Bad Boy 1022H User manual

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 1022H 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.
 

Precautions and instructions described in this manual and safety decals, such as DANGER, WARNING and
CAUTION decals, are important for your and machine's safety. If these instructions are not followed, you and the
vehicle can be severely injured and damaged. Read such precautions and instructions carefully for your safety.
If any DANGER, WARNING or CAUTION decal is damaged or missing, order it from your dealer and have it
attached to the original position.
Important safety instructions are described with various symbols throughout this manual. Make sure to follow
such instructions. Their design and meanings are as follows:
MEANINGS OF SAFETY SYMBOLS


DANGER




   

Notes 
WARNING
CAUTION
IMPORTANT

HOW TO USE THIS MANUAL

This manual is intended for technicians with mid to high level of service knowledge and skills for BAD BOY
TRACTORS. Make sure to understand this manual fully for rapid and accurate inspection and service.

This manual is a single book for the 1022H TRACTOR and contains several useful chapters such as Introduction,
Disassembly and reassembly of major point, Engine accessories, HST system, Transmission, Front axle (4WD), Rear
axle and Brakes, Power steering system, Hydraulic system and Electric accessories and instruments and diagrams
in this manual are described based on the standard model so they may be different from your vehicle due to different
specications by models. However, the same instructions should be followed for service.

This manual is structured as follows:


CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR POINT 1022H TRACTOR
K19W026A
FIG. 2-7 Starter motor/Alternator
4. Disconnect the engine harness from the
alternator, starter motor, water temperature
sensor, oil pressure.
K19W029A
FIG. 2-10 Air cleaner assembly
7. Remove the air cleaner inlet pipe.
Remove the inlet/outlet pipes from radiator.
B22W-202010
2-10
K19W028A
FIG. 2-9 Fuel hoses
6. Remove the fuel hoses and assembly.
NOTE
• It is better for the lower nuts of mounting
rubbers to be removed completely and the
upper nuts should be removed slightly in or-
der to reassemble the engine easily.
1
2
3
4
5

HOW TO USE THIS MANUAL
󱲸
This indicates the current chapter.
󱲹
Generally, gures and diagrams are placed in the upper section of a page while information and description
are set in the lower section. However, a large table or diagram may take a whole page. Each gure is assigned
with a gure number and a large gure may be set in a A3-size page like a circuit diagram.
󱲺
This indicates the corresponding model.
󱲻
This indicates the publication category and date of this manual.
󱲼
Each page is given with the corresponding number:
Example: 2-10

The component names used in this manual are set to reect their functions so they may not be consistent with
the ones in other materials, such as the part list and user's manual, labels and decals.
Also, as the gures and diagrams in this manual are based on the product at the time of its publication, so they
may differ from your actual product. The specication and other information in this manual are subject to change
without notice for design change or improvement of the product.

TABLE OF CONTENTS
󱵠

󱵠

󱵠

󱵠

󱵠

󱵠

󱵠

󱵠

󱵠

󱵠

󱵠


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1. INTRODUCTION ...................................... 1-3
2. SAFETY INSTRUCTION.......................... 1-4
3. WARNING SIGNS IN THIS MANUAL ..... 1-5
4. SAFETY SIGNS ....................................... 1-6
4.1 Recognize safety information.................1-6
4.2 Signal words ..........................................1-6
4.3 Read safety instruction ..........................1-6
4.4 Protection children.................................1-6
4.5 Use of rops and seat belt....................... 1-7
4.6 Precaution to avoid tipping .................... 1-7
4.7 Park tractor safely.................................. 1-7
4.8 Keep riders off tractor............................1-8
4.9 Handle fuel safely-avoid res ................1-8
4.10 Stay clear of rotating shafts .................1-8
4.11
Always use safety lights and devices ...............1-8
4.12 Practice safe maintenance................... 1-9
4.13 Avoid high-pressure uids .................... 1-9
4.14 Prevent battery explosions................... 1-9
4.15 Prevent acid burns ............................. 1-10
4.16 Service tractor safely ......................... 1-10
4.17 Battery disconnect ............................. 1-10
4.18 Work in ventilated area .......................1-11
4.19 Using external control .........................1-11
4.20 Tractor runaway ..................................1-11
4.21 Safety starter switch ...........................1-11
5. SAFETY DECALS ..................................1-12
5.1 Decals on the dash cover .................... 1-13
5.2 Decals on the chassis ......................... 1-14
6. UNIVERSAL SYMBOLS.........................1-15
7. TRACTOR TYPES AND PUNCHED
IDENTIFICATION MARKS ....................1-16
7.1 Model name plate................................. 1-17
7.2 Engine model identic ation and
serial number location......................... 1-17
7.2.1 Engine identication location (1) .... 1-17
7.2.2 Engine epa decal (2) ...................... 1-18
7. 2. 3
Description of engine model number.....1-18
8. SPECIFICATIONS...................................1-19
9. GEAR TRAIN DIAGRAMS .................... 1-22
10.
PRECAUTION FOR TRACTOR OPERATION 1-23
10.1 Instruments ........................................ 1-23
10.1.1 Monitor light array......................... 1-24
10.2 Controls ............................................. 1-25
10.3 Filling diagram & capacity table......... 1-26
10.4 Maintenance chart ............................. 1-27
10.4.1 Engine .......................................... 1-27
10.4.2 Transmission................................ 1-28
CHAPTER 1 INTRODUCTION
TABLE OF CONTENTS

