026 00 Short Spindle Shaft w Locking 037 8002 00 Dust Cover 1 2 3 4 5 6 7 037 8001 00 Double Bearing for spindle PAGE 52 f 2 091 2061 00 En N sn e ED b Right Hood Diesel cat ED 1 Bad Boy Oval Logo Decal Cat Powered Decal 091110100 091410200 091110300 Brake Speed control speed Control Left Right 091 1104 00 019 2063 00 Throttle Preheat Decal ARMORTE Logo Deca Floorboaed 091 0919 00 Armortek Decal CAUTION ver E7 o 021205000 081330090 091 3015 00 Low Sulfur Decal 091 3309 00 Caution Decal Front Grill 091 0917 00 Deck Belt Route Decal 61 Decal hydraulic tank 091306020 091 3012 00 091 3017 00 Swing Away Patent Decal Danger Decal Spindle Discharge Pump Belt Route Decal 091 1105 00 091 0918 00 Outlaw Deck Height Decal 72 Decal PAGE 53 2014 LIMITED WARRANTY FOR BAD BOY COMMERCIAL MOWER CZT STAND ON DIESEL OUTLAW OUTLAW EXTREME and OUTLAWXP 1 WHAT THIS WARRANTY COVERS AND FOR HOW LONG Bad Boy Inc wil at its option repair or replace without charge any part covered by the warranty which is found to be defective in material and or workmanship within two 2 years after date of sale to the original retail purchaser unless the product is used for rental purposes in which case this warranty is limited to ninety
16. 0236 000 041 0226 00 Pump Belt 72 61 041 8411 00 041 5048 00 CATERPILLAR CAT 28hp Oil Filter 063 2010 00 Air Filter CAT 28hp Inner CAT 28hp Outer 063 2060 00 063 2050 00 CATERPILLAR CAT 35hp Oil Filter 063 2010 00 Air Filter CAT 35hp Inner CAT 28hp Outer 063 2060 00 063 2050 00 Motor Oil 15w40 Reference Owner s Manual Hydro Oil 20w50 8 quarts PAGE 3 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 14 Diesel engines use 15W40 engine oil Conventional or Synthetic may be used Refer to the engine s service manual 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 Diesel models have 12 psi in both front and rear tires 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 Diesel model serial numbers are found on the SIN plate underneath seat
17. 1 2 Brass Washer 31 2 019 5007 00 1 2 Lock 32 2 013 7018 00 1 2 Hex Nut 33 2 018 6049 00 3 8 x 1 Hex Bolt 34 3 019 5029 00 13 8 Flat Washer 35 3 019 5037 00 3 8 Lock Washer 36 3 013 6014 00 3 8 Hex Nut 37 4 018 5025 00 5 16 x 1 1 4 Hex Bolt 4 019 8044 00 5 16 Flat Washer 39 4 013 8043 00 5 16 Nut 40 6 018 0016 00 5 16 18 X 1 Button Head Bolt 4 1 086 0004 00 Starer To Chassis Cable Diesel 42 1 015 6050 00 Engine Fan Diesel 4 1 201 8009 00 Diesel Side Motor Mount Left 44 1 063 2010 00 Filter 45 1 019 2050 00 Brass Washer For Weld 46 2 018 6012 00 3 8 x 1 1 2 Hex Bolt 47 1 013 5201 00 3 8 Flange Nut 48 1 044 2006 00 1 4 5 8 Clevis 49 1 020 2000 00 3 32 X 1 2 Cotter pin PAGE 45 35 HP CAT Diesel Engine b S PAGE 46 EHP Diesel Engine PART NUMBER DESCRIPTION 1 1 0560040 SEH CAT Diesel Engine 2 1 Diesel Throne Bracket 4 Tier 3 1 Stub Shaft 37176 187 Lock Washer s 1 _ 203 8005 00 Ar Cleaner Support Diesel 67172 ors2ooroo 125 x 25mm Hex Head Bot 7 2 Mi 125 x 30mm Hex Head Bolt 8 10 Joiseostoo 5 16 Lock Washer 6 5
18. 2 Jam 17 2 019 6017 00 635 ID Plastic Washer 18 1 025 7036 00 1 2 x 1 2 Spacer 19 1 018 7016 00 12 13 x GR 5 Hex Bolt Zinc 20 1 026 2100 00 Outlaw Height Indicator Plate Outer 21 1 040 4000 00 Deck height lever pin 22 1 031 0100 00 Outlaw Deck Lever Lock 23 5 019 2003 00 2390 x 750 x 062 Nylon Washer 24 4 018 0009 00 3 8 x 1 3 4 Carriage Bolt 25 3 025 5203 00 3 4 OD x 1 2 ID x 34 Length 26 4 013 5202 00 3 8 Nylock Flange Nut 27 1 079 3200 00 Outiaw Diesel Floor Panel 28 1 081 2008 00 Foot Assist Floor Mat 29 11 040 6080 00 Ratchet Fastener 30 1 018 8064 00 1 4 x 5 8 BS C S 18 8 SS 31 1 064 2006 00 Floor board Cable W Swivel Ends 32 o13 8049 00 5 16 18 Nylon Flange Nut 33 2 018 8065 00 5 16 x 1 Carriage Bolt 2 019 6042 00 360 ID Plastic Washer 35 1 026 0013 00 Outlaw Deck Lift Pedal 36 1 030 0010 00 5 16 18 x1 Thumb Screw Zinc 37 1 040 5000 00 Pull Pin 38 4 030 7039 00 1 4 x 1 1 2 Self Tapping Screw 39 4 019 7040 00 1 4 Flat Washer 40 2 029 7037 00 14 Rubber Bumper 41 1 087 6100 00 250 Gas Spring 61 Deck 42 1 018 2050 00 10mm Damper Stud Steering 1 013 9002 00 5 16 Flange Nut w Serrations 44 4 032 3000 00 Actuator Bar Bushing SF 1620 4 45 1 089 3050 00 2 X 3 ROPS Fits All 2012 Diesel Models PAGE 31 Diesel Frame Diesel Frame Actuator Floor Board and Hei
