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Bad Boy 1025H User Manual

Bad Boy 1025H
268 pages
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PREFACE
This manual is to provide servicing personnel with extensive information on the structure, service procedure,
removal and installation procedure, disassembly, troubleshooting and more for the 1025H TRACTOR with
high-end technology to ensure precise and rapid service.
Most accidents are resulted from negligence in safety precautions and directions, so it is very necessary to follow
such precautions and directions to avoid any safety accident beforehand. Service technicians should provide
quality service to prevent any safety accident and enhance customer satisfaction so they should fully understand
the service procedure, methods, inspection points and safety precautions for accurate service.
To ensure optimum condition of your tractor, it is highly recommended to use only BBT genuine parts which are
manufactured under strict quality assurance policy for premium quality, durability and reliability. BBT is always
committed to provide best quality products through extensive research, study and development.
Information in this manual is subject to change without notice for improvement of the product.
Please keep this manual in a safe place. If there is any typo, incorrect information or question about this manual,
feel free to contact BBT.
(Oct. 2020)
BAD BOY TRACTORS Co. Ltd.
Remark
This manual does not contain all accidents and preventive measures that can occur during ser-
vice. Make sure to have this tractor serviced only by professional technicians with care.
-
erwise, it can affect the tractor's performance seriously.


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Questions and Answers:

Bad Boy 1025H Specifications

General IconGeneral
BrandBad Boy
Model1025H
CategoryTractor
LanguageEnglish

Summary

PREFACE

MEANINGS OF SAFETY SYMBOLS

DANGER

Marks imminent danger resulting to death or serious injury.

WARNING

Marks imminent danger resulting to death or serious injury.

CAUTION

Marks possibility of slight/moderate injury or physical damage.

IMPORTANT

Indicates important procedures or information for better work.

HOW TO USE THIS MANUAL

Target readers

Identifies the intended audience for this service manual.

Order of contents

Outlines the sequence and structure of the manual's chapters.

Body structure of this manual

Explains the layout and organization of information within the manual.

CHAPTER 1 INTRODUCTION

Introduction

Provides a general overview of the manual's purpose and scope.

Safety instruction

Details essential safety guidelines for operating and servicing the tractor.

Warning signs in this manual

Explains the meaning and significance of warning symbols used throughout the manual.

Safety signs

Covers recognition and understanding of various safety signs and symbols.

Safety decals

Lists and describes safety decals found on the tractor for hazard identification.

Universal symbols

Defines common symbols used on the tractor and in the manual.

Tractor types and punched identification marks

Explains how to identify tractor models and locate serial numbers.

Specifications

Presents technical data and specifications for the tractor model.

Gear train diagrams

Illustrates the mechanical layout of the tractor's gear systems.

Precaution for tractor operation

Provides critical safety measures for operating the tractor.

USE OF ROPS AND SEAT BELT

PRECAUTION TO AVOID TIPPING

PARK TRACTOR SAFELY

KEEP RIDERS OFF TRACTOR

HANDLE FUEL SAFELY-AVOID FIRES

STAY CLEAR OF ROTATING SHAFTS

ALWAYS USE SAFETY LIGHTS AND DEVICES

PRACTICE SAFE MAINTENANCE

AVOID HIGH-PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

SERVICE TRACTOR SAFELY

WORK IN VENTILATED AREA

USING EXTERNAL CONTROL

TRACTOR RUNAWAY

SAFETY STARTER SWITCH

SAFETY DECALS

Safety decals

Information regarding the safety decals installed on the machine.

DECALS ON THE DASH COVER

DECALS AROUND THE SEAT

DECALS ON THE CHASSIS

UNIVERSAL SYMBOLS

Universal symbols

Defines common symbols used on the tractor and in the manual.

TRACTOR TYPES AND PUNCHED IDENTIFICATION MARKS

Tractor types and punched identification marks

Explains how to identify tractor models and locate serial numbers.

MODEL NAME PLATE

ENGINE MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION

ENGINE EPA DECAL (2)

DESCRIPTION OF ENGINE MODEL NUMBER

SPECIFICATIONS

Specifications

Presents detailed technical specifications for the tractor's various systems.

