Bad Boy 4025H Service Manual

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40 SERIES

4035CH, 4035H, 4025H

SERVICE MANUAL

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latest Parts Manual update on the Tractor tab

of the Bad Boy Mowers Dealer Zone.

TRACTOR

Revised: 3/5/21

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Page 1 40 SERIES TRACTOR 4035CH, 4035H, 4025H SERVICE MANUAL Before ordering parts please check for the latest Parts Manual update on the Tractor tab of the Bad Boy Mowers Dealer Zone. Revised: 3/5/21...
Page 2 Please keep this manual in a safe place. If there is any typo, incorrect information or question about this manual, feel free to contact BBT. (Oct. 2020) BAD BOY TRACTORS Co. Ltd. ※ Remark This manual does not contain all accidents and preventive measures that can occur during ser- ...
Page 3 MEANINGS OF SAFETY SYMBOLS Precautions and instructions described in this manual and safety decals, such as DANGER, WARNING and CAUTION decals, are important for you and your 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.
Page 4 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 5 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 6 TABLE OF CONTENTS ◆ GENERAL INFORMATION ................◆ ENGINE ......................◆ TRANSMISSION .................... ◆ FRONT AXLE ....................◆ HYDRAULIC SYSTEM .................. ◆ ELECTRIC SYSTEM ..................◆ CABIN AND HVAC SYSTEM ................. ◆ INDEX ......................
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Page 8 Chapter 1 General InformatIon taBle of ContentS 1. GENERAL INFORMATION FOR SERvICE .. 1-8 6. COMPONENTS OF TRACTOR ..... 1-28 For safe operation ......... 1-8 Front and rear exterior view ....1-28 1.1.1 Work place ........1-8 Interior view ......... 1-30 1.1.2 Working clothes and other 7.
Page 9 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 1. GENERAL INFORMATION FOR SERvICE 1.1 FOR SAFE OPERATION 1.1.1 WORk PLACE A58W003A A58W004A DANGER CAUTION sufficient ventilation: The work place should be properly illuminated.  When grinding or sanding a painted surface or ...
Page 10 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 1.1.2 WORkING CLOTHES AND OTHER SAFETY GEARS 1.1.3 TOOL A58W006A A58W007A CAUTION DANGER Wear proper working clothes to ensure your Have a proper support and lifting equipment   safety. ready always. Make sure to wear working clothes, safety hat, Never work on the tractor only with a wood support safety gloves, safety goggles and other safety gears or other type of block or jack.
Page 11 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 1.1.4 STANDARD PARTS, LUBRICANT, 1.1.6 TORqUE PART GREASE AND OIL ad Boy A58W009A A58W011A CAUTION WARNING Use only the specified standard parts. follow the torque specified in this manual. [Otherwise] It can shorten the service life and [Otherwise] It can cause a serious accident.
Page 12 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 1.1.8 SAFETY DURING SERvICE K20W150A K20W152A WARNING CAUTION keep flammables away during fueling Stop the engine during inspection and service keep flammables, such as a cigarette, match Make sure to stop the engine during inspec- ...
Page 13 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 1.1.9 WASTE DISPOSAL K20W154A K20W156A DANGER WARNING keep flammables away during battery inspection If waste is not disposed properly, it can pollute keep flammables away from the vehicle while the environment and destroy the ecosystem. ...
Page 14 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 2. LOCATION OF DECALS To ensure safe work, check the location of the safety decals and always keep the safety precautions. Keep the safety decals intact. If any decals is damaged or missing, attach a new decal. ROPS MODEL 1, 2, 3 5, 6...
Page 15 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR (1) No.: TA00036924A (5) No.: TZE4190000C4 WARNING SURFACE DIESEL ONLY TZE4190000C4 (2) No.: TZE5130000C4 (6) No.: TZE5110000B4 DANGER Start only from seat in park or neutral. Starting in gear kits. TZE5110000B4 TZE5130000C4 (3) No.: TZE5180000C4 (7) No.: TZE5160000B3 TO AVOID PERSONAL INJURY: 1.
Page 16 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION (8) No.: TZE5170000B3 WARNING TO AVOID PERSONAL INJURY OR DEATH FROM ROLL-OVER; 1. Kukje recommends the use of a Roll-Over Protective Structures(ROPS) and seat belt in almost all applications 2. Remove the ROPS only when it substantially interferes with operation or itself presents a safety risk.
Page 17 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR (13) No.: TZE5770000B3 TO AVOID PERSONAL INJURY(OPERATING ON SLOPES) 1. If descending a slope, never disengage the clutch or shift levers to neutral. Doing so could cause the tractor to speed up out of control. 2.
Page 18 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION CABIN MODEL B40W102A 40BW-202010...
Page 19 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR (1) No.: TA00028501A (2) No.: NTE5220000C4 CAUTION Work in ventilated area. Do not work long hours air conditioner, because it This structure’s make exhaust air. if you don't have an air cleaner, protective capability open the door and get outside air into the area.
Page 20 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION (5) No.: TA00028504A (6) No.: NTE5150000C4 WARNING Engine Oil Before using this machine please check the engine oil level. If low please add oil before operating this unit. Do not mix oils. Only use oil from one manufacture at a time.
Page 21 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR (9) No.: TZE5130000C4 (12) No.: TZE4190000C4 DIESEL ONLY TZE4190000C4 (13) No.: TA00015596B WARNING TO AVOID PERSONAL INJURY: 1. Keep PTO shield in place at all times. 2. Do not operate the PTO at speeds faster TZE5130000C4 than the speed recommended by the implement manufacturer...
Page 22 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION (15) No.: TZE5140000B3 WARNING BEFORE DISMOUNTING TRACTOR: 1. PARK ON LEVEL GROUND WHENEVER POSSIBLE. If parking on a gradient. position tractor at right angles to the slope. 2. ALWAYS SET PARKING BRAKE. Leaving transmission in gear with the engine stopped will not prevent tractor from rolling.
Page 23 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 3. GENERAL INFORMATION FOR MAINTENANCE 3.1 TIGHTENING TORqUE 3.1.1 HEx. BOLT Unit: N.m (kgf.m) [lbf.ft] ITEM NO GRADE OR 4 T 8.8 T 10.9 T 12.9 T (0.9) (1.1) (0.9) (1.3) (1.4) [6.4] [8.1] [10] (2.0) (2.6)
Page 24 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 3.2 OIL, GREASE, FUEL AND COOLANT SPECIFICATIONS ITEM CAPACITY SPECIFICATION REMARkS 27 ℓ (7.13 u.s. gal) Fuel Diesel fuel (KS 2) Summer: S, Winter: W 4.3 ℓ (1.14 u.s. gal) Engine oil SAE15W-40 Final Tier4 : Grade CJ or higher Grease Small amount High load No.
Page 25 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 3.4 USING STANDARD PART AND ADHESIvE Snap ring for shaft Snap ring for hole Section applied with force 6015W113A 6015W115A 5. Replace the split pin with a new one and fix it firmly. Oil groove 6015W114A 1.
Page 26 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 3 - 3.5 mm Scraper Liquid sealant Tool Apply 6015W117A 6015W119A 7. Use a liquid sealant removal scraper (flat) to CAUTION remove any sealant left on the case. Make sure Spread liquid sealant. Otherwise, it can leak. not to make any scratch bigger than 0.3 mm Apply sealant to the inner side of the attached ...
Page 27 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 4. INSPECTION AND CORRESPONDING ACTION CAUTION To inspect or service the tractor, stop the engine on level ground, apply the parking brake and chock  the wheels in advance. 4.1 DAILY INSPECTION To prevent any future problem, it is important to be aware of the condition of the tractor. Therefore, check the followings before starting the engine: 4.1.1 CHECkING WORk PLACE • Check that the work place hasn't had any problem.
Page 28 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 5. GENERAL INFORMATION FOR SERvICE 5.1. MACHINE HISTORY AND INFORMATION If you have any question or want to ask for service, check the operating hours, serial number, engine number and engine model of the tractor. 5.1.1 SERIAL NUMBER 5.1.3 ENGINE NUMBER B40W108A...
Page 29 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 6. COMPONENTS OF TRACTOR 6.1 FRONT AND REAR ExTERIOR vIEW ROPS MODEL B40W103A (1) Head lamp (4) Turn signal lamp (7) Top link (2) Steering wheel (5) ROPS assembly (8) Draw bar hitch assembly (3) Side step (6) Combination lamp (9) Lower link...
Page 30 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION CABIN MODEL B40W104A (4) Washer fluid filler (1) Work lamp (FR) (7) Work lamp (RR) (2) Rear view mirror (5) Turn signal lamp (8) Wiper (RR) (3) Wiper (FR) (6) Antenna (9) Fuel inlet cap 40BW-202010...
Page 31 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 6.2 INTERIOR vIEW ROPS MODEL F50W103A B40W111A (1) Brake pedal (7) Hazard switch (13) 4WD lever (2) Parking brake lever (8) Key switch (14) Range gear shift lever (3) Turn signal light switch (9) HST pedal (Forward) (15) Seat adjust lever (4) Accelerator lever (10) HST pedal (Reverse)
Page 32 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION CABIN MODEL B40W105A K3CW115A (1) Hazard switch (6) PTO gear shift lever (11) PTO select switch (16) Position control lever (2) Cruise switch (7) Tilt lever (12) Accelerator lever (17) Differential lock pedal (3) Combination switch (8) Parking brake lever (13) HST pedal (Forward) (18) Stop valve knob...
Page 33 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 7. TRACTOR SPECIFICATIONS 7.1 ExTERIOR DIMENSIONS ROPS MODEL B40W109A DIMENSION mm (in.) 2,643 1,671 3,426 1,201 1,165 1,451 (104.06) (65.79) (134.88) (13.19) (47.28) (45.87) (57.13) 40BW-202010...
Page 34 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION CABIN MODEL B40W110A DIMENSION mm (in.) 2,258 1,671 3,426 1,203 1,130 1,413 (88.9) (65.79) (134.88) (13.50) (47.36) (44.49) (55.63) 40BW-202010...
