Bad Boy Mowers DIESEL 1500cc Owner's, Service & Parts Manual
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Bad Boy Mowers DIESEL 1500cc Owner's, Service & Parts Manual

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DIESEL 1500
ZERO-TURN MOWER
OWNER'S, SERVICE & PARTS MANUAL
For additional information, please see us at
www.badboymowers.com
cc
MODEL
Bad Boy, Inc.
102 Industrial Drive
Batesville, Arkansas 72501
©2017 12-6

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  • Page 1 DIESEL 1500 MODEL 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 ©2017 12-6...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Basic Information ..................... Section 1 Page 4 Bad Boy Safety Guidelines ..................Section 2 Page 5 Operation ......................... Section 3 Page 9 Maintenance ......................Section 4 Page 10 Storage and Transportation ..................Section 5 Page 10 Troubleshooting and FAQ ..................Section 6 Page 12 Controls ........................
  • Page 3 Outer Filter Air Filter 063-2060-00 063-2050-00 Caterpillar Perkins Fuel Filter 063-2011-00 063-2011-01 Hydraulic Filter 063-8014-00 Motor Oil 15W-40 Motor Oil – Reference Owner’s Manumal. 20W-50 Motor Oil- Bad Boy Hydrostatic Oil Recommended (Approximately 2.5 Quarts/Transaxle) Hydraulic Oil 085-6000-00 PAGE 3...

  • Page 4: Basic Information

    The Warranty Registration form must be completed within 30 days 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 nontransferable. Warranty registration should be completed by the selling dealership using the on-line registration site.
  • Page 5 SECTION 2: 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 a way that can cause damage to people or property.
  • Page 6 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.
  • Page 7 TOWING 1500CC Diesel: Max pulling weight: 650lbs. Max at 5°: 570lbs. Max tongue weight: 61” = 110lbs.; 72” = 115lbs. 2.40 Tow only with a machine that has a hitch specifically designed for towing. Do not attach towed equipment except at the hitch point. 2.41 Follow the manufacturer’s recommendation for weight limits for towed equipment and towing on slopes.
  • Page 8 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) This machine is not equipped with ROPS from the factory.

  • Page 9: Operation

    The machine could lose traction on a decline or tip backwards on an incline. 3.14 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing time will decrease. Avoid operating your mower on side hills of over 5 degrees, inclines of over 10 degrees, and declines of over 15 degrees.

  • Page 10: Maintenance

    SECTION 4: MOWER MAINTENANCE Interval Every 50 First Every 100 Every Every Daily Hours or Hours or Section Maintenance Annually* hours Annually* Hours Hours Check and add engine oil Section3  Section 2 Check all belts for proper alignment  (Pump) 6 (Deck) Check tire pressure and wheel lug nuts Section 5...
  • Page 11 MAINTENANCE LOG 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:...
  • Page 12 SECTION 6: TROUBLESHOOTING Q: How do I prevent an uneven cutting 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.

  • Page 13: Controls

    SECTION 7: 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 the RUN position.

  • Page 14: Moving Inoperable Mower

    Your Bad Boy Mower Weighs: ***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.

  • Page 15: Mower Blade Maintenance

    SECTION 10: MOWER BLADE MAINTENANCE 10.1 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 grass leaving a brown frayed top on the grass within a few hours.

  • Page 16: How To Choose The Right Blade

    HOW TO CHOOSE THE RIGHT BLADE Essentially there are only TWO basic styles of mowing blades used or approved for use on our current products: 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.

  • Page 17: Mowing Tips

    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 between these header strips overlapping each lap by about 1/8 the width of the mower’s deck.

