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Bad Boy 1025H Manual

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Operator's manual (144 pages)

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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 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.

※ 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.

Table of Contents

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phillip mosier

April 12, 2025

What drives the Hydrolics pump on 1025H tra ctor

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1 comments:

Mr. Anderson

April 12, 2025

The hydraulic pump on the Bad Boy 1025H tractor is driven by the engine.

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Summary of Contents for Bad Boy 1025H

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 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.
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 around the seat ...... 1-13 3. WARNING SIGNS IN THIS MANUAL ..1-5 5.3 Decals on the chassis ......
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Page 9: Introduction
CHAPTER 1 INTRODUCTION 1. INTRODUCTION This tractor service manual is for qualified service personnel engaged in servicing and overhauling 1025H 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 1025H 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.
Page 11: Warning Signs In This Manual
1025H 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 1025H 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
1025H 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 1025H 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
1025H TRACTOR CHAPTER 1 INTRODUCTION 4.12 PRACTICE SAFE MAINTENANCE 4.13 AvOID HIGH-PRESSURE FLUIDS Understand service procedure before doing work. Escaping fluid under pressure can penetrate the skin 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 1025H 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: Using External Control
1025H TRACTOR CHAPTER 1 INTRODUCTION 4.18 USING EXTERNAL CONTROL 4.20 SAFETY STARTER SWITCH 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.
Page 18: Safety Decals
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.
Page 19: Decals On The Dash Cover
1025H TRACTOR CHAPTER 1 INTRODUCTION 5.1 DECALS ON THE DASH COvER 25HW004A 5.2 DECALS AROUND THE SEAT K25W002A B25W-202010...
Page 20: Decals On The Chassis
CHAPTER 1 INTRODUCTION 1025H TRACTOR 5.3 DECALS ON THE CHASSIS 25HW006A 25HW006A B25W-202010...
Page 21: Universal Symbols
1025H 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 1025H 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
1025H 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 1025H TRACTOR 7.2.2 ENGINE EPA DECAL (2) 7.2.3 DESCRIPTION OF ENGINE MODEL NUMBER Ex) 3 TNV 80 F - S DKTF2 3 TNV 80 F - 0 0 0 0 0 Customer code Rated RPM EPA Tier4 below 19kW cerified...
Page 25: Specifications
1025H TRACTOR CHAPTER 1 INTRODUCTION 8. SPECIFICATIONS MODEL 1025H Maker YANMAR Model 3TNV80F-SDKTF Type Water cooled 4 cycle, 3 cylinder diesel Out put (KW (ps)/rpm) 17.8 (24.2) / 3,000 Number of Cylinder Displacement 1,267 cc Bore and Stroke 80 mm x 84 mm...
Page 26 CHAPTER 1 INTRODUCTION 1025H TRACTOR MODEL 1025H Type Independent Control Electro-Hydraulic Clutch Multiple wet Disk Shaft SAE 1-3/8,6 spline Rear PTO Speed 540 rpm @ Engine 2,903 rpm Shaft 15 Splines Mid PTO Speed 2,000 rpm @ Engine 2,875 rpm...
Page 27: Gear Train Diagrams
1025H TRACTOR CHAPTER 1 INTRODUCTION 9. GEAR TRAIN DIAGRAMS K25W005A B25W-202010...
Page 28: Precaution For Tractor Operation
CHAPTER 1 INTRODUCTION 1025H TRACTOR 10. PRECAUTION FOR TRACTOR OPERATION 10.1 INSTRUMENTS 25HW008A 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 29: Monitor Light Array
1025H TRACTOR CHAPTER 1 INTRODUCTION 10.1.1 MONITOR LIGHT ARRAY K25W210A High Beam Lamp is operated on the combination switch. Low beam lamp is operated on the combination switch. PTO MONITOR LAMP This lamp will turn on when PTO clutch is engaged.
Page 30: Controls
CHAPTER 1 INTRODUCTION 1025H TRACTOR 10.2 CONTROLS 25HW009A K25W007A K25W008A B25W-202010...
Page 31: Filling Diagram & Capacity Table
1025H TRACTOR CHAPTER 1 INTRODUCTION 10.3 FILLING DIAGRAM & CAPACITY TABLE K25W211A Filling point Fillings Quantity Liter (US gal) 50/50 : Ethylene Glycol/Water (L.L.C) RADIATOR 3.8 ℓ (1 US gal) ASTM D4985 / D6210 API : Over CF-4 grades Above:25°C (77°F)…SAE30 or 10W-30 ENGINE 2.7 ℓ...
Page 32: Maintenance Chart
CHAPTER 1 INTRODUCTION 1025H TRACTOR 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 33: Transmission
1025H TRACTOR CHAPTER 1 INTRODUCTION 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 34 CHAPTER 1 INTRODUCTION 1025H TRACTOR ○ 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 CHAPTER 2 DISASSEMBLY AND REASSEMBLY TABLE OF CONTENTS 1. GENERAL PRECAUTIONS FOR 2. OPERATION CHART FOR DISASSEMBLY SEPARATION AND REINSTALLATION 2-3 AND REASSEMBLY BY MAJOR BLOCkS .. 2-7 1.1 Before operation ........2-3 3. SEPARATION OF MAJOR COMPONENTS .. 2-8 1.2 Precautions to be followed when 3.1 Separation of the front axle installing standardized parts ....
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Page 37: General Precautions For Separation And Reinstallation
1025H 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 38: O-Rings
CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H 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 39: Bolts And Nuts
1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1.2.7 BOLTS AND NUTS 1.2.9 OTHER PRECAUTIONS 1. Special bolts are installed at several locations, so 1. Be sure not to damage any finished surfaces or parts. be sure not to interchange them other bolts.
Page 40 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR BOLT TIGHTENING TORQUE (Unit : kgf·m / N·m / lb·ft) 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 41: Operation Chart For Disassembly And Reassembly By Major Blocks
1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 2. OPERATION CHART FOR DISASSEMBLY AND REASSEMBLY BY MAJOR BLOCkS K25W216A B25W-202010...
Page 42: Separation Of Major Components
CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H 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 43: Separation Of The Engine And The Front Axle Bracket
1025H 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 44 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 5. Disconnect the head lamp wiring. FIG.2-6 Side cover FIG.2-8 Head lamp wiring K25W014A 4. Disconnect the negative and positive battery cables. Remove the ground wiring between engine and chassis, other wirings.
Page 45 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 7. Remove the air cleaner. 9. Remove the bolt which is tightened to muffler. FIG.2-10 Air cleaner assembly FIG.2-12 Muffler Bolt Suction pipe K25W018A K25W020A NOTE 8. Remove the inlet/outlet/drain pipe of radiator from •...
Page 46 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 11. Disconnect the accelerator and parking brake 12. Disconnect the other wirings and Fuel hoses. cable. FIG.2-15 Other wirings FIG.2-14 Accelerator cable K25W023A FIG.2-15 Other wirings K25W022A Glow Plug K25W024A FIG.2-15 Other wirings...
Page 47 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 13. Remove the hydraulic pipes. 15. Remove the cover on the floor panel (Center) if required. Remove the slow return grip ahead of FIG.2-16 Hydraulic pipes time. FIG.2-18 Drive shaft...