Page 35 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 7.2 MAjOR SPECIFICATIONS MAjOR ITEMS 4025H 4035H 4035H Model A1700N6 A1700N5 A1700N4 Type Vertical, water cooled 4-cycle, diesel engine Emission regulation Final Tier4 Number of cylinders Bore and stroke mm (in.) 88 X 94 (3.46 X 3.70) Total displacement cc (in 1,714 (104.59)
Page 36 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION MAjOR ITEMS 4025H 4035H 4035H ROPS MODEL : 8.0-16 6PR Front wheel 8.0-16 6PR CABIN MODEL : 7.0-16 6PR Tire size ROPS MODEL : 12.4-24 6PR Rear wheel 12.4-24 6PR CABIN MODEL : 11.2-24 6PR Steering system Fully hydraulic Transmission system...
Page 37 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 7.3 DRIvING SPEED SHIFT POSITION SPEED (FORWARD AND REvERSE) MODEL RANGE SHIFT km/h 0 ~ 4.5 0 ~ 2.80 CABIN MODEL 0 ~ 12.2 0 ~ 7.58 [11.2-24] 0 ~ 23.3 0 ~ 14.48 0 ~ 4.7 0 ~ 2.92 ROPS...
Page 38 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8. PERIODIC INSPECTION 8.1 PERIODIC MAINTENANCE SCHEDULE TABLE RUNNING OPERATING HOUR (HOUR OR YEAR) HOURS 100 150 200 250 300 350 400 450 500 550 600 650 700 1YR 2YR ITEMS  ● ● Engine oil Engine ...
Page 39 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR RUNNING OPERATING HOUR (HOUR OR YEAR) HOURS 100 150 200 250 300 350 400 450 500 550 600 650 700 1YR 2YR ITEMS ● ● ● ● ● ● ● ● ● ● ● ●...
Page 40 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2 INSPECTION DESCRIPTION 8.2.1 FUELING INTO FUEL TANk CAUTION CAUTION When fueling, be careful not to spill fuel and  watch out for any smoke or flame around. Make sure to fuel only with the engine stopped. A42W103A Before working on this machine, lower any ...
Page 41 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.2 CHECkING ENGINE OIL 8.2.3 CHECkING COOLANT AMOUNT WARNING CAUTION Never mix different types of oil, but use the Hot coolant or steam from the pressurized   only engine oil specified by BBT. (sAe 15W-40, cooling system can be surged leading to a final Tier4: grade CJ or higher) serious scald.
Page 42 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.4 CHECkING LAMPS 8.2.6 CLEANING RADIATOR DUST GRILL CAUTION Check and clean the dust grill after stopping  the engine. B40W106A 1. Check the head lamps, turn signal lamps and brake lamps. 2. If any lamp is malfunctioning or damaged, A48W112A replace it with a new one.
Page 43 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.7 CHECkING INSTRUMENT CLUSTER SIGNALS 8.2.8 CHANGING ENGINE OIL ROPS MODEL CAUTION Make sure to stop the engine before chang-  ing engine oil. Make sure that the engine is sufficiently  cooled down enough to touch by a hand. B40W107A CABIN MODEL F42W118A...
Page 44 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.9 REPLACING ENGINE OIL FILTER CAUTION Be sure to use the only BBT genuine oil fil-  ter not to damage the engine. Replace the oil filter only after the engine is stopped and cooled down.
Page 45 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.10 REPLACING HST FILTER 8.2.11 REPLACING TRANSMISSION/ HYDRAULIC FILTER CAUTION replace the transmission fluid filter only af-  ter the engine is stopped and cooled down. Be sure to use the BBT genuine oil filter to ...
Page 46 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.12 CHANGING TRANSMISSION FLUID/HYDRAULIC OIL 1. Start the engine and activate several hydraulic functions to increase oil temperature. 2. Park the tractor on level ground and lower the implement onto the ground. 3. Stop the engine, remove the ignition key and apply the parking brake.
Page 47 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.13 ADjUSTING BRAkE PEDAL 8.2.14 ADjUSTING FAN BELT TENSION 1. Release the parking brake. CAUTION ROPS MODEL Stop the engine before adjusting the tension  of the fan belt. When adjusting the fan belt tension, be care- ...
Page 48 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.15 CHECkING FUEL LINE 8.2.16 CLEANING AIR CLEANER ELEMENT A48W119A A48W120A 1. Check the fuel line (1) and clamp for leakage. 1. Open the air cleaner cover (1) and pull out the air cleaner element. 2.
Page 49 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.17 BATTERY 8.2.18 CHECkING RADIATOR AND INTAkE HOSES A42W106A A48W122A CAUTION keep any spark or flame away from the bat-  tery. It can cause explosion with its gas. To avoid a spark, disconnect the negative ...
Page 50 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.19 APPLYING GREASE F42W140A F42W141A F42W139A F42W142A B40W115A 1. Apply grease every 50 hours of use. 2. Check the target positions and apply a proper amount of grease on them before beginning your work. Make sure to apply grease on them especially after working in a wet field.
Page 51 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.20 ADDING ANTI-FREEzE CAUTION Never remove the cap when the coolant tem-  perature is over the boiling point. To release pressure, unscrew the radiator cap (1) slight- ly. Then, unscrew it completely. Never pour cold water or coolant onto the ...
Page 52 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.21 FUSE AND RELAY ROPS MODEL ITEM SPECIFICATION DESCRIPTION Fuse 1 Panel Fuse 2 20 A Brake lamp Fuse 3 Battery charge Fuse 4 Glow/Heat Fuse 5 Fuel pump, Stop solenoid Fuse 6 20 A Spare Fuse 7 10 A...
Page 53 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR CABIN MODEL ITEM SPECIFICATION DESCRIPTION Fuse 1 Panel Fuse 2 20 A Brake lamp Fuse 3 Battery charge Control unit Fuse 4 10 A Fuse 5 10 A Fuel pump, Stop solenoid Fuse 6 20 A Spare Fuse 7...
Page 54 4025H/4035H/4035CH TRACTOR CHAPTER 1 GENERAL INFORMATION 8.2.22 TIRE INFLATION PRESSURE 8.2.23 CHECkING TOE-IN 1. Per formance and expectancy of life of tires depend on maintaining tire's inflation pressure properly. 2. If tire inflation pressure is insufficient, it can cause premature wear. If it is excessive, it can reduce traction and increase wheel slip.
Page 55 CHAPTER 1 GENERAL INFORMATION 4025H/4035H/4035CH TRACTOR 8.2.24 ADjUSTING FRONT WHEEL TOE-IN 8.2.25 TIGHTENING WHEEL BOLT F42W149A B40W118A Tighten all the bolts on the wheel after initial 4 and 1. Unscrew the mounting nut (1) on the tie rod. 8 hours of operation. Then, check tightness of the 2.
Page 56 Chapter 2 engine taBLe OF COntentS 4.4.3 DPF Check LED Lamp ...... 2-23 1. ExtErior and namEs of parts ..2-3 4.4.4 CAN communication ......2-26 1.1 Specification ..........2-3 4.4.5 PC RS232 communication (Low speed 1.2 Engine dimensions........2-4 data download and Reprogram) ..2-28 1.3 Name of each part ........2-5 4.4.6 PC USB2 communications 1.4 Emissions regulations .......2-6 (high speed data download) .... 2-29 1.4.1 emissions regulations value ....2-6 4.4.7 RTC(Real Time Check) power supply (Warranty for 5 years) ..
Page 57 tablE of contEnts 6.2.4 Alternator .......... 2-62 6.4.6 Oil pump ..........2-82 6.2.5 After-Treatment Device (ATD) ... 2-62 6.4.7 Camshaft ........... 2-83 6.2.6 Exhaust manifold ......2-62 6.4.8 Injection pump ........2-83 6.2.7 Fuel injection pipes ......2-63 6.4.9 Idle gear ..........2-84 6.2.8 Fuel drain line ........2-63 6.4.10 Gear case ........2-85 6.2.9 Fuel injection valve (Injector) .... 2-63 6.4.11 Frame and oil suction pipe ....2-85 6.2.10 Glow plug ........2-63 6.4.12 Oil pan ..........
Page 58 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 1. ExtErior and namEs of parts 1.1 spEcification K25W225A F42W220A a1700n6 a1700n5 a1700n4 Type Vertical Water-Cooled 4 Cycle Diesel Engine EPA Final Tier4 Emission Regulation (Power Category - 19≤kW<37, a1700n6 : 8≤kW<19) No. of Cylinders Bore × Stroke 88×94 Displacement 1,714 Combustion System IDI (Indirect Injection) Intake System Natural Aspirated Horse Power kW(HP) 18.3(24.5) 22(30) 25.7(35) Compression Ratio 21.3 : 1 Direction of Rotation CCW from Flywheel Side Cooling System Pressurized Radiator...
Page 59 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 1.2 EnginE dimEnsions F42W222B 40BW-202010...
Page 60 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 1.3 namE of Each part F42W225A (1) Fuel filter (5) Fuel injection pump (9) Starter motor (2) Intake manifold (6) Alternator (10) Flywheel (3) Water pump (7) After-treatment device (11) Turbo charger (4) Oil filter (8) DP sensor * T he pictures show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. notE • the pictures are only a reference to show a typical engine. 40BW-202010...
Page 61 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 1.4 Emissions rEgulations Each country conducts the emissions regulations on non-road diesel engine to prevent environmental contamination. The regulations values and enforcement time are different by each power category. 1.4.1 Emissions rEgulations valuE Unit: [g/kW-hr] Emissions nox + thc nation output (kw) rEgulations (nox + nmhc) Final Tier-4 8 ~ 19 0.40 Final Tier-4 (4.7)
Page 62 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 1.4.3 warranty condition of Emission rEgulations valuE In the maintenance of engine, make sure the warranty conditions are observed and at the same time maintenance considers degradation as time goes by next maintenance. The case of EPA certificate engine should observe as following conditions in order to keep emission regulations.
