Bad Boy Diesel 7200 Mode d’emploi

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

DIESEL 1500cc MODEL

TABLE OF CONTENTS

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 12)

Troubleshooting and FAQ....................................................................................Section6(page 13)

Controls ............................................................................................................. Section 7 (page 14)

Moving In-operable Mower............................................................................. Section 8 (page 15)

Instrumentation ................................................................................................. Section 9 (page 15)

Mower Blade Maintenance.................................................................................Section10(page 16)

Greasing Bearings............................................................................................Section 11 (page 16)

How to choose the right blade ..............................................................................................Page 17

Mowing Tips .........................................................................................................................Page 18

PAGE 2

Service Section ..................................................................................................................Page 19

Parts Section ......................................................................................................................Page 33

Limited Warranty ................................................................................................................Page 58

This manual applies to the following equipment:

Bad Boy Diesel Series

Diesel 7200 72˝ 1500cc 4-Cylinder Diesel

Diesel 6100 61˝ 1500cc 4-Cylinder Diesel

PAGE 3

72" Hi-Lift Fusion Wave Blade

Blade 038-7230-00 038-7215-00

61" Hi-Lift Fusion Wave Blade

Blade 038-6080-00 038-6091-00

Deck

Belt

Pump

Belt

CATERPILLAR

Oil Filter

Air

Filter

Fuel Filter

Motor Oil

Hydraulic Filters

Hydraulic Oil 20W-50 Motor Oil (2 quarts per side) Bad Boy Hydrostatic Oil Recommended

COMMONLY USED ITEMS AND PART NUMBERS

041-2525-00

72"

041-0236-00

61"

063-2050-00 063-2060-00

063-2010-00

Outer Inner

063-2011-00

15W-40 (Reference Owner's Manual)

063-8014-00

Gator Blade

038-5400-00

Gator Blade

038-6081-00

72"

041-8411-00

61"

041-5048-00

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.

Refer to the engine’s service manual.

1.2 All Bad Boy hydraulic systems use 20W-50 engine oil (Conventional or Synthetic). Bad Boy

Hydrostatic oil is recommended.

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

1.4 Outlaw models have 12 psi in both front and rear tires.

1.5 Most Briggs, Kohler, Kawasaki, and Vanguard engines hold approximately two (2) quarts of motor oil.

Be careful not to over fill engine oil. Refer to the 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 form is completed and forwarded to Bad Boy, Inc.,

at time of delivery. Warranty is non transferable. Warranty registration should be completed by the

selling dealership using the on-line registration site.

Model/Serial Number

Your Outlaw model serial numbers are found on the SIN plate underneath seat. 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. 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

2.1 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. If the machine is equipped with Roll Over Protection (ROPs), always buckle

your seat belt.

2.4 Only allow responsible adults who are familiar with the instructions to operate this machine.

2.5 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.

2.9 Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction as material may

ricochet back toward the operator. Stop the blades when crossing gravel surfaces.

2.10 Never operate the machine without the discharge chute, grass catcher, or other safety devices correctly in place and functioning

properly.

2.11 Slow down before turning.

2.12 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.

2.13 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.

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

2.15 Do not operate the machine while under the influence of alcohol or drugs.

2.16 Watch for traffic when operating near or crossing roadways.

2.17 Always wear eye protection when operating or servicing the machine.

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

2.19 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.

2.21 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.

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.

2.22 Mow up and down slopes, not across.

2.23 Watch for holes, ruts, bumps, rocks, or other hidden objects that tall grass can obscure. Uneven terrain could overturn the machine.

2.24 Choose a low ground spend when operating the machine on a slope.

2.25 Do not mow on wet grass, the tires may lose traction.

2.26 Do not attempt to coast down a slope in the neutral position.

2.27 Avoid starting, stopping, or turning on a slope. If the tires lose traction, disengage the blades and proceed slowly, straight

down the slope.