Page 48: Separation Of The Fuel Tank And The Front Axle Bracket
CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 3.3 SEPARATION OF THE FUEL TANk AND THE FRONT AXLE BRACkET. Parts which can be inspected during This operation INSTALLATION - Fuel tank Reassemble in reverse order of removal. - Instrument panel...
Page 49 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 9. Remove the knobs and steering wheel. 11) Disconnect the wires. Remove the instrument panel and cover when all FIG.2-22 wires are disconnected. Remove the bolts which are tightened to fuel tank bracket (LH, RH).
Page 50: Separation Of The Front Axle Bracket And The Transmission
CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 3.4 SEPARATION OF THE FRONT AXLE BRACkET AND THE TRANSMISSION Parts which can be inspected during This operation 3. Remove the control rod (F/R). - HST unit and pedal linkage FIG.2-25...
Page 51 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 5. Remove the hydraulic pipes. 7. Remove the bolts which are tightened to front axle bracket. FIG.2-27 FIG.2-29 K25W039A 8. Remove the drive shaft. FIG.2-30 K25W037A 6. Disconnect the wire.
Page 52 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR INSTALLATION 9 Remove the bolts which are tightened to front axle Reassemble in reverse order of removal. bracket. 1. During reassembly, make sure the splines stay aligned. Apply a thin coat of molybdenum grease(TB1901) to FIG.2-31...
Page 53: Separation Of The Exterior Component And The Transmission
1025H 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 lever cover (LH, RH), fender (LH, RH) - Fender assembly (LH, RH) after loosening the bolts.
Page 54 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 3. Remove the seat assembly after removing the pin. 4. Remove the ROPS after loosening the bolts (M12-40). Remove the seat frame comp. after loosening the It is possible to be separated in the middle of the bolts and nuts.
Page 55: Separation Of The Hydraulic Cylinder Case And Transmission
1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.6 SEPARATION OF THE HYDRAULIC CYLINDER CASE AND TRANSMISSION Parts which can be inspected during This operation 2. Remove the seat assembly. - Control valve 3. Remove the lever cover (RH).
Page 56 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR 6. Detach the delivery pipe from the hydraulic 7. Remove the bolts which are tightened to cylinder case. hydraulic cylinder case. 8. Detach the hydraulic cylinder case assembly from FIG.2-39 Delivery pipe the rear transmission.
Page 57: Separation Of The Transmission And Chassis
1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 3.7 SEPARATION OF THE TRANSMISSION AND CHASSIS Parts which can be inspected during This operation INSTALLATION - MID PTO gears Reassemble in reverse order of removal. - Final gears and brake system 1.
Page 58 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR REMOVAL ▶ MID PTO ASSEMBLY ▶ REAR AXLE HOUSING ASSEMBLY (LH, RH) 1. Remove the MID PTO assembly after loosening NOTE the bolts (M10-25). • As both sides can be disassembled in the same...
Page 59 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS ▶ HST UNIT 6. Remove the slow return grip. 8. Detach the drive shaft. Remove the floor panel (center). FIG.2-45 Drive shaft FIG.2-43 Floor panel K25W055A K25W053A NOTE • Be careful not to deform the fan.
Page 60 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR ▶ TRANSMISSION ASSEMBLY 10. Remove the slow control grip. 12. Detach the drive shaft. 4WD shaft don’t need to be detached. Remove the floor panel (Center). FIG.2-48 11. Remove the seat assembly and frame comp. and panel.
Page 61 1025H TRACTOR CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 14. Remove the hydraulic pipes. 16. Remove the bolts which are tightened to the front axle bracket. FIG.2-50 FIG.2-52 K25W062A 17. Support or lift up the transmission and the front axle bracket with crane or stand.
Page 62 CHAPTER 2 DISASSEMBLY AND REASSEMBLY OF MAJOR COMPONENTS 1025H TRACTOR INSTALLATION Reassemble in reverse order of removal. NOTE • When all the components are reassembled, con- structions shall follow as previous instruction. B25W-202010...
Page 63 CHAPTER 3 ENGINE ACCESSORIES TABLE OF CONTENTS 1. RADIATOR ..........3-3 2. AIR CLEANING SYSTEM ......3-11 1.1 General description ......3-3 2.1 General description ......3-11 1.2 Radiator ..........3-4 2.2 Element air cleaner ......3-12 1.3 Specifications ........3-5 2.2.1 Specifications ....... 3-12 1.4 Removal of the radiator ......3-5 2.2.2 Disassembly .........
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Page 65: Radiator
1025H 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 66: Radiator
CHAPTER 3 ENGINE ACCESSORIES 1025H 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 67: Specifications
1025H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 1.3 SPECIFICATIONS Description 1025H Radiator core type CF (Wave fin) Core train number 2 trains Radiator fin pitch 2 mm Thermal radiator area 6.2530 m Pressure valve opening pressure 0.9 ± 0.15 kgf/cm Coolant capacity 5.2 ℓ...
Page 68: Inspection Of Each Part
CHAPTER 3 ENGINE ACCESSORIES 1025H 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 69: Inspection For Radiator Clogging
1025H 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 70: Radiator Reassembly
CHAPTER 3 ENGINE ACCESSORIES 1025H 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 Both valves are held against their seats by springs •...
Page 71: Daily Inspection
1025H 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 72: Trouble Shooting
CHAPTER 3 ENGINE ACCESSORIES 1025H 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 73: Air Cleaning System
1025H TRACTOR CHAPTER 3 ENGINE ACCESSORIES 2. AIR CLEANING SYSTEM 2.1 GENERAL DESCRIPTION FIG. 3-10 Air Cleaner K19W075A (1) BODY (3) COVER ASSEMBLY (2) PAPER ELEMENT OUTER (4) DUST UNLOADING VALVE FIG. 3-10 Air Cleaner K19W076A (1) AIR INLET (3) AIR OUTLET...
Page 74: Element Air Cleaner
CHAPTER 3 ENGINE ACCESSORIES 1025H TRACTOR 2.2 ELEMENT AIR CLEANER 2.2.1 SPECIFICATIONS Model 1025H Type Dry, paper element filtering type Rated intake air volume (M /min) Effective filter area (M 0.44 air venting resistance (mmAg) 110 or less Total filtering efficiency (%)
Page 75: Inspection Of Each Part
1025H 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 76: Element Installation
CHAPTER 3 ENGINE ACCESSORIES 1025H 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 77 CHAPTER 4 HST SYSTEM TABLE OF CONTENTS 1. INTRODUCTION ........4-3 7. TESTS AND ADJUSTMENT ....4-18 1.1 Introduction ..........4-3 7.1 Hydrostatic pedal and neutral adjustment ......4-18 2. GENERAL SPECIFICATIONS ....4-4 7.2 Hydrostatic pump pressure test ..4-19 3.
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Page 79: Introduction
1025H 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 80: General Specifications
CHAPTER 4 HST SYSTEM 1025H TRACTOR 2. GENERAL SPECIFICATIONS HST FOR UNROAD VEHICLES ITEM SPECS PUMP 0 ~ 20.0 cc/rev HST Capacity MOTOR 20.0 cc/rev Pump swash plate angle 0˚ ± 18˚ Direction of input rotation From the position of clockwise input shaft Charge relief set pressure 8.0 ~ 10 Kg/cm...