Page 63 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 2. main function and pEriodic chEck 2.1 pEriodic chEcklist Periodic checks and maintenance are very important for keeping the engine in optimum condition. The check contents and times are indicated in below table. So be sure to observe. Every Every Every 1000hrs 2000hrs part itEm daily 50hrs 250hrs 500hrs or 1 years or 2 years Check the fuel level and refill ○ Clean the fuel tank ○ Check the fuel filter and hose ○ related coolant Fuel System Replace the fuel filter element.
Page 64 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 2.2 chEck thE main function • Checking the main function is the best way for performance guarantee and long life of engine. Please note the following information to the engine to maintain. 2.2.1 visual chEck • Visual check of around the engine: confirm the fuel, lubricating oil, coolant system, fuel and water leakage. Check the hose of the each part, V-belt, and the tightening status of clamp. Check the damage of components or loosening the bolt &nut. • If you have trouble when a visual check, please refer to this manual for repairing it. 2.2.2 lubricating oil • Diesel engines operate under differed conditions than gasoline engines, so proper oil should be used. • If defective oil is used or lubricating oil is not changed regularly, accelerated wear of moving components and engine life may be seriously shortened. • Oil viscosity grade use the class SAE 15W-40 , above API CJ-4 level (Final Tier4). * Please refer to next graphic and use the proper oil. K25W229A • Before engine operating, check the lubricating oil level whether it is set at the right level between the L(low) mark and the H(high) mark. If necessary, add lubricating oil. If the oil is contaminated or viscosity is low, it should be changed. 1) While checking the lubricating oil, keep the engine horizontal. 2) Wait for about 15 minutes after shutting off the engine to check the oil level. 3) Check the oil level 5~6 minutes later after refilling the lubricating oil.
Page 65 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 2.2.3 fuEl • The characteristics of diesel engine fuel (Cetane, specific gravity, viscosity, etc) has a effect on engine start, power out, fuel consumption, the functionality of a chain of fuel, knock, emission, etc. Use the fuel that has Cetane value 40-48 and use a lower viscosity at low temperature. K25W231A K25W230A (1) Lubricating oil (2) Dip stick • Lubricating oil and element replacement for 1st time is after operating engine for 50hrs. And then 2nd time and thereafter is every 250 hr.
Page 66 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 2.2.4 coolant • Replace the fuel filter: every 250hrs. • The coolant must use the soft water (such as tap water, etc). Hard water such as well water I f water or dust deposits are in fuel, replace the causes scale deposits on the coolant system. fuel filter.
Page 67 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 2.2.5 v-bElt. 2.2.6 EvEry 50hrs chEck 1. R eplace the lubricating oil and oil filter: Replace the lubricating oil and oil filter at the first 50hrs. 2. Check the tension of the V-belt. 2.2.7 chEck EvEry 250hrs 1. R eplace the lubricating oil and oil filter: Replace the lubricating oil and oil filter every 250 hrs after replacing it at first 50 hrs. 2. Check & clean the radiator fan. 3. Clean the air cleaner.
Page 68 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 3. dEfEct diagnosis and managEmEnt troublE causE rEpairing 1) I f discharged, charge or replace. 2) I f lack of the capacity 1) L ack of battery capacity because of the cold weather, raise slowly the temperature, or charge or replace. 2) C onnection of battery cable is loosen, Correction S tarter switch but does broken, or corroded. (excessive resistance) not pinion. 3) F ailure of spline which gets in gear pinion of Correct the spline. the armature shaft. 4) F ailure of the magnetic switch plunger. Or Correction or replace coil disconnection and short.
Page 69 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR troublE causE rEpairing 8) C onnection area of high pressure pipe is Re-tighten loose. 9) I njection pump sticking. Correction or replace. 10) S pray failure of Injection valve. Correction or replace E ngine starts but will not 11) I nappropriate injection pressure. Correction keep running 12) G low plugs failure. Correction or replace. 13) C ompress pressure failure. Check the valve and valve seat - Closing of valve failure - Correction - Cylinder gasket packing failure - Replace - The piston, piston ring, cylinder wear - Replace 1) F uel pipe clogged or filter polluted.
Page 70 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE troublE causE rEpairing 1) C oolant shortage or fur forms Refill or clean up 2) F an is loose, damage, or not balanced Correction or replace 3) W ater pump performance degradation. Correction or replace 4) V alve clearance unsuitable Correction Engine overheat 5) R esistance increase in exhaust system. Clean up or Replacement 6) C logging the radiator air path. Clean up 7) I nappropriate injection timing. Correct the injection timing 8) C ylinder head gasket breakage. Replace the head gasket.
Page 71 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR troublE causE rEpairing Check and if necessary, 1) F uel leak replace all the pipe and re- tighten connection area. - T wisting, crushing of the return line is checked. Defective parts are replaced. 2) C logging of the return pipe or hose - I f lines were clogged, bleed air after boring the compressed air. Fuel consumption excessive 3) I nappropriate injection timing. Correction 4) C heck the compression pressure. Correction or replace 5) I njection valve failure (spray, pressure, etc) Correction or replace 6) I njection pump failure Correction or replace (excessive injection quantity)
Page 72 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE troublE causE rEpairing 1) M ismatch the injection timing. Correction 2) I njection pressure failure Correction 3) F ailure of the injection function. Disassembly& Correction 4) S hortage of the intake air Clean the air cleaner Engine knocking 5) L ubricating oil enter into the combustion chamber. - Oil up - Correction - Oil down - Correction - Oil viscosity is low. - Replace the appropriate oil. 6) E ngine temperature is low. Warm-up. 1) I njection timing is late. Correction 2) C ompression pressure is low.
Page 73 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 4. dpf systEm This section explains how to operate the DPF 4.2 dpf data loggEr systems and help maintenance methods according 4.2.1 installation to warning alarm levels. This data logger enables It can be operated the date in initial installation comprehensive monitoring of the DPF conditions through CAN communication scanner and can be to need DPF cleaning, check the cause of trouble...
Page 74 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 4.3 fEaturEs (input / output) 4.3.1 data loggEr spEcification itEm spEc I nput Current Range Maximum 200mA (Using Ignition key battery) Input Voltage Range 7V ~ 18V Leakage current DPS sensor power supply Maximum 50mA, 5V±0.2V DPS Sensor 0 ~ 5V EGTS Sensor 1 Kohm pull-up in logger CAN Communication CAN low, high to communicate with scanner, 250Kbps for DPF status check Communication to download data stored in “DPF data logger” or to reprogram RS232 communication and check DPF condition L ED Lamp Warn the DPF conditions (working 1 Amp) 4.3.2 hardwarE block diagram of dpf data loggEr K25W235A 40BW-202010...
Page 75 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 4.4 ElEctric spEcification 4.4.1 dps sEnsor introduction Check the pressure difference between DPF inlet and outlet to measure the collected SOOT. circuit K25W236A tablE NOMINAL OUTPUT CHARACTERISTICS DIFFERENTIAL PRESSURE (kPaD) K25W237A 40BW-202010...
Page 76 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 4.4.2 Egts sEnsor (Exhaust gas tEmpEraturE sEnsor) diagnostics introduction The following sensor diagnostics are when the Check the temperature of the exhaust gas from sensor is properly connected with a 5kohm pull-up DPF and data logger records the temperature of the load to Vcc. exhaust gas in Logger. fault pin output circuit Open 1 > 96%Vcc...
Page 77 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR tablE part chEck Rs = R1 + R0 (1 + αT + βT α = 3.8285 10 Logger β = 3.8285 10 rs (Ω) 1Kohm t (°c) uo (v) 169.7 0.725 185.1 0.781 EGTS 200.5 0.835 219.6 0.900 K25W241A 238.5 0.963 1) SCANNER 275.9 1.081 1 ] (DIAGNOSTIC) - 4] Engine - 1] DPF Logger - 312.7 1.191 1] Self check - 10] Exhaust gas Temperature. 349.0 1.293 Voltage - 11] Exhaust gas Temperature.Voltage 384.6...
Page 78 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 4.4.3 dpf chEck lEd lamp introduction Check lamp to show the DPF conditions. circuit K25W242A wiring IG KEY Logger K25W243A 40BW-202010...
Page 79 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR dpf lamp on/off • If IGNITION KEY ON: Lamp ON for 1 sec dangEr lEvEl condition lamp display 1. △P > setting values(Pressure, time) It means DPF is clogged with Particular. EMERGENCY Continuous 2. EGTS > setting value(Temp. time) It means that DPF almost melt. CAUTION Sensor malfunction Every 0.5sec. Working time > setting value(working time) Every 2.0sec. CHECK (*possible erasing lamp with scanner) *) Setting1: emergency differential pressure setting: only super-user can set using scanner SCANNER – 1 ] DIAGNOSTIC - 4] Engine - 1] DPF Logger - 2] Change setting - 1] DPS Warning Pressure – F1(Increase) or F5(Decrease) *) Setting2: emergency pressure time setting: only super-user can set using scanner SCANNER – 1 ] DIAGNOSTIC - 4] Engine - 1] DPF Logger - 2] Change setting - 2] DPS Warning Time – F1(Increase) or F5(Decrease) *) Setting3: emergency exhaust temperature setting: only super-user can set using scanner SCANNER – 1 ] DIAGNOSTIC - 4] Engine - 1] DPF Logger - 2] Change setting - 3] EGTS Warning...
Page 80 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE K25W244A *) D PF Cleaning: DPF check lamp blinking in every 2 seconds indicates that engine operation hour exceeds setting value to make alarm for DPF cleaning maintenance. DPF check lamp will turn off if “Cleaning” is selected via scanner after DPF cleaning. action whEn lamp turns on dangEr lEvEl tEmporary action lamp display 1. Stop tractor and engine if lamp light blinks while driving 2. Call customer service EMERGENCY Continuous...