19. 20 1 019 4008 00 1 4 Lock Washer 21 1 013 8039 00 1 4 Hex Nut 22 1 018 8052 00 1 4 x 3 4 Hex Bolt 23 1 030 7040 00 1 4 x 1 Hex Head tek screw Diesel Hydraulic Cooler Only on 35Hhp Diesel ITEM QTY PART NUMBER DESCRIPTION 1 1 057 5950 00 Cooler Holder 2 2 061 8012 00 Hydraulic Cooler 4 018 8052 00 1 4 x 3 4 Hex Bolt 4 019 4008 00 1 4 Lock Washer 5 4 013 8039 00 1 4 Hex Nut 8 2 018 5344 00 5 16 x 2 1 2 Bolt 9 2 013 8043 00 5 16 Nut 10 2 025 8000 00 378 x 625x 1 750 Spacer Zinc 11 4 051 8063 00 3 8 clear hose price per foot 12 4 072 8065 00 3 8 hose clamp Diesel Air Filter Assembly ITEM QTY PART NUMBER DESCRIPTION 1 1 088 1018 00 Canister for All Diesel Models 2 1 088 1017 00 Enginaire Air canister cap 3 1 088 1019 00 Mounting Bracket For Diesel Alr Filter 1 063 2050 00 Diesel Air Filter Outer 5 1 063 2060 00 Diesel Air Filter Inner 6 1 088 1020 00 Debris Plug Enginaire Filter 7 2 013 8043 00 5 16 Nut 8 2 019 8051 00 5 16 Lock Washer 9 2 018 5344 00 5 16 x 2 1 2 Bolt 10 2 025 8000 00 378 x 625x 1 750 Spacer Zinc 11 1 051 3002 00 Air Intake Hose Diesel Air Filter Canister 12 2 072 2002 00 2 1 2 Hose Clamp 1 Enginaire Canister VLR Complete Assembly PAGE 43 28Hp CAT Diesel Engine
20. 5 6050 00 Steering Push Rod Diesel 33 1 031 9050 00 Adjustable Steering Arm Right Assembly Componets 14 17 18 19 20 28 29 34 1 031 9000 00 Adjustable Steering Arm Left Assembly Componets 14 15 16 17 18 19 20 35 1 013 0085 00 1 2 13 Hex Flange GR G ZC PAGE 27 Diesel Tanks Diesel Tanks Assembly ITEM QTY PART NUMBER DESCRIPTION 1 1 067 3000 00 Left Fuel Tank with Fender 2 r1 1066 8090 00 Diesel Fuel 3 5 inch Neck 3 1 1083 4014 00 Hour Meter 4 1 079 3402 00 Control Panel Left 5 2 018 1040 00 Light Plug 6 1 077 8076 00 Ignition Switch x 1 042 9000 00 Ignition Key 8 1 067 3001 00 Right Fuel Tank with Fender 9 1 1089 1000 00 Oil Light 10 1 056 8058 00 11 1 078 8077 00 Deck Lift Joystick 12 1079 3405 00 Diesel Control Panel Right 2012 13 1 1086 7001 00 2 Water Temperature Gauge 14 1 1086 7000 00 2 Pressure Gauge 15 1 1031 2010 00 Left Tank Support AOS 16 1 031 2011 00 Right Tank Aupport AOS 17 8 1018 2015 00 10 32 1 Button Head Bolt 18 10 018 2007 00 5 16 x 1 Bolt 19 10 019 8044 00 5 16 Flat Washer 20 10 019 8051 00 5 16 Lock Washer 21 1 080 7000 00 Diesel Seat Frame 22 4 018 8065 00 5 16 x 1 Carriage 23 a 013 9002 00 5 16 Flange Nut 24 4 1019 6042 00 360 ID Plastic Washer 25 2 013 5202
21. 87 x 1 2 Hex Bot 1 1002 90000 SY Key E 019 8054 00 505 Nyon Spacer as 4 0152000 Dj Pange Not 36 1 028007000 72 Diesel Dec Panhard Linkage Bar 3 2 EE rd Deck Arm Assembly a oaz 5056 qn Fange Bushing For Deck Arm upper 3 4 032 5057 00 Fange for Lower Deck Am E 4 013 7021 00 5 8 Sd NE Nut 018609200 SIE 2 1 2 Hex Bol 2 gt 045 505600 Tumtbuciie Top unk 2 2018 00 1 x 3 1 2 Pange Bot Grade 8 2 2551840 502 ID X 73 OD X 1500 Leng as 2 02 90000 5 3 Deck 1er Pulley 1 018 8019 00 1 27 47 Bot Grade 8 37 1 MEET 1 3 4 Pulley Spacer 3 1 039694540 Deck ier 2 01901700 135 ID PER Washer E 1 ETE SIE Hex Bot 51 1 013 530100 58 11 Nylon Insert Jam Hal Nut 1 025 520700 3 4 0D x 1D x 3M Length E 1 01701650 112 13 x GR S Hex Bo nc E 1 EE 12009 Dec Pump ter Spring 55 1 018109000 12 x 2 Carriage Bott E 1 ETE 17 Fat Washer 57 2 1090007 MES 12 Bote E z 0103740 1213X 2 14 GR Hex Bos E 2 EI 5 Unk Adjustable Deck Hange E 1 041 2525 00 822250 Fis 72 Diesel 1 EET Deck Ier Componets 5 45 0 52 53 2 EE 5 34 ier Pulley 727 Decks ony 2 1018000220 1 23 Grade Hex Bolt PAGE 51 037 8000 50 amp 8000 00 Double Bearing Spindle 037 8000 50 amp 8000 00 PART NUMBER DESCRIPTION 037 8005 50 Aluminum Spindle Housing 037 8005 00 Spindle Housing Dble Brg 037 8003 00 Tube Spacer Double Bearing Spindle 037 2050 0
