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Bad Boy 1022H Manual
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Bad Boy 1022H Manual

Bad Boy 1022H Manual

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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.
※ 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.
Use only genuine parts, including engine oil and transmission fluid, specified in this manual. Oth-
erwise, it can affect the tractor's performance seriously.
Never attempt to duplicate contents and figures in this manual without prior approval by BBT.
PREFACE
(Oct. 2020)
BAD BOY TRACTORS Co. Ltd.

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Robert L. & Thelma June Allard
March 11, 2025

water temp sensor. question: is the sensor next to the oil level dip stick for the oil pressure or water temperature?

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Summary of Contents for Bad Boy 1022H

  • Page 1 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.
  • Page 2 MEANINGS OF SAFETY SYMBOLS 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.
  • Page 3 HOW TO USE THIS MANUAL 1. Target readers 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.
  • Page 4 HOW TO USE THIS MANUAL ① Chapter This indicates the current chapter. ② Body Generally, figures 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 figure is assigned with a figure number and a large figure may be set in a A3-size page like a circuit diagram.
  • Page 5 TABLE OF CONTENTS ◆ INTRODUCTION ................◆ DISASSEMBLY AND REASSEMBLY OF MAJOR POINT ....◆ ENGINE ACCESSORIES ..............◆ HST SYSTEM ................. ◆ TRANSMISSION ................◆ FRONT AXLE (4WD)............... ◆ REAR AXLE AND BRAKES ............◆ POWER STEERING SYSTEM ............◆...
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  • Page 7: Table Of Contents

    CHAPTER 1 INTRODUCTION TABLE OF CONTENTS 1. INTRODUCTION ........1-3 5. SAFETY DECALS ........1-12 5.1 Decals on the dash cover ....1-13 2. SAFETY INSTRUCTION ......1-4 5.2 Decals on the chassis ......1-14 3. WARNING SIGNS IN THIS MANUAL ..1-5 6.
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  • Page 9 CHAPTER 1 INTRODUCTION 1. INTRODUCTION This tractor service manual is for qualified service personnel engaged in servicing and overhauling 1022H TRACTOR. Use of this publication is not recommended for field operators since they usually do not have access to special tools and shop equipment essential for most servicing.

  • Page 10: Safety Instruction

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 2. SAFETY INSTRUCTION ALWAYS PRACTICE SAFETY BY THINkING BEFORE ACTION AvOID FIRE HAZARDS -Keep fire extinguishers easily available and in good operating condition. All relevant personnel should know how to operate fire fighting equipment. -Keep a first aid kit in an easily accessible location.

  • Page 11: Warning Signs In This Manual

    1022H TRACTOR CHAPTER 1 INTRODUCTION 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 Serious hazard with a very high level of risk of either serious injury or death DANGER Hazard or unsafe practice that can lead to severe injury or death.

  • Page 12: Safety Signs

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 4. SAFETY SIGNS 4.1 RECOGNIZE SAFETY INFORMATION 4.3 READ SAFETY INSTRUCTION This symbol, Safety-Alert Symbol, means ATTENTION! Carefully read all safety instructions given in this YOUR SAFETY IS INvOLvED. The message that follows manual for your safety. Tempering with any of the the symbol contains important information about safety.

  • Page 13: Use Of Rops And Seat Belt

    1022H TRACTOR CHAPTER 1 INTRODUCTION 4.5 USE OF ROPS AND SEAT BELT 4.6 PRECAUTION TO AvOID TIPPING The Roll Over Protective Structure (ROPS) has been Do not drive where the Tractor could slip or tip. certified to industry and/or government standards.

  • Page 14: Keep Riders Off Tractor

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 4.8 kEEP RIDERS OFF TRACTOR 4.10 STAY CLEAR OF ROTATING SHAFTS Do not allow riders on the Tractor. Entanglement in rotating shaft can cause serious injury or death. Riders on Tractor are subject to injury such as being stuck by foreign objects and being thrown off of the Keep PTO shield in place at all times.

  • Page 15: Practice Safe Maintenance

    1022H TRACTOR CHAPTER 1 INTRODUCTION 4.12 PRACTICE SAFE MAINTENANCE 4.13 AvOID HIGH-PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin Understand service procedure before doing work. causing serious injury. Keep hands and body away Keep the surrounding area of the Tractor clean and dry.

  • Page 16: Prevent Acid Burns

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 4.15 PREvENT ACID BURNS 4.16 SERvICE TRACTOR SAFELY Sulfuric acid in battery electrolyte is poisonous. It is Do not wear a necktie, scarf or loose clothing when strong enough to burn skin, cause holes in clothing you work near moving parts.

  • Page 17: Work In Ventilated Area

    1022H TRACTOR CHAPTER 1 INTRODUCTION 4.18 WORk IN vENTILATED AREA 4.20 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.

  • Page 18: Safety Decals

    CHAPTER 1 INTRODUCTION 1022H 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.

  • Page 19: Decals On The Dash Cover

    1022H TRACTOR CHAPTER 1 INTRODUCTION 5.1 DECALS ON THE DASH COvER T19W006A T19W008A B22W-202010...

  • Page 20: Decals On The Chassis

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 5.2 DECALS ON THE CHASSIS T19W007A B22W-202010...

  • Page 21: Universal Symbols

    1022H TRACTOR CHAPTER 1 INTRODUCTION 6. UNIvERSAL SYMBOLS Some of the universal symbols have been shown below with an indication of their meaning Engine speed Pressured- Corrosive open slowly substance rev/minX100) "Tortoise” Slow Continuous Hours, recorded or minimum variable Setting "Hare”...

  • Page 22: Tractor Types And Punched Identification Marks

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 7. TRACTOR TYPES AND PUNCHED IDENTIFICATION MARkS The tractor serial number is shown on the left hand side of the tractor as shown in the picture. The engine number is stamped on the top of the engine block.

  • Page 23: Model Name Plate

    1022H TRACTOR CHAPTER 1 INTRODUCTION 7.1 MODEL NAME PLATE 7.2 ENGINE MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION The plate indicates the model and type of the tractor. 7.2.1 ENGINE IDENTIFICATION LOCATION (1) 1. Model name 2. Production I.D No. The production I.D reference number is as shown...

  • Page 24: Engine Epa Decal (2)

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 7.2.2 ENGINE EPA DECAL (2) 7.2.3 DESCRIPTION OF ENGINE MODEL NUMBER 3 TNV 74F - S DKTF2 3 TNV 74 F - 0 0000 Customer code Rated RPM EPA Tier 4 below 19 kW certified...

  • Page 25: Specifications

    1022H TRACTOR CHAPTER 1 INTRODUCTION 8. SPECIFICATIONS MODEL 1022H Maker YANMAR 3TNV74F Model Water cooled 4 cycle, 3 cylinder diesel Type 16(21.7) / 3,200 Out put (KW (ps)/rpm) Number of Cylinder 993 cc Displacement Bore and Stroke 74 mm x 77mm 23.1 : 1...
  • Page 26 CHAPTER 1 INTRODUCTION 1022H TRACTOR MODEL 1022H Wet Disc, Foot operated Inner dia. 65 mm (2.5 in.) 109 mm (4.3 in.) Brake Outer dia. Number of lining 3.4 mm (0.13 in.) Brake thickness Type Independent Control Electro-Hydraulic Clutch Multiple wet Disk...
  • Page 27 1022H TRACTOR CHAPTER 1 INTRODUCTION MODEL SIZE Front BAR F 16 X 7.50-8PR Rear BAR R 24X12.00-12PR TIRE Front TURF F 16X7.50-8PR Rear TURF R 24X12.00-12PR * SPEED CHART(Engine Rated Speed : 3,200 rpm) 7.20 (4.47 mph) 15.24 (9.47 mph) 7.18 (4.46 mph)

  • Page 28: Gear Train Diagrams

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 9. GEAR TRAIN DIAGRAMS T19W009A B22W-202010...

  • Page 29: Precaution For Tractor Operation

    1022H TRACTOR CHAPTER 1 INTRODUCTION 10. PRECAUTION FOR TRACTOR OPERATION 10.1 INSTRUMENTS 22HW008A NOTE • Oil pressure warning light and charge light on the monitor array will light when the main switch is turned from OFF to ON. • All lights on the panel go out automatically when the engine is started and its speed is increased to a specific level.

  • Page 30: Monitor Light Array

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 10.1.1 MONITOR LIGHT ARRAY K19W011A LOW BEAM LAMP Low beam lamp is operated on the combination switch. PTO MONITOR LAMP This lamp will turn on when PTO clutch is engaged. FUEL EMPTY WARNING LAMP This lamp shows warning that the fuel in fuel tank goes empty.

  • Page 31: Controls

    1022H TRACTOR CHAPTER 1 INTRODUCTION 10.2 CONTROLS 22HW009A K19W013A K19W014A B22W-202010...

  • Page 32: Filling Diagram & Capacity Table

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 10.3 FILLING DIAGRAM & CAPACITY TABLE K19W015A Filling point Fillings Quantity Liter (US gal) 50/50 : Ethylene Glycol/Water (L.L.C) 3.5 ℓ (0.93 US gal) RADIATOR ASTM D4985 / D6210 API : Over CF-4 grades Above:25°C (77°F)…SAE30 or 10W-30 1.8ℓ...