Page 81 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 4.4.4 can communication introduction A circuit connecting to scanner, which helps check a condition of DPF and repair. circuit K25W245A wiring SCANNER Logger OBDII connector TLE 6250 HIGH SCAN -TOOL SIDE CONN tranceiver 120 ohm K25W246A 40BW-202010...
Page 82 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE scannEr chEck 1) Connect scanner tool to OBDII terminal in IG key off or on 2) Ignition key on 3) Press a power button on scanner 4) SCANNER – 1] DIAGNOSTIC - 4] Engine - 1] DPF Logger - 1] Auto check 5) It indicates an error between Logger and CAN communication when displaying “00” value on data list 6) Call customer service department for inspection of scanner if communication is not running 40BW-202010...
Page 83 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 4.4.5 pc rs232 communication (low spEEd data download and rEprogram) introduction A circuit connecting to scanner, which helps check a condition of DPF and repair. 1) Using 4 pins connecter between RS232 connecter and Data logger connector 2) 4pin connector (RS232_RX, RS232_TX, RS232_GND, USB1_CONNECT) 3) L ogger reprogram : Connect RS232-to-USB Interface module to PC and start to download HEX file when turn IG_KEY ON while running reprogram execution file provided 4) USB1_CONNECT : Signal to detect connecting RS232-to-USB I/F module from external 5) D ata Download from Logger : Select downloading times to setting key among 2 second/10 second/ 60 second because it needs about 19 hours to download at a speed of 115200BR (115200,8,N,1) wiring Logger...
Page 84 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 4.4.6 pc usb2 communications (high spEEd data download) introduction High speed downloading tool for DPF engineer only 1) Maximum length of USB connector should not exceed 200 mm and it has 6 pin connector only 2) N eed 4 pin connecter ((USB2 power supply, USB2 ground, USB2_POSI, USB2_NEG) for high speed download in option and it does not connect to wire-harness. 3) C ommunication speed: 1GB data will take 200 seconds to download with a speed of 12megaBR (Using extra logger connecter) wiring Logger...
Page 85 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 4.5 notE 4.6 warranty 4.5.1 running tEmpEraturE rangE 4.6.1 wE guarantEE dpf data loggEr • -40°C ~ 105°C for 5 yEars aftEr shipmEnt 4.5.2 casE: watEr-proof casE 40BW-202010...
Page 86 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5. sEctional viEw for major componEnts 5.1 cylindEr block K25W2A61A componEnts (17) Bearing ass’y, thrust (1) Block ass’y, cylinder (9) Plug 50 (2) Block, cylinder (10) Plug pt 1/4 (20) Gasket, head (3) Bearing cap 1 (11) Plug, pt 3/8 (21) Bolt(head, cylinder) (4) Bearing cap 2 (12) Plug(block heater) (23) Plug pt 1/8 (5) Bolt, bearing cap (13) Bush(cam shaft) (27) Bolt(head, cylinder) (6) Spring pin (14) Bearing ass’y, main(std) (28) Pin(oil) (7) Plug 30 (15) Packing (8) Plug 12 (16) Bolt 8 ×12 40BW-202010...
Page 87 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.2 gEar casE F42W202A componEnts (1) Flange, gear case (9) Cover (20) Flange bolt, M8 × L22 (2) Stud bolt, M8 X L22 (10) Packing (21) Flange bolt, M8 × L60 (3) Stud bolt, M8 X L20 (11) Knock pin (22) Flange bolt, M8 × L90 (4) Gear case ass’y (12) Stud bolt (23) Flange bolt, M8 × L85 (5) Gear case (14) Copper packing, Ø8 (24) Flange bolt, M8 × L50 (6) Oil seal (16) O-ring (32) O-ring (7) Lub-oil filler cap (18) Flange nut, M8 (8) O-ring (19) Bolt, M8 X L16 40BW-202010...
Page 88 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.3 flywhEEl housing and oil pan K25W2A61A componEnts (1) Parallel pin (7) Lower cover (13) Oil seal housing ass’y (2) Flange mounting (8) Knock pin (14) Oil seal housing (3) Flange bolt, M8 X L25 (9) Flange bolt, M8×L12 (15) Oil seal (4) Oil pan (10) Flange bolt, M8×L50 (16) Flange bolt, M8×L30 (5) Lub-oil drain plug, M14 (11) Flange bolt, M8×L100 (17) Magnet (6) O-ring (12) Flange bolt, M8×L120 (18) Flange bolt, M10×L25 40BW-202010...
Page 89 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.4 cylindEr hEad and hEad covEr K25W2A63A componEnts (1) Head ass’y, cylinder (15) Spring, valve (28) Circlip (41) Hose, plain (2) Head, cylinder (16) Retainer, valve spring (29) Bolt, stud (42) Clip, hose 20 (3) Guide, suc valve (17) Cotter, valve spring (30) Washer 12 (43) Oil filler (4) Guide, exh valve (18) Cap, valve (31) Cover, head (44) O-ring (P) (5) Seat, suc valve (19) Shaft ass’y, rocker arm (32) Packing, head cover (45) Lift (6) Seat, exh valve (20) Support (A) (33) Cap, hood (46) Bolt, flange 8 x 16 (34) O-ring (P) (47) Pre chamber (7) Plug 40 (21) Support (B) (8) Plug 22 (22) Spring(rocker arm)
Page 90 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.5 intakE manifold K25W2A64A componEnts (1) Manifold, int. (3) Bolt, flange 8 x 30 (5) Nut, hexagon flange (2) Packing(manifold, int) (4) Bolt, stud 8 x 35 (8) Tube, breather 40BW-202010...
Page 91 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.6 Exhaust manifold K25W2A66A componEnts (1) Manifold, exhaust (4) Nut, flange 8 (7) Gasket(silencer) (2) Gasket, exh. Manifold (5) Bolt, flange 8 x 80 (3) Bolt, stud (6) Bolt, stud 8 x 22 40BW-202010...
Page 92 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.7 camshaft and drivE gEar K25W2A67A componEnts (1) Tappet (7) Hex. flange bolt (15) Spring washer (2) Push rod (8) Idle gear shaft (16) Hex. nut (3) Camshaft assembly (9) Idle gear assembly (17) Packing (4) Camshaft gear (10) Bushing (idle gear) (18) Hydraulic pump gear cover (5) Sliding key (11) Bolt (idle shaft) (19) Hydraulic pump drive gear assembly (6) Thrust bearing (camshaft) (12) Fuel injection pump gear (20) Ball bearing (with deep groove) 40BW-202010...
Page 93 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.8 crankshaft and piston K25W2A68A componEnts (1) Crank shaft ass’y (16) Fly wheel ass’y (single 3cyl) (26) Piston ring (oil) (2) Crank shaft (17) Fly wheel (single 3cyl) (27) Pin, piston (3) Pin, parallel 8 × 16 (19) Gear, ring (28) Ring, retainer (5) Gear, crank (20) Bearing, ball 6302 (29) Connecting rod ass’y (8) Key 7 × 14 (21) Piston ass’y (30) Connecting rod (11) V-pulley(crank shaft) (22) Piston (33) Bush(piston pin) (13) Washer(V-pulley) 8 (23) Piston ring ass’y (34) Bolt(connecting rod) (14) Bolt(V-pulley) (24) Piston ring (1st) (35) Bearing, crank pin (15) Bolt, fly wheel (25) Piston ring (2nd) 40BW-202010...
Page 94 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.9 lubrication systEm F42W209A componEnts (1) Lub-oil pump ass’y (17) Bolt, oil cooler (26) Oil suction pipe (2) Lub-oil pump (18) Space, oil cooler (27) Packing, oil suction pipe (3) Oil pump gear (19) Oil pressure control valve (28) Flange bolt, M8 x L35 (4) Packing, oil pump (20) Bracket, oil filter (29) Flange bolt, M8 x L16 (5) Bolt, M6 x L25 (21) Packing, oil filter (34) Guide, dipstick (6) Washer,sealing (22) O-ring (36) Dipstick (7) Screw,hexagon head cap (23) Flange bolt, M8 x L20 (37) Oil pressure switch (15) Oil filter (24) Bracket, oil cooler (16) Oil cooler (25) Flange bolt, M6 × L12 40BW-202010...
Page 95 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.10 cooling systEm F42W212A componEnts (1) Water pump ass’y (10) Copper packing, Ø10 (19) Cooling hose A (2) O-ring (11) Coolant temp. Sensor (20) Cooling hose B (3) Packing, water pump (12) Flange bolt, M8 × L60 (21) 90˚ Elbow (4) Packing, cover (13) Flange bolt, M8 × L55 (22) Hose clamp, Ø25 (5) Thermostat (14) V-pulley (23) Hose clamp, Ø22 (6) Cover, thermostat (15) V-belt (24) Joint, pt 1/4 (7) Flange bolt, M8 × L18 (16) Spacer, cooling fan (8) Copper packing, Ø16 (17) Flange bolt, M8 × L35 (9) Sensor, glow plug (18) Taper plug, pt 3/8 40BW-202010...
Page 96 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.11 fuEl injEction pump K25W2A71A componEnts (1) Fuel injection pump ass’y (5) Bracket,pump (A) (9) Nut, flange (2) Support (6) Bracket,pump (B) (10) Key,woodruff (3) Hook (7) Screw, hexagon head cap (4) E-type retaining-ring (8) Bolt, flange 8 x 16 40BW-202010...
Page 97 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.12 fuEl injEction systEm and valvE K25W2A72A componEnts (1) Fuel injection valve assembly (14) Fuel pipe assembly (B) (19) Hex. mounting nut (10) Bracket (fuel pipe) (15) Fuel pipe assembly (C) (22) Return hose (11) Bracket rubber (fuel pipe) (16) Fuel pipe assembly (D) (23) Hose clip (12) Bracket plate (17) Return pipe assembly (24) Joint (13) Fuel pipe assembly (A) (18) Packing (joint) (25) Hex. flange nut 40BW-202010...