22. A DELS DIESEL OWNER S SERVICE amp PARTS MANUAL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 870 698 0090 12 TABLE CONTENTS PAGE 2 Basic Information Section 1 page 4 Bad Boy Safety Guidelines Section 2 pages 5 8 Operation Section 3 pages 9 Maintenance Section 4 page 10 Storage and Transportation Section 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 Mowing Tips SERVICE SECTION BEGINS ON PAGE 17 PARTS SECTION BEGINS ON PAGE 25 LIMITED WARRANTY PAGE 54 This manual applies to the following equipment Bad Boy Diesel Series Diesel 7200 72 35hp 4 Cylinder Diesel Diesel 6100 61 35hp 4 Cylinder Diesel Diesel Compact 6100 61 28hp 3 Cylinder Diesel COMMONLY USED ITEMS AND PART NUMBERS 72 Blade Hi Lift Fusion Gator Blade Wave Blade 038 7230 00 038 5400 00 038 7215 00 61 Blade Hi Lift Fusion Gator Blade Wave Blade 038 6080 00 038 6081 00 038 6091 00 Deck Belt 27 61 61 Compact 041 2525 00 041
23. LL IMPLIED WARRANTIES ARE EXCLUDED Some states do nol allow imitations on how long an implied warranty lasts so the above limitations may not apply to you 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 lmtatanis exclusion s may not apply to you 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 addtional 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 This warranty extends only o turf equipment operated under normal conditions and property serviced and maintained The warranty expressly does not cover any defects damage or deterioration due to normal use wear and tear or exposure 1 normal maintenance services such as change cleaning lubncalion adjustment i replacement of services items such as oi lubricants spark plugs belts rubber hoses or other items subject to normal service replacement iv damage or defects arising aut of or relating to misuse neglect alteration negligence or accident v repair or replacement arising from operation of or use of the turf equipment whi
24. Lever Spring 2 2 032 5055 00 Bushing for 2012 Drive Arms 3 2 019 8027 00 515 ID Nylon Shoulder Washer 4 3 032 8024 00 507 ID Nylon Bushing 5 2 024 6034 00 1 4 Drive in Grease Fitting 1 019 6017 00 635 ID Plastic Washer 7 1 013 8050 00 1 2 13 Nylon Flange Nut Orange 8 1 013 8043 00 5 16 Nut 8 1 018 8063 00 5 16 3 4 Hex Bolt 10 1 027 8819 00 Drive Arm Lever Housing Left 11 2 013 6051 00 3 8 Fine Threaded Jam Nut 12 2 019 5037 00 3 8 Lock Washer 13 2 019 7000 00 505 1 125 Oil Impregnated washer 14 1 031 9010 00 Upper Tube Adjustable Steering 15 1 031 9017 00 Upper adjuster Steering Arm Left 15 1 o31 9014 00 Lower Adjuster Steering Arm Left 17 1 o69 4010 00 Black Steering Grip 18 2 045 5000 00 Black Knob for Adjustable Steering Arm 19 1 018 5043 00 3 8 x 1 1 4 Carriage Bolt 30 4 018 2020 00 5 16 18 1 2 HWH Bolt Steering 21 1 031 9020 00 Steering Arm Elbow Left 22 2 087 808000 Damper 23 2 018 2050 00 10mm Damper Ball Stud Steering 24 2 013 9002 00 5 16 Flange Nut 25 1 035 6060 00 Streering Push Rod 28Hp Diesel Push Rod 26 2 013 6051 00 3 8 Fine Threaded Jam Nut 27 2 099 6046 00 3 8 24 Ball Joint 28 1 031 9015 00 Lower Adjuster Steering Arm Right 29 1 031 9016 00 Upper Adjust Steering Arm Right 30 1 031 9025 00 Steering Arm Elbow Right 31 1 027 8820 00 Drive Arm Lever Housing Right 32 1 03
25. Nut 1 2 Nut a7 2 Jo72 8090 00 Diesel Camp 1 3 4 Vin 48 2 Joisez00 5 6 x 11 7 Hex Bot as 2 ors20r00 3187 Range Rut so 1 nis205000 Brass Washer for Weldon Hinge 1 06670020 Temperature Sender 2012 Gauge PAGE 47 Tumbukles only on ISHP Diesels E m PAGE 48 Dj BESET 0 3 eese ETE B FEE 3 eene DT NE B Ded tae Ra ENE Gr Er Fe s Ur ove Rer 7 se itr ELI ELI EEND s EE w sesse Ei EET EI ge te Rag n ee ENE EET ENE ONE EI 3 Cc ETE ase Fw Toe id E FEE TEL s eremo ETE essere 5 Wen re Dm ONE Vr eU mer VE Fever E DELIS B I EI De Ra Rr a SGT Core eo B EI E 3 Basle Soria Zine ein Dd w 3 EET Li B ESRA EDE v s sess EE P EE EI GE eth prs WER SBE x 1 eres EET e ocd sarwa Se EN 27 EI El 3 same EET lt essor ETUI 1 eroe RRA Ol TEER een HEDE aver any on SP Dad E EN 77 Tere Bao bed Arn EE 1 ET 2707 EE 3 ELE EER II Ei De les r3 EL Eie Wen Forge hr PAGE 49 Diesel 72 Deck Assembly