  • Page 33: Maintenance Chart

    1022H TRACTOR CHAPTER 1 INTRODUCTION 10.4 MAINTENANCE CHART Periodical check and service table 10.4.1 ENGINE ○ Inspection, Replenish, and Adjustment ● △ Replacement Cleaning and/or washing ★ Consult your Dealer Inspection and servicing intervals Hour of operation Inspection Judgment criteria...

  • Page 34: Transmission

    CHAPTER 1 INTRODUCTION 1022H TRACTOR 10.4.2 TRANSMISSION ○ Inspection, Replenish, and Adjustment ● △ Replacement Cleaning and/or washing ★ Consult your Dealer Inspection and servicing intervals Hour of operation Inspection (X10 on hour meter) Daily Intervals after that Judgment criteria mm (in)
  • Page 35 1022H TRACTOR CHAPTER 1 INTRODUCTION ○ Inspection, Replenish, and Adjustment ● △ Replacement Cleaning and/or washing ★ Consult your Dealer Inspection and servicing intervals Hour of operation Inspection (X10 on hour meter) Daily Intervals after that Judgment criteria mm (in)
  • Page 36 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
  • Page 37 CHAPTER 2 DISASSEMBLY AND REASSEMBLY TABLE OF CONTENTS 1. GENERAL PRECAUTIONS FOR 3. SEPARATION OF MAJOR COMPONENTS .. 2-8 SEPARATION AND REINSTALLATION .. 2-3 3.1 Separation of the front axle 1.1 Before operation........2-3 and axle bracket ........2-8 3.2 Separation of the engine 1.2 Precautions to be followed when installing standardized parts ....
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  • Page 39: General Precautions For Separation And Reinstallation

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1. GENERAL PRECAUTIONS FOR SEPARATION AND REINSTALLATION 1.1 BEFORE OPERATION 1.2 PRECAUTIONS TO BE FOLLOWED WHEN INSTALLING STANDARDIZED PARTS 1. Always be safety-conscious in selecting clothes to 1.2.1 ROLLER OR BALL BEARINGS wear and suitable tools to use.

  • Page 40: O-Rings

    CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 1.2.3 O-RINGS 1.2.5 SPRING (ROLL) PINS 1. O-rings should be coated with grease before installing. 2. Installed O-rings should have no slack or twist. 3. Installed O-rings should maintain proper air tightness.

  • Page 41: Bolts And Nuts

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1.2.7 BOLTS AND NUTS 1.2.9 OTHER PRECAUTIONS 1. Be sure not to damage any finished surfaces or parts. 1. Special bolts are installed at several locations, so be sure not to interchange them other bolts.
  • Page 42 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR (Unit : kgf·m / N·m / lb·ft) BOLT TIGHTENING TORQUE Spec Coarse Fine Coarse Fine Coarse Fine 0.07 ~ 0.09 / 0.69 ~ 0.88 / 0.51 ~ 0.65 0.35 ~ 0.45 / 0.50 ~ 0.70 /...

  • Page 43: Operation Chart For Disassembly And Reassembly By Major Blocks

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCkS K19W019A Coupling-Hydraulic (kgf-m) 1/4” 3/8” 1/2” 3/4” 1” 1-1/4” 1-1/2” B22W-202010...

  • Page 44: Separation Of Major Components

    CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 3. SEPARATION OF MAJOR COMPONENTS 3.1 SEPARATION OF THE FRONT AXLE AND AXLE BRACkET Parts which can be inspected during this operation FIG. 2-2 Front axle - Center pin - Final case...

  • Page 45: Separation Of The Engine And The Front Axle Bracket

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.2 SEPARATION OF THE ENGINE AND THE FRONT AXLE BRACkET Parts which can be inspected during This operation INSTALLATION - Engine assembly 1. Install the front axle assembly. - Air cleaner - Radiator 2.
  • Page 46 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 4. Disconnect the engine harness from the alternator, 7. Remove the air cleaner inlet pipe. starter motor, water temperature sensor, oil Remove the inlet/outlet pipes from radiator. pressure. FIG. 2-10 Air cleaner assembly FIG.
  • Page 47 1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 9. Lift up the engine assembly with the hoist. INSTALLATION FIG. 2-12 Engine hook Reassemble in reverse order of removal. 1. Loosen the nuts slightly which are mounted to the engine.

  • Page 48: Separation Of The Fuel Tank And The Frame Component

    CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 3.3 SEPARATION OF THE FUEL TANk AND THE FRAME COMPONENT Parts which can be inspected during this operation. NOTE - Fuel tank • Remove the rear tires if necessary. • Disconnect the wiring of fuel gauge.

  • Page 49: Separation Of The Front Axle Bracket And The Transmission

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.4 SEPARATION OF THE FRONT AXLE BRACkET AND THE TRANSMISSION Parts which can be inspected during This operation 4. Remove the ROPS. Remove the bolts which are tightened to 3P hitch.
  • Page 50 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 6. Disconnect the wirings between the engine 7. Remove the hydraulic pipes and gear pump. harness and the rear harness. Remove the bracket of valve. FIG. 2-20 FIG. 2-21 K19W039A...
  • Page 51 1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 7-1) Remove the drive shaft. 8. Remove the link B comp. 7-2) Remove the brake rod and the spring. FIG. 2-23 7-3) Remove the neutral lever comp and the spring.
  • Page 52 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR INSTALLATION Reassemble in reverse order of removal. 5-a. Adjust the location of pedals in A part of FIG. 2-25. 1. During reassembly, make sure the splines stay FIG. 2-25 aligned (4WD Shaft). Apply a thin coat of molybdenum grease (TB1901) to the splines prior to reassembly.
  • Page 53 1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 7. Install the hydraulic pipes. 11) In case of rotating to reverse Install the bracket of valve. 11-1. loosen the locking screw slightly. 8. Connect the wirings. 11-2. Turn the neutral lever towards forward a little.
  • Page 54 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR HOW TO CHECK AND ADJUST THE NEUTRAL INSPECTION FOR THE DYNAMIC BRAKING TEST If the pedal is too slow in returning to "Neutral" position NOTE when releasing the foot from the pedal, adjust the HST •...

  • Page 55: Separation Of The Exterior Component And The Transmission

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.5 SEPARATION OF THE EXTERIOR COMPONENT AND THE TRANSMISSION Parts which can be inspected during This operation 2. Remove the seat assembly. Remove the mat and floor panel. - Floor panel assembly - Seat assembly FIG.
  • Page 56 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 4. Remove the lever cover (LH, RH). 6. Remove the Mid frame comp. Remove the fender assembly. Remove the frame comp (LH/RH) and the hitch frame comp. together. FIG. 2-34 Fender FIG.

  • Page 57: Separation Of The Hydraulic Cylinder Case And Transmission

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.6 SEPARATION OF THE HYDRAULIC CYLINDER CASE AND TRANSMISSION 7. Remove the cover comp. after loosening the bolts. Parts which can be inspected during This operation - Control valve FIG. 2-37 Covers...
  • Page 58 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR 2. Remove the drain pipe. 4. Detach the delivery pipe from the hydraulic cylinder case. FIG. 2-39 Hydraulic pipe FIG. 2-41 Hydraulic cylinder T19W013A 3. Detach the link B comp.

  • Page 59: Separation Of The Transmission And Rear Axle Housing

    1022H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.7 SEPARATION OF THE TRANSMISSION AND REAR AXLE HOUSING Parts which can be inspected during This operation INSTALLATION - MID PTO gears Reassemble in reverse order of removal. - Final gears and brake system - HST unit and input metal and PTO solenoid valve 1.
  • Page 60 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1022H TRACTOR NOTE • Be careful not to damage the hydraulic func- tional components from dust or other foreign matter. ▶ REAR AXLE HOUSING ASSEMBLY (LH, RH) NOTE • As both sides can be disassembled in the same way, only side (RH) will be explained here 2.
  • Page 61 CHAPTER 3 ENGINE ACCESSORIES TABLE OF CONTENTS 1. RADIATOR ..........3-3 2. AIR CLEANING SYSTEM .......3-11 2.1 General description ......3-11 1.1 General description ........3-3 2.2 Element air cleaner ......3-12 1.2 Radiator ..........3-4 1.3 Specifications ........3-5 2.2.1 Specifications......... 3-12 2.2.2 Disassembly ........
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  • Page 63: Radiator

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 1. RADIATOR 1.1 GENERAL DESCRIPTION The pressure cooling system includes mainly the FIG. 3-1 radiator, water pump, multi-blade fan, and the thermostat. During the warm-up period, the thermostat remains closed and coolant is directed through by-pass to the suction side of the water pump.

  • Page 64: Radiator

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 1.2 RADIATOR The radiator consists of radiator cores, a tank to flow coolant, plates to install the radiator, and a fan guide. Fin-tube type cores are used and the cores and tank is made of anti corrosive aluminum and aluminum alloy.

  • Page 65: Specifications

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 1.3 SPECIFICATIONS Description 1022H CF (Wave fin) Radiator core type Core train number 2 trains Radiator fin pitch 3.5 mm 6.2530 m Thermal radiator area Pressure valve opening pressure 0.9 ± 0.15 kgf/cm 3.5 ℓ...

