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- Owner's, Service & Parts Manual
Bad Boy Diesel 7200 Owner's, Service & Parts Manual
Summary of Diesel 7200
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 ©2015 12-11 diesel 1500 cc model.
Page 2: Table of Contents
Table of contents basic information ................................................................................................ Section 1 (page 4) bad boy safety guidelines ............................................................................. Section 2 (pages 5–8) operation ...............
Page 3
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 c...
Page 4: Section 1:
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, ...
Page 5: Section 2:
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 t...
Page 6: Slope Operation
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. ...
Page 7: Service:
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 runn...
Page 8: Safety Interlock System
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 ...
Page 9: Section 3:
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 t...
Page 10: Section 4:
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 sys...
Page 11
Page 11 performed: performed performed: performed performed performed: performed performed: performed performed performed: performed: performed performed performed performed performed: performed: performed: performed: performed: date: hours: date: hours: date: hours: date: hours: date: hours: date: ...
Page 12: Section 5:
Section 5: mower storage & transportation 5.1 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. 5.3 disconnect the negative battery cable when machine will be stored for more than 30 days....
Page 13: Section 6:
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, c...
Page 14: Section 7:
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. Switch will automatically return to he run position. 7.2 throttle control—a cable is connect...
Page 15: Section 8:
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 pump...
Page 16: Section 10:
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...
Page 17
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: 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 la...
Page 18: 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. • don’t cu...
Page 19: Service Section
Service section section 1: hydrostatic system page 19 the hydraulic reservoir tank on the diesel 1500cc model is located under the seat. There is a dipstick that indicates the current hydraulic oil level. Use only 20w-50 motor oil in this tank. Conventional or synthetic oil may be used. Bad boy hydr...
Page 20
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...
Page 21: Section 2: Drive Belt
Section 2: drive belt section 3: engine shown on the right is the tensioner for your pump belt. Adjusting this will either increase or decrease tension on the belt. Use a ¾” wrench to loosen the jam nuts and either tighten for more belt tension or loosen for less belt tension. The belt tension shoul...
Page 22
Page 22 1) after the engine has been run at the normal operating temperature, stop the engine. 2) remove the oil drain plug located underneath the engine. Allow the oil to drain into a drain pan. After the oil has drained, the oil drain plug should be cleaned and installed. 3) remove the oil filter ...
Page 23
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. 3.2 changing your fuel filter 1) 1your cat 150...
Page 24
Page 2 4 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 ofte...
Page 25: Section 4: Electrical System
Section 4: electrical system page 25 the fuses on the 1500cc 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. Ensure that th...
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Page 26.
Page 27: Section 5: Frame
Section 5: frame page 27 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 65-75 ft. Lbs. Re- to...
Page 28
Page 28 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 block...
Page 29: Section 6: Cutting Deck
Section 6: cutting deck page 29 deck belt removal 1) remove ignition key. 2) raise the deck to its highest position. 3) remove the right pulley cover. 4) while lifting up on the belt (as shown in the photograph), rotate the pulley until the belt is free of the pulley. Exercise caution while performi...
Page 30
Page 30 leveling the deck 1) start on a flat level surface and set the air pressure in all four tires to 12 psi. 2) get two 2x4s and make sure that the wider sides are similar length. 3) take off the foot pedal and raise the floor plate. 4) lower the deck onto the 2x4s and pin the deck into its top ...
Page 31
The deck spring tension is critical. If the tension is too high, premature failure of the deck belt and blade spindles can occur. If the tension is too low, the belt can ‘jump off’ or slip on the pulleys. This results in reduced cut quality and early belt failure. Spring tension adjustments can be m...
Page 32
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 ¾” wrench on top of the pulley bolt to keep the ...
Page 33: Parts Section
Parts section page 33 suspension fork assembly description part number qty item suspension fork top/side combo 023-0020-00 1 1 suspension fork - bottom left 023-0012-00 1 2 suspension fork - bottom right 023-0013-00 1 3 front suspension fork spindle 037-0010-00 1 4 1/2" flange nut 013-5300-00 2 5 1/...
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Page 34 25 30 27 8 18 17 8 9 8 26 20 18 17 7 6 4 28 24 15 15 11 21 13 10 23 22 16 12 14 29 1500cc diesel drive arms 5 3 1 3 32 34 2 19 3 1 3 2 31 33 welded to frame.
Page 35
Page 35 parts list description part number qty item drive lever spring 034-8025-00 4 1 bushing for 2012 drive arms 032-5055-00 4 2 .515 id nylon shoulder washer 019-8027-00 8 3 1/4" press in grease fitting 024-6034-00 2 4 1/2-13 nylon flange nut 013-8050-00 2 5 5/16" nut 013-8043-00 2 6 5/16" x 3/4"...