26. Start Switch EJ 1 Start Sath Boot Diesel 25 1 ozrenss oo Waring Piezo Buzzer 1 Auto Shut Down for Cat Diesels 27 7 forsoso 10 Nylock Nut EJ 3 01520000 1024 X 5 8 Buttonhead Bolt 28 1 o12 2030 00 397 Hex ut 3 072 8006 00 3 2 Hose Camp a 4 o72 006500 3 8 ose camp 32 3 019 s029 00 3 8 Flat Washer 3 2 3 87 Flange Nut 3 2 org Sooo HIE 1 EJ 1 Battery Held Down 17 Back Battery Cable Diesel E 1 064400000 Red Battery Cable Diesel EI 2006 Seat Pate 3 2 ors sooo 360 ID Plastic Washer ENE 5 16 18 nylon Pange Nut En 2 5 16 Camage Bot E 1 orraosocoo Grammer Suspension Seat 3 05259 5 16 Pange Nut 1 14202 Hex Bot 45 1 Joan 5 16 18 Nylon Pange Nut 2 1 4 20 Hex Flange Znc w Seratons 37 1 034 1075 00 arson Spring for Seat latch 2 360 ID Paste Washer 1 esrezooon Seat Latch Lever 1 51618x 2 Hex CIS GRS ZC 1 orazos Cooler Cover E 020700200 5 16 x washer head type F screw E 3 018201500 3 213 172 Flange Bok Grade 8 3 forsso 177 Flange Nut EJ 1 036 5300 00 Seat Such Adapter PAGE 35 Diesel Pump Plate Assembly DETAIL B PAGE 36 Disi Pune
27. a rsen Siren x 1 25 Key 1 Pump Set 2p 2 506 Fange ut lt 3 esos SHE x 1 Cine BOF i us 3916 x 5 Hex Bokt Grade 5 lt 3 foss SIE x Hox Bolt SP Decken i ena Tus Fe 2 EI 5 2 Jose 2 osa 308 Washer 1 ousoxzo EE Fl Bo 5 1 fosse ENE WEE Era 1 orsessroo EIE a 4 ER fe Ine tee s 1 EET a 5 fons Wes Panoa 5 1 Let Pump ADS Dis 3549 Dis 3 0934070 Pump 160c gt AOS Dis 35 Dee m 1 Jose Purp be for SPP Ds 1 fossas Deel Pump oniy on 72 Deck a i esse Das Pump dle Assembly Components 345578910 for 72 1 osea SB 1 2 Bot for 72 Deck PAGE 37 Diesel Back Pump Cover ON PAGE 38 Ony On 3SHP Diesel 95 DETAIL A PAGE 39 Dies Suspension amp Back Pump Cover Assemblies TEN PART NUMBER DEE 1 ET Desc Back Pump Cover 2008 Bottom 2 1 osovou Back Cover Hnge Bracket 3 1 oes Diesel Back Pomp Cover 2008 Top esame Dese Hoo 5 2 oranes 5 16 x Bot 5 S 26010 Plastic Washer 7 7 osa 18 S BS CIS 18 8 55 5 2 oxe a062 00 5184 carriage bot 5 or3 s002
28. ch is not in accordance with operating instructions as specified in the operators manual or other operational Instructions provided by Bad Boy ine vi repair or replacement arising as a result of any operation fram 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 affected the turf equipment so as to change the intended use of the product i repair replacement necessitated by use of parts accessories or supplies including gasoline lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Bad Boy Ine vii repairs or replacements resulting from parts or accessories which have adversely affected the operation performance of durability of the turt equipment or ix damage or defects due to 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 recommended parts As a condition to this 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 Tis warranty gives you specific legal rights and you may also have other rights which vary from state to stat
29. dditional 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 16 SERVICE SECTION SECTION 1 HYDROSTATIC SYSTEM To change hydro oil on Diesel 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 Conventional or synthetic oil may be used Bad Boy recommends that the hydro oil and filters be changed within the first 50 hours of usage and every 500 hours thereafter or once a year Diesel Models 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 othe
30. e with the ROPS secured in the upright position 2 77 Ifthe surrounding environment e g low lying limbs signage etc makes it impossible to mow with the ROPS upright lower the ROPS at the hinge point mow the area then immediately secure the ROPS upright 2 78 Upright ROPS are taller than then operators head Be aware of this and your surrounding environment as referenced above The mower and operator may clear low lying items but the ROPS may not 2 79 Always wear the provided seat belt when ROPS are utilized Failure to use the seat belt severely handicaps the safety benefits of the ROPS 2 80 In the event of a roll over replace the ROPS before resuming use of the machine PAGE 8 31 3 2 3 3 3 4 3 5 3 6 37 38 39 340 341 342 343 344 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 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
31. earing damage is done The torque for Suspension forks should be 50 ft Ibs Torque rear wheel lugs to 65 75 ft Ibs Re torque 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 PAGE 22 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 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 from 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 le