  • Page 66: Inspection Of Each Part

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 1.5 INSPECTION OF EACH PART 1.5.1 INSPECTION FOR RADIATOR WATER LEAkS Water leaks are liable to occur at the fitting portion b. Leak test with a radiator cap tester between the upper tank and the core section or With the inlet and outlet pipes plugged up and the between the lower tank and the core section.

  • Page 67: Inspection For Radiator Clogging

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 1.5.2 INSPECTION FOR RADIATOR CLOGGING To inspect the radiator cores to see if they are clogged NOTE with fur or rust, remove the radiator cap and check • When cleaning the radiator cores with pres-...

  • Page 68: Radiator Reassembly

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 1.6 RADIATOR REASSEMBLY - Function test: Reassemble the radiator in the reverse order of disassembly. The pressure type radiator cap has a pressure valve and a vacuum as shown in the figure. NOTE • The rubber hoses should be clamped securely...

  • Page 69: Daily Inspection

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 1.7 DAILY INSPECTION 1.7.1 COOLANT LEvEL INSPECTION AND COOLANT REPLACEMENT When the radiator is hot after operation, be sure to wait until the coolant cools down sufficiently before removing the radiator cap. If this is not done, heated vapor might burst out and cause burns. Use fresh water from a faucet as the coolant.

  • Page 70: Trouble Shooting

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 1.8 TROUBLE SHOOTING Problems Causes Countermeasures (1) Replenish coolant and inspect water (1) Low coolant level leaks. (2) Fatigued pressure valve spring (2) Replace radiator cap. (3) Loose or broken fan belt (3) Adjust belt tension or replace.

  • Page 71: Air Cleaning System

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 2. AIR CLEANING SYSTEM 2.1 GENERAL DESCRIPTION FIG. 3-10 Air Cleaner K19W075A (3) Cover assembly (1) Body (2) Paper element outer (4) Dust unloading valve FIG. 3-10 Air Cleaner K19W076A (3) Air outlet (1) Air inlet...

  • Page 72: Element Air Cleaner

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 2.2 ELEMENT AIR CLEANER 2.2.1 SPECIFICATIONS Model 1022H Dry, paper element filtering type Type Rated intake air volume (M /min) Effective filter area (M 0.44 air venting resistance (mmAg) 110 or less Total filtering efficiency (%)

  • Page 73: Inspection Of Each Part

    1022H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 2.3 INSPECTION OF EACH PART 2.4 CLEANING THE AIR CLEANER 2.3.1 INSPECTION OF THE CLEANER BODY Clean the air cleaner after 100 hours of operation or less depending on conditions in the following manner.

  • Page 74: Element Installation

    CHAPTER 3 ENGINE ACCESSORIES 1022H TRACTOR 2.5 ELEMENT INSTALLATION Install the element in the reverse order of disassembly, but follow these instructions. 1. Each tightening clamp must be secured and care must be taken not to miss the latch. 2. Before installing the element, clean the rubber packing on the top of the element.
  • Page 75 CHAPTER 4 HST SYSTEM TABLE OF CONTENTS 1. INTRODUCTION ........4-3 7. TESTS AND ADJUSTMENT ....4-17 1.1 Introduction ..........4-3 7.1 Hydrostatic pedal and neutral adjustment ..4-17 7.2 Hydrostatic pump pressure test ... 4-18 2. GENERAL SPECIFICATIONS ....4-4 7.3 Charge pump pressure test ....4-20 3.
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  • Page 77: Introduction

    1022H TRACTOR CHAPTER 4 HST SYSTEM 1. INTRODUCTION 1.1 INTRODUCTION This Manual describes the specifications, structure, mechanism, and handling about a two-shaft HST used as a continuously variable transmission for road vehicles in order to prevent any nonconformity of handling and keep its good performance for the long run.

  • Page 78: General Specifications

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 2. GENERAL SPECIFICATIONS HST FOR UNROAD VEHICLES Specifications Item 0~23 cc/rev PUMP HST Capacity 23 cc/rev MOTOR Basic DIRECTION OF INPUT ROTATION From the position of clockwise input shaft 9-10 bar , VG46, 50˚C, 8 L/min CHARGE RELIEF SET PRESSURE Within 0.3 bar...

  • Page 79: Component Location

    1022H TRACTOR CHAPTER 4 HST SYSTEM 3. COMPONENT LOCATION 3.1 HYDRAULIC HOSES AND LINES FIG. 4-1 T19W015A (1) Hydraulic oil filter (5) Drain pipe (9) Charge pipe (2) Suction pipe (6) Steering pipe (10) PTO pipe (3) Gear pump (7) Steering valve...

  • Page 80: Hydrostatic Control Linkage

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 3.3 HYDROSTATIC CONTROL LINkAGE FIG. 4-3 T19W016A (1) Holder comp (6) Neutral arm comp (11) Brake Pedal comp (2) Control rod assembly (7) Reverse pedal comp (12) Brake Rod (3) Pedal shaft comp. (13) Brake sensor (8) Stopper comp (4) Arm comp.

  • Page 81: Hydrostatic System Schematic

    1022H TRACTOR CHAPTER 4 HST SYSTEM 3.4 HYDROSTATIC SYSTEM SCHEMATIC FIG. 4-4 T19W017A B22W-202010...

  • Page 82: Troubleshooting

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 4. TROUBLESHOOTING In case that HST shows troubles, it is as a general rule to replace the Assy. For a more clear-cut explanation and understanding, here is a detailed outline of troubles, causes, checking points, and actions.
  • Page 83 1022H TRACTOR CHAPTER 4 HST SYSTEM TROUBLE CAUSE CHECk LIST ACTION 1. The flow rate of Charge is Measure the pressure of short because of having Charge Circuit and check Wash the Filter/Strainer, or that it reaches its specified Filter or Strainer (Main replace with a new one.

  • Page 84: Diagnostics

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 5. DIAGNOSTICS Test conditions: - Operator in seat - Key switch in RUN position Test/Check point Normal If Not normal 1. Control pedals Pedal should move freely Check linkage from pedals to pump Test conditions:...

  • Page 85: Theory Of Operation - Hydrostatic System

    1022H TRACTOR CHAPTER 4 HST SYSTEM 6. THEORY OF OPERATION - HYDROSTATIC SYSTEM The hydrostatic system provides a means to transfer. Power from the engine to the final drive to the wheels. It also provides infinitely variable speed control, forward or reverse, by foot pedal operation.

  • Page 86: Charge Circuit

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 6.2 CHARGE CIRCUIT • MOTOR HST Circuit has an internal gap, so it is equipped with CHARGE CIRCUIT to compensate the weak point. Oil <Figure-c> shows a rotation parts in Axial Piston discharged from CHARGE PUMP is to be supplied to Pump, and 9 pistons are inserted to Cylinder Block.
  • Page 87 1022H TRACTOR CHAPTER 4 HST SYSTEM 3. BACKWARD (LEVER : a side)---------------------- 2. FORWARD (LEVER: b side )------------------------ --------------------------------------------- Figure-e -----------------------------------------------Figure-g In case of rotating the input shaft of HST to the CCW The operation principle is the same as the above direction and tilting LEVER from its neutral position to FORWARD operation.

  • Page 88: Handling Precautions

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 6.4 HANDLING PRECAUTIONS 6.4.1 STORAGE 6.4.4 SHAFT COUPLING CAUTION WARNING • In case of keeping it over one month, a 1. A special carefulness will be taken when clean hydraulic oil (operating oil) has to be...

  • Page 89: Starting

    1022H TRACTOR CHAPTER 4 HST SYSTEM 6.4.7 OIL TEMPERATURE MANAGEMENT 6.4.6 STARTING CAUTION WARNING • As for hydraulic unit, the most important thing 1. Fill a hydraulic oil (operating oil) in HST Case. is to how extent a driving temperature is main- 2.

  • Page 90: Regular Check & Replacement Cycle Of Hydraulic Oil

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 6.5 REGULAR CHECk & REPLACEMENT CYCLE OF HYDRAULIC OIL CAUTION • Even at the first washing, there may be sedimentation (ex: sludge) in circuit tank while doing a long drive. It can lead to damage of HST, deterioration of hydraulic oil, and malfunction of it.

  • Page 91: Tests And Adjustment

    1022H TRACTOR CHAPTER 4 HST SYSTEM 7. TESTS AND ADJUSTMENT 7.1 HYDROSTATIC PEDAL AND NEUTRAL ADJUSTMENT REASON To ensure that tractor does not move unless the forward or the reverse pedal is depressed. PROCEDURE 1. Operate the hydrostatic control pedals. They should return by themselves to the neutral position.

  • Page 92: Hydrostatic Pump Pressure Test

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 7.2 HYDROSTATIC PUMP PRESSURE TEST REASON CAUTION • AvOID SUDDEN TRACTOR MOvEMENT. To ensure that internal parts of the hydrostatic pump Tractor could move suddenly causing severe are not worn excessively, and the relief valves are injure or damage to equipment during test operating properly.
  • Page 93 1022H TRACTOR CHAPTER 4 HST SYSTEM FIG. 4-8 RESULTS If pressure will not reach 180~210kgf/cm in either direction, check charge. • Pressure (SEE ”CHARGE PUMP PRESSURE TEST) 1. If charge pressure is good and hydrostatic pump pressure will not get up to relief pressure hydrostatic pump is worn or damaged.

