Bad Boy Mowers DIESEL 1500cc Owner'S, Service & Parts Manual Download | Manualshive

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PARTS SECTION: 1500CC DIESEL FRAME

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Summary of Contents for Mowers DIESEL 1500cc

Page 1: ...ZERO TURN MOWER OWNER S SERVICE PARTS MANUAL For additional information please see us at www badboymowers com Bad Boy Inc 102 Industrial Drive Batesville Arkansas 72501 2017 12 6 DIESEL 1500cc MODEL...

Page 2: ...tation Section 5 Page 10 Troubleshooting and FAQ Section 6 Page 12 Controls Section 7 Page 13 Moving In operable Mower Section 8 Page 14 Instrumentation Section 9 Page 14 Mower Blade Maintenance Secti...

Page 3: ...Blade Hi Lift Fusion 038 7230 00 Gator Blade 038 5400 00 Wave Blade 038 7215 00 Deck Belt 61 041 0236 00 72 041 2525 00 Pump Belt 61 041 5048 00 72 041 8411 00 Oil Filter Caterpillar 063 2010 00 Perki...

Page 4: ...r to engine s service manual WARRANTY REGISTRATION 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...

Page 5: ...olutely necessary Always look down and behind before and while backing 2 9 Never direct discharged material toward anyone Avoid discharging material against a wall or obstruction as material may ricoc...

Page 6: ...ine by putting your foot on the ground 2 31 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 2 32 Be aware of wh...

Page 7: ...a water heater or furnace 2 51 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 t...

Page 8: ...be tested frequently Following are instructions to test these very important safety precautions Note the operator must be seated properly on the machine during these tests and the engine should have b...

Page 9: ...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 3 9 Increase RPM by sliding the th...

Page 10: ...ystem supplemental coolant additive test addDealer Clean Radiator Section 3 Maintenance by hour or annually whichever comes first Maintenance by hour or every six months whichever comes first Check ai...

Page 11: ...e 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 Per...

Page 12: ...also check for any bare wires and or bad connections 6 3 Q What should I 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...

Page 13: ...er 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...

Page 14: ...cessories 8 4 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 5 Hopefully you ll never need to use...

Page 15: ...check for blade damage if mower strikes rock branch or other objects that could potentially damage the blade REMEMBER NEVER CHECK BLADE WHILE ENGINE IS ON NEVER CHECK BLADES WHILE BLADES ARE ENGAGED S...

Page 16: ...re 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...

Page 17: ...s 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 D...

Page 18: ...SURFACE CHANGING YOUR HYDRAULIC OIL AND FILTER 1 Place an oil drain pan under the engine plate and place the hydraulic return lines that go into the top of the hydraulic reservoir tank into the oil pa...

Page 19: ...they do no move 2 With the bypass valve open and the engine running slowly move the directional drive arms in the forward and reverse directions 5 to 6 times as air is purged from the unit the oil le...

Page 20: ...the jam nuts and either tighten for more belt tension or loosen for less belt tension The belt tension should be set to 50 60 lbs Use a belt tension gauge to ensure the proper tension Your dealer or s...

Page 21: ...rain plug should be cleaned and installed 3 Remove the oil filter 4 Check the oil filter for any metal debris that may indicate engine wear 5 Clean the sealing surface of the cylinder block 6 Apply cl...

Page 22: ...n a suitable container Dispose of the drained fluid correctly 3 Close drain 4 The second fuel filter is a canister located above the fuel water separator 5 Close the fuel supply valve 6 Clean the outs...

Page 23: ...he back of the mower Unlatch the four latches that hold the cap onto the filter housing 2 Remove the outer air element and inspect it If it is dirty it might be necessary to use low air pressure to cl...

Page 24: ...5 are located behind the right swing away tank 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...

Page 25: ...PAGE 25 ELECTRICAL SYSTEM CONTINUED WIRING DIAGRAM...

Page 26: ...of the two turnbuckles 4 Total Grease at every oil change The pump belt tensioner is located at the rear of the engine and has a grease fitting at its pivot point Grease at every engine oil change The...

Page 27: ...s free of the pulley Exercise caution while performing this step as fingers can easily become caught between the belt and pulley DECK BELT INSTALLATION 1 Use proper safety precaution when preforming p...