32. en these header strips overlapping each lap by about 1 8 the width of the mower s deck 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 third of the grass leaf at any one cutting 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 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 When 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 different direction with each mowing especially with lawns of shorter grass types Altering the direction ensures more even cut since grass blades will grow more erect and less likely to develop into a set pat
33. ere the inspection and or warranty work is performed Engines are warranted separately by their respective manufacturer The avaiable warranties covering this tem are furnished with each mower Bad Boy Inc does not assume any warranty obligation iabilly or modification for this item which is covered exclusively by the stated warranty of the respective manufacturers Tires blades deck anti scalping wheels are considered to be consumable wear items and are therefore not warranted Batteries are warranted for six months free replacement from the real purchase date against materials or workmanship defects The battery warranty must be obtained through the battery manufacturer HOW TO OBTAIN SERVICE UNDER THIS WARRANTY Warranty service can be arranged by contacting the dealer whore you purchased the mower or by contacting Bad Boy Inc Proof of the date of purchase may be required to verify warranty coverage B Warranty claims will not be reviewed or paid unless the warranty registration card is received by Bad Boy Inc within 30 days of the retail purchase date C Warranty claims requiring parts returned will ba salad upon relum of parts to Bad Boy for inspection 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 A
34. ft to right PAGE 23 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 Bolts used have standard threads Re torque the blade bolts to 90 110 Ibs 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 24 xS Ls mon x Diesel CAT 27 DS as Ge EO Suspension Fork Assembly NN E 3 y 2 ANS Y Suspension Fork Assembly NU I Pa ITEM QTY PART NUMBER DESCRIPTION 023 0020 00 2221 Su
35. ght Indicator ITEM QTY PART NUMBER DESCRIPTION 1 1 070 5550 00 Diesel 4 72 Frame 2 2 017 7008 00 pillow block 2bolt sealmaster 3 018 5006 00 1 2 x 1 1 2 Hex Bolt 4 4 019 5007 00 1 2 Lock Washer 5 013 7018 00 1 2 Hex Nut 6 1 028 7920 00 Actuator Bar 7 1 031 7000 00 Height Indicator Lever 8 013 9002 00 5 16 Flange Nut 1 019 6042 00 360 ID Plastic Washer 10 028 5203 00 Height Indicator Bar 11 1 018 2007 00 5 16 x 1 Bolt 12 1 039 2008 00 Deck Stop Bracket 2008 13 1 035 7033 00 Actuator 14 1 018 6036 00 1 2 x2 1 2 Hex Bolt 15 025 7036 00 1 2 x 1 2 Spacer 16 019 8054 00 505 Nylon Spacer 013 8050 00 1 2 13 Nylon Flange Nut Orange 018 4010 00 11 2 Nylcock Nut 1 2 Jam 018 5049 00 1 2 x 2 Hex Bolt 019 5702 00 1 2 Washer Grade 8 077 5300 00 Deck Stop Switch 22 2 018 8056 00 1024x1 AlleneadBolt 23 013 2000 00 M6x1 0x20MM 8 8 Hex Bolts Zinc 24 079 6000 00 Floor Panel 25 081 2007 00 AOS Floor 26 040 6080 00 Ratchet Fastener Floorboard 27 018 8064 00 1 4 x 5 8 Buttonhead Bolt 064 2006 00 Floor board Cable W Swivel Ends 29 019 4008 00 1 4 Lock Washer 30 013 8039 00 1 4 Hex Nut 31 019 7040 00 1 4 Flat Washer 32 030 7039 00 1 4 x 1 1 2 Self Tapping Screw w u 029 7037 00 14 Rubber Bumper
36. ings 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 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 units Operator s Manual or Parts List It is true there 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 blades 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 15 MOWING TIPS 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 betwe
37. l and Filters Check filters once 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 7 Change Hydraulic Fluid and Filters 4 8 Refer to manufacturer manual for specific information on maintenance schedules MOWER STORAGE amp TRANSPORTATION 54 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 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 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 541 Secure mower with at least two straps capable of securing weight of mower PAGE 10 61 61 6 2 6 2 6 3 6 3 64 64 6 5 6 5 6 6 6 6 TROUBLESHOOTING Q How do I prevent uneven cutti