  • Page 94: Charge Pump Pressure Test

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 7.3 CHARGE PUMP PRESSURE TEST 4. Cycle all controls to relieve any pressure that may REASON be in the hydraulic system. To ensure that charge pump is operating at specified FIG. 4-10 pressure to supply oil to hydrostatic pump.

  • Page 95: Hydraulic System Bleed Procedure

    1022H TRACTOR CHAPTER 4 HST SYSTEM 7.4 HYDRAULIC SYSTEM BLEED PROCEDURE 8. Operate rockshaft several times until it operates REASON smoothly. To remove air trapped in the hydraulic system which 9. Stop the engine and check the hydraulic reservoir will prevent proper operation.

  • Page 96: Repair

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 8. REPAIR 8.1 HYDROSTATIC SPLITTING 9. Remove the hydraulic pipes and gear pump. PREPARE THE TRACTOR Cut the clamps. 1. Park tractor on a level surface. Disconnect the wiring harness. 2. Shut off engine.
  • Page 97 1022H TRACTOR CHAPTER 4 HST SYSTEM 9. Remove the drive shaft. INSTALLATION Remove the HST unit. Install the reverse order of disassembly. FIG. 4-13 1. Clean the surface of input metal before installing the O-Rings. 2. Apply grease or gear oil to O-rings.

  • Page 98: Hydrostatic Overhaul

    CHAPTER 4 HST SYSTEM 1022H TRACTOR 8.2 HYDROSTATIC OvERHAUL 8.2.1 TOOLS Tool Name Size & Set value Rubber hammer Driver (-) 150mm Snap ring plier (For inner hole) Snap ring plier (For shaft) Torque wrench 400 kgf.cm, 800kgf.cm Socket wrench...

  • Page 99: Disassembly Procedure

    1022H TRACTOR CHAPTER 4 HST SYSTEM 8.2.3 DISASSEMBLY PROCEDURE PROCESS DRAWING DESCRIPTION (Figure-1) 1. Take off VALVE CASING. a . Loosen SOCKET BOLT (45)[M8x40L] 8pcs. b . Take off VALVE CASING (ASS'Y). Refer (Figure-1) ☆ Be careful not to drop VALVE PLATE.
  • Page 100 CHAPTER 4 HST SYSTEM 1022H TRACTOR PROCESS DRAWING DESCRIPTION (Figure-4) 3. Disjoin CYL'D BLOCK a . Take off GASKET, PIN (l4), SPRING (CHARGE) (20) Refer (Figure-4) (Figure-5) h . Take off CYL'D BLOCK ASS'Y (Motor side) Refer (Figure-5) (Figure-5a) ! Be carefu l not to lost WASHER (24).
  • Page 101 1022H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (Figure-6) c. Take off CYL'D DLOCK ASS'Y (Pump Side) Refer (Figure-6) (Figure-6a) ! Be careful not to lost WASHER (24) Refer (Figure-6a) (Figure-6b) 4. COMPONENTS OF CYL'D BLOCK ASS'Y (COMMON FOR PUMP, MOTOR)
  • Page 102 CHAPTER 4 HST SYSTEM 1022H TRACTOR PROCESS DRAWING DESCRIPTION (Figure-7) 5. Separate SHAFT (M) Refer (Figure-7) (Figure-8) 6. Disjoin THRUST BALL BEARING (15) (Motor side) a. Using the princ iple of leverage, separate THRUST BALL BEARING (lS) with L-WRENCH Refer (Figure-8) (Figure-9) 7.
  • Page 103 1022H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (Figure-10) 8. Separate DRY BEARING (19) with a driver ( - ) Refer (Figure-10) (Figure-11) 9. Separate THROTTLE GUIDE (12). Refer (Figure-11) (Figure-12) 10. Separate SNAP RING (39) (Pump side). Refer (Figure-12) (Figure-13) 11.
  • Page 104 CHAPTER 4 HST SYSTEM 1022H TRACTOR PROCESS DRAWING DESCRIPTION (Figure-14) 12. Separate SNAP RING (38) (LEVER Side) Refer (Figure-14) (Figure-15) 13. Separate LEVER (lO). Refer (Figure-15) (Figure-16) 14. Separate BALL BEARING (29), OIL SEAL (33), SNAP RING (37). Refer (Figure-16) (Figure-17) 15.Disassemble VALVE CASING...

  • Page 105: Pre-Assembly Precautions

    1022H TRACTOR CHAPTER 4 HST SYSTEM 8.2.4 PRE-ASSEMBLY PRECAUTIONS 1. Wash each part with a cleaning (washing) oil and dry it with a clean air. 2. Take a special care in handling each part to prevent stain by dirt or foreign materials, and any possible puncture, traces of holes or any other physical damage.
  • Page 106 CHAPTER 4 HST SYSTEM 1022H TRACTOR PROCESS DRAWING DESCRIPTION (Figure-21) 19. Assembly of DRY BEARING (19). Refer (Figure-21) (Figure-22) 20. Assembly of SWASH PLATE. a) Assembly of THROTTLE GUIDE (1 2). (LEVER side) b) Adjust SWASH PLATE (6) to the hole and assemble...
  • Page 107 1022H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (Figure-24) 21. Assembly of SHAFT (M) (8). Refer (Figure-24) (Figure-25) 22. Assembly of CYL'D BLOCK ASS'Y. Refer (Figure-25) (Figure-26) 23. Assembly of GASKET. a) Assembly of PIN (14). b) Fit GASKET (17) in PIN.
  • Page 108 CHAPTER 4 HST SYSTEM 1022H TRACTOR PROCESS DRAWING DESCRIPTION (Figure-27) 24. Assembly of VALVE CASING ASS'Y. a) Assembly of PLUG (44)[UNF3/4-16] 4pcs. b) Assembly of PLUG (43)[UNF1/2-20] 1pcs. c) After assembling RELIEF ASS'Y put together SPRING (RELIEF PLUG) (54) 2pcs and then PLUG (53)[UNF3/4- 16 RELIEF] 2pcs.
  • Page 109 1022H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (Figure-30) f) Apply a grease lightly on the it and Assembly of CHECK (CHARGE) (13). Refer (Firgure-30) (Figure-31) 25. Assembly of MAIN CASING ASS'Y and VALVE CASING ASS'Y. a) Join SOCKET BOLT (45)[M8x40L] 8pcs with TORqUE WRENCH.
  • Page 110 CHAPTER 4 HST SYSTEM 1022H TRACTOR (Figure-33)PRESS-FITTING PART OF VALVE CASING K19W114A • Install the NEEDLE BEARING that LOT NO. is shown B22W-202010...
  • Page 111 1022H TRACTOR CHAPTER 4 HST SYSTEM (Figure-34) PRESS-FIT SHAFT (P) BEARING K19W115A B22W-202010...
  • Page 112 CHAPTER 4 HST SYSTEM 1022H TRACTOR (Figure-35) PRESS-FITTING PART OF REAR COVER (P) (Figure-37)LEVER ASS’Y PRESS-FITTING PART K19W116A K19W118A (Figure-36)SHAFT (P) ASS’Y PRESS-FITTING PART K19W117A B22W-202010...
  • Page 113 1022H TRACTOR CHAPTER 4 HST SYSTEM (Figure-38) Assembly drawing K19W119A B22W-202010...
  • Page 114 CHAPTER 4 HST SYSTEM 1022H TRACTOR (Figure-39) Section drawing K19W120A B22W-202010...
  • Page 115 CHAPTER 5 TRANSMISSION TABLE OF CONTENTS 1. GENERAL DESCRIPTION ...... 5-3 1.1 Wheel driving system ......5-3 1.2 PTO drive system ........5-3 1.3 Power train diagram .......5-3 2. SPECIFICATIONS ........5-4 2.1 Wheel drive system ........5-4 2.2 PTO drive system ........5-4 3.
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  • Page 117: General Description

    1022H TRACTOR CHAPTER 5 TRANSMISSION 1. GENERAL DESCRIPTION 1.1 WHEEL DRIvING SYSTEM The wheel driving system is composed of the following major components: WHEEL DRIVE SYSTEM Engine Pulley HST system Range shift gears Transmission Front drive change gears PTO Clutch...

  • Page 118: Specifications

    CHAPTER 5 TRANSMISSION 1022H TRACTOR 2. SPECIFICATIONS 2.1 WHEEL DRIvE SYSTEM Unit : km/h 1022H Engine rated rpm : 3,200 rpm Speed shift range Main speed shift L (Low) 0.517 (15/29) Reduction ratio Speed range shift 1.095 (23/21) H (High) 0.485 (16/33)

  • Page 119: Disassembly, Inspection And Reassembly

    1022H TRACTOR CHAPTER 5 TRANSMISSION 3. DISASSEMBLY, INSPECTION AND REASSEMBLY 3.1 HST UNIT, RANGE GEARS, 4WD GEARS AND PTO CLUTCH, REAR PTO GEARS, MID PTO GEARS FIG. 5-1 K19W121A B22W-202010...