Page 81: Component Location
1025H TRACTOR CHAPTER 4 HST SYSTEM 3. COMPONENT LOCATION 3.1 HYDRAULIC HOSES AND LINES FIG.4-1 K25W066A (1) HYDRAULIC OIL FILTER (6) DELIVERY PIPE (10) POWER STEERING PIPE (LH, RH) (2) SUCTION PIPE (7) DRAIN PIPE (11) HST UNIT (3) GEAR PUMP...
Page 82: Hydrostatic Control Linkage
CHAPTER 4 HST SYSTEM 1025H TRACTOR 3.3 HYDROSTATIC CONTROL LINkAGE FIG. 4-3 K25W068A (1) HOLDER COMP (5) FORWARD PEDAL COMP (9) CAM ARM COMP (2) CONTROL ROD ASSEMBLY (6) REVERSE ARM COMP (10) DAMPER, OIL 110 (3) PEDAL SHAFT COMP.
Page 83: Hydrostatic System Schematic
1025H TRACTOR CHAPTER 4 HST SYSTEM 3.4 HYDROSTATIC SYSTEM SCHEMATIC FIG. 4-4 K25W069A B25W-202010...
Page 84: Troubleshooting
CHAPTER 4 HST SYSTEM 1025H 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 85 1025H 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 Filter or Strainer (Main that it reaches its specified replace with a new one.
Page 86: Diagnostics
CHAPTER 4 HST SYSTEM 1025H 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 87: Theory Of Operation - Hydrostatic System
1025H 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 88 CHAPTER 4 HST SYSTEM 1025H TRACTOR FIG. 1(a) FIG. 1(b) B25W-202010...
Page 89 1025H TRACTOR CHAPTER 4 HST SYSTEM • MOTOR FIG. 2(a) <Figure-2> shows a rotation part (Shaft and Cylinder Block) in Axial Piston Pump, and 9 pistons are inserted to Cylinder Block. At the end of Cylinder Block, there is Valve Plate with two crescent passages (Ps and Pd), and the two crescent passages are connected to inlet pipe and discharge pipe, respectively.
Page 90: Charge Circuit
CHAPTER 4 HST SYSTEM 1025H TRACTOR 6.2 CHARGE CIRCUIT HST Circuit has an internal gap, so it is equipped with (c) BACKWARD (TRUNNION BAR :β side) Charge Circuit to compensate the weak point. ------------------------------------------------------Figure-2(b) Oil discharged from Charge Pump is to be supplied to The operation principle is the same as the above Pump and Motor through Check Valve.
Page 91: Handling Precautions
1025H TRACTOR CHAPTER 4 HST SYSTEM 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 92: Starting
CHAPTER 4 HST SYSTEM 1025H TRACTOR 6.4.6 STARTING 6.4.7 OIL TEMPERATURE MANAGEMENT WARNING CAUTION 1. Fill a hydraulic oil (operating oil) in HST Case. • As for hydraulic unit, the most important thing is to how extent a driving temperature is main- 2.
Page 93: Regular Check & Replacement Cycle Of Hydraulic Oil
1025H TRACTOR CHAPTER 4 HST SYSTEM 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 94: Tests And Adjustment
CHAPTER 4 HST SYSTEM 1025H TRACTOR 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 95: Hydrostatic Pump Pressure Test
1025H TRACTOR CHAPTER 4 HST SYSTEM 7.2 HYDROSTATIC PUMP PRESSURE TEST REASON CAUTION • AvOID SUDDEN TRACTOR MOvEMENT. Tractor To ensure that internal parts of the hydrostatic pump could move suddenly causing severe injure or are not worn excessively, and the relief valves are damage to equipment during test procedure.
Page 96 CHAPTER 4 HST SYSTEM 1025H TRACTOR RESULTS If pressure will not reach 250 ~ 280 kgf/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 97: Charge Pump Pressure Test
1025H TRACTOR CHAPTER 4 HST SYSTEM 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 pressure to supply oil to hydrostatic pump.
Page 98: Hydraulic System Bleed Procedure
CHAPTER 4 HST SYSTEM 1025H TRACTOR 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 99: Repair
1025H TRACTOR CHAPTER 4 HST SYSTEM 8. REPAIR 8.1 HYDROSTATIC SPLITTING PREPARE THE TRACTOR 1. Park tractor on a level surface. 8. Detach the HST control rod. 2. Shut off engine. Release hydraulic pressure by FIG. 4-8 operating all controls.
Page 100 CHAPTER 4 HST SYSTEM 1025H TRACTOR INSTALLATION Install the reverse order of disassembly. 1. Clean the surface of input metal before installing the O-Rings. 2. Apply grease or gear oil to O-rings. 3. Tighten the screws attaching hydrostatic unit to the input metal.
Page 101: Hydrostatic Overhaul
1025H TRACTOR CHAPTER 4 HST SYSTEM 8.2 HYDROSTATIC OvERHAUL 8.2.1 TOOLS Tool Name Size & Set value Plastic hammer Light alloy core 0.3 kgf Driver(-) 150 mm Snap ring plier (For inner hole) H-2, H-3 Snap ring plier (For shaft)
Page 102: Disassembly Procedure
CHAPTER 4 HST SYSTEM 1025H TRACTOR 8.2.3 DISASSEMBLY PROCEDURE PROCESS DRAWING DESCRIPTION (FIG.1) 1. Take off FRONT COVER. a. Take off WRENCH BOLT(50)[M10x45L] 6pcs and WRENCH BOLT(49)[M10x40L] 2pcs. b. Take off FRONT COVER (ASSY) (See Figrue-1) Note : B e careful not to drop VALVE PLATE.
Page 103 1025H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (FIG.-4) b. Take off GASKET(40) and PIN(29) [2pcs]. (See Figrue-4) Note : I t is easier to do disassembly if putting DRIVER(-) in the groove and hold it up. K25W083A (FIG.-5) 4. Take off CYLINDER BLOCK ASSY (Pump side) Note : B e careful not to lose PIN(15) [3pcs].
Page 104 CHAPTER 4 HST SYSTEM 1025H TRACTOR PROCESS DRAWING DESCRIPTION (FIG.-7) COMPONENTS OF CYLINDER BLOCk ASSY (COMMON for Pump and motor) (11) CYLINDER BLOCK ......1 (18) PISTON ..........9 (17) SET PLATE ........1 (16) BALL GUIDE ........1 (12) SPRING SEAT ........2 (14) SNAP RING ........2 (13) SPRING ...........1...
Page 105 1025H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (FIG.-10) b. Take off SEAL CAP(7) and SEAL CAP(43). (See Figure-10) K25W089A (FIG. -11) c. Take off SNAP RING(6)[2pcs] on motor and pump side. (See Figure-11) K25W090A (FIG.-12) d. As shown in the left figure, give a tap to the section of SHAFT(3) on pump side with a PLASTIC HAMMER and separate it from BODY(1).
Page 106 CHAPTER 4 HST SYSTEM 1025H TRACTOR PROCESS DRAWING DESCRIPTION (FIG. -13) e. As shown in the left figure, give a tap to the section of SHAFT(25) on pump side with a PLASTIC HAMMER and separate it from BODY(1). (See Figure-13) K25W092A (FIG.
Page 107 1025H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (FIG. -16) c. On the side, give a tap to SWASH PLATE with a PLASTIC HAMMER and remove COVER(20) from BODY(1). (See Figure-16) K25W095A (FIG. -17) d. Take off SWASH PLATE(2) from BODY(1). (See...