CHAPTER 2 DISASSEMBLY AND REASSEMBLY

General precautions for separation and reinstallation

Provides essential guidelines and safety measures before disassembling or reassembling components.

Operation chart for disassembly and reassembly by major blocks

Outlines the overall procedure for disassembling and reassembling the tractor in major sections.

Separation of major components

Details the step-by-step process for separating key tractor components.

BEFORE OPERATION

PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS

Roller or Ball bearings

Details the correct procedures and precautions for installing roller and ball bearings.

Oil seals

Explains the proper methods for installing oil seals without causing damage.

O-RINGS

SNAP RINGS

SPRING (ROLL) PINS

COTTER PINS

BOLTS AND NUTS

AFTER INSTALLATION, EACH GREASE FITTING SHOULD BE FILLED WITH GREASE

OTHER PRECAUTIONS

SEPARATION OF THE FRONT AXLE AND AXLE BRACKET

SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACKET

SEPARATION OF THE FUEL TANK AND THE FRONT AXLE BRACKET

SEPARATION OF THE FRONT AXLE BRACKET AND THE TRANSMISSION

SEPARATION OF THE EXTERIOR COMPONENT AND THE TRANSMISSION

SEPARATION OF THE HYDRAULIC CYLINDER CASE AND TRANSMISSION

SEPARATION OF THE TRANSMISSION AND CHASSIS

CHAPTER 3 ENGINE ACCESSORIES

Radiator

Covers the general description, specifications, removal, inspection, and reassembly of the radiator.

Air cleaning system

Details the air cleaner's description, specifications, disassembly, inspection, and cleaning.

Inspection for radiator water leaks

INSPECTION FOR RADIATOR CLOGGING

VISUAL INSPECTION OF THE EXTERIOR PARTS

INSPECTION OF THE RADIATOR CAP

COOLANT LEVEL INSPECTION AND COOLANT REPLACEMENT

ANTIFREEZE

RADIATOR REASSEMBLY

DAILY INSPECTION

TROUBLE SHOOTING

GENERAL DESCRIPTION

ELEMENT AIR CLEANER

SPECIFICATIONS

Lists the technical specifications for the dry, paper element air cleaner.

DISASSEMBLY

Provides instructions for removing the air cleaner cover and element.

INSPECTION OF EACH PART

Inspection of the cleaner body

Guides on inspecting the air cleaner body for cracks or damage.

Inspection of rubber hoses

Details how to check rubber hoses for fatigue or damage.

INSPECTION OF THE PAPER ELEMENT

Explains how to check the paper element for damage after cleaning.

CLEANING THE AIR CLEANER

ELEMENT INSTALLATION

CHAPTER 4 HST SYSTEM

Introduction

Provides an overview of the two-shaft HST system used in road vehicles.

General specifications

Presents technical specifications for the HST system.

Component location

Identifies the location of key components within the HST system.

Troubleshooting

Lists common problems and their solutions for the HST system.

Diagnostics

Provides diagnostic steps to identify HST system issues.

Theory of operation - hydrostatic system

Explains the working principles of the hydrostatic transmission system.

Tests and adjustment

Covers procedures for testing and adjusting HST system parameters.

Repair

Covers the steps involved in repairing the HST system, including disassembly and assembly.

Hydraulic hoses and lines

Hydrostatic transmission

Hydrostatic control linkage

Hydrostatic system schematic

TROUBLESHOOTING

DIAGNOSTICS

THEORY OF OPERATION - HYDROSTATIC SYSTEM

PUMP, MOTOR CIRCUIT (VARIABLE PUMP)

Describes the operation of the variable displacement axial piston pump.

CHARGE CIRCUIT

HST OPERATION

Handling Precautions

Storage

Guidelines for storing the HST unit properly to prevent damage.

Operating Oil (Hydraulic Oil)

Specifies the recommended hydraulic oil and precautions for its use.

Pollution Management

Emphasizes the importance of maintaining hydraulic oil cleanliness (NAS9 Level).

Shaft Coupling

Details precautions for handling the HST input/output shaft coupling.

Defect of lever shaft

Describes potential issues and precautions related to the HST lever shaft.

Starting

Oil Temperature Management

Piping

Regular Check & Replacement Cycle of Hydraulic Oil

TESTS AND ADJUSTMENT

HYDROSTATIC PEDAL AND NEUTRAL ADJUSTMENT

Provides step-by-step instructions for adjusting the hydrostatic pedal and neutral position.