  • Page 120: Disassembly

    CHAPTER 5 TRANSMISSION 1022H TRACTOR 3.1.1 DISASSEMBLY Removal of HST system and change parts. Separate the engine from the rear transmission referring to the paragraph of SECTION 8. REPAIR in CHAPTER 4. 1. Remove the HST unit and filter. Remove the levers of 4WD, PTO and range shifting.
  • Page 121 1022H TRACTOR CHAPTER 5 TRANSMISSION 2. Remove the input metal and hydraulic filter. FIG. 5-3 K19W123A (1) GEAR PUMP ASSY (1) CASE , REAR TM (2) ADAPTOR COMP , SUCTION UPPER (2) PLUG , HEX-SOCKET (3) BOLT , HEX-SOCKET (3) PIN , PARALLEL/A (4) BAND CLAMP 32 (4) BOLT , HEX FLANGE (11xM10x1.5P-35)
  • Page 122 CHAPTER 5 TRANSMISSION 1022H TRACTOR 3. Remove the 4WD shift arm, range shift arm and PTO shift linkage. Remove the hydraulic cylinder assembly. Separate the input metal from rear TM gradually. Be careful not to damage all parts. Remove the gear pump gears, drive gears, 4WD gears and PTO gears and mid PTO gears.
  • Page 123 1022H TRACTOR CHAPTER 5 TRANSMISSION 4. Remove the bolts which are tightened to rear axle housing (10x M10x1.5p-35). Remove the diff-lock arm and diff-lock linkage. Separate the rear axle housing from the rear TM gradually. Take out the pinion shaft, spiral bevel gear, stopper ring and brake system.
  • Page 124 CHAPTER 5 TRANSMISSION 1022H TRACTOR 5. Disassembly, inspection and reassembly of the PTO clutch assembly FIG. 5-6 K19W126A (1) SHAFT, PTO CLUTCH (9) PISTON (16) C-RING, HOLE (80) (2) BEARING BALL (6204) (10) SPRING (17) BEARING, BALL (6204) (3) O-RING (P16)
  • Page 125 1022H TRACTOR CHAPTER 5 TRANSMISSION g. When pushing respective bearings into the shaft FIG. 5-7 or hole, be careful only to push their inner or outer races. h. Install the snap ring in correct direction. i. After reassembly, check to see that the hub turns smoothly by locking the PTO clutch.

  • Page 126: Reassembly And Inspection

    CHAPTER 5 TRANSMISSION 1022H TRACTOR 3.1.2 REASSEMBLY AND INSPECTION Reassemble the parts in the reverse order of disassembly. NOTE • When installed, all parts should be washed with clean oil ahead of time. 1. Put the rear transmission case to safety area.
  • Page 127 1022H TRACTOR CHAPTER 5 TRANSMISSION FIG. 5-10 - PTO counter gears K19W130A (13) BEARING, BALL (1) COVER, PTO (7) CAP, PTO SHAFT (19) PIN, SPRING (2) GEAR, SPUR 38T (8) BOLT, HEX/SP (14) C-RING, SHAFT (20) C-RING, SHAFT (3) BEARING, BALL...
  • Page 128 CHAPTER 5 TRANSMISSION 1022H TRACTOR 3. Install the bearings (13, 14) and stopper ring (15) to the spiral bevel pinion (12). Install the spiral bevel pinion to the rear transmission case. Install the range gears and PTO clutch gears and 4WD gears together.
  • Page 129 1022H TRACTOR CHAPTER 5 TRANSMISSION FIG. 5-13 NOTE • When the shifting stay is installed into the shifting fork, Install the spring and ball and stay to the fork as shown in the picture. And after applying the grease on the O-ring.
  • Page 130 CHAPTER 5 TRANSMISSION 1022H TRACTOR NOTE FIG. 5-15 K19W135A • Install the spring pin as shown in the picture. FIG. 5-16 Range gears K19W136A B22W-202010...
  • Page 131 1022H TRACTOR CHAPTER 5 TRANSMISSION 4. Install the gears for gear pump. 6. Install the rear axle shaft (LH) to the rear transmission case. FIG. 5-17 Install the sealant (11), stopper ring (12), bearing (13), washer (14), stopper ring (15) and to the rear axle shaft (10).
  • Page 132 CHAPTER 5 TRANSMISSION 1022H TRACTOR 7. Install O-rings to 4WD arm comp. Apply the grease FIG. 5-20 on the O-rings. Install the 4WD arm comp (5) into the range arm comp through the input metal. NOTE • Apply the adhesive (TB1215) on the rear transmission case.
  • Page 133 1022H TRACTOR CHAPTER 5 TRANSMISSION 8. Apply a coat of molybdenum of molybdenum disulfide-based grease (Three bond TB1901 or equivalent) to revolving or sliding parts prior to reassembly. Assemble the bevel gears and washers and pinion gears into the differential case.
  • Page 134 CHAPTER 5 TRANSMISSION 1022H TRACTOR 9. Install the rear axle housing (RH) to the rear transmission case. Install the sealant (27), stopper ring (28), bearing (29), washer (30), stopper ring (31) and to the rear axle shaft (26). NOTE • Apply the adhesive (TB1215) on the outside of sealant (27).
  • Page 135 1022H TRACTOR CHAPTER 5 TRANSMISSION 11. Rear PTO and MID PTO OPERATION FIG. 5-23 K19W143A a. Start the engine, and wait for 5 minutes to warm up the engine. PTO shifting lever is engaged to rear PTO or MID PTO.

  • Page 136: Inspection

    CHAPTER 5 TRANSMISSION 1022H TRACTOR 3.1.3 INSPECTION Before and after disassembly, inspect each part for serious worn or damaged part, and replace if necessary. Inspect bearings such as ball bearings and needle bearings for abnormalities in rotation such as irregularity, hitching by turning them with pressure applied by hand.

  • Page 137: Drive Train

    1022H TRACTOR CHAPTER 5 TRANSMISSION 3.2.2 DRIvE TRAIN FIG. 5-25 K19W145A 3.2.3 REAR AXLE ASSEMBLY FIG. 5-26 K19W146A B22W-202010...

  • Page 138: Troubleshooting

    CHAPTER 5 TRANSMISSION 1022H TRACTOR 4. TROUBLESHOOTING 4.1 WHEEL DRIvE SYSTEM Problems Causes Countermeasures Insufficient or improper lubricant Replenish or replace Excessive splines of change shaft, spline hub, etc Replace Transmission makes noise in neutral Worn or broken bearings Replace...

  • Page 139: Pto Drive System

    1022H TRACTOR CHAPTER 5 TRANSMISSION 4.2 PTO DRIvE SYSTEM Problem Causes Counter measures PTO shift lever is in neutral Shift lever positively to ON Defective PTO switch Replace PTO does not spin with Clogged PTO hydraulic line Wash clean, Replace...
  • Page 140 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
  • Page 141 CHAPTER 6 FRONT AXLE (4WD) TABLE OF CONTENTS 1. GENERAL DESCRIPTION ...... 6-3 2. SPECIFICATIONS ........6-4 3. DISASSEMBLY, INSPECTION AND REASSEMBLY ......6-5 3.1 Pivot pin ..........6-5 3.1.1 Disassembly ........6-6 3.1.2 Inspection ......... 6-7 3.1.3 Reassembly ........6-8 3.2 Front differential ........6-9 3.2.1 Disassembly ........
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  • Page 143: General Description

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 1. GENERAL DESCRIPTION FIG. 6-1 K19W147A The 4WD front axle is a center pivot type. The front wheel drive mechanism is incorporated as a part of the axle. The front wheel drive power is taken off the rear transmission and transmitted to the differential in the front axle where the power is divided into right and left and to the respective final cases.

  • Page 144: Specifications

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 2. SPECIFICATIONS FIG. 6-2 K19W148A 1022H Toe-in (mm) 3° Camber Wheel alignment Caster 0° King pin 12° Pivot Pin Diameter (mm) Ø22 Pivot bush (mm) Ø22xØ25xL25 Front axle Housing Inner Diameter (mm) Ø25 LH : 50˚, RH : 45˚...

  • Page 145: Disassembly, Inspection And Reassembly

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3. DISASSEMBLY, INSPECTION AND REASSEMBLY 3.1 PIvOT PIN FIG. 6-3 K19W149A (13) PIN (1) SUPPORT, 4WD ASSY (7) COUPLING (2) BOLT, HEX/S (8) 4WD UNIVERSAL JOINT SHAFT ASSY (14) BUSH (22X25X25) (3) BEARING, BALL...

  • Page 146: Disassembly

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 3.1.1 DISASSEMBLY FIG. 6-4 K19W150A 1. Dismount the front axle assembly by referring to the pertinent paragraph in chapter 2. 2. Disconnect the steering hoses (LH, RH). 3. Suspend the front axle bracket with a chain.

  • Page 147: Inspection

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.1.2 INSPECTION 1. FRONT AXLE BUSH BORE DIAMETER 2. FRONT AXLE PIN DIAMETER Measure the bore diameter of the bush in the front Measure the diameter of the pin at bush contact axle housing at the pin contact point with a micro- point with a micro-meter or vernier calipers.