Page 98 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.13 fuEl systEm F42W213A componEnts (1) Fuel filter ass’y (3) Bolt, flange (5) Hose, fuel ass’y (2) Bracket, fuel filter (4) Bolt, flange (6) Hose clip 40BW-202010...
Page 99 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.14 start motor F42W219A componEnts (1) Starter (3) Spring washer (5) Caution plate (2) Stud bolt, M12 x L30 (4) Nut, M12 40BW-202010...
Page 100 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.15 altErnator and ElEctric systEm K25W2A53A componEnts (1) Alternator(12V-45A) (37) Nut 8 (42) Washer (43) Plug, thermostat (1) Alternator(12V-70A) (38) Bracket (36) Bolt 10 (39) Washer (44) Connector (36) Bolt 8 (41) Washer, lock (49) Bolt 8×30 (37) Nut 10 (42) Washer 40BW-202010...
Page 101 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 5.16 dpf application systEm F42W215A componEnts (1) DPF (5) Gasket (9) DPF bracket (2) DPF support(A) (6) Bolt, flange (10) Bolt, flange (3) Nut, flange 8 (7) DPF support(B) (11) Bolt, flange (4) Stud bolt (8) Bolt, flange 40BW-202010...
Page 102 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 5.17 dpf’s sEnsor option F42W217A componEnts (1) Temperature sensor (3) Hose A, diff. Pressure sensor (2) DPF diff, pressure sensor (4) Hose B, diff. Pressure sensor 40BW-202010...
Page 103 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6. disassEmbly and sErvicE 6.1 EnginE rEmoval rops modEl K42W217A A42W203A 3. D isconnect the steering cylinder hose (1), hydraulic pump suction hose (2), steering unit hose (3) and hydraulic pipe (4) from left side of the engine. K42W218A 1. O pen the hood to disconnect the head lamp wiring connector (1), gas cylinder (2). Then, unscrew the hood mounting bolts (3) to remove the hood.
Page 104 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE K42W223A K42W225A 6. R emove the exhaust pipe (1) and DPF assembly (2) [Tier-4 engine only]. A42W201A 8. R emove the air cleaner (1) and reservoir tank (2). Remove the oil cooler(3). K42W224A 7. R emove the battery (1). K42W226A 9. Remove the ECU (1). 40BW-202010...
Page 105 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR K42W227A K42W229A 10. D isconnect the radiator hose (Upper: 1, Lower: 2). K42W230A 12. D isconnect the positive (+) battery line (1) and negative (-) battery line (2). Then, disconnect K42W228A glow plug wiring (3), fuel solenoid connector(4) 11. U nscrew the radiator support mounting bolts and oil pressure switch c onnector (5) and (1)(4EA) to remove the radiator support (2) and organize the engine wiring into the instrument...
Page 106 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE B40W206A K42W235A K42W233A K42W236A 14. R emove the front wheel (1) and front axle (2). (Refer to "Disassembly and assembly" in chapter 5). K42W234A 15. U nscrew the bracket assembly mounting bolts (1)(16EA) of front axle and remove the front axle bracket assembly (2). 40BW-202010...
Page 107 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR cabin modEl B40W201A A42W202A 16. I nstall a engine removal hooks and use a hoist to lift the engine. Then, unscrew the engine and clutch housing mounting bolts (1)(8EA) and nuts (2)(2EA) to remove the engine assembly (3) using a hoist. K3CW202A 1. O pen the hood and disconnect the negative (-) battery cable (1).
Page 108 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE K3CW203A K3CW205A 3. D isconnect the hydraulic hose (1), steering hydraulic hose (2), steering unit hose (3) and cabin heater hoses (4) from left side of the engine. B40W202A 2. D isconnect the head lamp wiring connector (1), unscrew the hood mounting bolts (2) and remove the gas cylinder (3) to remove the hood (4). K3CW206A K3CW207A 40BW-202010...
Page 109 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR K3CW208A K3CW209A K3CW212A 5. D isconnect the ECU connector (1) and A /C condenser pressure sensor connector (2). K3CW210A K3CW213A 6. D isconnect the connectors of the A/C compressor (1), glow plug (2), stop solenoid (3), fuel pump (4), engine oil pressure switch (5) and cabin wiring (6). K3CW211A 4. D isconnect the connectors of the DPF sensor (1), water temp. sensor (2), alternator (3), starter motor (4) and cabin wiring (5). K3CW214A 7. D isconnect the A /C refrigerant hose (1) and accelerator cable (2).
Page 110 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE K3CW215A K3CW218A 8. D isconnect the fuel supply hose (1) and fuel 10. R emove the 4WD lever (1) and range shift lever return hose (2) from the right side of the tractor. (2) from the lower left section of the cabin. K3CW216A K3CW219A K3CW217A K3CW220A 9. D isconnect the F-R shuttle rod (1), clutch rod (2) 11. R emove the step (RH) (1) and disconnect the and brake rod (LH) (3). brake rod (RH) (2), front SCV cable (3) and steering unit hose (4).
Page 111 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR K3CW221A K3CW223A 12. R emove the differential connecting lever (1) and hydraulic adjusting shaft (2). K3CW224A 14. U nscrew the mounting bolts (Front : 1, Rear : 2). K3CW222A 13. R emove the PTO shift grip (1), main shift lever grip (2) and position control lever grip (3) from in the cabin. 40BW-202010...
Page 112 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE B40W203A K3CW228A 16. D isconnect the exhaust pipe (1) and remove the DPF assembly (2) from the upper section of the engine. B40W204A K3CW229A 17. R emove the battery (1) and ECU (2). B40W205A 15. I nstall a cabin removal jig and remove the cabin slowly with a hoist. K3CW230A 18. R emove the compressor (1), tension belt (2) and tension pulley (3). 40BW-202010...
Page 113 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR K3CW231A K3CW233A 19. R emove the hood support (1), intake hose (2), fuel filter (3) and fuel pump (4). K3CW234A 21. R emove the condenser (1). K3CW232A 20. Remove the air cleaner (1) and reservoir tank (2). 40BW-202010...
Page 114 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE K3CW235A K42W228A 23. U nscrew the radiator support mounting bolts (1) (4EA) to remove the radiator support (2) and radiator (3). K3CW236A 22. D isconnect the radiator hoses (Upper: 1, Lower: 2) and cabin heater pipe (3). K42W229A 24. D isconnect the positive (+) battery cable (1) and negative (-) battery cable (2). 40BW-202010...
Page 115 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR K3CW237A B40W206A 25. D isconnect the suction tube (1) and discharge hose (2) of the hydraulic pump. K42W233A 27. R emove the front wheel (1) and front axle (2). (Refer to "Disassembly and assembly" in chapter 5). K3CW238A 26. R emove the propeller shaft (1). (Refer to "Propeller shaft disassembly and assembly" in chapter 5) K42W234A 28. U nscrew the bracket assembly mounting bolts (1)(16EA) of front axle and remove the front axle bracket assembly (2). 40BW-202010...
Page 116 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.2 disassEmbly of EnginE 6.2.1 gEnEral prEcautions 1. Select place that must be neatly arranged. 2. Disassemble parts must be carefully handled for prevention of injury or taint. Prepare some vessels for keeping of disassemble parts. 3. Prepare the solvent and compressed air for cleaning of parts. 4. Use the tools that are in good condition and be sure you understand how to use them before performing any job.
Page 117 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.2.3 v-bElt, v-pullEy 6.2.5 aftEr-trEatmEnt dEvicE (atd) K25W250A K25W252A 1. Loosen the bolts that hold the V-pulley. 1. Loosen the bolts that hold the ATD. 2. Loosen the tension bolt and the bolt that hold the 2. Loosen the nuts that connect the ATD and DPF alternator, remove the V-belt after relaxation of belt. fixing housing. 3. Disassemble the V-pulley. 3. Disassemble the ATD. (When disassembling the ATD, should be careful because ATD is heavy.) 6.2.4 altErnator 6.2.6 Exhaust manifold K25W251A K25W253A 1. Loosen the bolt and washer that hold the upper 1. Loosen the bolts and nuts that hold the exhaust side of alternator.
Page 118 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.2.7 fuEl injEction pipEs 6.2.9 fuEl injEction valvE (injEctor) K25W254A K25W284A 1. Loosen the bolts that hold fuel injection pipes 1. Disassemble the injectors. assembly. 2. Disassemble the sealing washers and nozzle 2. Loosen the nuts in fuel injection pump side. spaces. 3. Loosen the nuts in head cover side. 3.
Page 119 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.2.11 intakE manifold 6.2.13 oil filtEr K25W257A K25W259A 1. Loosen the clamp that holds breather hose 1. Disassemble the oil filter using by tool. connecting Intake manifold and cylinder head. 2. Loosen the bolts and nut that hold the intake manifold. 3. Disassemble the intake manifold. 4. Disassemble the packing. 5. Do not re-use the packing. 6.2.12 watEr pump 6.2.14 oil coolEr K25W258A...
Page 120 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.2.15 hEad covEr 6.2.17 push rod K25W261A K25W263A 1. Loosen the nuts that hold the head cover. Disassemble the push rod. (Arrange the push rod in order from front side after disassemble it.) 2. Disassemble the head cover. 3. Disassemble the packing from head cover. 4. Do not re-use the packing. 6.2.16 rockEr-arm shaft K25W262A 1. Loosen the bolts that hold the rocker arm shaft 2. Disassemble the rocker arm shaft. 40BW-202010...
Page 121 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.2.19 fuEl filtEr 6.2.18 cylindEr hEad K25W264A K25W267A 1. Loosen the clamp that holds hose connecting fuel filter pump and fuel injection pump. 2. Loosen the bolts that hold the fuel filter bracket. 3. Disassemble the fuel filter and fuel filter bracket. 6.2.20 oil pan K25W265A 1. Loosen the 14 clamping bolts in order. (Order: Outside(14) → Inside(1)) 2. Disassemble the cylinder head assembly. 3. Disassemble the gasket. 4. Do not re-use the gasket. caution • do not cause scratch to the upper plane of cylinder block and the lower plane of the cyl- inder head.