HYDROSTATIC PUMP PRESSURE TEST

CHARGE PUMP PRESSURE TEST

HYDRAULIC SYSTEM BLEED PROCEDURE

REPAIR

HYDROSTATIC SPLITTING

Details the steps required to split the hydrostatic unit for repair.

HYDROSTATIC OVERHAUL

TOOLS

Lists the special and ordinary tools required for hydrostatic unit overhaul.

PRE-DISASSEMBLY PRECAUTIONS

Outlines critical steps to take before beginning the disassembly of the hydrostatic unit.

DISASSEMBLY PROCEDURE

Provides detailed, step-by-step instructions for disassembling the hydrostatic unit.

PRE-ASSEMBLY PRECAUTIONS

Details important precautions to follow before reassembling the hydrostatic unit.

ASSEMBLY PROCEDURE

Provides step-by-step instructions for reassembling the hydrostatic unit.

Assembly of SHAFT

Assembly of SEAL CAP

Assemble SHOE PLATE

Assembly of CYLINDER BLOCK(ASSY)

Assembly of GASKET

Assemble FRONT COVER S/A

CHAPTER 5 TRANSMISSION

General description

Provides an overview of the tractor's transmission systems, including wheel drive and PTO.

Specifications

Presents technical specifications for the wheel drive and PTO systems.

Disassembly, inspection and reassembly

Covers the procedures for disassembling, inspecting, and reassembling transmission components.

Troubleshooting

Lists common problems related to the transmission and their solutions.

Wheel driving system

PTO drive system

WHEEL DRIVE SYSTEM

PTO DRIVE SYSTEM

HST unit, range gears, 4WD gears and PTO clutch

Disassembly

Disassembly, inspection and reassembly of the PTO clutch assembly

Rear PTO gears

Disassembly

Provides instructions for disassembling the rear PTO gears.

INSPECTION

REASSEMBLY

MID PTO ASSEMBLY

Disassembly

Provides instructions for disassembling the MID PTO assembly.

Inspection

Covers inspection of MID PTO components for wear or damage.

Reassembly

Details the reassembly steps for the MID PTO assembly.

Rear PTO and MID PTO OPERATION

Rear transmission

Disassembly

Provides instructions for disassembling the rear transmission components.

INSPECTION

REASSEMBLY

TROUBLESHOOTING

WHEEL DRIVE SYSTEM

Addresses issues like noise, gears not engaging, and disengaging.

PTO DRIVE SYSTEM

CHAPTER 6 FRONT AXLE (4WD)

General description

Provides an overview of the 4WD front axle system, its type, and function.

Specifications

Lists the technical specifications for the front axle alignment and components.

Disassembly, inspection and reassembly

Covers the procedures for disassembling, inspecting, and reassembling the front axle.

Trouble shooting

Lists common problems with the front axle and their solutions.

PIVOT PIN

DISASSEMBLY

INSPECTION

FRONT AXLE BUSH BORE DIAMETER

Details how to measure the front axle bush bore diameter.

FRONT AXLE PIN DIAMETER

Explains how to measure the front axle pin diameter.

REASSEMBLY

FRONT DIFFERENTIAL

DISASSEMBLY

Details the steps for disassembling the front differential.

DISASSEMBLY

INSPECTION

REASSEMBLY

Front diff case

4WD shaft assembly

FINAL CASE

FINAL CASE (A)

Lists components for the final drive case A.

FINAL CASE (B)

Lists components for the final drive case B.

DISASSEMBLY

INSPECTION

REASSEMBLY

TROUBLE SHOOTING

STEERING WHEEL HARD TO TURN

Addresses causes and countermeasures for stiff steering.

VIBRATING OR PULLING STEERING WHEEL

Covers causes and solutions for steering wheel vibration or the vehicle pulling to one side.

STEERING WHEEL TENDS TO TURN TO THE RIGHT OR LEFT WHILE TRAVELING ON STRAIGHT PAVED ROAD

Explains how to correct steering drift when driving straight.

EXCESSIVE OR ECCENTRIC WEAR OF TIRE

Discusses tire wear issues and their potential causes and remedies.