Page 108 CHAPTER 4 HST SYSTEM 1025H TRACTOR PROCESS DRAWING (FIG.-18) K25W097A 9. Disassembly of PUMP BLOCK a. Take off CHECK VALVE. Pull out PLUG(36), and take off SPRING(35) and RELIEF VALVE ASSY(34) (2 spots of the right and left) B25W-202010...
Page 109: Pre-Assembly Precautions
1025H 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 110 CHAPTER 4 HST SYSTEM 1025H TRACTOR PROCESS DRAWING DESCRIPTION (FIG.-21) 2. Assembly of SHAFT a. Assemble Pump’s SHAFT ASSY[SHAFT(3), Ball bearing(4) Snap ring(6) in BODY(1). b. Assemble Motor’s SHAFT ASSY[SHAFT (25), ball bearing(4), and snap ring(6)] in BODY(1). (See Figure-21) ※...
Page 111: Cylinder Block
1025H TRACTOR CHAPTER 4 HST SYSTEM PROCESS DRAWING DESCRIPTION (FIG. -23) 4. Assemble SHOE PLATE (10) of Motor and Pump Side. (See Figure-23) K25W102A (FIG.-24) 5. Assembly of CYLINDER BLOCK(ASSY) Note : M ake sure to apply a hydraulic oil (operating oil) on the sliding face of Swash Plate before putting CYLINDER BLOCK (ASSY) together.
Page 112 CHAPTER 4 HST SYSTEM 1025H TRACTOR PROCESS DRAWING DESCRIPTION 8. Assemble FRONT COVER S/A. (FIG. -26) a. Attach CHECK(30), SPRING(31), and SPRING HOLDER(32) onto FRONT COVER(26), and assemble WRENCH BOLT(33)[M6x10L]. b. Assemble PIN(28) [2pcs] and VALVE PLATE(38)(39) on FRONT COVER(26). (See Figure-26) Note : G rease has to be spread not to have VALVE PLATE drop off before assembly.
Page 113 1025H TRACTOR CHAPTER 4 HST SYSTEM FIG.-30. Press-Fitting of SHAFT BEARING K25W108A B25W-202010...
Page 114 CHAPTER 4 HST SYSTEM 1025H TRACTOR FIG.-32. FRONT COVER PRESS-FITTING PART FIG.--33. FRONT COVER ASSY Press-fit OIL SEAL(41) up to the depth of 10mm from the end face of FRONT COVER. K25W110A K25W109A NOTE NOTE 1 : ( 27)Needle Bearing(2pcs) is marked on drawing.
Page 115 1025H TRACTOR CHAPTER 4 HST SYSTEM (FIG.-34) SEAL CAP SETTING K25W111A B25W-202010...
Page 116 CHAPTER 4 HST SYSTEM 1025H TRACTOR (FIG.-35) Assembly drawing K25W112A B25W-202010...
Page 117 1025H TRACTOR CHAPTER 4 HST SYSTEM (FIG.-36) Section drawing K25W113A B25W-202010...
Page 118 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 119 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 ......5-4 2. SPECIFICATIONS ........5-5 2.1 Wheel drive system ......5-5 2.2 PTO drive system .........5-5 3.
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Page 121: General Description
1025H 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 Flange HST system Range shift gears Transmission Front drive change gears PTO Clutch Differential gears...
Page 122: Power Train Diagram
CHAPTER 5 TRANSMISSION 1025H TRACTOR 1.3 POWER TRAIN DIAGRAM K25W158A B25W-202010...
Page 123: Specifications
1025H TRACTOR CHAPTER 5 TRANSMISSION 2. SPECIFICATIONS 2.1 WHEEL DRIvE SYSTEM Unit : km/h 1025H Speed shift range Engine rated rpm : 3,000 rpm Main speed shift L (Low) 0.596 (14/20 * 23/27) Reduction ratio Speed range shift H (High) 1.487 (14/20 * 34/16)
Page 124: Disassembly, Inspection And Reassembly
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3. DISASSEMBLY, INSPECTION AND REASSEMBLY 3.1 HST UNIT, RANGE GEARS, 4WD GEARS AND PTO CLUTCH FIG.5-1 K25W114A B25W-202010...
Page 125 1025H TRACTOR CHAPTER 5 TRANSMISSION 3.1.1 DISASSEMBLY Removal of HST system and change parts. Separate the engine from the rear transmission referring to the paragraph of "REPAIR" in CHAPTER 4. 1. Remove the HST unit and filter. FIG.5-2 K25W115A (1) HST ASSY, 20 CC...
Page 126 CHAPTER 5 TRANSMISSION 1025H TRACTOR 2. Remove the input metal and hydraulic filter. FIG.5-3 K25W116A NOTE • Disassembly of the hydraulic filter and gear pump should be done in a clean, dust-free place. And slightly separate the input metal from rear transmission not to damage the gears in TM. Pay special attention to avoid damage of the PTO solenoid valve.
Page 127 1025H TRACTOR CHAPTER 5 TRANSMISSION 3. When the input metal is separated from TM, the input gears are removed together. FIG.5-4 K25W117A (1) METAL, INPUT (6) C-RING, SHAFT (30) (2) GEAR, INPUT 14T (7) WASHER, 55X40X4 (3) BEARING, NEEDLE CAGED (KT323717)
Page 128: Piston
CHAPTER 5 TRANSMISSION 1025H TRACTOR 4. Remove PTO clutch assembly and gears. FIG.5-5 K25W118A (1) BEARING, BALL (6304) (10) O-RING, P21 (19) CLUTCH, DISK (2) IDLE, PTO 33T (11) SHAFT, PTO CLUTCH (20) PLATE, SEPARATE (3) BEARING, BALL (6203) (12) BEARING, BALL (6006) (21.
Page 129 1025H TRACTOR CHAPTER 5 TRANSMISSION 5. Disassembly, inspection and reassembly of the PTO clutch assembly FIG.5-6 K25W119A (1) SHAFT, PTO CLUTCH (9) PISTON (17) BEARING, BALL (6204) (2) BEARING BALL (6006) (10) SPRING (18) HUB, PTO CLUTCH (3) O-RING (P21)
Page 130 CHAPTER 5 TRANSMISSION 1025H TRACTOR 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 131 1025H TRACTOR CHAPTER 5 TRANSMISSION 6. Remove the 4WD gears. FIG.5-10 K25W122A (1) SHAFT, 4WD (D=22) (4) BEARING, BALL (6004) (2) GEAR, 4WD 22T (5) C-RING, HOLE (42) (3) BEARING, BALL (6302) (6) SEAL, OIL / D20428 B25W-202010...
Page 132 CHAPTER 5 TRANSMISSION 1025H TRACTOR 7. Remove the range gears. 8. Remove the range shift linkage. Remove the no. 1, 2, 3, 4 if necessary. FIG.5-12 FIG.5-11 K25W124A (1) STAY, RANGE (2) FORK, RANGE (3) SPRING (4) BALL, STEEL (5/16)
Page 133 1025H TRACTOR CHAPTER 5 TRANSMISSION 9. Remove the 4WD shift linkage. Take out the spring pin by special tool to protect its spring pin and pipe. Remove the plug(M16) and take out the ball guide, spring and ball. FIG.5-13 K25W125A...