38. lect or improper maintenance If an evaporative emission control system component does fail in a manner that would cause the equipment to no longer meet the requirements of 40 CFR 1060 within the first two years Bad Boy Inc will replace the defective component Your evaporative emission control system may include parts such as fuel tanks fuel lines carbon canisters fuel caps valves vapor hoses clamps or connectors 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 way that can cause damage to people or property Seek additional training when possible to learn more about safety techniques and practices This cutting machine is capable of amputating hands and feet and throwing objects Failure to observe the following safety instructions could result in serious injury or death GENERAL OPERATION 21 Read understand and follow all instructions on the machine and in the manual before starting 2 2 Do not put hands or feet near rotating parts or under the machine Keep clear of the discharge opening at all times 2 3 Always remain seated while operating the machine the machine is equipped with Roll Over Protectio
39. 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 Increase RPM by sliding the throttle to fast position toward the rabbit Owners must become familiar with the controls before operating a zero turn radius vehicle Start slowly and build your skill level Have ample practice before using the machine at full capabilities Be comfortable with machine before engaging blades Know what each component controls before using machine 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 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing time will decrease Avoid operating your mower on side hills of over 5 degrees inclines of over 10 degrees and declines of over 15 degrees PAGE 9 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 Oi
40. n ROPs always buckle your seat belt 24 Only allow responsible adults who are familiar with the instructions to operate this machine 25 Clear the area of objects such as rocks wire toys etc which could be thrown by the blades 2 6 Always maintain a safe distance from people and pets just prior to and during operation Stop the machine 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 29 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 210 Never operate the machine without the discharge chute grass catcher or other safety devices correctly in place and functioning properly 241 Slow down before turning 242 Always disengage blades place steering controls in neutral engage parking brake and remove ignition key when leaving operators seat Never leave a running machine unattended 213 Disengage blades when not mowing Shut off engine and wait for all parts to come to a complete stop before cleaning the machine inspecting the machine for damage removing the grass catcher or unclogging the discharge guard 214 Always operate machine in daylight or with adequate working lights 215 Do not operate the machine while under the influence of alcohol or drugs 246 Watch for t
41. ne dispenser nozzle 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 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 If fuel is spilled on clothing change clothing immediately Never overfill fuel tank Replace gas cap and tighten securely GENERAL SERVICE 256 257 258 259 260 261 262 263 264 265 266 267 268 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect Keep all nuts and bolts tight to be sure the equipment is in safe working condition Never operate a poorly maintained machine Do not touch hot areas of the machine Never interfere with the intended function of a safety device or reduce the protection provided by a safety device Check their proper operation regularly Keep the entire machine free of grass leaves or other debris build up Clean up oil or fuel spillage and remove any fuel soaked debris Failure to so can affect the safety and functionality of the machine as well as increase the danger of a fire due to contact with the hot surfaces of the machine Allow machine to cool before storing If you strike something with the mower turn the mower and blades off engage the parking brake and inspect the machine for damage Repai