2.28 Keep all movement on slopes slow and gradual. Sudden changes in speed or direction could cause the machine to roll over.

2.29 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.

2.30 Do not try to stabilize the machine 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 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 children 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

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.

2.42 Never allow children or others in or on towed equipment.

2.43 On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

2.44 Travel slowly and allow extra distance to stop.

PAGE 6

SERVICE:

SAFE HANDLING OF DIESEL

To avoid personal injury or property damage, use extreme care in handling diesel.

2.45 Extinguish all cigarettes, cigars, pipes, and all other sources of ignition.

2.46 Use only an approved diesel container.

2.47 Never remove fuel cap or add fuel with the engine running.

2.48 Allow engine to cool before refueling.

2.49 Never fuel the machine indoors.

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

2.51 Remove diesel 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 fuel dispenser nozzle.

2.52 Never fill diesel 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.

2.53 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.

2.54 If fuel is spilled on clothing, change clothing immediately.

2.55 Never overfill fuel tank. Replace fuel cap and tighten securely. Fuel tank is full when level reaches bottom of fill tube.

GENERAL SERVICE

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

2.57 Keep all nuts and bolts tight to be sure the equipment is in safe working condition. Never operate a poorly maintained machine.

2.58 Do not touch hot areas of the machine.

2.59 Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their

proper operation regularly.

2.60 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 do 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.

2.61 Allow machine to cool before storing.

2.62 If you strike something with the mower, turn the mower and blades off, engage the parking brake, and inspect the machine for

damage. Repair, if necessary, before resuming.

2.63 Never make any adjustments or repairs with the engine running.

2.64 Check grass catcher components and the discharge guard frequently and replace with manufacturer’s recommended parts,

when necessary.

2.65 Mower blades are sharp. Wrap the blade or wear gloves before servicing them.

2.66 Check parking brake operation frequently. Adjust and service as required.

2.67 Maintain or replace safety and instruction labels, as necessary.

2.68 Do not attempt to mount a tire without the proper equipment and experience to perform the job.

PAGE 7

2.69 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 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.

2.71 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 On a 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.

2.74 Next, start the engine as stated in the “Mower Operation Section”, disengage parking brake, and Very Slowly begin to rise from

the seat; the engine should stop.

If any of these tests 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 machine with the ROPS secured in the upright position.

2.77 If the 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

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.

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.

PAGE 9

PAGE 10

Every 50 First Every 100 Every Every

Daily hours or 75 hours or 250 500 Section

Maintenance annually* hours annually* hours hours

Check and add engine oil ●Section 3

Section2

●(Pump) 6

(Deck)

Check condition of blades ●Section 6

Check for fuel and oil leakage ●Section 3

Check cooling system coolant ●Section 3

Engine air cleaner inspection ●Section 3

●Section 3

Tighten nuts and screws ●Section 5

Grease mower ●Section 5

Engine oil sample**Dealer ●

Change hydraulic oil and filter ●Section 1

Engine oil and filter change ●Section 3

Replace fuel filter ◊ ●Section 3

●

Radiator - clean ●Section 3

Interval

Check all belts for proper

alignment

Check tire pressure and wheel

lug nut

Check battery terminal

connections

●

Section 5

Section 4

Initial change of hydraulic oil

and filter ●Section 1

Replace air element and pre-

cleaner ◊

Fuel system primary filter/water

sepatator inspection

Fuel tank water and sediment

drain ●

◊ Check air and fuel filter more often in dusty conditions

Dealer Get maintenance performed at a registered dealership

Section 3

Cooling system coolant sample

Dealer

●

*Maintenance by hour or annually, whichever comes first

**Maintenance by hour or every six months, whichever comes first

Cooling system supplemental

coolant additive - test/add Dealer

●

SECTION4:MOWERMAINTENANCE

Autres manuels pour Diesel 7200

Ce manuel convient aux modèles suivants

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