Bad Boy Mowers 48031001 User Manual

PTO

GRASS COLLECTION

SYSTEM

DESIGNED FOR:

MODEL 48031001

BAD BOY PUP SERIES MOWERS

OPERATOR’S MANUAL

ASSEMBLY OPERATION MAINTENANCE

MANUAL PART#: Q0336 $4.00 REV: 0

PTO GRASS COLLECTION SYSTEM

TABLE OF CONTENTS

SECTION PAGE

Safety - ------------------------------2
Safety Alert Symbols----------------------3
Warranty -----------------------------4

I INTRODUCTION AND DESCRIPTION- - ------------5

1-1 Introduction - ------------------------5
1-2 Description - ------------------------5

II INSTALLATION FOR USE ----------------------5

2-1 Preparation Of Mower ------------------5
2-2 PTO Assembly Installation - - - ------------6
2-3 Belt Installation -----------------------6
2-4 Cam Assembly Adjustment - - - ------------7
2-5 Lower Frame Installation ----------------7
2-6 Mount Tube Stiffener Installation -----------7
2-7 Upper Frame Assembly Installation----------11
2-8 Top Assembly To Upper Frame Assembly
Installation ----------------------------11
2-9 Boot To Mower Deck Installation------------11
2-10 Blower Cone Installation ----------------12
2-11 Impeller Blade Removal/Replacement - ------12

Safety

SECTION PAGE

2-12 Lengths Of Hose Adjustment - ------------13
2-13 Upper Hose Installation ----------------13
2-14 Lower Hose To Blower Cone Installation------13
2-15 -----------13

Lower Hose To Boot Installation
2-16 Front Weight Installation ----------------13
2-17 ------14

Installation/Removal Of Collection Bags

III OPERATING INSTRUCTIONS - ------------------15

3-1 General Safety -----------------------15
3-2 Operation & Tips On Mowing- - ------------15
3-3 Disengagement Of The Blower ------------15
3-4 Unloading The Collection System -----------15

IV MAINTENANCE ----------------------------15

4-1 Maintenance Checklist ------------------15
4-2 Lubrication- - ------------------------16

V PARTS AND SERVICE ------------------------16

5-1 Parts And Service Information - ------------16
Safety Decals - - ------------------------17
Torque Specifications - - - ------------------18
Notes- - ------------------------------19

1.

Read the operator’s manual carefully and familiarize yourself with the proper use of your attachment. Do not allow
anyone who is not acquainted with the Safety Instructions to use your attachment.

2.

Know the controls and how to stop quickly. READ THE OPERATOR’S MANUAL!

3.

Do not allow children to operate the vehicle. Do not allow adults to operate it without proper instruction.

4.

Be especially watchful of children and pets darting into the area while operating.

5.

Keep your eyes and mind on your unit while mowing or operating your attachment. Don’t let others distract you.

6.

Do not attempt to operate your unit or mower when not in the driver’s seat.

7.

Always stop unit when emptying the container.

8.

Stop unit, shut off deck and attachment, set parking brake, shut off mower engine and remove spark plug wire

before removing clogs or removing or replacing hose, boot, blower cone, or performing any maintenance.

9.

Mow up and down the face of slopes (not steeper than 10 degrees); never across the face of the slope.

10.

It is recommended that the container be kept only half full when negotiating any slopes. Start mowing on slopes

when the container is empty.

11.

Inspect your lawn and remove any foreign objects before mowing. Never deliberately run the mower across any

foreign object.

12.

Wear ear protection if the noise level is offensive.

13.

Wear eye protection to prevent debris from damaging your eyes.

14.

Be alert for all other traffic when driving on public roads or highways.

15.

Moisture content in most grasses can damage mower and grass collector components. Also, dry grass and leaves
left in the bags can be a fire hazard. Always make sure the bags are completely empty and the blower and hoses are
fully cleaned before storage.

2

SAFETY

WARNING!

vacuum collector adapter are fastened securely in place.

WARNING!

blades and the blower impeller have stopped rotating.

WARNING!

STOPPING THE MOWER’S ENGINE AND WAITING FOR ALL MOVING PARTS TO COME TO A
COMPLETE STOP.

WARNING!

across the face. attempt to mow excessively steep slopes, and use caution when turning on any slope.

NEVER

Do not work around the mower deck boot or the blower area until you are certain that the mower

To avoid serious injury, perform maintenance on the vacuum collector;

Set the parking brake. Always remove the ignition key before beginning maintenance.

For your own personal safety, mow and the face of slopes and

NEVER

operate the unit unless the discharge guard and either the deflector assembly or the

ONLY AFTER

ALWAYS UP DOWN NEVER

Safety Alert Symbol

“ATTENTION! BECOME

!