  • Page 148: Reassembly

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 3.1.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, NOTE following these instructions. • Slanted or forced installation of the bush should be avoided, and the bore surface of the bush should not be damaged.

  • Page 149: Front Differential

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.2 FRONT DIFFERENTIAL FIG. 6-10 K19W156A (13) GEAR, DIFF 15T (1) PINION, BEVEL 9T (7) C-RING, HOLE 52 (2) BEARING, BALL 6205 (8) SEAL, OIL (14) PIN, SPRING 4x25 (3) WASHER, 25X42X2 (9) BEARING, BALL 6008...

  • Page 150: Disassembly

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 3.2.1 DISASSEMBLY 1. As concerns operation prior to removal of the front 5. Remove the oil seal, axle, refer to the paragraph covering disassembly pull out the snap rings. of the center pivot.

  • Page 151: Inspection

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.2.2 INSPECTION 6. Remove the bearings, spacer collar 1. Visually check the bearing surfaces of the bevel pinion and ring gear teeth. 7. Remove the C-ring and washer and bearings. NOTE FIG. 6-13 •...

  • Page 152: Reassembly

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 3.2.3 REASSEMBLY Reassembly the parts in reverse order of disassembly, 4. 4WD shaft assembly following these instructions. a. Install the snap ring (4) and bearing (3) in the 4wd support (1). 1. Each friction surface should be coated with grease b.

  • Page 153: Final Case

    1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.3 FINAL CASE FIG. 6-18 K19W163A ▶ FINAL CASE (A) (17) SEAL, OIL (1) AXLE HOUSING, FRONT (9) CASE, RH FINAL DRIVE A (10) BOLT, HEX/S M12x35 (2) SHAFT, LH (18) BEARING, BALL 6909...

  • Page 154: Disassembly

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 3.3.1 DISASSEMBLY 3.3.3 REASSEMBLY 1. Drain oil from the final case (LH/RH) by removing Reassemble the parts in reverse order of disassembly, the drain plug (12) and air breather plug (12). following these instructions.
  • Page 155 1022H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3. Install the bearing (6304), shaft, bearing (6908), 7. Install the wheel shaft and the bevel gear and and snap ring in the final drive case B. bearing (6205). 8. Install the O-ring after applying the grease.

  • Page 156: Trouble Shooting

    CHAPTER 6 FRONT AXLE (4WD) 1022H TRACTOR 4. TROUBLE SHOOTING PROBLEMS AND PROBABLE CAUSES COUNTERMEASURES ● STEERINg WHEEL HARD TO TURN 1) Too low tire inflation Inflate to specified value 2) Broken thrust bearing Replace 3) Stuck or broken ball joint of tire-rod end Grease or replace...
  • Page 157 CHAPTER 7 REAR AXLE AND BRAkES TABLE OF CONTENTS 1. GENERAL DESCRIPTION .......7-3 2. SPECIFICATIONS ........7-3 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY ......7-4 3.1 Rear axle housing and brake system ..7-4 3.1.1 Disassembly ........7-5 3.1.2 Inspection ......... 7-8 3.1.3 Reassembly ........
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  • Page 159: General Description

    1022H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 1. GENERAL DESCRIPTION FIG. 7-1 K19W169A The rear axle system is of the central axle type, which contains the final reduction gears, differential gears with diff-lock, and brakes. The power from the engine is transmitted to the right and left wheel pinions through the differential gears, and reduced in the revolution to the rear wheels by the wheel gears.

  • Page 160: Disassembly, Inspection, And Reassembly

    CHAPTER 7 REAR AXLE AND BRAKES 1022H TRACTOR 3. DISASSEMBLY, INSPECTION, AND REASSEMBLY Separate the rear axle housing from the rear transmission referring to paragraph in Chapter 2 3.1 REAR AXLE HOUSING AND BRAkE SYSTEM FIG. 7-2 K19W170A B22W-202010...

  • Page 161: Disassembly

    1022H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 3.1.1 DISASSEMBLY 1. Removal of the brake rod linkage. 2. Release the parking brake linkage. 3. Detach the spring (24) and the brake rod. 4. Remove the spring pin (16) and arm comp. and brake pedal.
  • Page 162 CHAPTER 7 REAR AXLE AND BRAKES 1022H TRACTOR 9. Remove the rear axle housing assembly (1) from the rear transmission case. NOTE • Extract the rear axle housing assembly with crane. Remove the spur gear 10T (2) and the snap ring (4) and the spiral bevel gear and bearing and brake system.
  • Page 163 1022H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 11. Remove the arm comp (16). Remove the differential gear assembly and diff-lock system. Remove the spur gear 56T (11). Remove other parts as shown in the below picture. FIG. 7-5 K19W173A...

  • Page 164: Inspection

    CHAPTER 7 REAR AXLE AND BRAKES 1022H TRACTOR 3.1.2 INSPECTION 1. FRICTION PLATES. 3. SEPARATOR PLATE Replace the plates whose surfaces have been Measure the thickness and replace the plate whose become glossy by carbonization or whose thickness thickness exceeds the usable limit or whose surfaces exceeds the usable limit.

  • Page 165: Reassembly

    1022H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 3.1.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, NOTE follow these precautions. • When installing the brake disc, Disc plate and separator should be arranged in correct order. • Apply an grease to the oil seal and take care not 1.

  • Page 166: Trouble Shooting

    CHAPTER 7 REAR AXLE AND BRAKES 1022H TRACTOR 4. TROUBLE SHOOTING PROBLEM CAUSES COUNTERMEASURES 1) REAR AXLE · Worn or damaged bearing Replace Noises · Worn gear or wheel shaft Replace 2) BRAkE SYSTEM · Insufficient depressing of brake pedals...
  • Page 167 CHAPTER 8 POWER STEERING SYSTEM TABLE OF CONTENTS 1. GENERAL DESCRIPTION ...... 8-3 4. DISASSEMBLY, INSPECTION, AND REASSEMBLY ......8-7 2. SPECIFICATIONS ........8-4 4.1 Major component of steering valve (reference) ..... 8-7 2.1 Gear pump ..........8-4 4.2 Special tools ..........8-8 2.2 Power steering valve unit .......8-4 4.3 Disassembly ..........8-9 2.3 Oil tank ..........8-4...
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  • Page 169: General Description

    1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM 1. GENERAL DESCRIPTION The hydraulics of this power-assisted steering system are actuated by a specially designed steering valve System. Non Load reaction valve blocks the L,R cylinder ports in neutral condition and does not transmits the reaction load of the tire to the steering wheel in neutral.

  • Page 170: Specifications

    CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR 2. SPECIFICATIONS 2.1 GEAR PUMP MODEL 1022H Delivery (cc/rev) 1,800 rpm 14.6 LPM Pump performance 100 (kgf/cm 2,990 rpm 24.2 LPM Rated pressure (kgf/cm Maximum pressure (kgf/cm 500 ~ 3,200 Rated operation speed (rpm) Rotation direction C.W as viewed from shaft end...

  • Page 171: Function (Reference)

    1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM 3. FUNCTION (REFERENCE) SHINJIN is a hydrostatic steering unit which can be SHINJIN-ON used with an add-on steering column, SHINJIN-T or Open center steering units have open connection with the steering column integrated with the unit.

  • Page 172: Manual Steering Pressure

    CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR 3.1.1 MANUAL STEERING PRESSURE 3.1.3 SHOCk vALvES (REFERENCE) Under normal operating where the steering pumps The shock valves protect the steering unit against supplies an adequate oil flow at the required pressure, shocks from external forces on the steering cylinder.

  • Page 173: Disassembly, Inspection, And Reassembly

    1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM 4. DISASSEMBLY, INSPECTION, AND REASSEMBLY 4.1 MAJOR COMPONENT OF STEERING vALvE (REFERENCE) FIG. 8-2 K19W182A (1) Dust seal ring (11) Cross pin (18) O-ring (2) Housing spool and sleeve (12) Set of springs...

  • Page 174: Special Tools

    CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR 4.2 SPECIAL TOOLS A. Holding tool, code no. SJ150L9001-01 D. Assembly tool for dust seal ring, code no. SJ150L0396 -01 K19W183A K19W186A B. Assembly tool for shaft seal ø17.5, E. Pliers for piston in pressure relief valve, code no.

  • Page 175: Disassembly

    1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM 4.3 DISASSEMBLY Separate the orbitrol referring to FIG. 8-2 of SECTION. STEP 4. Disassembly, Inspection and Reassembly 4.1 Major - Gear wheel set (17, 18) component of steering valve (orbitrol). Hold a hand under the gearwheel set to keep the gearwheel from falling out.

  • Page 176: Cleaning, Inspection, Replacement And Lubrication

    CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR 4.5 REASSEMBLY STEP 1. STEP 9. - Housing (2) - Cross pin (11) Place the OSPM housing horizontally in the holding Press the pin out of the spool set. tool, with the hole for the output shaft facing the tool.
  • Page 177 1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM STEP 4. STEP 7 - Springs (12) - Housing /spool/sleeve (2) Insert the curved springs between the flat springs and a. With the housing still horizontal in the holding tool push them into place (see sketch).
  • Page 178 CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR STEP 10 STEP 14. - Cardan shaft (13) - Special screws (20, 22,23) Fit the cardan shaft into the inner spool and allow it to Fit screws (with O-rings). Remove the retainer fork.
  • Page 179 1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM STEP 18. Dust seal (1) Guide the dust seal ring down over the shaft end press into place in the housing with assembly tool. SJ 150L0396 - 01. NOTE • The dust seal must be fitted after testing so that any leakage from the shaft seal can be detected.