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1
B22W-202010 1-3
CHAPTER 1 INTRODUCTION1022H TRACTOR
1. INTRODUCTION
This tractor service manual is for qualied service personnel engaged in servicing and overhauling 1022H
TRACTOR. Use of this publication is not recommended for eld operators since they usually do not have access
to special tools and shop equipment essential for most servicing.
Servicing procedures outlined herein contain sufcient information to return all component parts of a tractor to
new condition. In discussion of each component parts, it is assumed that a complete overhaul is been performed
consequently,
complete disassembly and reassembly are outlined. The mechanic is relied upon to decide how far disassembly
must be carried when complete overhaul is not required.
Study unfamiliar service procedures thoroughly and clearly understood before attempting disassembly. Specic
data essential for proper overhaul, such as running clearances and torque value, have been provided in interline
of Inspection and reassembly procedures of each group section.
This manual was compiled from latest information available at time of publication.
Manufacturer reserves the right to make changes at any time without notice.
Whenever the terms "left“ and "right" are used, They means as viewed by the operator when seated in the
operator's seat.
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B22W-202010
1-4
CHAPTER 1 INTRODUCTION 1022H TRACTOR
2. SAFETY INSTRUCTION
ALWAYS PRACTICE SAFETY BY THINKING BEFORE ACTION
AVOID FIRE HAZARDS
-Keep re extinguishers easily available and in good operating condition.
All relevant personnel should know how to operate re ghting equipment.
-Keep a rst aid kit in an easily accessible location.
-Do not smoke while handling fuel,or other highly ammable material.
-Do not use an open pail for transporting fuel.
-Use of an approved fuel container.
-Dispose of all fuel-soaked rags in covered containers where cigarettes cannot be dropped carelessly.
-Do not smoke and avoid open ame when charging,jumping,or boosting batteries.
-Batteries give off gas which is ammable and explosive.
-Do not charge batteries in a closed area. Provide proper ventilation to avoid explosion of accumulated gases.
Avoid acid burns.
-Wear safety goggles when handling battery electrolyte.It contains sulfuric acid which is a poison and can cause
blindness.Avoid it contacting eyes,skin,or clothing. sulfuric acid will eat through clothing and can cause severe
burns to skin.
AVOID HIGH-PRESSURE FLUIDS
1) Before beginning work on hydraulic system components,turn off engine and operate hydraulic control levers
to relieve internal hydraulic pressure.
2) Oil under pressure can penetrate skin and lead to personal injury.Treat sources of oil pressure with extreme
care,wearing safety goggles.
3) If hydraulic leak develops,correct immediately.Escaping hydraulic oil can have extremely high pressure. A
stream of high pressure oil may easily penetrate skin just like modern needless vaccination equipment,but
with the exception that hydraulic uid may cause blood poisoning.
It is imperative that connections are tight and that all lines and pipes should be in good condition.
If injured by escaping hydraulic uid,see a doctor at once.
STAY CLEAR OF PTO
1) Entanglement in rotating drive line can cause serious injury or death.
2) Keep tractor master shield and drive line shield in place at all times except for special applications as directed
in the implement operator's manual.
3) Wear fairly tight tting clothing. Stop the engine and be sure PTO driveline is stopped before making adjustment,
connections or cleaning out PTO drive equipment.
SERVICE TIRES SAFELY
Tire changing can be dangerous and should be done by trained personnel using proper tools and equipment.
Do not re-inate a tire that has been run at or seriously under-inated. Have it checked by qualied personnel.
Use wheel handling equipment adequate for weight involved when removing and installing wheels.