NOISE

Addresses common sources of noise in the steering and front axle systems.

DIFFERENT STEERING ANGLES IN BOTH DIRECTIONS

Explains how to adjust steering angles for consistent left and right turns.

CHAPTER 7 REAR AXLE AND BRAKES

General description

Provides an overview of the rear axle system, including reduction gears, differential, and brake system.

Specifications

Lists the technical specifications for the rear axle and brake system components.

Disassembly, inspection, and reassembly

Covers the procedures for disassembling, inspecting, and reassembling the rear axle housing and brake system.

Trouble shooting

Lists common problems related to the rear axle and brake system and their solutions.

GENERAL DESCRIPTION

SPECIFICATIONS

DISASSEMBLY, INSPECTION, AND REASSEMBLY

REAR AXLE HOUSING AND BRAKE SYSTEM

Details the disassembly, inspection, and reassembly of the rear axle housing and brake components.

DISASSEMBLY

INSPECTION

FRICTION PLATES

Details how to inspect friction plates for glossiness or wear.

METAL BRAKE AND COVER

Guides on inspecting the metal brake and cover for abnormalities.

SEPARATOR PLATE

Explains how to measure the separator plate thickness.

WHEEL SHAFT

Covers inspection of the wheel shaft for wear or damage.

BEARINGS

Guides on checking bearings for smooth rotation.

OIL SEALS

Advises on replacing oil seals during reassembly.

REASSEMBLY

TROUBLE SHOOTING

REAR AXLE

Addresses noise issues in the rear axle and their causes.

BRAKE SYSTEM

Covers common brake system problems, including insufficient force, noise, overheating, and disengagement.

CHAPTER 8 POWER STEERING SYSTEM

General description

Provides an overview of the power-assisted steering system and its components.

Specifications

Lists the technical specifications for the power steering system components.

Function (reference)

Offers reference information on the function and operation of the steering unit.

Disassembly, inspection, and reassembly

Covers the procedures for disassembling, inspecting, and reassembling the power steering system.

Troubleshooting

Lists common problems with the power steering system and their solutions.

GENERAL DESCRIPTION

SPECIFICATIONS

GEAR PUMP

Lists the specifications for the power steering gear pump.

POWER STEERING VALVE UNIT

Details the specifications for the power steering valve unit.

OIL TANK

Provides specifications for the power steering oil tank.

FUNCTION (REFERENCE)

TECHNICAL DATA (SINJIN)

Lists technical data related to the SINJIN hydrostatic steering unit.

MANUAL STEERING PRESSURE

PRESSURE RELIEF VALVE

SHOCK VALVES (REFERENCE)

CHECK VALVE

PRESSURE DROP IN NEUTRAL

DISASSEMBLY, INSPECTION, AND REASSEMBLY

MAJOR COMPONENT OF STEERING VALVE (REFERENCE)

Identifies the major components of the steering valve unit.

SPECIAL TOOLS

DISASSEMBLY

CLEANING, INSPECTION, REPLACEMENT AND LUBRICATION

REASSEMBLY

TROUBLESHOOTING

STEERING WHEEL IS VERY HEAVY TO TURN

Addresses causes and countermeasures for stiff steering.

RETURN TO NEUTRAL IS TOO SLOW

Troubleshoots issues with the steering system not returning to neutral promptly.

FREE PLAY OF STEERING WHEEL

Covers causes and solutions for excessive free play in the steering wheel.

STEERING WHEEL RESISTANCE WITH TURNING

Addresses problems related to steering wheel resistance during turns.

CHAPTER 9 HYDRAULIC SYSTEM

General description

Provides an overview of the tractor's hydraulic system components and operation.

Specifications

Lists the technical specifications for the hydraulic system.

Major component of the hydraulic system

Identifies and describes the main components of the hydraulic system.

Hydraulic system

Details the overall hydraulic system construction and circuit.

Troubleshooting

Lists common problems with the hydraulic system and their solutions.

GENERAL DESCRIPTION

SPECIFICATIONS

MAJOR COMPONENT OF THE HYDRAULIC SYSTEM

Hydraulic system

Shows the components and layout of the hydraulic system.

DIVIDER VALVE AND PTO SOLENOID VALVE

GENERAL DESCRIPTION

Explains the function of the divider valve in controlling fluid direction.