Page 36
Page 36 24 9 22 35 32 33 34 26 27 25 11 13 12 26 27 25 14 27 6 5 4 2 9 3 7 1 23 25 27 26 11 13 12 15 14 26 27 25 10 20 18 21 19 21 21 17 21 18 18 26 25 8 15 diesel tanks 16 37 36 39 4 30 28 31 29 38.
Page 37
Page 37 diesel tanks assembly description part number qty item left fuel tank with fender 067-3000-00 1 1 hour meter 083-4014-00 1 2 control panel (left) 079-3402-00 1 3 light plug 018-1040-00 2 4 ignition switch 077-8076-00 1 5 ignition key 042-9000-00 1 6 left tank support 031-2010-00 1 7 right ta...
Page 38
Page 38 37 38 39 40 41 42 24 22 20 21 15 16 14 36 35 13 12 11 10 2 8 18 17 19 6 3 4 5 7 1 44 diesel frame 33 26 23 25 9 43 27 29 30 32 31 28 29 34.
Page 39
Page 39 diesel frame, actuator, floor board, and height indicator description part number qty item diesel 4cyl 72" frame 070-5550-00 1 1 actuator bar 028-7920-00 1 2 height indicator lever 031-7000-00 1 3 5/16" flange nut 013-9002-00 1 4 .360 id plastic washer 019-6042-00 1 5 height indicator bar 02...
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Page 40 detail a detail b detail c a b c 42 40 39 41 44 43 61 40 53 52 9 59 60 20 17 31 21 11 4 2 3 21 4 31 32 18 54 55 58 33 57 56 12 16 14 6 28 1 6 13 7 15 19 22 25 29 28 26 29 28 45 48 51 47 46 49 37 36 10 38 24 1500cc diesel seat frame 35 33 34 23 43 40 65 63 50 63 64 63 65 62 66 67 68 27 30 11 ...
Page 41
Page 41 diesel seat frame description part number qty item hand brake assembly 069-8054-00 1 1 filter head 062-8013-00 2 2 hydraulic filter 063-8014-00 2 3 filter head fitting 024-5050-00 4 4 1/4-20 x 9 carriage bolt 018-8051-00 2 5 switch 077-8073-00 3 6 5/16" x 1 3/4" hex bolt 018-8059-00 2 7 1/4"...
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Page 42 detail a detail b detail c a b c 31 29 36 58 30 37 38 32 33 35 34 39 45 45 47 46 53 53 53 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 43 62 4 7 8 6 44 3 diesel pump plate assembly 21 10 9 72" deck only 56 61 65 66 64 48.
Page 43
Page 43 diesel pump plate assembly description part number qty item pump plate diesel 026-8030-00 1 1 3/8" x 1 1/4" carriage bolt 018-5043-00 6 2 1/4" drive in grease fitting 024-3050-00 1 3 4 3/4" idler pulley 033-6001-00 1 4 pump idler bracket only for 61" deck 039-5950-00 1 5 1/2-13 nylon flange ...
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Page 44 4 49 48 58 18 17 16 44 47 46 45 11 1 10 7 10 3 5 6 9 2 9 8 12 6 13 1500cc diesel back pump cover 7 14 6 9 15 13 6 12.
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Page 45 detail a a 52 53 43 56 27 34 40 35 30 32 31 33 36 37 33 25 54 19 24 20 28 26 21 22 23 29 27 23 55 22 21 41 51 34 1500cc diesel suspension 39 50 38 42 57.
Page 46
Page 46 diesel suspension & back pump cover assemblies description part number qty item diesel back pump cover 2008 bottom 014-5920-00 1 1 back cover hinge bracket 039-0070-00 1 2 diesel back pump cover 2008 top 014-5921-00 1 3 diesel hood 4 cyl 059-8010-00 1 4 5/16" x 1" carriage bolt 018-8065-00 2...
Page 47
Page 47 15 2 4 3 9 8 6 7 5 11 12 14 radiator assembly diesel hydraulic cooler 5 4 2 2 5 4 3 8 10 9 11 12 12 11 1 13 1 22 19 20 21 16 17 18 23 6 10
Page 48
Page 48 radiator assembly description part number qty item radiator- diesel 061-5000-00 1 1 radiator screen-diesel 094-5088-00 1 2 diesel clamp 1 3/4" vinyl 072-8090-00 1 3 top radiator hose for diesel 051-3000-00 1 4 bottom radiator hose for diesel 051-3001-00 1 5 1 1/8" hose clamp 072-2003-00 4 6 ...