42. ng 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 Q What should 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 secure at switch Also check PTO fuse underneath operator console 10amps 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 Q Do you offer touch up paint for your mowers A Touch up paint is available Contact your local dealer f
43. nly 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 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 freguently include extra cutting 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 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 clipp
44. or more information Q How durable is the electric deck lift 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 deck weighs approximately 250 pounds which is only 25 of working capability If deck lift will not operate check fuse located underneath operator console 15amp PAGE 11 14 PAGE 12 71 72 73 74 75 76 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 Pre Heat Button Before starting engine push to pre heat for easier starting 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
45. orque 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 PAGE 19 SECTION 4 ELECTRICAL SYSTEM 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 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 Ensure that the ground is connected clean and tight On most models the ground wire is 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 PAGE 20 MW E E EE Q 9 mO Ca EER 1 H 1 PAGE 21 SECTION 5 FRAME For non suspension models torque front fork castle nut to 40 ft lbs Be sure to spin the fork while torquing the nut to ensure that no b
46. r if necessary before resuming Never make any adjustments or repairs with the engine running Check grass catcher components and the discharge guard frequently and replace with manufacturer s recommended parts when necessary Mower blades are sharp Wrap the blade or wear gloves before servicing them Check parking brake operation frequently Adjust and service as required Maintain or replace safety and instruction labels as necessary Do not attempt to mount a tire without the proper equipment and experience to perform the job PAGE 7 269 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 70 Park machine on level ground Never allow untrained personnel to service machine Understand service procedure before doing work SAFETY INTERLOCK SYSTEM Your Bad Boy mower is equipped 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 seat the parking brake drive lever neutral position the mower blade engagement switch and the ignition switch These interlocks are vitally important and must be tested frequently Following are instructions to test these very important
47. r 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 stay clear of moving rear tires loosen bypass bolt Ve to turns move drive arms forward and backward 4 to 6 times slowly 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 PAGE 17 SECTION 2 DRIVE BELT Shown above is a typical pump belt tensioner for Outlaw models Factory setting is about 030 about the thickness of a credit card between coils as shown Shown to the right is a typical pump belt layout for most models SECTION 3 ENGINE 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 located underneath the radiator until air bubbles are no longer visible PAGE 18 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 Ibs on all models Ret