Page 28: ...pair of 9 16 wrenches loosen the deck hanger chain turn buckles located at the rear of the deck adjust the chain turn buckles up or down to adjust left to right measurements only Adjust in small incr...

Page 29: ...ck at its lowest setting Use a belt tension gauge to ensure the proper tension Your dealer or service center will have a belt tension gauge or you can buy one from the Bad Boy Parts Department by call...

Page 30: ...ill or a wrench and an extension to gain more leverage You might need to put a 3 4 wrench on top of the pulley bolt to keep the blade from spinning Bolts used have right handed threads Re torque the b...

Page 31: ...PAGE 31...

Page 32: ...List ITEM QTY PART NUMBER DESCRIPTION 15 1 012 7003 00 Seal 16 1 013 8050 00 1 2 13 Nylon Flange Nut 17 2 025 5203 00 Spacer 3 4 OD x 1 2 ID x 3 4 Length 18 1 025 5202 00 Front Wheel Spanner 19 1 018...

Page 33: ...9002 00 5 16 Flange Nut 17 4 018 2050 00 10mm Damper Ball Stud Steering 18 2 013 0085 00 1 2 13 Hex Flange GR G ZC 19 2 087 8080 00 Steering Damper 20 1 031 9017 70 Upper adjuster Steering Arm Left 21...

Page 34: ...EL TANKS PAGE 34 23 9 21 34 31 32 33 25 26 24 11 13 12 25 26 24 14 26 6 5 4 2 9 3 7 1 22 24 26 25 11 13 12 15 14 25 26 24 10 1 8 f t 39 5 3 ft 19 1 5 ft 20 1 16 ft 20 17 1 5 ft 20 18 18 25 24 8 15 16...

Page 35: ...00 3 16 Fuel Line 20 4 16 ft 051 8067 00 1 4 Fuel Line Hose 21 1 086 0035 00 Wiring Harness 35 28 Diesel 22 2 066 8090 00 Diesel Fuel Cap 3 5 Neck 23 1 067 3001 00 Right Fuel Tank with Fender 24 10 01...

Page 36: ...PARTS SECTION 1500CC DIESEL FRAME PAGE 36 39 40 41 42 43 44 24 22 20 21 15 16 14 36 35 13 12 11 10 2 8 18 17 19 6 3 4 5 7 1 46 33 26 23 25 9 45 27 32 31 28 34 30 29 37 38 29...

Page 37: ...7039 00 4 21 14 Rubber Bumper 029 7037 00 2 22 Diesel Weight Bar Bracket 028 1000 00 1 23 3 8 x 4 1 2 Bolt 018 2005 00 4 24 3 8 Nylock Nut 013 5041 00 4 25 58lb Diesel Weight 088 2000 00 1 26 2014 Ne...

Page 38: ...FRAME PAGE 38 39 38 57 36 49 48 8 55 56 19 16 27 20 10 4 2 3 20 4 27 28 17 50 51 54 29 53 52 11 15 13 5 25 1 5 6 12 14 18 21 23 26 25 24 26 25 41 44 42 45 33 32 34 22 31 29 30 66 38 36 61 59 46 43 58...

Page 39: ...ITEM QTY PART NUMBER DESCRIPTION 38 4 013 9002 00 5 16 Flange Nut 39 1 026 2006 00 Seat Plate 40 1 071 4055 17 Grammer Seat With Seatbelt 41 2 013 8049 00 5 16 18 Nylon Flange Nut 42 1 034 1075 00 To...

Page 40: ...ATE ASSEMBLY PAGE 40 31 29 36 58 30 37 38 32 33 35 34 39 45 45 47 46 53 53 1 3 ft 53 3 ft 53 50 52 51 49 57 14 13 1 15 16 17 27 28 42 54 26 59 63 40 19 20 41 11 17 25 22 24 23 12 2 55 2 55 18 5 60 21...

Page 41: ...r 34 4 018 6012 00 3 8 x 1 1 2 Hex Bolt Parts List ITEM QTY PART NUMBER DESCRIPTION 35 4 019 5029 00 3 8 Flat Washer 36 4 024 2080 00 90 Degree Adaptor 6801 L 8 8 Fitting 37 2 024 5002 00 90 Degree Fi...