Page 134: Reassembly And Inspection
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.1.2 REASSEMBLY AND INSPECTION Reassemble the parts in the reverse order of 2. Reassemble the range shift linkage. disassembly. Install the O-ring(7) to the hook comp.(6) and the NOTE rear transmission case after applying the grease on the O-ring.
Page 135 1025H TRACTOR CHAPTER 5 TRANSMISSION 3. Reassemble the range gears. 5. Install the PTO clutch assembly in the rear transmission case. Install the input gear and PTO input gear to input metal. Multi-purpose grease should be applied sufficiently on the seal before installing the input metal.
Page 136 CHAPTER 5 TRANSMISSION 1025H TRACTOR 7. Install the hydraulic filter. 8. Reassemble the drive shaft assembly. NOTE 1) W hen installing the coupling PTO on the flywheel, be sure to install the bolts to flywheel. 2) A pply a thin coat of molybdenum disulfide-based grease(Three bond TB1901 or equivalent) to re- volving or sliding parts prior to reassembly. 3) W hen installing the coupling PTO on the flywheel, take care not to damage this clutch damper and cooling fan. 4) Apply an ANTI RUST 720S or equivalent after installing clutch damper in order to prevent from rust.
Page 137: Rear Pto Gears
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.2 REAR PTO GEARS FIG.5-22 K25W132A B25W-202010...
Page 138: Disassembly
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.2.1 DISASSEMBLY Removal of Rear PTO gears. Separate the hydraulic cylinder case from the rear transmission referring to the paragraph of "SEPARATION OF THE HYDRAULIC CYLINDER CASE AND TRANSMISSION" in CHAPTER 2. 1. Separate the Top link, the lift rod comp (LH/RH) from hydraulic cylinder case.
Page 139 1025H TRACTOR CHAPTER 5 TRANSMISSION 3. Remove the PTO change lever. 4. Remove the PTO shield if necessary. Remove the PTO lever (no. 17). Remove the drawbar bracket comp (no. 3). Remove the spring pin (no. 14). FIG.5-26 Remove the bolt and plate (no. 15, 16).
Page 140: Inspection
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.2.2 INSPECTION 5. Remove the seal and C-ring (no. 5, 4). Before and after disassembly, inspect each part for serious worn or damaged part, and replace if Remove the PTO counter shaft (no. 2). necessary.
Page 141: Snap Ring
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.2.3 REASSEMBLY Reassemble the parts in reverse order of removal. 1-5) Assemble the gears and collar and bearing (6205) while holding them. NOTE 1-6) Install the snap ring, pay attention to the • Each part should be washed clean before re- direction of assembly.
Page 142 CHAPTER 5 TRANSMISSION 1025H TRACTOR 2-4) Install the snap ring, pay attention to the direction of assembly. 2-5) Install the seal cap in the case after applying the adhesive (TB1215) on its outer surface. FIG.5-31 K25W141A 3. Reassemble the PTO shield if removed. Reassemble the drawbar bracket component.
Page 143: Mid Pto Assembly
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.3 MID PTO ASSEMBLY FIG.5-32 K25W142A (1) CASE, MID PTO (10) C-RING, SHAFT (17) (2) PLUG ASSY, DRAIN (MAGNET) (11) CAP COMP, MID PTO SHAFT (3) PIN, PARALLEL/A (D10X22) (12) BOLT, HEX/S (M6X12) (4) BOLT, HEX/S (M10X25)
Page 144: Disassembly
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.3.1 DISASSEMBLY 3.3.2 INSPECTION 1. Disassemble the Mid PTO assembly from the rear Before and after disassembly, inspect each part transmission case. for serious worn or damaged part, and replace if necessary. 2. Remove the snap ring (no. 10) and pull out the pin (no.
Page 145: Reassembly
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.3.3 REASSEMBLY Reassemble the parts in reverse order of removal. 1. Install the bearings to the shaft. NOTE FIG.5-34 • Each part should be washed clean before re- assembly. • Every time a gear installed, its smooth rotation should be checked.
Page 146: Rear Pto And Mid Pto Operation
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.4 REAR PTO AND MID PTO OPERATION FIG.5-36 K25W146A 1. Start the engine, and wait for 5 minutes to warm up the engine. PTO shifting lever is engaged to rear PTO or MID PTO. PTO switch is ON while engine works, the hydraulic fluid of PTO Valve flows to PTO clutch through hydraulic line.
Page 147: Rear Transmission
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.5 REAR TRANSMISSION FIG.5-37 K25W147A B25W-202010...
Page 148: Disassembly
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.5.1 DISASSEMBLY Removal the differential gears. Separate the rear axle assembly and the rear transmission from each other and then remove the hydraulic cylinder case referring to paragraph of SECTION OF THE HYDRAULIC CYLINDER CASE AND TRANSMISSION in CHAPTER 2.
Page 149 1025H TRACTOR CHAPTER 5 TRANSMISSION FIG.5-39 K25W147A (1) HOUSING, REAR AXLE LH (21. BOLT, HEX FLANGE M10X60 (2) SHAFT, WHEEL (22) BOLT, HEX FLANGE M10X75 (3) SEAL, SHAFT 40 (23) O-RING, P16 (4) C-RING, HOLE 62 (24) PLUG, M16 (5) BEARING, BALL 6007...
Page 150 CHAPTER 5 TRANSMISSION 1025H TRACTOR 2. Remove the 3 point hitch. 3. Remove the hydraulic cylinder case assembly. FIG.5-40 K25W150A 4. Removal of the rear axle housing (LH/RH). Remove the nuts/washers and lower link plate. Draw out the rear axle housing (LH/RH) by holding it with crane.
Page 151 1025H TRACTOR CHAPTER 5 TRANSMISSION 5. Removal of the diff-lock pedal linkage. Pull out the spring pin (no. 27, 28) after holding the spring(no. 23) by special tool. Pull out the spring pin (no. 29) and diff-lock shaft and diff-lock fork.
Page 152: Inspection
CHAPTER 5 TRANSMISSION 1025H TRACTOR 3.5.2 INSPECTION 6. Removal of the differential gear assembly. Before and after disassembly, inspect each part for the items mentioned below. Pull out the bearings (no. 12) by special tool. Parts which deviate from the specified values should Remove the bolts (no.
Page 153: Reassembly
1025H TRACTOR CHAPTER 5 TRANSMISSION 3.5.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, following these instructions. 1. Ring gear, Drive pinion and related parts. Each part should be washed clean before reassembly. Every time a gear and bearing installed, its smooth rotation should be checked.
Page 154 CHAPTER 5 TRANSMISSION 1025H TRACTOR 3. Install the snap ring and shims in rear transmission case. 4. Install the differential assembly and shims and diff case metal. The backlash should be adjusted to specified value. 5. Install the diff lock pedal linkage.
Page 155 1025H TRACTOR CHAPTER 5 TRANSMISSION NOTE NOTE • Strike the circumference of the ring gear both • Inspection of the tooth bearing sides with a copper hammer by turning the • Apply an even coat of oil-dissolved minimum ring gear manually and check to see that the on the drive pinion teeth and turn the drive backlash remains unchanged.
Page 156: Troubleshooting
CHAPTER 5 TRANSMISSION 1025H 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 157: Spring
1025H 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 158 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 159 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 ......... 6-10 3.2.1 Disassembly .........
