Bad Boy 1025H 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 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.
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 1025H 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
specications 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 1025H 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.
B25W-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 reect 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 specication and other information in this manual are subject to change
without notice for design change or improvement of the product.
TABLE OF CONTENTS
This page intentionally left blank
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 Work in ventilated area..................... 1-10
4.18 Using external control........................1-11
4.19 Tractor runaway.................................1-11
4.20 Safety starter switch..........................1-11
5. SAFETY DECALS..................................1-12
5.1 Decals on the dash cover................... 1-13
5.2 Decals around the seat ...................... 1-13
5.3 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 identication and
serial number location...................... 1-17
7.2.1 Engine identication 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 ....................1-21
10. PRECAUTION FOR TRACTOR
OPER ATION......................................... 1-22
10.1 Instruments....................................... 1-22
10.1.1 Monitor light array....................... 1-23
10.2 Controls ............................................ 1-24
10.3 Filling diagram & capacity table ....... 1-25
10.4 Maintenance chart............................ 1-26
10.4.1 Engine ........................................ 1-26
10.4.2 Transmission .............................. 1-27
CHAPTER 1 INTRODUCTION
TABLE OF CONTENTS
This page intentionally left blank
1
B25W-202010 1-3
CHAPTER 1 INTRODUCTION1025H TRACTOR
1. INTRODUCTION
This tractor service manual is for qualied service personnel engaged in servicing and overhauling 1025H 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 sufcient 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. Specic
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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B25W-202010
1-4
CHAPTER 1 INTRODUCTION 1025H 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- inate a tire that has been run at or seriously under- inated. Have it checked by qualied personnel.
Use wheel handling equipment adequate for weight involved when removing and installing wheels.
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B25W-202010 1-5
CHAPTER 1 INTRODUCTION1025H TRACTOR
3. WARNING SIGNS IN THIS MANUAL
The following warning symbols in this manual draw additional attention to items of importance for the safe and
correct operation of the tractor.
SIGN MEANING OF SIGN
DANGER
Serious hazard with a very high level of risk of either serious injury or death
WARNING
Hazard or unsafe practice that can lead to severe injury or death.
CAUTION
Hazard or unsafe practice that can lead in injury or death.
IMPORTANT
Instructions for the correct operation of the machine which, if followed, will
ensure that it performs at it’s best
B25W-202010
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CHAPTER 1 INTRODUCTION 1025H TRACTOR
4. SAFETY SIGNS
4.1 RECOGNIZE SAFETY INFORMATION 4.3 READ SAFETY INSTRUCTION
4.4 PROTECTION CHILDREN
This symbol, Safety-Alert Symbol, means ATTENTION!
YOUR SAFETY IS INVOLVED. The message that follows
the symbol contains important information about safety.
Carefully read the message.
Carefully read all safety instructions given in this
manual for your safety. Tempering with any of the
safety devices can cause serious injuries or death.
Keep all safety signs in good condition. Replace
missing or damaged safety signs.
Keep your tractor in proper condition and do not allow
any unauthorized modications to be carried out on
the Tractor, which may impair the function/safety and
affect Tractor life.
Keep children and others away from the Tractor while
operating.
BEFORE YOU REVERSE
- Look behind Tractor for children.
- Do not let children to ride on Tractor or any implement.
4.2 SIGNAL WORDS
A signal word [DANGER, WARNING OR CAUTION] is
used with safety alert symbol.
DANGER identies the most serious hazards. Safety
signs with signal Word [DANGER OR WARNING] are
typically near specic hazards. General precautions
are listed on CAUTION safety signs.
DANGER
WARNING
CAUTION
1
B25W-202010 1-7
CHAPTER 1 INTRODUCTION1025H TRACTOR
4.5 USE OF ROPS AND SEAT BELT 4.6 PRECAUTION TO AVOID TIPPING
4.7 PARK TRACTOR SAFELY
The Roll Over Protective Structure (ROPS) has been
certied to industry and/or government standards.
Any damage or alternation to the ROPS, mounting
hard-ware, or seat belt voids the certication and will
reduce or eliminate protection for the operator in the
event of a roll-over. The ROPS, mounting hardware,
and seat belt should be checked after the rst 100
hours of Tractor and every 500 hours thereafter for
any evidence of damage, wear or cracks. In the event
of damage or alteration, the ROPS must be replaced
prior to further operation of the Tractor.
The seat belt must be worn during machine operation
when the machine is equipped with a certied ROPS.
Failure to do so will reduce or eliminate protection for
the operator in the event of a roll over.
Do not drive where the Tractor could slip or tip.
Stay alert for holes and rocks in the terrain, and other
hidden hazards.
Slow down before you make a sharp turn.
Driving forward out of a ditch or mired condition could
cause Tractor to tip over backward. Back out of these
situations if possible.
Before working on the Tractor ;
Lower all equipment to the ground.
Stop the engine and remove the key.
B25W-202010
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CHAPTER 1 INTRODUCTION 1025H TRACTOR
4.8 KEEP RIDERS OFF TRACTOR
Do not allow riders on the Tractor.
Riders on Tractor are subject to injury such as being
stuck by foreign objects and being thrown off of the
Tractor.
Handle fuel with care; it is highly ammable. Do not
refuel the Tractor while smoking or near open ame
or sparks.
Always stop engine before refueling Tractors.
Always keep your tractor clean of accumulated grease,
and debris. Always clean up spilled fuel.