48. raffic when operating near or crossing roadways 247 Always wear eye protection when operating or servicing the machine 248 Always wear ear protection such as earplugs while mowing 249 Use extra care when loading or unloading the machine into a trailer or truck 2 20 Be alert of surroundings Watch for rocks stumps mounds depressions and low hanging limbs or objects that could be potentially hazardous while mowing Data indicates that operators 60 years of age and above are involved in a large percentage of riding mower related injuries These operators should periodically evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury 22 PAGE 5 SLOPE OPERATION Slopes are a major factor related to loss of control and tip over accidents which can result in severe injury or death Operation on all Slopes requires extra caution If you cannot back up the slope or you feel uneasy on it do not mow it 222 223 224 2 25 226 227 228 229 230 231 232 Mow up and down slopes not across Watch for holes ruts bumps rocks or other hidden objects that tall grass can obscure Uneven terrain could overturn the machine Choose a low ground spend when operating the machine on a slope Do not mow on wet grass the tires may lose traction Do not attempt to coast down a slope in the neutral position Avoid starting stopping or turning on a slope If the tires lose
49. ren to operate the machine 2 38 Never leave key in the ignition especially around children 2 39 Use extreme care when approaching blind corners shrubs trees or other objects that may block your view of a child TOWING 240 Towonly with a machine that has a hitch specifically designed for towing Do not attach towed equipment except at the hitch point 241 Follow the manufacturer s recommendation for weight limits for towed equipment and towing on slopes 242 Never allow children or others in or on towed equipment 243 On slopes the weight of the towed equipment may cause loss of traction and loss of control 244 Travel slowly and allow extra distance to stop PAGE 6 SAFE HANDLING OF GASOLINE To avoid personal injury or property damage use extreme care in handling gasoline Gasoline is extremely flammable and the vapors are explosive 2 45 2 46 2 47 2 48 2 49 250 251 252 258 254 255 Extinguish all cigarettes cigars pipes and all other sources of ignition Use only an approved gasoline container Never remove gas cap or add fuel with the engine running Allow engine to cool before refueling Never fuel the machine indoors Do not store machine near open flame or source of ignition such as a water heater or furnace Remove gas powered equipment from the truck or trailer and refuel it on the ground If this is not possible then refuel such equipment with a portable container rather than from a gasoli
50. spension Fork Top Side Combo REN 023 0012 00 Suspension Fork Bottom Left 20 29 023 0013 00 Suspension Fork Bottom Right 037 0010 00 Front Suspension Fork Spindle 013 5300 00 172 Flange Nut 018 2030 00 x 1 Hex Bolt 019 5007 00 1 2 Lock Washer 019 5707 00 1 2 Washer Grade IPIS 1 1 1 T 2 2 3 4 2 032 9002 00 Vibration Mount Red Dot 30 1 013 601600 1 Fine Thread Nut 11 2 019 300000 1 Lock Washer 12 2 019 5038 00 5 8 Flat Washer 13 2 018 3001 00 5 8 x 5 8 Shoulder Bolt 14 2 032 5052 00 Bronze Bushing SF 2024 8 15 2 010 7001 00 Bearing 16 1 012 7003 00 17 1 013 8050 00 1 2 13 Nylon Flange Nut Orange 18 2 025 5203 00 3 4 OD x 1 2 ID x 344 Length 19 1 025 5202 00 Front Wheel Spanner 20 1 018 300200 1 2 x 10 Bolt 21 1 013 9004 00 1 Fine Thread 1 2 Nut 22 1 014 7005 00 Dust Cover 23 1 022 3070 00 13 x 6 50 No Flat Large Bore Orange front Assembly 26 2 022 7010 00 1 3 4 Bearing Large Bore Front Rim 25 2 018 2080 00 in 13 x 1 1 4 Hex Bolt 1 023 7915 98 Suspension Fork Assembly PAGE 25 Diesel Drive Arms Items Per Side PAGE 26 Diesel Drive arms TTEM QTY PART NUMBER DESCRIPTION 1 1 034 8025 00 Drive
51. ss leaving a brown frayed top on the grass within a few hours A dull blade will also reguire 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 before leaving the operating position Grease Type NGLI grade 2 multi purpose gun grease Grease the front caster pivots Clean the grease fittings with 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 HOW CHOOSE THE RIGHT BLADE Essentially there are o
52. tern 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 In 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 blade A demonstrates what a leaf blade should look like after mowing with a sharp blade Leaf blade B demonstrates a leaf blade that was injured by a dull mower blade 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 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 a

2014 Diesel Parts Manual

Contents

Download Pdf Manuals

Related Search

Related Contents