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Page 161: General Description
1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 1. GENERAL DESCRIPTION FIG.6-1 K25W159A 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 162: Specifications
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 2. SPECIFICATIONS FIG.6-2 K25W160A 1025H Toe-in (mm) Camber 3° Wheel alignment Caster 0° King pin 12° Pivot Pin Diameter (mm) Ø24 Pivot bush (mm) Ø24 x Ø27 x L25 Front axle Housing Inner Diameter (mm) Ø27...
Page 163: Disassembly, Inspection And Reassembly
1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3. DISASSEMBLY, INSPECTION AND REASSEMBLY 3.1 PIvOT PIN FIG.6-3 K25W161A (1) AXLE HOUSING, FRONT (8) NUT, HEX SLOT & CASTLE (16) BEARING, BALL 6004zz (2) CAP ASSY, OIL (9) PIN, SPLIT (17) C-RING, HOLE 42...
Page 164: Disassembly
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 3.1.1 DISASSEMBLY FIG.6-4 K25W162A 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 165: Pin
1025H 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 166: Reassembly
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 3.1.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, following these instructions. 1. When installing the bushes, abide by the following precautions. 2. Clean the surface in the front axle housing which the bush is located ahead of time.
Page 167 1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 12. When the tie-rods are reinstalled, the toe-in should be adjusted. At the same time, the steering angles of the both wheels should also be adjusted. 13. Be sure the dimension C and D is same size and adjust E and F as same dimension (B-A : 2~6 mm) FIG.
Page 168: Front Differential
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 3.2 FRONT DIFFERENTIAL FIG.6-10 K25W168A (1) SHIM, A (T=0.1) (10) CASE, FR DIFF (2) SPACER (45X47X3) / 48.3X3.68 (11) BEARING, BALL (6010) (3) PINION, SPIRAL BEVEL 8T (12) GEAR, SPIRAL BEVEL 25T (4) TAPER ROLLER BEARING (33005) (13) C-RING, SHAFT (40) (5) COLLAR 48.3X3.68...
Page 169: Disassembly
1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.2.1 DISASSEMBLY 1. As concerns operation prior to removal of the front 5. Remove the oil seal, pull out the snap rings. axle, refer to the paragraph covering disassembly 6. Pull out the pinion shaft assembly.
Page 170 CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 8. Remove the lock nut after releasing the calking of 10. Remove snap ring (no. 13). the lock nut. 11. Remove the bevel gear and bearings. 9. Remove the bearings, spacer collar and shims.
Page 171: Inspection
1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.2.2 INSPECTION 3.2.3 REASSEMBLY 1. Visually check the bearing surfaces of the bevel Reassembly the parts in reverse order of disassembly, pinion and ring gear teeth. following these instructions. NOTE 1. Each friction surface should be coated with grease •...
Page 172 CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR NOTE • When any of the bevel pinion, ring gear, taper bearing, collar etc has been replaced, inspect the bevel pinion assembly for gear play in the front axle housing. Specified gear play 0.1-0.2 mm (in) (0.004-0.008 in)
Page 173 1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 5. 4WD shaft assembly a. Install the snap ring and bearing(6004zz) in the 4WD support(no. 15). b. Install the 4WD support assembly with bolts(no.18) to front axle bracket. c. Install the shaft(no.20) after installing the snap ring.
Page 174: Final Case
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 3.3 FINAL CASE FIG.6-18 K25W176A ▶ FINAL CASE (A) (21) SHAFT, LH (D=22) (28) CASE, FINAL DRIVE A (35) BEARING, BALL (6304) (22) SHAFT, RH (D=22) (29) GEAR, BEVEL 14T (36) WASHER, SPRING (M12)
Page 175: Disassembly
1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 3.3.1 DISASSEMBLY 3.3.2 INSPECTION 1. Drain oil from the final case (LH/RH) by removing Before and after disassembly, inspect each part the drain plug(no.15) and air breather plug(no. 5). for serious worn or damaged part and replace if necessary.
Page 176: Reassembly
CHAPTER 6 FRONT AXLE (4WD) 1025H TRACTOR 3.3.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, 3. Install the bearing (6304), shaft, bearing (6908), following these instructions. and snap ring in the final drive case B. FIG.6-21 1. Install the bevel gear with bearing together and Install the snap ring in the final case A.
Page 177 1025H TRACTOR CHAPTER 6 FRONT AXLE (4WD) 5. Install the bearing(6206). 6. Install shaft and the snap ring (C-30). NOTE • This snap ring should be seated securely in its groove. Pay attention to correct direction. 7. Install the bevel gear and bearing(6205).
Page 178: Trouble Shooting
CHAPTER 6 FRONT AXLE (4WD) 1025H 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 •...
Page 179 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 181: General Description
1025H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 1. GENERAL DESCRIPTION FIG.7-1 K25W182A 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 182: Disassembly, Inspection, And Reassembly
CHAPTER 7 REAR AXLE AND BRAKES 1025H 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 K25W183A (1) HOUSING, REAR AXLE LH...
Page 183: Disassembly
1025H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 3.1.1 DISASSEMBLY 1. Removal of the brake rod linkage 2. Release the parking brake linkage and the cruise linkage. 3. Detach the brake rods (no. 6 : no. 7, 12, 13, 14).
Page 184 CHAPTER 7 REAR AXLE AND BRAKES 1025H TRACTOR 8. Remove the nut and spring washer (no. 19, 18) and plate (no. 17) in advance. Remove the bolts (no. 20, 21, 22). FIG.7-4 K25W185A (20) BOLT, HEX FLANGE M10X40 (10EA) (22) BOLT, HEX FLANGE M10X75 (4EA) (21) BOLT, HEX FLANGE M10X60 (4EA) 9.
Page 185 1025H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 10. Remove the snap ring(no. 40). Remove the brake cover. Pull out the pinion shaft assembly. Remove the brake metal after pulling out spring. Remove the nut and spring washer(no. 44, 45).
Page 186: Inspection
CHAPTER 7 REAR AXLE AND BRAKES 1025H 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 187: Reassembly
1025H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 3.1.3 REASSEMBLY Reassemble the parts in reverse order of disassembly, follow these precautions. 4. Replace the oil seal Install the bearing and the snap ring into the axle 1. Make sure that brake metal, friction surfaces, etc...
Page 188 CHAPTER 7 REAR AXLE AND BRAKES 1025H TRACTOR 5. press the wheel shaft after apply grease on the inner surface of the seal and shaft sufficiently. 6. Install the wheel gear, the bearing, and snap ring on the wheel shaft and retain them.
Page 189: Trouble Shooting
1025H TRACTOR CHAPTER 7 REAR AXLE AND BRAKES 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 190 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 191 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 193: General Description
1025H 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 194: Specifications
CHAPTER 8 POWER STEERING SYSTEM 1025H TRACTOR 2. SPECIFICATIONS 2.1 GEAR PUMP MODEL 1025H Delivery (cc/rev) 1,000 rpm 10.8 LPM Pump performance 170 (kgf/cm 2,600 rpm 28.7 LPM Rated pressure (kgf/cm Maximum pressure (kgf/cm Rated operation speed (rpm) 800~3,000 Rotation direction C.W as viewed from shaft end...
