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Bad Boy 40 Series User Manual

Bad Boy 40 Series
501 pages
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40 SERIES TRACTOR
4035CH, 4035H, 4025H
SERVICE MANUAL
Before ordering parts please check for the
latest Parts Manual update on the Tractor tab
of the Bad Boy Mowers Dealer Zone.
Revised: 3/5/21
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Bad Boy 40 Series Specifications

General IconGeneral
BrandBad Boy
Model40 Series
CategoryTractor
LanguageEnglish

Summary

GENERAL INFORMATION

1.1 GENERAL INFORMATION FOR SERVICE

Provides essential information for servicing the tractor, including safety precautions and general guidelines for service operations.

1.1.8 SAFETY DURING SERVICE

Details critical safety measures to be followed during service operations to prevent injuries and accidents.

3. GENERAL INFORMATION FOR MAINTENANCE

Covers essential maintenance information, including tightening torques and specifications for fluids and parts.

3.2 OIL, GREASE, FUEL AND COOLANT SPECIFICATIONS

Lists the required types and capacities of oil, grease, fuel, and coolant for the tractor.

4. INSPECTION AND CORRESPONDING ACTION

Outlines procedures for inspecting the tractor and taking corresponding actions to ensure proper operation.

4.1 DAILY INSPECTION

Details the daily checks required to maintain the tractor's condition and prevent future issues.

7. TRACTOR SPECIFICATIONS

Provides detailed specifications for the tractor, including dimensions and performance data.

7.2 MAJOR SPECIFICATIONS

Lists key specifications for the engine, capacity, dimensions, tread, and tires of the tractor models.

8. PERIODIC INSPECTION

Outlines the schedule for periodic inspections and maintenance tasks based on operating hours.

8.1 PERIODIC MAINTENANCE SCHEDULE TABLE

A table detailing maintenance items, inspection intervals, and required actions based on running hours.

ENGINE

1. EXTERIOR AND NAMES OF PARTS

Identifies and illustrates the external components and parts of the engine.

1.3 NAME OF EACH PART

Provides detailed diagrams and labels for each major external engine component.

2. MAIN FUNCTION AND PERIODIC CHECK

Explains the engine's primary functions and outlines the periodic inspection checklist.

2.2 CHECK THE MAIN FUNCTION

Details how to check the engine's main functions for performance guarantee and longevity.

5. SECTIONAL VIEW FOR MAJOR COMPONENTS

Presents exploded views and component lists for major engine parts.

5.1 CYLINDER BLOCK

Provides a sectional view and component breakdown of the cylinder block.

5.8 CRANKSHAFT AND PISTON

Details the sectional view of the crankshaft and piston assembly, including components.

6. DISASSEMBLY AND SERVICE

Provides instructions and procedures for disassembling and servicing the engine.

6.1 ENGINE REMOVAL

Step-by-step instructions for safely removing the engine from the tractor.

7. MAINTENANCE STANDARD TABLE

Lists standard maintenance procedures and specifications, including bolt tightening torques.

7.1 MAIN BOLT TIGHTENING TORQUE

Provides specific torque values for major bolts during engine maintenance.

TRANSMISSION

1. OVERVIEW

Provides a general overview of the transmission system, including specifications.

1.1 SPECIFICATION

Details the technical specifications for the transmission system components.

2. STRUCTURE AND OPERATING PRINCIPLE

Explains the internal structure and operating principles of the transmission system.

2.1 MAIN SHIFT

Describes the main shift mechanism and its operation.

2.2 F-R SHUTTLE SHIFT

Explains the operation and principle of the F-R shuttle shift system.

5. DISASSEMBLY AND SERVICE

Provides instructions for disassembling and servicing the transmission system components.

5.1 CLUTCH HOUSING REMOVAL

Details the procedure for removing the clutch housing assembly.

5.2 TRANSMISSION CASE ASSEMBLY DISASSEMBLY

Provides instructions for disassembling the transmission case assembly.

FRONT AXLE

1. OVERVIEW

Provides a general overview of the front axle system, including specifications.

1.1 SPECIFICATIONS

Details the technical specifications for the front axle components.

2. INSPECTION AND ADJUSTMENT

Covers inspection and adjustment procedures for the front axle system.

2.1 TOE-IN

Details the procedure for measuring and adjusting the front wheel toe-in.

3. TROUBLESHOOTING

Provides common problems and their solutions related to the front axle system.

5. DISASSEMBLY AND SERVICE

Offers instructions for disassembling and servicing the front axle components.

5.1 FRONT AXLE CASE ASSEMBLY REMOVAL

Step-by-step guide for removing the front axle case assembly.

5.2 FRONT AXLE CASE COMPONENT DISASSEMBLY

Details the disassembly procedures for the components of the front axle case.

5.2.2 FRONT DIFFERENTIAL

Provides disassembly instructions for the front differential component.

HYDRAULIC SYSTEM

1. CIRCUIT DIAGRAM FOR HYDRAULIC SYSTEM

Presents the overall circuit diagram for the tractor's hydraulic system.

3. MAJOR COMPONENT SPECIFICATIONS

Lists key specifications for major hydraulic system components like pumps and valves.

3.7 HST

Details the specifications for the Hydro-Static Transmission (HST) system.

4. STRUCTURE AND OPERATION

Explains the internal structure and operating principles of hydraulic system components.

4.1 STEERING VALVE

Describes the structure and operation of the steering valve.