  • Page 18: Service Section

    Use only 20W-50 motor oil in this tank. Conventional or synthetic oil may be used. Bad Boy Hydrostatic Oil is recommended. Bad Boy recommends that the hydraulic oil and filters be changed within the first 50 hours of use; then at intervals of 250 usage hours.
  • Page 19 PURGING PROCEDURE Due to the effects air has on the efficiency in hydrostatic drive applications, it is critical that the air is purged from the system. These purge procedures should be implemented any time a hydrostatic system has been opened to facilitate maintenance or any additional oil has been added to the system.
  • Page 20 Use a belt tension gauge to ensure the proper tension. Your dealer or service center will have belt tension gauge or you can buy one from the Bad Boy Parts Department by calling 866-622-3269 and asking for the Parts Department. (Part...
  • Page 21 To access the engine, remove the knob on top of the engine cover plate. The oil drain plug is located on the bottom of the engine. Bad Boy recommends that the oil and filter be changed after the initial first 8 hrs of use, and at intervals of 250 usage hours or yearly, whichever occurs first after that.
  • Page 22 1500CC DIESEL (CONTINUED) When servicing the fuel system on the 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 23 1500CC DIESEL (CONTINUED) 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.
  • Page 24 SECTION 4: ELECTRICAL SYSTEM The fuses on the 1100cc Diesel are located behind the left swing away tank. The top 40-amp fuse is the main fuse and the two 15-amp fuses are for the linear actuator and for the clutch. Always check the condition of the wiring harness ground cable.
  • Page 25 ELECTRICAL SYSTEM (CONTINUED) WIRING DIAGRAM PAGE 25...
  • Page 26 SECTION 5: FRAME The front fork nuts require a torque of 40ft-lbs. First remove the dust cap. While applying this torque, turn the fork itself to ensure no damage is done to the bearing. This operation is only necessary if a repair requires it. Torque rear wheel lugs to 65-75ft.
  • Page 27 SECTION 6: CUTTING DECK DECK BELT REMOVAL Use proper safety precaution when preforming procedures. Raise the deck to its highest position. Remove the right pulley cover. While lifting up on the belt (as shown in the photograph), rotate the pulley until the belt is free of the pulley.
  • Page 28 LEVELING THE DECK Start on a flat level surface and set the air pressure in all four tires to 12 psi. Measure the deck at all four corners. The deck should be level from left to right but 1/4" lower in the front than in the rear. adjustments can be made by adjusting the deck hangers in their slots.
  • Page 29 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 from the Bad Boy Parts Department by calling 866-622-3269 and asking for the Parts Department. (Part Number 041-9999-00).
  • Page 30 BLADE REMOVAL 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. Use a 15/16" socket and impact drill, or a wrench and an extension to gain more leverage. You might need to put a 3/4"...
  • Page 31 PAGE 31...