  • Page 180: Troubleshooting

    CHAPTER 8 POWER STEERING SYSTEM 1022H TRACTOR 5. TROUBLESHOOTING PROBLEMS AND PROBABLE CAUSES COUNTER MEASURES 1. STEERING WHEEL IS vERY HEAvY TO TURN 1) Poor assemble between steering column and unit. (1) Spline of column and unit are assembled tightly.
  • Page 181 1022H TRACTOR CHAPTER 8 POWER STEERING SYSTEM PROBLEMS AND PROBABLE CAUSES COUNTER MEASURES 4. STEERING WHEEL RESISTANCE WITH TURNING (1) Worn of spline gear column - Replace column - Wash,and Adjust fluid level and pressure properly (2) Depressed control set...
  • Page 182 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
  • Page 183 CHAPTER 9 HYDRAULIC SYSTEM TABLE OF CONTENTS 1. GENERAL DESCRIPTION ...... 9-3 2. SPECIFICATIONS ........9-4 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM ....9-5 3.1 Hydraulic system ........9-5 3.2 Divider valve and PTO solenoid valve..9-6 3.2.1 General description......9-6 3.2.2 Gear pump body and optional valve (unloading) ....9-6 3.2.3 PTO solenoid valve ......
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  • Page 185: General Description

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 1. GENERAL DESCRIPTION The hydraulic system is composed of a gear pump, valves, oil filter, cylinder (actuator), piping, etc. The implement lift is operated by a control valve which is actuated by the control lever through a link mechanism.

  • Page 186: Specifications

    CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR 2. SPECIFICATIONS Model 1022H Hitch lift capacity, (kg) Piston And cylinder 600 / 480 At lower link top end / 24 inches behind link arms Cylinder port leaks (cc/min) (under a pressure of 9800kpa (100 kgf/cm...

  • Page 187: Major Component Of The Hydraulic System

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM 3.1 HYDRAULIC SYSTEM FIG. 9-2 28 27 29 T19W023A (34) TUBE (1) SHAFT , LIFT (16) O-ring (2) BUSH , 35X42X40 (17) POPPET (41) GUIDE , SPRING...

  • Page 188: Divider Valve And Pto Solenoid Valve

    CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR 3.2 DIvIDER vALvE AND PTO SOLENOID vALvE 3.2.1 GENERAL DESCRIPTION Gear pump body is installed to bypass working fluid of a specified pressure constantly from the main circuit into the main control valve and power steering valve through a priority valve. Gear pump has a function to be a zero pressure in the power steering line with a optional valve.

  • Page 189: Pto Solenoid Valve

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 3.2.3 PTO SOLENOID vALvE This solenoid is switched on or off by operating the PTO switch. The oil pressure flows from the back pressure of the power steering valve. When the PTO solenoid is switched 「ON」 , 「 OFF」 .
  • Page 190 CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR FIG. 9-6 T19W025A B22W-202010...

  • Page 191: Flow-Control Valve (Slow-Return Check Valve)

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 3.3 FLOW-CONTROL vALvE (SLOW-RETURN CHECk vALvE) 3.3.1 GENERAL DESCRIPTION This valve regulates the lowering speed of the lift by controlling the unloading flow from the lift cylinder to the tank. FIG. 9-7 K19W200A (1) GUIDE, SPRING...

  • Page 192: Relief Valve

    CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR 3.4 RELIEF vALvE 3.4.1 GENERAL DESCRIPTION This valve regulates the maximum pressure in the whole hydraulic circuit. The regulated pressure can be set with the adjust screw. This valve is installed into the gear pump block.

  • Page 193: Gear Pump

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 3.5 GEAR PUMP 3.5.1 GENERAL DESCRIPTION This pump induces fluid from one side and delivers it to the power steering valve and main control valve through gear pump body by rotating the PTO gears meshed.

  • Page 194: Strainer Suction

    CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR 3.6 STRAINER SUCTION FIG. 9-12 K19W205A 3.6.1 GENERAL DESCRIPTION The tractor is equipped with the hydraulic filter. 3.6.2 SPECIFICATIONS Applicable oil GEAR OIL SAE 80W90 Rated flow rate (ℓ/min.) Filtration density (mesh) 150 mesh Filtration area 82 cm Working oil temperature (°C)

  • Page 195: Hydraulic System

    1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 4. HYDRAULIC SYSTEM NOTE NOTE • Hydraulic system must be washed clean, and • Apply grease to the O-ring in advance. care must be taken to prevent any foreign 8. Install the fork to piston control lever after installing substances.
  • Page 196 CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR FIG. 9-13 FIG. 9-14 Direction of the bush K19W207A K19W206A FIG. 9-15.Lift arm K19W208A FIG. 9-16. Hydraulic cylinder. T19W027A B22W-202010...
  • Page 197 1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM NOTE FIG. 9-19 • Be sure not to over operate within specified spool stroke (9mm between up and down at neutral position) FIG. 9-17 K19W212A (1) VALVE, CONTROL (5) O-RING, P12 (2) BOLT, HEX/S (M8X25) (6) LEVER COMP, POSITION (3) FORK, VALVE...

  • Page 198: Troubleshooting

    CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR 5. TROUBLESHOOTING Problems Causes Countermeasures 1) Insufficient engine speed Raise engine speed slightly Maintain oil level by replenishing with the 2) Insufficient transmission oil same kind of oil 3) Air taken in through suction Tighten securely or replace broken parts.
  • Page 199 1022H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM Problems Causes Countermeasures 3. Lift lowers even Lap after disassembling,cleaning,repairing 1) Stuck poppet flaws with oil stone when adjust knob is closed fully with 2) Poor valve seat Replace valve adjust Handle (While engine is...
  • Page 200 CHAPTER 9 HYDRAULIC SYSTEM 1022H TRACTOR Problems Causes Countermeasures Inspect,clean,and eliminate dust. Repair Poorly connected piping flaws with oil stone if necessary. Retighten. 11. Oil leaks from Poor O-ring Replace piping or joints Replace with a new one after washing clean Broken piping related parts.
  • Page 201 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS TABLE OF CONTENTS 1. GENERAL DESCRIPTION ....10-3 5. GENERAL ELECTRICAL ARRANGEMENT ..10-15 5.1 Engine harness assembly ....10-16 2. SPECIFICATIONS ........10-3 5.2 Rear harness assembly ..... 10-18 3. BATTERY ..........10-4 6. WIRING DIAGRAM .......10-19 3.1 Inspection of electrolyte level ....10-4 3.2 Inspection of electrolyte specific gravity ..10-4 7.
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  • Page 203: General Description

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1. GENERAL DESCRIPTION The basic electrical system of tractors consists of the engine cranking system, battery charging system, lighting system, meters, switches, etc. For further information concerning the engine cranking equipment and battery charging equipment, please refer to the engine manual.

  • Page 204: Battery

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 3. BATTERY 3.2 INSPECTION OF ELECTROLYTE 3.1 INSPECTION OF ELECTROLYTE LEvEL SPECIFIC GRAvITY As the battery repeats charging and discharging The specific gravity of the electrolyte lowers as the during operation.The water content in the electrolyte...

  • Page 205: Battery Charging

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 3.3 BATTERY CHARGING If the specified gravity of the battery electrolyte in lower than 1.220 (at 20 °C),the battery should be recharged,because leaving an undercharged battery without recharging it will lead to permanent battery damage.The battery is subject to self-discharge at a...

  • Page 206: Battery Testing Charts

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 3.4 BATTERY TESTING CHARTS STEP 1 vISUAL INSPECTION Check for obvious damage such as cracked or broken case that shows loss of electrolyte, thermal damage,etc. Obvious damage No obvious damage Replace battery...
  • Page 207 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS STEP 3 Load test 1. Connect voltmeter and ampere load equal to ½ the cold cranking amperes (18°C) rating of the battery for 15 seconds. 2. Observe voltage at 15 seconds with load on. Disconnect load 3.

  • Page 208: Meters And Switches

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 4. METERS AND SWITCHES 4.1 METERS 4.1.1 REMOvAL 4.1.2 TACHO/HOUR METER 1. Remove the Dash cover (2). 1. CONSTRUCTION 2. Disconnect the negative cable from battery. An electric tachometer is employed along with a tachosensor.

  • Page 209: Fuel Gauge

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.1.3 FUEL GAUGE ▶ FUEL GAUGE SENSOR (vARIABLE RESISTOR) 1. CONSTRUCTION Check each resistance value with a tester at each float When the fuel tank is full, the float is at the top and position as shown in FIG.

  • Page 210: Starter Switch

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 4.2 STARTER SWITCH REMOVAL INSPECTION 1. Remove the dash cover (2). 1. The main switch circuit, switching positions, and terminals are as shown in the figures. 2. Remove the ring nut holding the starter switch using a conventional screw driver.