4.3 HYDRAULIC PUMP

Details the specifications and operation of the hydraulic pumps.

4.11 HST(HYDROSTATIC TRANSMISSION)

Provides information on the structure and passage composition of the HST system.

4.11.1 HST PASSAGE COMPOSITION

Details the internal passages and component arrangement of the HST.

5. TROUBLESHOOTING

Lists common problems with the hydraulic system and their solutions.

7. DISASSEMBLY AND SERVICE

Provides instructions for disassembling and servicing major hydraulic system components.

7.1 HYDRAULIC CYLINDER CASE ASSEMBLY DISASSEMBLY AND ASSEMBLY

Details the disassembly and assembly procedures for the hydraulic cylinder case.

7.8 HYDRAULIC PUMP DISASSEMBLY

Provides step-by-step instructions for disassembling the hydraulic pump.

ELECTRIC SYSTEM

1. MAJOR ELECTRIC SYSTEM SPECIFICATIONS

Lists the key specifications for the tractor's major electrical system components.

3. CIRCUIT CONFIGURATION BY MAJOR FUNCTION

Illustrates the circuit configurations based on major electrical functions.

4.2 IGNITION SWITCH ON

Explains the operation and circuit related to the ignition switch when turned ON.

4.3 PREHEAT

Describes the preheat operation circuit and its characteristics.

4.4 PTO OPERATION

Details the operation of the PTO system in LINK and IND modes.

4.5 INSTRUMENT CLUSTER AND SENSORS

Provides information on the instrument cluster and various sensors.

4.6 COMBINATION SWITCH AND HEAD LAMP

Explains the operation of the combination switch for head lamps, turn signals, and horn.

4.7 TURN SIGNAL LAMP SWITCH, HAZARD WARNING FLASHER AND FLASHER UNIT

Details the turn signal lamp switch, hazard warning flasher, and flasher unit operations.

5.2.1 IGNITION SWITCH

Describes the ignition switch installation and operation.

5.2.3 FUSE BOX

Provides information on the fuse box layout and fuse functions.

5.2.8 FLASHER UNIT

Details the installation and operation of the flasher unit for turn signals.

5.2.9 CRUISE CONTROLLER

Explains the installation and function of the cruise control system.

5.2.10 PTO SWITCH

Describes the PTO switch installation and operation.

5.2.11 STOP LAMP SWITCH

Details the installation and operation of the stop lamp switch.

5.2.12 SAFETY START NEUTRAL SWITCH

Explains the function and installation of the safety start neutral switch.

5.2.13 STARTER

Provides information on the starter motor specifications and operation.

5.2.14 ALTERNATOR

Details the alternator installation, function, and connector tests.

5.2.16 COOLANT TEMPERATURE SENSOR (PREHEATING)

Explains the coolant temperature sensor installation and resistance values.

5.2.17 COOLANT TEMPERATURE SENSOR (METER)

Describes the coolant temperature sensor installation and its function for the meter.

5.2.19 FUEL SENSOR

Details the fuel sensor installation, function, and resistance by float position.

5.2.20 GLOW PLUG

Explains the glow plug installation and its function for engine starting.

5.2.22 COMBINATION SWITCH

Describes the combination switch installation and its wiring diagram.

5.2.23 DPF LOGGER

Provides information on the DPF logger installation and connector/circuit diagram.

7. TROUBLESHOOTING

Lists common problems related to the electric system and their solutions.

CABIN AND HVAC SYSTEM

1. CABIN

Details the components and inspection of the tractor cabin.

1.2 MAJOR COMPONENT INSPECTION

Covers inspection procedures for major cabin components like lamps and switches.

1.3 SECTIONAL VIEW FOR MAJOR COMPONENTS

Provides sectional views and component breakdowns for major cabin parts.

1.3.1 CABIN FRAME ASS’Y

Details the components and assembly of the cabin frame.

1.4 COMPONENT DISASSEMBLY AND ASSEMBLY

Provides instructions for disassembling and assembling cabin components.

1.4.1 CABIN REMOVAL

Step-by-step guide for safely removing the cabin assembly.

2. HVAC SYSTEM

Provides overview, specifications, and flow diagrams for the HVAC system.

2.1 SPECIFICATIONS

Lists the technical specifications for the HVAC system components.

2.2 HVAC SYSTEM FLOW DIAGRAM

Illustrates the flow diagram of the HVAC system.

2.3 HVAC SYSTEM INSPECTION

Covers inspection procedures for the HVAC system, including refrigerant checks.

2.3.1 REFRIGERANT GAUGE TEST

Details the procedure for testing refrigerant pressure using gauges.

2.5 COMPONENT DISASSEMBLY AND ASSEMBLY

Provides instructions for disassembling and assembling HVAC system components.

2.5.1 AIR CONDITIONER (HVAC) DISASSEMBLY

Details the disassembly steps for the air conditioner (HVAC) unit.

2.5.2 HVAC ASSEMBLY COMPONENTS DISASSEMBLY

Provides disassembly instructions for the components of the HVAC assembly.

2.6 TROUBLESHOOTING

Lists common problems with the HVAC system and their solutions.

2.6.1 GENERAL INFORMATION

Provides general information for troubleshooting HVAC system issues.

2.6.2 COOLING PROBLEM

Addresses common problems related to the cooling function of the HVAC system.

2.6.3 HEATING PROBLEM

Details troubleshooting steps for issues related to the heating function of the HVAC system.

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