Page 195: Function (Reference)
1025H 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 196: Manual Steering Pressure
CHAPTER 8 POWER STEERING SYSTEM 1025H 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 197: Disassembly, Inspection, And Reassembly
1025H 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 198: Special Tools
CHAPTER 8 POWER STEERING SYSTEM 1025H 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 199: Disassembly
1025H 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 200: Cleaning, Inspection, Replacement And Lubrication
CHAPTER 8 POWER STEERING SYSTEM 1025H 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 201 1025H 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 202 CHAPTER 8 POWER STEERING SYSTEM 1025H 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 203 1025H 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 204: Troubleshooting
CHAPTER 8 POWER STEERING SYSTEM 1025H 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 205 1025H TRACTOR CHAPTER 8 POWER STEERING SYSTEM PROBLEMS AND PROBABLE CAUSES COUNTER MEASURES (1) Worn of spline gear column - Replace column (2) Depressed control set - Wash,and Adjust fluid level and pressure properly (3) Air trapped in cylinder and pipe line...
Page 206 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 207 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 Divider valve ........9-6 3.2.3 PTO solenoid valve ......
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Page 209 1025H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 1. GENERAL DESCRIPTION B25W-202010...
Page 210: Specifications
CHAPTER 9 HYDRAULIC SYSTEM 1025H TRACTOR 2. SPECIFICATIONS Model T254 HST Hitch lift capacity, (kg) Piston And cylinder 600 / 480 At lower link top end / 24 inches behind link arms Cylinder port leaks (cc/min) Control Valve (under a pressure of 9800kpa(100 kgf/cm...
Page 211: Major Component Of The Hydraulic System
1025H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM 3. MAJOR COMPONENT OF THE HYDRAULIC SYSTEM 3.1 HYDRAULIC SYSTEM FIG. 9-2 K19W195A (1) SHAFT, LIFT (16) O-RING (34) TUBE (2) BUSH, 35X42X40 (17) POPPET (41) GUIDE, SPRING (3) BUSH, 40X46X40 (21) VALVE, CONTROL...
Page 212: Divider Valve And Pto Solenoid Valve
CHAPTER 9 HYDRAULIC SYSTEM 1025H TRACTOR 3.2 DIvIDER vALvE AND PTO SOLENOID vALvE 3.2.1 GENERAL DESCRIPTION Divider valve 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 fixed orifice. Divider valve has a function to control the fluid direction for the main control valve and the front end loader with a changeover lever.
Page 213: Pto Solenoid Valve
1025H 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 214 CHAPTER 9 HYDRAULIC SYSTEM 1025H TRACTOR FIG. 9-6 K25W214A B25W-202010...
Page 215: Flow-Control Valve (Slow-Return Check Valve)
1025H 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 216: Relief Valve
CHAPTER 9 HYDRAULIC SYSTEM 1025H 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 divider valve.
Page 217: Gear Pump
1025H 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 218: Strainer Suction
CHAPTER 9 HYDRAULIC SYSTEM 1025H TRACTOR 3.6 STRAINER SUCTION FIG.9-12 K25W196A 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) 120 ~ 150 mesh Filtration area 82 cm Working oil temperature (°C)
Page 219: Hydraulic System
1025H 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 substances. 8. Install the fork to piston control lever after installing •...
Page 220 CHAPTER 9 HYDRAULIC SYSTEM 1025H TRACTOR FIG. 9-13 FIG. 9-14 Direction of the bush K19W207A K19W206A FIG. 9-15.Lift arm K19W208A FIG. 9-16. Hydraulic cylinder. K19W209A B25W-202010...
Page 221 1025H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM NOTE FIG. 9-19 • Be sure not to over operate within specified spool stroke (9 mm 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 222: Troubleshooting
CHAPTER 9 HYDRAULIC SYSTEM 1025H 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 223 1025H TRACTOR CHAPTER 9 HYDRAULIC SYSTEM Problems Causes Countermeasures 3. Lift lowers even Lap after disassembling,cleaning,repairing 1) Stuck poppet when adjust knob flaws with oil stone is closed fully with 2) Poor valve seat Replace valve adjust Handle (While engine is...
Page 224 CHAPTER 9 HYDRAULIC SYSTEM 1025H 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 225 CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS TABLE OF CONTENTS 1. GENERAL DESCRIPTION ....10-3 5. GENERAL ELECTRICAL ARRANGEMENT ........10-15 2. SPECIFICATIONS ......... 10-3 5.1 Engine harness assembly ....10-16 3. BATTERY ..........10-4 5.2 Main harness assembly ....10-17 3.1 Inspection of electrolyte level .....10-4 5.3 Rear harness assembly....
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Page 227: General Description
1025H 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 228: Battery
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H 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 229: Battery Charging
1025H 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 230: Battery Testing Charts
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H 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 231 1025H 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 232: Meters And Switches
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 4. METERS AND SWITCHES 4.1 METERS 4.1.1 REMOvAL 4.1.2 TACHO/HOUR METER 1. Disconnect the negative cable from battery. 1. CONSTRUCTION 2. Remove the dash cover, upper (no. 2). An electric tachometer is employed along with a tachosensor.
Page 233: Fuel Gauge
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.1.3 FUEL GAUGE 1. CONSTRUCTION ▶ FUEL GAUGE SENSOR (vARIABLE RESISTOR) 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.10-7.if the measured values...
Page 234: Starter Switch
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 4.2 STARTER SWITCH REMOVAL INSPECTION 1. Remove the dash cover (Upper). 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 235: Combination Switch
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.3 COMBINATION SWITCH REMOVAL INSPECTION 1. Remove the dash cover upper. Each switch circuit is as shown, so check each switch for a continuity across respective terminals with a 2 Remove the light switch knob and turn signal switch tester.
Page 236: Stop Light Switch
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 4.4 STOP LIGHT SWITCH • Lighting FIG. 10-15 Stop light switch Color (Yellow / (Red/ (Orange / code (Red) Green) Yellow) red) 9 : B1*1 5 : T 4 : 1 10 : 2 ●...
Page 237: Fuse
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 4.6 FUSE Fuses are installed in the main fuse box. Each fuse is connected as follows Three fusible links are installed to protect the wiring FIG.10-18 from burning due to a short circuit.
Page 238: Trailer Socket (Reference)
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H 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 Color Socket No. Description...
Page 239: General Electrical Arrangement
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 5. GENERAL ELECTRICAL ARRANGEMENT FIG.10-24 K25W204A B25W-202010...
Page 240: Engine Harness Assembly
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 5.1 ENGINE HARNESS ASSEMBLY FIG.10-25 K25W205A B25W-202010...
Page 241: Main Harness Assembly
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 5.2 MAIN HARNESS ASSEMBLY FIG.10-26 K25W206A B25W-202010...
Page 242: Rear Harness Assembly
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 5.3 REAR HARNESS ASSEMBLY FIG.10-27 K25W207A B25W-202010...
Page 243: Wiring Diagram
1025H TRACTOR CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 6. WIRING DIAGRAM FIG.10-28 K25W208A B25W-202010...
Page 244: Troubleshooting
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H 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 245: Instrumentation
1025H 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 246: Glow System
CHAPTER 10 ELECTRIC ACCESSORIES AND INSTRUMENTS 1025H TRACTOR 7.4 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 247: Charging System
1025H 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 248 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 249 CHAPTER 11 INDEX TABLE OF CONTENTS 1. INDEX .............11-2...
Page 250 CHAPTER 11 INDEX 1025H TRACTOR Disassembly, inspection, and reassembly ....7-4 Disassembly, inspection, and reassembly ....8-7 After installation, each grease fitting should be filled with grease..........2-5 Divider valve ............9-6 Air cleaning system ..........3-11 Divider valve and pto solenoid valve ...... 9-6 Always use safety lights and devices .....