  • Page 211: Combination Switch

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.3 COMBINATION SWITCH REMOVAL INSPECTION 1. Remove the dash cover (Lower). Each switch circuit is as shown, so check each switch for a continuity across respective terminals with a 2. Remove the combination switch.

  • Page 212: Stop Light Switch

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 4.4 STOP LIGHT SWITCH • Lighting FIG. 10-15 Stop light switch Color code (Red) (Red/Yellow) (Yellow) 3 : 1 8 : B1*1 2 : T ● ● ● *1 :Terminals **2: Switching positions •...

  • Page 213: Fuse

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.6 FUSE Fuses are installed in the main fuse box. FIG. 10-17 Fuse box Three fusible links are installed to protect the wiring from burning due to a short circuit. Each fuse is connected as follows K19W228A FIG.

  • Page 214: Trailer Socket (Reference)

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 4.7 TRAILER SOCkET (REFERENCE) A hella’s 7-pin trailer socket is equipped as an optional equipment.Lamp on a trailer can be operated through the socket. FIG. 10-23 K19W231A Specification Description Color Wire Housing...

  • Page 215: General Electrical Arrangement

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 5. GENERAL ELECTRICAL ARRANGEMENT FIG. 10-24 T19W029A B22W-202010...

  • Page 216: Engine Harness Assembly

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 5.1 ENGINE HARNESS ASSEMBLY FIG. 10-25 T19W030A B22W-202010...
  • Page 217 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS FIG. 10-26 T19W031A B22W-202010...

  • Page 218: Rear Harness Assembly

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 5.2 REAR HARNESS ASSEMBLY FIG. 10-27 T19W032A B22W-202010...

  • Page 219: Wiring Diagram

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 6. WIRING DIAGRAM FIG. 10-28 T19W033A B22W-202010...

  • Page 220: Troubleshooting

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 7. TROUBLESHOOTING IMPORTANT • Whenever effecting a repair the reason for the cause of the problem must be investigated and corrected to avoid repeating failure. • The following table lists problems and their possible causes with the recommended remedial action 7.1 LIGHTING SYSTEM...

  • Page 221: Instrumentation

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 7.2 INSTRUMENTATION Problems Causes Countermeasures Loose or broken wiring Inspect Circuit, tighten connections or renew wiring Defective meters Inspect and renew Inoperative or erratic meters Defective sensors Check and renew Defective Voltage regulator...

  • Page 222: Glow System

    CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR 7.3 GLOW SYSTEM Problems Causes Countermeasures Discharged Battery Check battery and charge or renew Loose or defective battery cable connections Inspect,clean,and tighten connections Check and ensure connectors securely Loose wire harness connections...

  • Page 223: Charging System

    1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 7.5 CHARGING SYSTEM Problems Causes Countermeasures Loose or worn alternator drive belt Check and adjust belt tension or renew Defective battery:It will not accept or hold Check condition of battery and renew Battery is low charge.Electrolyte level is low...
  • Page 224 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR CONVERSION TABLES Millimeters to inches 0.0394 1.0236 2.0079 2.9921 1.0630 3.0315 0.0787 2.0472 3.0709 0.1181 1.1024 2.0866 3.1102 0.1575 1.1417 2.1260 3.1496 0.1969 1.1811 2.1654 0.2362 3.1890 1.2205 2.2047 3.2283 0.2756 1.2598 2.2441...
  • Page 225 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS Inches to millimeters 0.3969 13/16 20.6375 1/64 25/64 9.9219 1/32 0.7938 13/32 10.3188 53/64 21.0344 3/64 27/32 21.4313 1.1906 27/64 10.7156 1/16 1.5875 7/16 11.1125 55/64 21.8281 5/64 1.9844 29/64 11.5094 22.2250 3/32 2.3813...
  • Page 226 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Feet to Meters Length 0.3050 1.8300 2.1350 0.0000 0.6100 0.9150 1.2200 1.5250 2.4400 2.7450 8.0532 3.3550 3.6600 3.9650 4.2700 4.5750 4.8800 5.1850 5.4900 5.7950 7.3200 7.9300 8.2350 21.1097 6.4050 6.7100 7.0150 7.6250 8.5400...
  • Page 227 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS Mile to kilometers miles miles 3.218 6.436 11.263 0.000 1.609 4.827 8.045 9.654 12.872 14.481 19.308 24.135 27.353 30.571 16.090 17.699 20.917 22.526 25.744 28.962 32.180 33.789 35.398 37.007 38.616 41.834 43.443 40.225...
  • Page 228 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Square inches to square centimeters Area 19.386 32.310 38.772 45.234 0.000 6.462 12.924 25.848 51.696 58.158 96.930 103.392 109.854 116.316 122.778 64.620 71.082 77.544 84.006 90.468 129.240 135.702 142.164 148.626 155.088 161.550 168.012 174.474 180.936 187.398 193.860 200.322 206.784 213.246 219.708 226.170 232.632 239.094 245.556 252.018...
  • Page 229 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS Cubic inches to Cubic Centimeters (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) 16.387 32.774 81.935 98.322 131.096 147.483 0.000 49.161 65.548 114.709 163.870 213.031 311.353 180.257 196.644 229.418 245.805 262.192...
  • Page 230 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Gallons (U.S) to Liters Volume US gal US gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 3.785 11.356 30.283 34.069 0.000 7.571 15.142 18.927 22.712 26.498 37.854 41.639 64.352 68.137...
  • Page 231 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS Gallons (IMP.) to Liters Imp. gal Imp. gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 13.6380 22.7300 27.2760 31.8220 36.3680 40.9140 0.0000 4.5460 9.0920 18.1840 45.4600 50.0060 54.5520 59.0980 63.6440 68.1900 72.7360 77.2820 86.3740...
  • Page 232 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Pounds to kilograms MASS 1.361 3.175 3.629 0.000 0.454 0.907 1.814 2.268 2.722 4.082 4.536 5.443 6.350 4.990 5.897 6.804 7.258 7.711 8.165 8.618 10.433 11.340 13.154 9.072 9.526 9.979 10.886 11.794 12.247...
  • Page 233 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS kilograms to Newton 39.228 49.035 88.263 0.000 9.807 19.614 29.421 58.842 68.649 78.456 137.298 186.333 98.070 107.877 117.684 127.491 147.105 156.912 166.719 176.526 235.368 284.403 196.140 205.947 215.754 225.561 245.175 254.982 264.789 274.596...
  • Page 234 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Pounds per square inches to kilograms per square centimeters Pressure lb/in lb/in (PSI) (PSI) Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm Kg/cm 0.0703 0.3516 0.6328 0.0000 0.1406 0.2109 0.2812 0.4219 0.4922...
  • Page 235 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS kilograms per square centimeters to kilo pascal Kg/cm Kg/cm 392.3 98.1 196.1 294.2 490.4 588.4 686.5 784.6 882.6 1373.0 1765.3 1863.3 980.7 1078.8 1176.8 1274.9 1471.1 1569.1 1667.2 2353.7 1961.4 2059.5 2157.5 2255.6...
  • Page 236 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Foot pounds to kilogram meters Torque ft lbs Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m Kg-m 0.138 0.276 0.414 0.552 0.690 0.828 0.966 1.104 1.242 1.380 1.932 2.346 1.518 1.656 1.794...
  • Page 237 1022H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS kilogram meters to newtonmeters Kg-m 39.230 49.030 9.810 19.610 29.420 58.810 68.650 78.450 88.260 137.330 147.130 176.550 186.360 98.100 107.910 117.710 127.520 156.910 166.750 225.620 235.430 245.230 255.010 264.850 274.650 284.460 196.200 206.010 215.810...
  • Page 238 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1022H TRACTOR Temperature Fahrenheit to Centigrade Centigrade to Fahrenheit ˚F ˚C ˚F ˚C ˚C ˚F ˚C ˚F 35.0 -28.9 -22.0 96.8 37.8 -26.1 -18.4 100.4 -23.3 40.6 -14.8 104.0 43.3 -20.6 -11.2 107.6 -17.8 46.1...
  • Page 239 CHAPTER 11 INDEX...
  • Page 240 CHAPTER 11 INDEX 1022H TRACTOR Divider valve and PTO solenoid valve ....9-6 Drive train ............. 5-23 After installation, each grease fitting should be filled with grease ......... 2-5 Air cleaning system ..........3-11 Element air cleaner..........3-12 Always use safety lights and devices ..... 1-8 Element installation ..........
  • Page 241 1022H TRACTOR CHAPTER 11 INDEX HST unit, range gears, 4wd gears and Model name plate ..........1-17 PTO clutch, rear PTO gears, mid PTO gears ..5-5 Monitor light array ..........1-24 Hydraulic hoses and lines........4-5 Hydraulic system ............ 9-5 Oil seals ..............
  • Page 242 CHAPTER 11 INDEX 1022H TRACTOR Reassembly ............7-9 Starter switch ............10-10 Reassembly ............8-10 Starting ..............4-15 Reassembly and inspection........5-12 Starting system ........... 10-22 Recognize safety information ......... 1-6 Stay clear of rotating shafts ........1-8 Regular check & replacement cycle Stop light switch..........
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