This Safety Alert Symbol means:

ALERT! YOUR SAFETY IS INVOLVED!”

This symbol is used to call attention to safety precautions that
should be followed by the operator to avoid accidents. When
you see this symbol, carefully read the message that follows
and heed its advice. Failure to comply with safety precautions
could result in death or serious bodily injury.

Safety Signs

The signal words and are used on the equipment safety signs. These words are
intended to alert the viewer to the existence and the degree of hazard seriousness.

!

!

Black letters on ORANGE

!

Black letters on YELLOW

DANGER, WARNING, CAUTION

This signal word indicates a potentially hazardous situation which, if not

DANGER

White letters on RED

WARNING

CAUTION

avoided, will result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

It may also be used to alert against unsafe practices.

This signal word indicates a potentially hazardous situation exist which, if
not avoided, will result in minor or moderate injury.

It may also be used to alert against unsafe practices.

3

PECO LIMITED WARRANTY FOR NEW PRODUCTS

A. WHAT IS WARRANTED?

PECO extends the following warranties to the original purchaser of each new PECO consumer product subject
to the following limitations:

1. PRODUCT WARRANTY:

delivered to the purchaser will be repaired or replaced, as PECO elects, without charge for parts or labor, if the
defect appears within 12 months from the date of delivery of the product to the original purchaser.

DEFECTIVE PARTS MUST BE RETURNED TO PECO FOR INSPECTION TO DETERMINE
VALIDITY OF WARRANTY CLAIMS.

2. PARTS REPLACED DURING WARRANTY:

warranty and is defective in material or workmanship as delivered to the purchaser will be repaired or replaced,
as PECO elects, without charge if the defect appears within 90 days from the date of installation of such part or
before the expiration of the original warranty period, whichever is later.

B. SECURING WARRANTY ADJUSTMENTS.

Call PECO for Return Authorization. Damaged or broken parts, other than engines or batteries, must be
returned to PECO Inc., 100 Airport Road, Arden, NC 28704 before any warranty adjustment can be authorized.
At the time of requesting warranty adjustment, the purchaser must present evidence for date of delivery of the
product. The purchaser shall pay any charge for the product to and from Arden, NC.

C. ITEMS NOT COVERED BY PECO WARRANTY.

Engines and batteries attached to PECO products are covered under a separate warranty by the respective
manufacturer.

D. UNAPPROVED ALTERATION OR MODIFICATION.

All obligations of PECO Inc., under this warranty, shall be terminated if products are altered or modified in ways
not approved by PECO Inc..

E. ACCIDENTS AND NORMAL MAINTENANCE.

The warranty covers only defective material and workmanship. It does not cover depreciation or damage
caused by normal wear, accident, improper use or abuse of products. The cost of normal maintenance and
normal replacement of service items such as belts, cutting blades, hoses, etc., which are not defective shall be
paid for by the purchaser.

F. NO REPRESENTATIONS ADDITIONAL WARRANTIES, DISCLAIMER.

Neither PECO Inc. nor any company affiliated with it makes any warranties, representations or promises as to
the quality of performance of its products other than those set forth herein. Except as described above, PECO

Inc. makes no other warranties

WARRANTIES OF FITNESS AND MERCHANTABILITY.

G. ANY MACHINE USED FOR RENTAL PURPOSES ARE GUARANTEED FOR 45 DAYS FROM DATE

OF ORIGINAL SALE ONLY.

H. REMEDIED EXCLUSIVE.

The only remedies the purchaser has in connection with the breach or performance of any warranty on PECO
Inc. consumer products are set forth above. In no event will PECO be liable for special incidental or
consequential damages.

1. NO SERVICE CENTER WARRANTY.

The selling Service Center makes no warranty on his own on any item warranted by PECO Inc. unless he
delivers to purchaser a separate written warranty certificate specifically warranting the item. The dealer has no
authority to make any representation or promise on behalf of PECO or to modify the terms of this warranty in
any way.

Any part of any consumer product, which is defective in material or workmanship as

ALL

Freight and mailing will be borne by the customer.

Any new PECO part which is furnished in performance of this

AND SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED

4

SECTION I

INTRODUCTION AND DESCRIPTION

1-1 Introduction

We are pleased to have you as a Bad Boy customer.
Your collection system has been designed to give you a
low maintenance, simple, and effective way to collect the
grass clippings from your mower. This manual is
provided to give you the necessary instructions to
properly mount and operate the collection system on
your mower. Please read this manual thoroughly.
Understand what each control is for and how to use it.
Observe all safety decal precautions on the machine and
noted throughout the manual.

NOTE:

or bottom are as viewed from the normal operator’s
position on the mower.