Page 122 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.2.21 framE and oil suction pipE 6.2.23 flywhEEl K25W269A K25W272A 1. Loosen the 20 bolts that hold frame. 1. Loosen the bolts that hold the flywheel. 2. Disassemble frame. 2. Disassemble the flywheel. 3. Clean the liquid packing on face of frame 4. Loosen the 2 bolts that hold the oil suction pipe. 5. Disassemble the oil suction pipe. 6.2.22 startEr 6.2.24 mounting flangE K25W271A K25W273A 1. Loosen the bolts that hold the starter motor. 1. Loosen the bolts that hold the mounting flange. 2.
Page 123 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.2.25 oil sEal housing 6.2.27 gEar casE K25W274A K25W276A 1. Loosen the 9 clamping bolts. 1. Loosen the bolts that hold the gear case. 2. Disassemble the oil seal housing. 2. Disassemble the gear case. 3. Clean the liquid packing on oil seal housing. 3. Clean the liquid packing on gear case flange and gear case. 6.2.26 crank pullEy 6.2.28 fuEl injEction pump K25W275A K25W277A 1. Loosen the bolt that holds the crank pulley. 1. Loosen the bolt that holds the fuel injection pump gear. 2.
Page 124 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.2.29 idlE shaft and idlE gEar 6.2.31 oil pump K25W278A K25W280A 1. Loosen the bolts that hold idle shaft and idle 1. Loosen the bolts using by hexagon wrench. gear. 2. Disassemble the oil pump. 2. Disassemble the idle shaft and idle gear. 3. Do not re-use the O-ring and packing. 6.2.30 cam shaft assEmbly 6.2.32 gEar casE flangE K25W279A K25W281A 1.
Page 125 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.3 main parts inspEction & maintEnancE 6.2.33 piston and connEcting rod 6.3.1 cylindEr hEad disassEmbly 1. Disassemble the valve cotter, spring, retainer by the valve spring with disassembly tools. 2. Disassemble the intake valve and exhaust valve. 3. Keep those disassembled parts by matching cylinders. chEck thE cylindEr hEad K25W282A 1. Loosen the bolts that hold small end of connecting rod.
Page 126 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE intakE & Exhaust valvE & valvE guidE ▶ valvE ▶ valvE guidE K20W255A K20W257A • M e a s u r e t h e va l ve s te m o u te r d i a m ete r. • Measure the distance between the valve guide If the wear is over the limit, replace the valve.
Page 127 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR ▶ valvE shEEt ▶ valvE spring K20W258A K20W260A Squareness, free-length, transformation, etc. of valve spring are direct cause of damage such as valve stem uneven wear, etc. Therefore check certainly it when disassembling. If the measurement value is over the limit, replace itEm spEcification limit Free length (A) 46 mm Inclination (B) 1.2 mm...
Page 128 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.3.2 cylindEr block 6.3.3 valvE dEvicE Rocker arm assembly needs to be maintained chEck thE cylindEr block clearly and exactly bec ause it is related with timing of the valve open & close and the engine ▶...
Page 129 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR tappEt push rod K20W264A K20W266A • Put the push rod on the sur face plate and measure the bending degree by gap gauge. If it is over the limit, replace it. (mm) Below 0.3 limit K20W265A If the measurement of the tappet outer diameter and cylinder block is over the limit, replace it. (mm) itEm spEcification limit Tappet outer 14.227 ~ 14.249 14.18 diameter Guide inside 14.260 ~ 14.280 14.30 diameter...
Page 130 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.3.4 piston & piston ring chEck thE piston ▶ piston outEr diamEtEr ▶ piston ring • If the main measurement value is over the limit, replace the pistons • If there is any damage or scratch on the surface, replace it • Piston outer diameter (mm) itEm spEcification limit Piston outer 87.95 ~ 87.97 87.90 diameter Minimum The side with manufacturer's clearance 0.060 ~ 0.080 mark shall face upward.
Page 131 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR ▶ connEcting rod Twist Parallel K20W270A K20W272A • Measure the clearance between piston ring and • Measure the parallel and twist degree of big end ring groove. and small end. If the measurement value is over (mm) the limit, replace it. itEm spEcification limit itEm spEcification limit First Ring 0.07 ~ 0.11 Twist and by 100 mm, Second Ring parallel 0.08 mm 0.07 ~ 0.11 0.05 mm degree Oil Ring 0.03 ~ 0.07 ▶...
Page 132 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.3.5 crank shaft rEplacE thE piston chEck thE crankshaft ▶ chEck thE crankshaft journal K20W274A 1. Replacing of piston ring and connecting rod K20W275A should be operated in clean surrounding. • If there is any crack or damage, replace it. 2. Make sure the piston ring is movable easily after • Measure every main part, and if it is over the limit, replace the main bearing. If necessary, replace the assembly. crankshaft. 3. Assemble the piston pin stop ring to the piston. (mm) 4.
Page 133 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.3.6 cam shaft chEck thE camshaft ▶ chEck thE crankshaft bEnding dEgrEE ▶ chEck thE camshaft’s figurE Check the wear on contacting surface between the tappet and the cam. Also, check the cam gear damage. Dial gauge V-Block V-Block...
Page 134 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.3.7 gEars chEck thE gEars ▶ chEck thE camshaft journal ▶ chEck thE gEars Flywheel side Intermediate bearing Gear side K20W279A Measure the outer diameter of camshaft by micrometer. The Oil clearance is calculated after measuring the K25W288A difference between camshaft inner diameter of the cylinder (1) Hydraulic pump drive gear (4) Crank gear...
Page 135 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4 thE EnginE assEmbly 6.4.3 crankshaft 6.4.1 caution bEforE assEmbling thE EnginE • Carefully clean and arrange disassemble parts. assEmbly procEdurE • Check the tool box and jig. • Prepare and check the spare parts. (Gasket, o-ring, packing, etc) • Clean the work place during assemble of the engine.
Page 136 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.4 piston and connEcting rod assEmbly procEdurE warning • use the hoist or lift for safe work. • thrust bearing assemble that the oil groove into outside. • assemble the bearing cap after same direc- tion with the cylinder block number.
Page 137 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.5 gEar casE flangE 6. Press the piston ring. (With jig) 7. Rotate it and locate the crankshaft pin to TDC. 8. Assemble the piston in cylinder. (Please be sure that piston and ring is not damaged.) 9. After assembly, crankshaft rotate 180° and locate BTDC. And assemble the connecting rod cap with new bearing. 10. Locate same direction between connecting rod big end and serial number of cap. 11. Assemble the cap bolt within the factory specification K25W281A and follow procedure. 1. Apply the liquid gasket on the gear case flange. A. Assemble the bearing cap bolt tentatively. (Use Loctite 5060 or similar liquid gasket.) B.
Page 138 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.7 camshaft 6.4.8 injEction pump assEmbly K25W279A 1. Apply the lubricating oil on the journal, cam, thrust bearing. K25W277A 1. Assemble the o-ring in fuel injection pump and in 2. Assemble the camshaft with turning it. gear case flange. (Assemble the key radius type 3. Assemble the bolts in cylinder block to hold the on the fuel injection pump shaft.) cam shaft. (Tightening torque: 2.7 kg•m) 2. Line up the injection pump gear and ‘B’ mark of 4. Cam shaft will be damaged if forcibly assembled. idle gear (See 5.3.9), and then assemble the bolt and spring washer to hold fuel injection pump tentatively.
Page 139 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.9 idlE gEar K25W298A K25W278A K25W299A 3. Rotate the crank pulley CCW until indicator of K25W288A dial gage doesn’t move by rotating the crank pulley. And then where gauge pin stopped line (1) Hydraulic pump drive gear (4) Crank gear (2) Camshaft gear (5) Idle gear up zero point of dial gauge by rotating the dial (3) Oil pump gear...
Page 140 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.10 gEar casE 6.4.12 oil pan K25W276A K25W268A 1. Apply the liquid packing on the gear case. (Use 1. Apply the liquid packing on the oil pan. (Use Loctite 5060 or similar product.). Loctite 5060 or similar product.) 2. Assemble the bolts to hold the gear c ase. 2.
Page 141 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.14 mounting flangE 6.4.16 crank pullEy K25W273A K25W275A 1. Assemble the mounting flange. 1. Assemble the crank pulley and washer. 2. Tighten the bolts to hold mounting f lange. 2. Tighten the bolt to crank pulley. (Tightening (Tightening torque: 2.7 kg•m) torque: 11.5 kg•m) 6.4.15 flywhEEl K25W272A 1. Assemble the flywheel. 2.
Page 142 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.17 cylindEr hEad 6.4.18 push rod K25W264A K25W2A01A 1. Assemble the push rod in socket of tappet in order. 2. Lubricate the lubricating oil on the push rod. K25W265A 1. Assemble the head gasket. 2. Tighten the bolts to the cylinder head in order. (Order: Inside(1) → Outside(14)) A. The bolt lubricates the lubricating oil. B. Assemble the cylinder head bolt tentatively. C. A ssemble the bolt according to factory procedure. (Tightening torque: 5.2kg•m) D. Disassemble to 360 deg. E. R e-tighten the bolt.(Tightening torque : 6.8 kg•m) F. T ightening it into 90 degree by using angle mapper. (Actual tightening torque: 12.0±1.0 kg•m) 40BW-202010...
Page 143 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.19 rockEr arm assEmbly adjustmEnt procEdurE of valvE clEarancE K25W262A 1. Apply the lubricating oil to rocker arm shaft and bush. And assemble the bolt to rocker arm shaft. K25W2A02A 2. The adjustment bolt of rocker arm should untie. 3. Assemble the bolt. (Tightening torque : 6.0 kg-m) K25W2A03A 1. Rotate the engine until the first cylinder stay on TDC. Line up the mark ‘→’ of crank pulley and the mark ‘0’ of gear case.
