Bad Boy Diesel Guide

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

(870) 698-0090

Diesel & Compact Diesel MODELS

Diesel & Compact Diesel

MODELS

TABLE OF CONTENTS

Basic Information ........................................................................................... Section 1 (pages 4–5)

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

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

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

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

Troubleshooting and FAQ ............................................................................... Section 6 (pages 8–9)

Controls ............................................................................................................... Section 7 (page 9)

Moving Inoperable Mower ................................................................................ Section 8 (page 10)

Instrumentation ................................................................................................. Section 9 (page 10)

Mower Blade Maintenance ................................................................................Section 10 (page 11)

Greasing Bearings ........................................................................................... Section 11 (pages 11)

How to choose the right blade ..............................................................................................Page 12

Mowing Tips ........................................................................................................................ Page 21

SERVICE SECTION BEGINS ON PAGE 13

PARTS SECTION BEGINS ON PAGE 22

LIMITED WARRANTY PAGE 50

PAGE 2

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

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 72˝ 61˝ 61˝ Compact

041-2525-00 041-0236-000 041-0226-00

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 (4 quarts)

Hydro Oil 20w50 (8 quarts)

COMMONLY USED ITEMS AND PART NUMBERS

PAGE 3

SECTION 1: BASIC INFORMATION

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

operators in maintaining and operating their machine. The information and instructions in this manual can

help you attain years of performance from your new Bad Boy. Also, check out our website to learn more

about the Bad Boy family.

1.1 Diesel engines use 15W40 engine oil. Conventional or Synthetic may be used.

1.2 All Bad Boy hydraulic systems use 20W50 engine oil. Conventional or Synthetic may be used.

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

1.4 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. The serial numbers are

necessary on the warranty registration form. Also, these numbers can assist you in the ordering of new

parts when replacements become necessary.

Parts/Service

Only Bad Boy replacement parts are to be used on your mower.

Replacement parts are available through your local Bad Boy Mower Dealer. Remember to always provide

the following information when ordering parts:

1. Correct part number

2. Correct serial number

All warranty repair and service must be handled through your authorized Bad Boy Mowers dealer.

To locate the nearest dealer, go to our website and click on Locate a Dealer.

PAGE 4

SECTION 2: MOWER 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.

Seek additional training when possible to learn more about safety techniques and practices.

SAFETY PRECAUTIONS

2.2 Always remain seated while operating machine.

2.3 Always maintain a safe distance from people and pets while mowing.

2.4 Always disengage blades, place steering controls in neutral, engage parking brake, and remove

ignition key when leaving operators seat.

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

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

2.7 Always wear eye protection while mowing and servicing.

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

2.9 If you strike something with the mower turn the blades and mower off, engage the parking

brake, and inspect the machine for damage before resuming.

2.10 Be aware of low hanging limbs or objects that could potentially be hazardous while mowing.

2.11 Never operate a poorly maintained machine.

2.12 Never carry passengers.

2.13 Always buckle seat belt, if provided one.

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

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

2.16 Never refuel machine when engine is running.

2.17 Never leave key in ignition, especially around children.

2.18 Never run engine in enclosed area.

2.19 Do not touch hot parts of machine.

2.20 Do not remove deck wheels.

2.21 Conditions that can affect traction resulting in the loss of control of machine: Wet terrain, Hills

or extreme angles, Depressions in the ground, Mounds of dirt, Extremely dry grass, Soil type

(gravel, sand, clay), Tire pressure

2.22 Be aware of what is located at the bottom of slopes. For example, Rocks, Water, Cliffs, Roads

and Highways

PAGE 5

2.23 Safety warning decals are located on the mower and should always be observed and followed.

2.24 Never operate the mower with the discharge chute open.

2.25 Prevent Fires—Remove grass and debris from engine compartment and muffler area, before

and after operating machine, especially after mowing or mulching in dry conditions.

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

furnace.

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

job.

2.28 Always maintain the correct tire pressure. Do not inflate the tires above the recommended

pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air

pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

2.29 Never operate machine in a closed area where dangerous carbon monoxide fumes can collect.

2.30 Let engine cool before storing!!!

2.31 Hydraulic hoses and lines can fail due to physical damage, kinks, age, and exposure. Check

hoses and lines regularly. Replace damaged hoses and lines.