Page 251 1025H TRACTOR CHAPTER 11 INDEX HST operation ............. 4-14 Measurement of the pump........9-11 HST unit, range gears, 4WD gears Measurement of the relief pressure ..... 9-10 and PTO clutch ............ 5-6 Meters..............10-8 Hydraulic hoses and lines........4-5 Meters and switches ..........10-8 Hydraulic system ............
Page 252 CHAPTER 11 INDEX 1025H TRACTOR Rear PTO and mid PTO operation ....... 5-28 Specifications ............6-4 Rear PTO gears ........... 5-19 Specifications ............7-3 Rear transmission..........5-29 Specifications ............8-4 Reassembly ............5-23 Specifications ............9-4 Reassembly ............5-27 Specifications ............9-12 Reassembly ............
Page 253 APPENDIX - CONvERSION TABLES...
Page 254 APPENDIX - CONVERSION TABLES Millimeters to inches 0.0394 1.0236 2.0079 2.9921 0.0787 1.0630 2.0472 3.0315 0.1181 1.1024 2.0866 3.0709 0.1575 1.1417 2.1260 3.1102 0.1969 1.1811 2.1654 3.1496 0.2362 1.2205 2.2047 3.1890 0.2756 1.2598 2.2441 3.2283 0.3150 1.2992 2.2835 3.2677 0.3543 1.3386 2.3228 3.3071...
Page 255 APPENDIX - CONVERSION TABLES Inches to millimeters 1/64 0.3969 25/64 9.9219 13/16 20.6375 1/32 0.7938 13/32 10.3188 53/64 21.0344 3/64 1.1906 27/64 10.7156 27/32 21.4313 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 15/32 11.9063 57/64 22.6219 7/64...
Page 256 APPENDIX - CONVERSION TABLES Feet to Meters Length 0.0000 0.3050 0.6100 0.9150 1.2200 1.5250 1.8300 2.1350 2.4400 2.7450 8.0532 3.3550 3.6600 3.9650 4.2700 4.5750 4.8800 5.1850 5.4900 5.7950 21.1097 6.4050 6.7100 7.0150 7.3200 7.6250 7.9300 8.2350 8.5400 8.8450 34.1661 9.4550 9.7600 10.0650 10.3700 10.6750 10.9800 11.2850 11.5900 11.8950 47.2225 12.5050 12.8100 13.1150 13.4200 13.7250 14.0300 14.3350 14.6400 14.9450...
Page 257 APPENDIX - CONVERSION TABLES Mile to kilometers miles miles 0.000 1.609 3.218 4.827 6.436 8.045 9.654 11.263 12.872 14.481 16.090 17.699 19.308 20.917 22.526 24.135 25.744 27.353 28.962 30.571 32.180 33.789 35.398 37.007 38.616 40.225 41.834 43.443 45.052 46.661 48.270 49.879 51.488 53.097...
Page 258 APPENDIX - CONVERSION TABLES Square inches to square centimeters Area 0.000 6.462 12.924 19.386 25.848 32.310 38.772 45.234 51.696 58.158 64.620 71.082 77.544 84.006 90.468 96.930 103.392 109.854 116.316 122.778 129.240 135.702 142.164 148.626 155.088 161.550 168.012 174.474 180.936 187.398 193.860 200.322 206.784 213.246 219.708 226.170 232.632 239.094 245.556 252.018 258.480 264.942 271.404 277.866 284.328 290.790 297.252 303.714 310.176 316.638 323.100 329.562 336.024 342.486 348.948 355.410 361.872 368.334 374.796 381.258...
Page 259 APPENDIX - CONVERSION TABLES Cubic inches to Cubic Centimeters (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) (cc) 0.000 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.483 163.870 180.257 196.644 213.031 229.418 245.805 262.192 278.579 294.966 311.353 327.740 344.127 360.514 376.901...
Page 260 APPENDIX - CONVERSION TABLES Gallons (U.S) to Liters Volume US gal US gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 0.000 3.785 7.571 11.356 15.142 18.927 22.712 26.498 30.283 34.069 37.854 41.639 45.425 49.210 52.996 56.781 60.566 64.352 68.137 71.923...
Page 261 APPENDIX - CONVERSION TABLES Gallons (IMP.) to Liters Imp. gal Imp. gal Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters 0.0000 4.5460 9.0920 13.6380 18.1840 22.7300 27.2760 31.8220 36.3680 40.9140 45.4600 50.0060 54.5520 59.0980 63.6440 68.1900 72.7360 77.2820 81.8280 86.3740 90.9200 95.4660 100.0120 104.5580 109.1040 113.6500 118.1960 122.7420 127.2880 131.8340...
Page 262 APPENDIX - CONVERSION TABLES Pounds to kilograms MASS 0.000 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 4.536 4.990 5.443 5.897 6.350 6.804 7.258 7.711 8.165 8.618 9.072 9.526 9.979 10.433 10.886 11.340 11.794 12.247 12.701 13.154 13.608 14.062 14.515 14.969 15.422...
Page 263 APPENDIX - CONVERSION TABLES kilograms to Newton 0.000 9.807 19.614 29.421 39.228 49.035 58.842 68.649 78.456 88.263 98.070 107.877 117.684 127.491 137.298 147.105 156.912 166.719 176.526 186.333 196.140 205.947 215.754 225.561 235.368 245.175 254.982 264.789 274.596 284.403 294.210 304.017 313.824 323.631 333.438 343.245...
Page 264 APPENDIX - CONVERSION TABLES 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 0.0000 0.0703 0.1406 0.2109 0.2812 0.3516 0.4219 0.4922 0.5625 0.6328 0.7031 0.7734 0.8437 0.9140 0.9843...
Page 265 APPENDIX - CONVERSION TABLES kilograms per square centimeters to kilo pascal Kg/cm Kg/cm 98.1 196.1 294.2 392.3 490.4 588.4 686.5 784.6 882.6 980.7 1078.8 1176.8 1274.9 1373.0 1471.1 1569.1 1667.2 1765.3 1863.3 1961.4 2059.5 2157.5 2255.6 2353.7 2451.8 2549.8 2647.9 2746.0 2844.0 2942.1...
Page 266 APPENDIX - CONVERSION TABLES 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 1.518 1.656 1.794 1.932 2.070 2.208 2.346 2.484 2.622 2.760 2.898...
Page 267 APPENDIX - CONVERSION TABLES kilogram meters to newtonmeters Kg-m 9.810 19.610 29.420 39.230 49.030 58.810 68.650 78.450 88.260 98.100 107.910 117.710 127.520 137.330 147.130 156.910 166.750 176.550 186.360 196.200 206.010 215.810 225.620 235.430 245.230 255.010 264.850 274.650 284.460 294.300 304.110 313.910 323.720 333.530 343.330 353.110...
Page 268 APPENDIX - CONVERSION TABLES Temperature Fahrenheit to Centigrade Centigrade to Fahrenheit ˚F ˚C ˚F ˚C ˚C ˚F ˚C ˚F -22.0 96.8 -28.9 35.0 -26.1 37.8 -18.4 100.4 -23.3 40.6 -14.8 104.0 -20.6 43.3 -11.2 107.6 -17.8 46.1 -7.6 111.2 -4.0 114.8 -17.2 48.9...

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