  • Page 32: Parts Section

    PARTS SECTION: DIESEL SUSPENSION FORK ASSEMBLY Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 023-0020-00 Suspension Fork Top/Side Combo 012-7003-00 Seal 023-0012-00 Suspension Fork - Bottom Left 013-8050-00 1/2-13 Nylon Flange Nut 023-0013-00 Suspension Fork - Bottom Right 025-5203-00 Spacer 3/4 OD x 1/2 ID x 3\4 Length 037-0010-00...
  • Page 33 PARTS SECTION: 1500CC DIESEL DRIVE ARMS Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 034-8025-00 Drive Lever Spring 099-6046-00 3/8-24 Ball Joint 019-8027-00 .515 ID Nylon Shoulder Washer 019-5702-00 1/2" Washer (Grade 8) 024-6034-00 1/4" Press in Grease Fitting 027-2017-00 Steering Block Assembly - Right 013-8050-00...
  • Page 34 PARTS SECTION: 1500CC DIESEL TANKS PAGE 34...
  • Page 35 PARTS SECTION: 1500CC DIESEL TANKS Parts List ITEM PART NUMBER DESCRIPTION 067-3000-00 Left Fuel Tank with Fender 083-4014-00 Hour Meter 079-3402-00 Control Panel (Left) 018-1040-00 Light Plug 077-8076-00 Ignition Switch 042-9000-00 Ignition Key 031-2010-00 Left Tank Support 031-2011-00 Right Tank Support 018-2015-00 10-32 x 1 Button Head Bolt 080-7000-00...
  • Page 36 PARTS SECTION: 1500CC DIESEL FRAME PAGE 36...
  • Page 37 PARTS SECTION: 1500CC DIESEL FRAME Diesel Frame, Actuator, Floor Board, and Height Indicator ITEM PART NUMBER DESCRIPTION 070-5550-00 Diesel 4cyl 72" Frame 028-7920-00 Actuator Bar 031-7000-00 Height Indicator Lever 013-9002-00 5/16" Flange Nut 019-6042-00 .360 ID Plastic Washer 028-5203-00 Height Indicator Bar 018-2007-00 5/16"...
  • Page 38 PARTS SECTION: 1500CC DIESEL SEAT FRAME DETAIL C DETAIL B DETAIL A PAGE 38...
  • Page 39 PARTS SECTION: 1500CC DIESEL SEAT FRAME Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 069-8054-00 Hand Brake Assembly 013-9002-00 5/16" Flange Nut 062-8013-00 Filter Head 026-2006-00 Seat Plate 063-8014-00 Hydraulic filter 071-4055-17 Grammer Seat With Seatbelt 024-5050-00 Filter Head Fitting 013-8049-00...
  • Page 40 PARTS SECTION: 1500CC PUMP PLATE ASSEMBLY DETAIL B 72" Deck only DETAIL C DETAIL A PAGE 40...
  • Page 41 PARTS SECTION: 1500CC PUMP PLATE ASSEMBLY Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 026-8030-00 Pump Plate Diesel 019-5029-00 3/8" Flat Washer 018-5043-00 3/8" x 1 1/4" Carriage Bolt 024-2080-00 90 Degree Adaptor 6801-L-8-8 Fitting 024-3050-00 1/4"...
  • Page 42 PARTS SECTION: 1500CC DIESEL BACK PUMP COVER PAGE 42...
  • Page 43 PARTS SECTION: 1500CC DIESEL BACK PUMP COVER Parts List ITEM PART NUMBER DESCRIPTION 014-5920-00 Diesel Back Pump Cover 2008 Bottom 039-0070-00 Back Cover Hinge Bracket 014-5921-00 Diesel Back Pump Cover 2008 Top 059-8010-00 Diesel Hood 4 Cyl 018-8065-00 5/16" x 1" Carriage Bolt 019-6042-00 .360 ID Plastic Washer 018-8064-00...
  • Page 44 PARTS SECTION: RADIATOR & HYDRAULIC COOLER ASSEMBLIES Radiator Assembly Radiator Assembly ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 061-5000-00 Radiator- Diesel 019-5029-00 3/8" Flat Washer 094-5088-00 Radiator Screen-Diesel 013-6014-00 3/8" Hex Nut 072-8090-00 Diesel Clamp 1 3/4" Vinyl 084-4015-00 Rubber Trim 051-3000-00 Top Radiator Hose for Diesel...
  • Page 45 PARTS SECTION: DIESEL AIR FILTER ASSEMBLY Diesel Air Filter Assembly Diesel Air Filter Assembly ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 088-1018-00 Canister for All Diesel Models 019-8051-00 5/16" Lock Washer 088-1017-00 Enginaire Air canister cap 018-5344-00 5/16" x 2 1/2" Bolt 088-1019-00 Mounting Bracket For Diesel Air Filter 025-8000-00...
  • Page 46 PARTS SECTION: 1500CC DIESEL ENGINE PAGE 46...
  • Page 47 PARTS SECTION: 1500CC DIESEL ENGINE Parts List ITEM PART NUMBER DESCRIPTION 201-8001-00 Hood Holder Diesel 032-4050-00 Rubber Isolator 018-7016-00 1/2" x 3" Hex Bolt 019-5010-00 1/2" Brass Washer 019-5007-00 1/2" Lock Washer 013-7018-00 1/2" Hex Nut 018-6049-00 3/8" x 1" Hex Bolt 019-5029-00 3/8"...
  • Page 48 PARTS SECTION: 1500CC DIESEL 61" DECK DETAIL C DETAIL A DETAIL B DETAIL D PAGE 48...
  • Page 49 PARTS SECTION: 1500CC DIESEL 61" DECK Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 060-6130-00 61" AOS Deck 018-1050-00 1/2 x 2" Carriage Bolt 033-5000-00 5 3/4" Deck Idler Pulley 019-0007-00 .517 Square Hole Round Washer 033-6004-00 6 1/4"...
  • Page 50 PARTS SECTION: 1500CC DIESEL 72" DECK DETAIL B DETAIL C DETAIL D DETAIL A PAGE 50...
  • Page 51 PARTS SECTION: 1500CC DIESEL 72" DECK Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 060-7201-00 72" ( Deck Only) 058-6000-00 Black, Round Stick-On Rubber Bumper 047-5000-00 5- Link Adjustable Deck Hange 013-0004-00 Acorn nut-pulley Cover 060-7211-00 72"...
  • Page 52 PARTS SECTION: 037-4000-00 DOUBLE BEARING SPINDLE Parts List ITEM PART NUMBER DESCRIPTION 037-4000-01 4000 Series Spindle Housing 037-4002-00 4000 Series Spindle Spacer 037-9050-00 Locking Collar w/ 1/4"-20 Set Screw 037-8002-00 Spindle Dust Cap 037-6026-00 Spindle Shaft 037-6029-00 Bearing - Peer 6206 PAGE 52...
  • Page 53 PARTS SECTION: DECALS 091-0902-00 091-1114-00 091-1101-18 BAD BOY FLOORBOARD LOGO DECAL STEERING SPEED BRAKE DECAL CONTROL DECAL 091-2001-18 091-0919-18 OVAL LOGO DECAL ARMORTEK5 DECAL 091-3060-00 SWING AWAY PATENT DECAL 091-1104-18 091-0917-18 091-0918-18 091-0360-18 THROTTLE DECAL 61" DECK DECAL 72" DECK DECAL...
  • Page 54 PAGE 54...

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