BBM DIESEL 1100cc MODEL ZERO-TURN MOWER. Manual - part 6

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SECTION 3: ENGINE

On the right is an overview of the CAT 1100cc Diesel 
Engine. To access the engine remove the knob on top of 
the engine cover plate. The oil drain plug is located on the 
bottom of the engine. Bad Boy recommends that the oil 
and filter be changed after the initial first 8 hrs of use, and 
at intervals of 250 usage hours or yearly, whichever 
occurs first after that. The oil capacity is approximately 
4.64 quarts. Cat Diesel Engine Oil 15W-40 is 
recommended for maximum protection. 

3.1 Changing your engine oil and oil filter: 

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 with a chain wrench.

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 clean engine oil to the new oil filter seals.

7)

Install the oil filter. Tighten the oil filter until the oil
filter seal contacts the cylinder block. Do not
overtighten the oil filter.

8)

Remove the oil filler cap. Fill the crankcase with
approximately 5.91 quarts of oil. When
refilling be careful not to overfill the
crankcase.

9)

Start the engine and run the engine at
“LOW IDLE” for two minutes. Perform this
procedure in order to ensure that the lubrication
system has oil and that the oil
filters are filled. Inspect the oil filter for leaks.

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10) Stop the engine and allow the oil to drain back to

the sump for a minimum of ten minutes.

11) Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “ADD”
and “FULL” marks on the oil level gauge.

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.

 

1)

Your CAT 1100cc Diesel has two fuel system

filters. The first is a filter/water separator.

2)

Open the drain on the bottom of the filter/water

separator. Catch the draining fluid in 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 outside of the fuel filter assembly.

7)

Remove the setscrew.

8)

Remove the canister. Ensure that any fluid is

drained into a suitable container.

9)

Assemble the following items: seals (8), seal (7),

canister (3), and bowl (10). Place washer (5) and

seal (6) on setscrew (2).

10)

Fasten the assembly to the fuel filter base with

setscrew (2).

11)

The fuel system will need to be primed after the

new filter is installed.

3.2 Changing your fuel filter: 

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 often in dusty 
conditions. 

3.3 Changing the air cleaner: 

1)

The air filter is located on the 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 clean it out
(30psi or less). Higher air pressure can
damage the pleats.

3)

Clean or replace both the inner and outer air
elements.

4)

Reattach the cap onto the filter housing.

Torque the clutch bolt to 50 ft-lbs. on all models. 
Retorque at every oil change.

 

Keep radiator screen clean and free of 
debris on liquid cooled models. Check 
screen hourly during dry conditions. Slide 
radiator screen up to remove. 

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SECTION 4: ELECTRICAL SYSTEM

The fuses on the 1100cc 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 the ground is connected, clean, and 

tight. On most models, the ground wire is connected to 

the negative side of the battery. 

Check the condition and connection of the relays. Two 

relays are located behind the left swing away tank and 

the other 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 out of the engine is 

the charging wire from the alternator. Check for 13.6—

14.2 volts DC at this wire with engine at full throttle. 

The linear actuator is the mechanism that raises and lowers 

the deck. If it ever starts to make noise when raising and 

lowering the deck you might find it necessary to tighten the 

nuts and bolts on the front and rear of the actuator. Be 

careful not to overtighten these as you can damage the 

actuator. Also if your actuator ever stops working make sure 

to check the main fuse or the linear actuator fuse