4.9 HANDLE FUEL SAFELY-AVOID FIRES
4.10 STAY CLEAR OF ROTATING SHAFTS
Entanglement in rotating shaft can cause serious
injury or death.
Keep PTO shield in place at all times.
Wear close tting clothing. Stop the engine and be
sure PTO drive is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
Use of hazard warning lights and turn signals are
recommended when towing equipment on public roads
unless prohibited by state or local regulations.
Use slow moving vehicle (SMV) sign when driving
on public road during both day & night time, unless
prohibited by law.
4.11
ALWAYS USE SAFETY LIGHTS AND DEVICES
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B25W-202010 1-9
CHAPTER 1 INTRODUCTION1025H TRACTOR
4.12 PRACTICE SAFE MAINTENANCE 4.13 AVOID HIGH-PRESSURE FLUIDS
Understand service procedure before doing work.
Keep the surrounding area of the Tractor clean and dry.
Do not attempt to service Tractor when it is in motion.
Keep body and clothing away from rotating shafts.
Always lower equipment to the ground. Stop the
engine.
Remove the key. Allow Tractor to cool before any work
repair is caused on it.
Securely support any Tractor elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Replace worn or broken parts. Replace damage/
missing decals.
Remove any buildup of grease or oil from the Tractor.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
Tractor.
Escaping uid under pressure can penetrate the skin
causing serious injury. Keep hands and body away
from pinholes and nozzles, which eject uids under
high pressure. If ANY uid is injected into the skin,
consult your doctor immediately.
Keep sparks, lighted matches, and open ame away
from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the poles.
4.14 PREVENT BATTERY EXPLOSIONS
B25W-202010
1-10
CHAPTER 1 INTRODUCTION 1025H TRACTOR
4.15 PREVENT ACID BURNS 4.16 SERVICE TRACTOR SAFELY
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, cause holes in clothing
and cause blindness if found entry into eyes.
For adequate safety always;
1. Fill batteries in a well-ventilated area.
2. Wear eye protection and acid proof hand gloves.
3. Avoid breathing direct fumes when electrolyte is
added.
4. Do not add water to electrolyte as it may splash off
causing severe burns.
If you spill acid on yourself;
1. Flush your skin with water.
2. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
Do not wear a necktie, scarf or loose clothing when
you work near moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
4.17 WORK IN VENTILATED AREA
Do not start the tractor in an enclosed building unless
the doors & windows are open for proper ventilation,
as tractor fumes can cause sickness or death. If it
is necessary to run an engine in an enclosed area
remove the exhaust fumes by connecting exhaust
pipe extension.
1
B25W-202010 1-11
CHAPTER 1 INTRODUCTION1025H TRACTOR
4.19 TRACTOR RUNAWAY
1. The tractor can start even if the transmission is
engaged position causing Tractor to runaway and
serious injury to the people standing nearby the
tractor.
For additional safety keep the pull to stop knob
(fuel shut off control) in fully pulled out position.
Transmission in neutral position, Foot brake engaged
and PTO lever in disengaged position while attending
to Safety Starter Switch or any other work on Tractor.
Stand well clear of the rear linkage and implements
when using the hitch remote switches or injury can
result from moving parts.
4.18 USING EXTERNAL CONTROL
1. Clutch operated safety switch is provided on all
Tractors which allow the starting system to become
operational only when the Clutch pedal is fully
pressed.
2. Do not By-pass this safety starter switch or work
on it. Only Authorized Dealers are recommended
to work on safety starter switch.
3. On some models Safety Starter switch is provided
on transmission High-low shifter lever and in PTO
shifter lever. The tractor can be started only if High-
low shifter lever is in neutral position.
4.20 SAFETY STARTER SWITCH
CAUTION
• To avoid injury, always engage park brake,
ensure HST is in Neutral position and PTO
switch is off when starting or running the engine.
• Safety Starter Switch is to be replaced after
every 2000 hours/4 years, whichever is earlier.
B25W-202010
1-12
CHAPTER 1 INTRODUCTION 1025H TRACTOR
5. SAFETY DECALS
The following safety decals are installed on the machine.
If a decal become damaged, illegible or is on the machine, replace it. The decal part number is listed in the
parts lists.
WARNING
• Before starting and operating know the operating and safety instructions in the operators Manual
and on the tractor.
• Clear the area of bystanders.
• Locate and know operation of controls.
• Start engine only from Operator’s seat with depressed Brake pedal, transmission in the neutral,
PTO disengaged and hydraulic control in lower position
• Slow down on turns, rough ground and slopes to avoid upset.
• Do not permit anyone but the operator to ride on the tractor. There is no safe place for rider.
• Lock brakes together, use warning lights and SMV emblem while driving on roads.
• Lower equipment, place gear shift levers in neutral, stop engine, remove the key and apply parking
brake before leaving the tractor seat.
•
FAILURE TO FOLLOW ANY OF THE INSTRUCTIONS ABOVE CAN CAUSE SERIOUS INJURY TO THE OPERATOR
1
B25W-202010 1-13
CHAPTER 1 INTRODUCTION1025H TRACTOR
5.1 DECALS ON THE DASH COVER
5.2 DECALS AROUND THE SEAT
25HW004A
K25W002A
B25W-202010
1-14
CHAPTER 1 INTRODUCTION 1025H TRACTOR
5.3 DECALS ON THE CHASSIS
25HW006A
25HW006A
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