Page 144 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.20 cylindEr hEad covEr adjustmEnt procEdurE K25W261A 1. Assemble the new gasket and head cover. 2. T i g hte n t h e n u t s t o h o l d t h e h e a d c ove r. K25W2A06A (Tightening torque : 2.0 kg-m).
Page 145 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.22 injEction valvE (injEctor) 6.4.24 intakE manifold K25W284A K25W257A 1. Assemble the new nozzle space cup and sealing 1. Assemble the intake manifold with new packing. washer. 2. Tighten the bolts and nuts to hold the intake 2. Assemble and use the flat plate of injector. manifold. (Tightening torque: 2.7 kg•m) (Tightening torque : 7.5 kg-m) 6.4.23 watEr pump 6.4.25 fuEl drain pipE K25W258A...
Page 146 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.4.26 fuEl supply pipE. 6.4.28 Exhaust manifold K25W253A K25W254A 1. Assemble the high pressure pipe. 1. Assemble the exhaust manifold with new gasket. 2. Tighten nuts between fuel injection pump and 2. Tighten the bolts and nuts to hold exhaust fuel injection valve. Use two wrenches in order manifold. (Tightening torque: 2.7 kg•m) to prevent rotating the relative parts. (Tightening torque : 2.7 kg-m)
Page 147 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.4.30 startEr 6.4.32 v-bElt K25W271A K25W250A 1. Assemble the starter. 1. Adjust the tension of alternator after that tighten the adjust bolt and bolts. 2. Tighten the bolts to hold starter. 6.4.31 altErnator 6.4.33 aftEr-trEatmEnt dEvicE (atd) K25W252A K25W251A 1. Assemble ATD. 1. Assemble the alternator. 2. Tighten the bolts to hold the ATD. ( W hen 2.
Page 148 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.5 EnginE opEration 6.5.1 opEration advancE prEparation work 1. Fill the new lubricating oil through the filler port. 2. Connect the coolant hose and fill the coolant. 3. Connect the fuel hose to fuel tank. 4. Execute the air bleeding of the fuel line. 6.5.2 EnginE opEration Because the friction surface is not used enough in case of the new engine, useful life could be shortened due to overload or over speed in oil film. Therefore must comply with the below. until thE first 50hrs 1. The engine operates between 1200rpm~1500rpm in no load until the temperature of the engine becomes normal operation condition. 2. Avoid the overload or continuous high speed operation. 3. Avoid the no load high speed operation. 4. Avoid the sudden acceleration or sudden stop of the engine. 5. Must comply with check and inspection procedure. 6.5.3 running-in opEration chEcklist Must comply with the following information while the initial running-in operation.
Page 149 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.6 EnginE important parts maintEnancE 6.6.1 fuEl injEction pump Injection pump is distributor injection type (VE) mounted on the gear case flange and driven by injection pump gear. The fuel is supplied in each cylinder by one plunger rotation and reciprocating motion. The fuel is sucked from fuel tank by external feed pump and internal feed pump. And then fuel send to injection pump through fuel filter. Low-pressure fuel sucks in pump chamber and is controlled by regulating valve. The fuel enter high pressure chamber through barrel suction port via injection pump head path from pump chamber. High-pressured fuel made by plunger inject through injection valve according to injection timing. Excessive fuel in injection pump returns fuel tank through fuel return hose via over flow valve. The injection pump is cooled and lubricated by the fuel circulation. Remaining fuel also returns fuel tank through over flow hose after collecting in the injection pump. Water in the fuel reduces pump useful life. Therefore must manage not to enter water, dirt into the fuel system.
Page 150 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.6.2 injEctor Spray shape of the injector is the important element that affects in efficiency. Therefore must properly adjust and maintain. injEctor spray shapE chEck K25W2A10A After injector injection pressure is adjusted to 120±5kg/cm , affix it in injector tester and every second 4~ 6 time fabricate the lever. Check the spray condition and if it is abnormal, injector replace or clean. 1. Check whether the spray condition is good. 2. The case which is defective, disassemble the injection valve and replace the injector tube or assembly. 3. After the spray stopped, check whether or not after drop. 4. The case which is defective, disassemble the injection valve and replace the injector tube or assembly. 40BW-202010...
Page 151 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR chEck and adjustmEnt of thE injEctor ▶ chEck and adjustmEnt of thE injEction opEning prEssurE 1. Mounting on injector in tester. 2. Handle of the tester is operated at 1time per second. 3. I ndicator of the manometer is slowly rising and indicator shakes during injection. After looking at starting shaking points of the indicator, check whether opening pressure is standard value.
Page 152 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.6.3 oil pump Oil pump, as trochoid pump, driven by crank shaft clEarancE of pump body, gear is compact as well as pressure fluctuation is outEr rotor and innEr rotor small. And 3.5kg/cm pressure supply to each part. When discharging pressure of the oil pump is low, Straight edge check the flow rate. And the case which does not have defective, the check of oil pump is necessary with the...
Page 153 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.6.4 prEssurE switch 6.6.5 cooling systEm This engine is water cooling type. Combustion heat and oil heat are absorbed by coolant and emitting those at the outside. As a result, engine can operate normally the engine. Coolant supplied by water pump circulates the oil cooler through coolant hose and absorbs the oil heat. And coolant absorbs combustion heat through water jacket of cylinder block and coolant path of cylinder head.
Page 154 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.6.6 ovErhEat If stopping the engine when overheating the engine, thErmostat stop the circulation of the coolant and overheating can be serious locally. Also if quick freezing, crack will be able to occur in cylinder head, cylinder block Thermostat etc,. Do not confusion In this case, engine rotates at low speed and coolant temperature does to make fall naturally.
Page 155 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.7 ElEctrical systEm 6.7.1 startEr basE circuit diagram Start Start Switch Switch Battery Neutral Hold-in Winding Safety Switch Contacts Solenoid Bat. pull-in Motor Cranking Winding Motor Battery Basic Wiring Circuit Basic Solenoid Circuit K20W2A62 spEcification itEm spEcification Output 12V / 2.2kW...
Page 156 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE ▶ pull in coil tEst of magnEtic ▶ no-load tEst switch(solEnoid) Potentiometer Ammeter Battery 12V Battery Starter Voltmeter Dis-connector Starter K20W2A64 K25W2A13A The case which connects battery between S-M 1. C onnect the starter motor, battery, voltmeter, terminal, if plunger comes in and the pinion comes ammeter and variable resistance as picture.
Page 157 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 6.7.2 altErnator basE circuit diagram K25W2A14A spEcification itEm contEnt Rectifier Alternator typE 12.0V / 50A capacity 1,000~18,000 rpm motor vElocity 14.7 ± 0.3V rEgulator sEtting voltagE -7 ± 3mV/°C tEmpEraturE compEnsatE 40BW-202010...
Page 158 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE chEck ▶ altErnator output voltagE tEst on ▶ ignition circuit tEst at ignition kEy EnginE running condition. on condition K20W2A80 K20W2A79 1. Unplug Ignition terminal of regulator connector 1. C o n n e c t p o s i t i ve (+) of vo l t m ete r l e a d to from voltage regulator alternator output Terminal (B+) and negative (-) lead to a ground on alternator.
Page 159 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR ▶ rotor ▶ stator K25W2A15A K25W2A17A 1. Check the conductivity of rotor coil. Confirm 1. Check the conductivity of stator. Confirm that that whether or not conductivity between slip whether or not conductivity between coil and rings. Measure the resistance value and if the lead. If it is not electric conduction, replace the resistance value is very small, it is short. But if...
Page 160 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 6.7.3 caution fact of ElEctric wiring altErnator • Do not reverse connection the battery. I f reverse connecting the plus (+) and minus (-) of battery cable, the diode of alternator is damaged and does not become charging. Also the starter coil burn out. Battery must be produced by correcting the length of battery cable or by making the structure which prevents a reverse connection in order for not to become the reverse connection. • Charging output voltage not use the control purpose. T he engine number of rotation and output voltage are not constant proportion. Therefore output voltage forbids using the control purpose.
Page 161 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 7. maintEnancE standard tablE 7.1 main bolt tightEning torQuE tightEning itEm sizE hExagon(mm) notE torQuE(kgf·cm) ① 800 kgf·cm ② 360° disassum. ③ 520kgf·cm(Long Cylinder head bolt M11×1.5 (1200 kgf·cm) bolt) 570kgf·cm(Short bolt) ④ ③+ 90° Connecting rod bolt M10×1.25 300kgf·cm + 60° (700 kgf·cm) Flywheel clamping bolt M10×1.25 300kgf·cm + 60° (900 kgf·cm) Metal cap clamping bolt M12×1.5 600kgf·cm + 60°...
Page 162 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 7.2 standard bolt & nut tightEning torQuE sizE normal finE normal finE normal finE thrEad thrEad thrEad thrEad thrEad thrEad 40 ± 5 kgf·cm 60 ± 10 kgf·cm 90 ± 10 kgf·cm 3.92 ± 0.49 N.m 5.88 ± 0.98 N.m 8.82 ± 0.98 N.m 2.89 ± 0.36 lbf.ft 4.33 ± 0.72 lbf.ft 6.50 ± 0.72 lbf.ft 60 ± 10 kgf·cm 130 ± 10 kgf·cm 135 ± 10 kgf·cm 5.88 ± 0.98 N.m 12.74 ± 0.98 N.m 13.23 ± 0.98 N.m 4.33 ± 0.72 lbf.ft 9.39 ± 0.72 lbf.ft 9.75 ± 0.72 lbf.ft...
Page 163 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 7.3 sErvicE data 7.3.1 cylindEr hEad itEm standard limit notE Cylinder head combustion below 0.03 0.15 surface distortion Intake 120° Valve seat angle Exhaust 90° Intake 1.73 2.23 Valve seat width Exhaust 2.12 2.62 Valve stem outer dia. Ø 7.96 ~ Ø 7.97 Ø 7.9 Intake valve Valve guide inner dia. Ø 8.010 ~ Ø 8.025 Ø 8.1 Oil clearance 0.040 ~ 0.055 0.15 Valve stem outer dia.