Page 49
Page 49 diesel air filter assembly description part number qty item canister for all diesel models 088-1018-00 1 1 enginaire air canister cap 088-1017-00 1 2 mounting bracket for diesel air filter 088-1019-00 1 3 diesel air filter- outer 063-2050-00 1 4 diesel air filter- inner 063-2060-00 1 5 debri...
Page 50
Page 50 25 26 44 11 4 12 2 5 9 8 6 21 9 8 7 41 40 39 38 24 26 22 17 16 15 20 23 52 3 42 34 30 35 36 31 32 18 19 46 10 29 20 14 13 23 43 28 1500cc cat diesel engine 45 1 47 48 48 50 47 49 49 33 37 51 54 53 4 11 6 8 27.
Page 51
Page 51 35hp diesel engine description part number qty item 1500cc cat diesel engine 015-5600-00 1 1 diesel throttle bracket (4 tier) 039-1010-00 1 2 stub shaft 017-3000-00 1 3 1/4" lock washer 019-4008-00 6 4 air cleaner support diesel 201-8005-00 1 5 m8 x 1.25 x 25mm hex head bolt 018-2001-00 6 6 ...
Page 52
Page 52 detail a detail b detail c detail d a b c d 36 57 58 32 55 37 9 29 9 35 9 11 9 2 33 9 59 8 7 22 23 9 2 50 9 31 30 28 23 6 44 4 53 1 21 17 40 3 15 16 14 38 39 25 24 41 10 43 27 51 51 42 20 13 18 19 diesel 61" deck 12 34 46 47 45 26 7 49 48 9 5 52 56 54.
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Page 53 diesel 61" deck description part number qty item 61" aos deck 060-6130-00 1 1 5 3/4" deck idler pulley 033-5000-00 2 2 6 1/4" drive pulley 033-6004-00 3 3 2015 deck idler spring outlaws 034-2020-00 1 4 60" discharge lower bracket 039-4863-00 1 5 deck idler 039-6945-00 1 6 1/2 x 3 1/2 flange ...
Page 54
Page 54 detail a detail b detail c detail d a b c d 41 50 40 42 24 1 23 24 22 21 25 24 20 24 28 30 29 24 47 26 27 5 10 6 9 8 2 7 3 4 14 15 12 18 16 17 33 32 34 24 28 35 24 37 36 31 44 45 46 39 43 38 11 24 18 19 32 diesel 72" deck 18 19 48 49 13 53 52 51 56 57 55 54.
Page 55
Page 55 diesel 72" deck description part number qty item 72" ( deck only) 060-7201-00 1 1 double bearing spindle 037-4000-50 3 2 5/8" lock washer 019-4807-00 3 3 5/8" x 1 1/2" grade 8 hex bolt (fine) 018-6020-00 3 4 1/2"-20 x 1 1/2 - grade 5 fine thread bolt 018-6019-00 3 5 1/2 belleville washer 019...
Page 56
Page 56 parts list description part number qty item 4000 series spindle housing 037-4001-00 1 1 4000 series spindle spacer 037-4002-00 1 2 locking collar w/ 1/4"-20 set screw 037-9050-00 1 3 spindle dust cap 037-8002-00 2 4 zt-aos spindle shaft 037-6026-00 1 5 bearing - 6206 037-6023-00 4 6 5 4 6 6 ...
Page 57
Page 57 091-5406-00 1500cc decal 091-2062-00 diesel instrument panel decal right 091-5402-00 cat powered decal 091-0902-00 logo decal - floorboard 091-0919-00 armortek decal 091-0918-00 72” decal 091-3060-00 swing-away patent decal 091-2050-00 low sulfur decal 091-1101-00 brake decal 091-1104-00 thr...
Page 58: 2016 Limited Warranty
2016 limited warranty for bad boy commercial mower (stand on, diesel, outlaw, outlaw extreme, and outlawxp) 1. What this warranty covers, and for how long: bad boy, inc. Will, at its option, repair or replace, without charge, any part covered by the warranty which is found to be defective in materia...
Page 59: Warranty Registration
Bad boy, inc. 102 industrial drive batesville, ar 72501 www.Badboymowers.Com technical support: ............................................................Techsupport@badboymowers.Com warranty: .....................................................................................Warranty@badboymower...
Page 60: Www.Badboymowers.Com
For additional information, please see us at www.Badboymowers.Com bad boy, inc. 102 industrial drive batesville, arkansas 72501.