2.32 Park machine on level ground. Never allow untrained personnel to service machine.

Understand service procedure before doing work.

SECTION 3: MOWER OPERATION

Never operate the machine with faulty equipment. Always be alert of sudden changes

in landscape, as the mower will react differently on slopes or embankments than it will

on flat surfaces. Never operate the mower with the discharge chute open. Do not cross

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

bystanders.

3.1 Place parking brake in up position

3.2 Drive arms must be in the “open” position. While sitting on the machine, each arm is

positioned away from the operator, to the right and left. Drive arms will lock into place and

must be in this position to start machine.

3.3 Put PTO switch in the OFF position.

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

must fasten seatbelt.

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

3.6 Make sure nothing is under or around machine.

3.7 Place key in ignition and turn.

3.8 Once machine is started, disengage the choke.

PAGE 6

3.9 Increase RPM by sliding the throttle to fast position, toward the rabbit.

3.10 Owners must become familiar with the controls before operating a zero-turn radius vehicle.

3.11 Start slowly and build your skill level. Have ample practice before using the machine at full

capabilities.

3.12 Be comfortable with machine before engaging blades. Know what each component controls

before using machine.

3.13 Your mower will perform differently on an incline /decline. Be cautious, slow down, and do

not make any sudden jerking movements with control arms. The machine could lose traction

on a decline or tip backwards on an incline.

3.14 Once you become comfortable with your Bad Boy Mower you will notice your overall mowing

time will decrease.

Avoid operating your mower on side hills of over 5 degrees, inclines of over 10 degrees,

and declines of over 15 degrees.

SECTION 4: MOWER MAINTENANCE

**Check each and provide maintenance when needed.

DAILY

4.1 Check Engine Oil

4.2 Check Engine Air Filter

4.3 Tire Pressure

4.4 Inspect Blades

EVERY 30 HOURS OF USAGE

4.5 Grease Machine

EVERY 500 HOURS OF USAGE

4.6 Change Engine Oil and Filters

After the first 250 hours of usage, change engine oil and filter

Check filters once a year if under 500 hours

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

EVERY 500 HOURS OF USAGE

4.7 Change Hydraulic Fluid and Filters

Within FIRST 50 hours of usage, change hydraulic oil and filters

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

PAGE 7

SECTION 5: MOWER STORAGE & TRANSPORTATION

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

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

5.3 Always secure machine properly when transporting machine.

5.4 Do not load machine on trailer with blades engaged.

5.5 Do not use ramps to load the machine.

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

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

conditions before loading / unloading.

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

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

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

SECTION 6: TROUBLESHOOTING

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

6.1 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.

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

6.2 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.

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.

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

6.4 A: We recommend that you use a name brand diesel fuel to ensure quality.

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

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

PAGE 8

6.6 Q: How durable is the electric deck lift?

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

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

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

SECTION 7: CONTROLS

7.1 Ignition Switch—Bad Boy Mowers have a three position ignition switch: off, run, and start.

With key inserted, rotate it clockwise to START position and release key when engine starts,

and switch will automatically return to he RUN position.

7.2 Throttle Control—A cable is connected to the engine throttle for controlling engine speed.

Move lever forward to increase engine rpm, move lever backward to decrease engine rpm.

7.3 Pre-Heat Button—Before starting engine push to pre-heat for easier starting.

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 Engage Switch—This switch engages the blades. Pull the switch up to engage the

blades and push the switch down to disengage the blades.

7.6 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.

7.5

7.3

7.4

7.1

7.6

7.2

PAGE 9

SECTION 8: MOVING INOPERABLE MOWER

8.1 Do not tow machine. Use a winch to load on a trailer for transporting.

8.2 ATTENTION: RETURN BYPASS VALVES TO OPERATING POSITION BEFORE RUNNING

MOWER FOLLOWING REPAIRS.

8.3 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.

8.4 Your Bad Boy Mower Weighs: Diesel SERIES: 1607—1935 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 do, use

extreme caution when moving machine!

SECTION 9: INSTRUMENTATION

9 .1 Electronic Hour Meter—Registers Hour increments up to 9,999.9 total hours. This meter

records the cumulative time the engine is running.

PAGE 10

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