Page 42: ...1500CC DIESEL BACK PUMP COVER PAGE 42 50 51 40 49 41 14 18 58 15 9 6 7 43 44 47 13 6 12 8 2 9 6 5 3 10 7 10 1 11 45 46 16 17 56 48 4 57 27 28 23 53 22 21 26 39 34 33 36 32 35 37 29 30 31 38 42 54 19 2...

Page 43: ...022 00 1 8x2 1 4 cotter pin Zinc 30 2 042 7041 00 Woodruff Key 31 2 013 7050 00 1 Castle Nut for Wheel Motor 32 8 013 5300 00 1 2 Flange Nut 33 8 018 6036 00 1 2 x 2 1 2 Hex Bolt 34 2 013 8047 00 5 16...

Page 44: ...el 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 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...

Page 45: ...ner 6 1 088 1020 00 Debris Plug Enginaire Filter 7 2 013 8043 00 5 16 Nut Diesel Air Filter Assembly ITEM QTY PART NUMBER DESCRIPTION 8 2 019 8051 00 5 16 Lock Washer 9 2 018 5344 00 5 16 x 2 1 2 Bolt...

Page 46: ...PAGE 46 32 27 40 39 40 42 44 45 26 15 12 29 12 13 28 30 15 13 36 13 37 17 35 5 3 33 32 27 25 38 40 40 35 5 3 31 15 34 18 37 12 29 43 22 24 1 21 23 14 13 12 7 2 19 7 7 4 4 5 6 8 9 10 18 20 11 14 13 12...

Page 47: ...1 018 4703 00 5 16 x 1 1 4 Carriage Bolt 24 1 013 8049 00 5 16 Nylon Flange Nut 25 1 039 1010 00 Diesel Throttle Bracket 4 Tier 26 1 017 3000 00 Stub Shaft 27 6 019 4008 00 1 4 Lock Washer 28 1 201 8...

Page 48: ...TS SECTION 1500CC DIESEL 61 DECK PAGE 48 36 55 56 53 60 9 30 9 21 9 11 9 2 34 9 57 8 7 23 24 9 2 48 9 32 31 29 24 6 58 4 51 1 22 17 39 3 15 16 14 37 38 26 25 40 10 42 28 49 49 41 20 13 18 19 12 35 44...

Page 49: ...nsert Jam Half Nut 30 8 018 3003 00 1 2 x 1 1 4 Carriage Bolt Parts List ITEM QTY PART NUMBER DESCRIPTION 31 1 018 1050 00 1 2 x 2 Carriage Bolt 32 1 019 0007 00 517 Square Hole Round Washer 33 2 018...

Page 50: ...N 1500CC DIESEL 72 DECK PAGE 50 23 35 22 24 6 1 5 6 4 3 7 6 2 6 10 12 11 6 30 8 9 45 49 46 51 48 53 47 52 44 56 57 54 61 58 60 15 14 16 6 10 17 6 19 18 13 66 27 28 21 25 20 50 6 61 59 14 61 59 33 34 5...

Page 51: ...00 1 2 13x2 Grade 8 Hex Bolt 32 6 018 0010 00 Deck Wheel Bolt 33 4 019 6050 00 360 ID Plastic Washer Black Parts List ITEM QTY PART NUMBER DESCRIPTION 34 12 058 6000 00 Black Round Stick On Rubber Bu...

Page 52: ...Y PART NUMBER DESCRIPTION 1 1 037 4000 01 4000 Series Spindle Housing 2 1 037 4002 00 4000 Series Spindle Spacer 3 1 037 9050 00 Locking Collar w 1 4 20 Set Screw 4 2 037 8002 00 Spindle Dust Cap 5 1...

Page 53: ...IMPACT PATENT DECAL 091 8000 00 EZ RIDE PATENT DECAL 091 3309 00 DECK BELT ROUTE DECAL 091 3015 00 CAUTION DECAL 091 3300 00 DANGER CAUTION DECAL 091 3012 00 DANGER DECAL 091 2063 18 PREHEAT DECAL 09...

Page 54: ...PAGE 54...

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