All references made to right, left, front, rear, top

1-2 Description

The collection system is designed for turf maintenance
where there is a need to collect the grass clippings as
the mower cuts the turf. It is also good for picking up
leaves and twigs in pre-season and post-season clean­up.

The blower, mounted on the right side of the unit, uses a
belt and gearbox system from the engine PTO shaft.
Drive train protection comes through belt slippage. The
blower draws grass clippings from the discharge area of
the cutter deck back to the 3 - 3.3 cubic foot collection
bags P#(G0002) at the rear portion of the mower frame.
The operator can engage the blower with a push of the
over-center linkage on the right side of the unit. Once the
bags are full with clippings, they can be released to
make for easy dumping.

Section II

INSTALLATION FOR USE

23HP, 32HP Vanguard & 26HP Briggs ELS

(2) flat washers P#(K0131) between clutch and pump
pulley, use (1) 7/16”-20 x 4” HHCS P#(K0359) and (1)
7/16” lock washer P#(K0053) to fasten engine pulley
assembly.

26HP Kawasaki

between clutch and pump pulley (has 2 existing washers
between clutch and pump pulley), use (1) M10-1.5 x
90MM HHCS P#(K0117) and (1) 7/16” lock washer
P#(K0053) to fasten engine pulley assembly.

27HP & 30HP Kohler

existing washer between clutch and pump pulley), use
(1) 7/16”-20 x 4” HHCS P#(K0359) and (1) 7/16” lock
washer P#(K0053) to fasten engine pulley assembly.

The added pulley will power the collection system. Note
that the center of the hub that is extended should be
upward toward the engine (Figure 1). Torque the bolt to
55 ft./lbs.

Figure 1.

Pump Pulley

Spacer (Existing)

See Above For

Quantity Of

Spacers To Add To

Existing Spacers

- Add (1) flat washer P#(K0131)

- Do not add washer (has 1

- Add

Pump
Pulley
(Existing)

2-1 Preparation Of Mower

Carefully dismantle shipping box from around the
components. Cut retaining straps and separate the
parts. The collection system will have various parts
located inside. Remove and sort all parts for easy
identification.

NOTE:

study the exploded drawings on pages 8,9 and 10.

From the underside of the mower engine remove the bolt
and bushing from the electric clutch assembly. Replace
these parts with the engine pulley assembly P#(A0611),
lock washer, and bolt. See the listing below for
information on what hardware will need to be used and
added for the various types of mower engine options:

Before each step of assembly it will help to

Electric

Clutch

(Existing)

Engine

Pulley

Assembly

7/16” Lock
Washer

See Above For

Bolt Type

5

2-2 PTO Assembly Installation

2-3 Belt Installation

Remove the (2) existing bolts and nuts from the right
side that fastens the mower’s rear frame to the
mower’s chassis. Align the (2) lower holes on the PTO
assembly P#(A0610) (Figure 2) to the (2) lower holes
on the mower’s rear frame. Fasten by using (2) 5/16”­18 x 1-1/4” Grade 8 HHCS P#(K0118) and (2) 5/16”­18 flange nuts P#(K1178). Once the PTO assembly is
fastened, drill a hole into the mower’s rear frame by
using the PTO assembly as a pilot and using a 5/16”
drill bit. Fasten by using (1) 5/16”-18 x 1-1/4” Grade 8
HHCs P#(K0118) and (1) 5/16”-18 flange nut
P#(K1178). See Figure 3 for finished installation.
Tighten all nuts and bolts.

Figure 2.

Drill Hole Here & Fasten w/
(1) 5/16” x 1-1/4” G8 HHCS
(1) 5/16” Flange Nut

Mower Rear Frame

PTO Assembly

Remove the pulley guard P#(B0075) by removing the (2)
1/4”-20 x ½” HHSTS P#(K0353), see page 9, diagram #
38 and #39 for part location. Loosen the (2) bolts that
secure the gear box assembly P#(A0429) to the PTO
mount plate (Figure 4). Loosen the adjustment bolt
P#(K0348) until the gear box assembly is at the far left
adjustment (the gear box is moved towards the mower’s
engine pulley). Connect the kevlar cord belt from the
engine pulley to the lower gear box pulley (Figure 5).

To tension the drive belt, turn the adjustment bolt
clockwise until there is 1” of deflection, with 10-11 lbs. of
pressure between the engine pulley and the gear box
pulley. Once the correct tension of the belt is achieved,
tighten the (2) bolts that secure the gear box assembly.

Figure 4.

Loosen Gear Box Bolts

Adjustment Bolt

Figure 3.

Fasten Lower PTO Assembly w/
(2) 5/16” x 1-1/4” G8 HHCS
(2) 5/16” Flange Nuts

Figure 5.

PTO Mount Plate

Gear Box Assy.

Engine Pulley

Belt

6