DIVIDER VALVE

Describes the operation and control of the divider valve.

PTO SOLENOID VALVE

FLOW-CONTROL VALVE (SLOW-RETURN CHECK VALVE)

GENERAL DESCRIPTION

Explains how the flow-control valve regulates lift lowering speed.

RELIEF VALVE

GENERAL DESCRIPTION

Explains the relief valve's role in protecting the hydraulic circuit.

MEASUREMENT OF THE RELIEF PRESSURE

Provides instructions for measuring the relief valve pressure.

GEAR PUMP

GENERAL DESCRIPTION

Explains the function of the gear pump in supplying fluid.

GEAR PUMP

Illustrates the gear pump mechanism.

MEASUREMENT OF THE PUMP

Describes how to measure the pump's performance.

STRAINER SUCTION

GENERAL DESCRIPTION

States that the tractor is equipped with a hydraulic filter.

SPECIFICATIONS

Lists the specifications for the hydraulic filter.

REPLACEMENT

Provides instructions for replacing the hydraulic strainer.

HYDRAULIC SYSTEM

TROUBLESHOOTING

Lift does not rise

Covers causes and solutions for the hydraulic lift not rising.

Too low rising speed of lift

Addresses issues related to slow lift speed and their remedies.

Lift lowers even when adjust knob is closed fully with adjust Handle (While engine is stopped)

Lift does not lower

Too slow lift lowering speed

When hydraulic control lever is raised, relief, valve beeps.

Fluid overheating

Pump noise

Excessive wear, deflection or damage of pump

Oil leaks outside pump

Oil leaks from piping or joints

Oil leaks around lift arm

Independent PTO clutch slips or is too slow in engaging

Independent PTO clutch is too quick in engaging

CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS

General description

Provides an overview of the tractor's basic electrical system components.

Specifications

Lists the specifications for the lighting system, monitoring system, fuses, and battery.

Battery

Covers battery inspection, charging, and testing procedures.

Meters and switches

Details the removal, inspection, and function of various meters and switches.

General electrical arrangement

Illustrates the overall layout and connections of the tractor's electrical system.

Wiring diagram

Presents a comprehensive wiring diagram for the tractor's electrical system.

Troubleshooting

Lists common electrical problems and their solutions.

GENERAL DESCRIPTION

SPECIFICATIONS

BATTERY

INSPECTION OF ELECTROLYTE LEVEL

Provides instructions for checking and maintaining the electrolyte level in the battery.

INSPECTION OF ELECTROLYTE SPECIFIC GRAVITY

Details methods for measuring battery specific gravity to determine its condition.

BATTERY CHARGING

BATTERY TESTING CHARTS

METERS AND SWITCHES

METERS

Details the removal and inspection of various meters.

FUEL GAUGE

Describes the construction and inspection of the fuel gauge assembly.

THERMOMETER

Explains the construction and inspection of the coolant temperature gauge.

STARTER SWITCH

Covers the removal and inspection procedures for the starter switch.

COMBINATION SWITCH

Details the removal and inspection of the combination switch (lights, turn signals).

STOP LIGHT SWITCH

Provides information on the stop light switch, including its terminals and switching positions.

RELAY UNIT

Describes the relay unit, including its capacity and terminals.

FUSE

Explains the location and function of fuses in the main fuse box.

TRAILER SOCKET (REFERENCE)

Describes the optional 7-pin trailer socket and its wiring.

GENERAL ELECTRICAL ARRANGEMENT

ENGINE HARNESS ASSEMBLY

MAIN HARNESS ASSEMBLY

REAR HARNESS ASSEMBLY

WIRING DIAGRAM

TROUBLESHOOTING

LIGHTING SYSTEM

Addresses issues with lights not illuminating, burning out, or turn signals not working.

INSTRUMENTATION

PTO does not operate

Inoperative horn

GLOW SYSTEM

STARTING SYSTEM

CHARGING SYSTEM

CHAPTER 11 INDEX

INDEX

Provides an alphabetical index for quick reference to topics within the manual.

APPENDIX - CONVERSION TABLES

CONVERSION TABLES

Contains tables for converting various units of measurement, such as millimeters to inches, and gallons to liters.

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