Page 164 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 7.3.2 cylindEr block itEm standard limit notE Ø 88.015 ~ Ø 88.025 Cylinder bore Ø 88.20 Ø 88.005 ~ Ø 88.015 Cylinder roundness 0 ~ 0.01 0.03 Cylindricity 0 ~ 0.015 0.03 7.3.3 valvE rockEr arm itEm standard limit notE Rocker arm shaft outer dia. Ø 15.959 ~ Ø 15.98 Ø 18.95 Intake & Exhaust Rocker arm inner dia. Ø 19.0 ~ Ø 16.021 Ø 19.09 rocker arm Oil clearance...
Page 165 CHAPTER 2 ENGINE 4025H/4035H/4035CH TRACTOR 7.3.5 piston ring itEm standard limit notE Ring groove width 2.06 ~ 2.08 Ring width 1.97 ~ 1.99 Top ring Ring and ring groove 0.07 ~ 0.110 clearance End clearance 0.20 ~ 0.35 Ring groove width 2.06 ~ 2.08 Ring width 1.97 ~ 1.99 ring Ring and ring groove 0.07 ~ 0.110 clearance End clearance...
Page 166 4025H/4035H/4035CH TRACTOR CHAPTER 2 ENGINE 7.3.7 camshaft itEm standard limit notE Camshaft journal outer diameter Ø 44.950 ~ Ø 44.964 Ø 44.89 Gear side Oil clearance 0.066 ~ 0.110 Camshaft journal outer diameter Ø 44.916 ~ Ø 44.930 Ø 44.89 Intermediate Oil clearance 0.070 ~ 0.130 Camshaft journal outer diameter Ø 44.950 ~ Ø 44.964 Ø 44.89 Flywheel side Oil clearance 0.066 ~ 0.110 7.3.8 crankshaft itEm standard limit notE Crankshaft journal outer dia.
Page 167 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 168 Chapter 3 transmission taBLe oF Contents 4.4 Lever ass’y, range shift ......3-20 1. Overview ..........3-2 1.1 Specification ..........3-2 4.5 Front drive shaft ........3-21 1.2 Power transfer ........3-3 4.6 4WD lever ..........3-22 1.2.1 Transmission assembly diagram ..3-3 4.7 Fork & lever, PTO ........3-23 1.2.2 Power flow chart ......3-4 4.8 Ring gear & diff.gear ass’y ....3-24 4.9 Differential ...........3-25 2.
Page 169 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 1. Overview 1.1 SpecificatiOn item SpecificatiOn Shuttle type Hydrostatic Main shift Range shift 3 speeds, constant-mesh Forward driving: 0 - 23.3 km/h (0 - 14.48 MPH) 7 - 16 CABIN Shifting gear Reverse driving: 0 - 23.3 km/h (0 - 14.48 MPH) MODEL 11.2 - 24 and Forward driving: 0 - 24.4 km/h (0 - 15.16 MPH) driving speed 8 - 16 ROPS Reverse driving: 0 - 24.4 km/h (0 - 15.16 MPH) MODEL 12.4 - 24 Type Independent PTO Stage PTO shift...
Page 170 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 1.2 pOwer tranSfer 1.2.1 tranSmiSSiOn aSSembly diagram 4025H : ( ) B40W401A 40BW-202010...
Page 171 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 1.2.2 pOwer flOw cHart 4025H : ( ) B40W402A 40BW-202010...
Page 172 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 2. Structure and Operating principle 2.1 main SHift A42W403B The engine torque is transferred to the HST through the HST input shaft (pump shaft) (1). Then, it is converted to hydraulic pressure in the HST to turn the HST motor shaft (2). As the HST motor shaft is connected to the range shift drive shaft (6), rotation of the range shift drive shaft turns the 26T gear (3) which then turns the range shift drive shaft (5) through the engaged 29T gear (4). Therefore, the amount of depression of the forward driving pedal determines the hydraulic pressure quantity for the HST input shaft (pump shaft), and this change of hydraulic pressure leads to consequential change in HST motor shaft speed, enabling continuous shift operation. 40BW-202010...
Page 173 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 2.2 f-r SHuttle SHift A42W404B As the HST input shaft (pump shaft) (1) is rotated by the engine torque, the internal piston delivers hydraulic pressure to the HST motor shaft (2). The HST pump shaft is installed with the swash plate which is tilted between -18° and +18°. The angle of the swash plate is changed according to the depressing condition of the HST pedal. When the swash plate of the HST pump shaft starts to tilt toward the positive x-axis from 0° (neutral position) gradually, the amount of hydraulic oil delivered to the HST motor shaft is increased, resulting in increase of the vehicle speed. When the swash plate moves toward the negative x-axis from 0°, the delivery direction of hydraulic oil is reversed, resulting in reverse rotation of the HST motor shaft. Therefore, the rotating direction of the HST motor shaft is switched between forward direction and reverse direction according to the selected direction (forward/reverse driving) of the HST pedal, and this direction control is applied to gears in the transmission to drive the vehicle forward or backward.
Page 174 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 2.3 range SHift A42W405B The torque delivered to the range shift drive shaft (1) turns the range shift drive gear shaft (4) through the 26T gear (2) and 29T gear (3). The 29T gear is rotated continuously. Also, the 20T gear (8) and 52T gear (6) are rotated as well as they are engaged with the 34T gear and 18T gear of the range shift drive gear shaft and 36T gear (5). On the other hand, the range shift drive shaft and countershaft (9) idle from each other due to their internal needle bearings. Therefore, the 20T gear (8) and 52T gear (6) are rotated, sliding. When the range shift driven 2nd gear (7) is pushed to the rightmost position for low speed (L) shift operation, the spline in the 52T gear is engaged with the spline on the range shift driven 2nd gear. Then, the torque reduced by engagement of the 52T gear and 18T gear of the range shift drive gear shaft is delivered to the countershaft through the range shift driven 2nd gear which is fixed to the countershaft with splines. For mid speed (M) shift operation, the torque is transferred to the countershaft after it is reduced by engagement of the 34T gear of the range shift drive gear shaft with the 36T range shift driven 2nd gear (7).
Page 175 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR pOwer tranSfer ▶ lOw Speed (l) R ange shift drive shaft (1) → 26T gear (2) → 29T gear (3) → Range shift drive gear shaft (4) → 18T gear → 52T gear (6) → 36T range shift driven gear 2nd (7) → Counter shaft (9) ▶ mid Speed (m) R ange shift drive shaft (1) → 26T gear (2) → 29T gear (3) → Range shift drive gear shaft (4) → 34T gear → 36T range shift driven gear 2nd (7) → Counter shaft (9) ▶ HigH Speed (H) R ange shift drive shaft (1) → 26T gear (2) → 29T gear (3) → Range shift drive gear shaft (4) → 36T gear (5) → 20T gear (8) → 36T range shift driven gear 2nd (7) → Counter shaft (9) 40BW-202010...
Page 176 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 2.4 ptO SHift 4025H : ( ) B40W116A As the HST input shaft (pump shaft) (1) is rotated by the engine torque and it is directly connected to the PTO shaft (2) with the joint, this forms the driveline system for PTO operation. As the PTO clutch (3) is engaged, the 65T and 60T gears of the PTO shaft (5), which are engaged with the 14T and 18T gears of the PTO drive gear shaft (4), are rotated. As the PTO hub is connected by shift operation of the PTO lever, PTO torque of the 1st is delivered to the PTO shaft.
Page 177 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 2.5 4wd A42W407B When the countershaft (1) rotates for range shift operation, the 52T gear, which is the 4WD drive gear (2) of the countershaft, rotates constantly. Therefore, when the 4WD driven gear (4) of the 4WD drive shaft (3) is moved to the left to be engaged with the 4WD drive gear, the 4WD drive and driven gears are engaged and rotated together. Then, the rotating power reduced at the reduction ratio by the 52T gear and 42T gear is delivered to the 4WD drive shaft to turn the front axle through the propeller shaft.
Page 178 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 2.6 rear axle B40W117A (1) Counter shaft (6) Differential side gear (B) (11) Rear axle gear (LH) (2) Ring gear (7) Differential side gear (A) (12) Rear axle gear (RH) (3) Differential case (8) Differential thrust assembly (13) Rear axle (4) Pinion shaft (9) Final pinion (R) (14) Oil seal (5) Differential pinion (10) Final pinion (L) (15) Rear axle housing 2.6.1 pOwer tranSfer When rotating force arrives at the counter shaft (1), it rotates the differential case (3) through the ring gear (2). As the differential rotates, the differential pinion (5) and differential side gear (7) inside the differential case to deliver the rotating force to the final pinion (9). Then, the speed of the rotating force at the final pinion is reduced through engagement of the 16 gear of the final pinion with the 65 rear axle gear (11), and it is finally transmitted to the rear axle (13), which is connected with splines, in order to rotate the rear wheels. 40BW-202010...
Page 179 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 3. OperatiOn and adjuStment 3.1 differential SyStem F42W430A The differential system is to rotate the left wheel and right wheel at different speeds for smooth turning. When turning, this system rotates the inner wheel in the turning direction slower and the outer wheel faster to turn the vehicle in the desired direction. Also, when a wheel gets stuck in mud, it is hard to escape the pit since the wheel in mud with no friction rotates at faster speed and the wheel on road with friction does not rotate due to the differential system. To prevent this situation, the vehicle is equipped with the differential lock. The differential lock moves the differential lock slide to fix the differential case and differential side gear together with the pin, resulting in rotation of the side gear on the other side as well. Therefore, the wheels on both sides are rotated at the same speed to escape the pit. The differential system consists of the ring gear (1), differential case (2), differential side gear (3), differential pinion (4), differential pinion shaft (5) and differential lock slide (6). 40BW-202010...
Page 180 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 3.2 brake 3.2.1 Overview A42W408A When the brake pedal (1) is depressed, the brake shaft (3), which is fixed with the brake pedal boss and spring pin (2), starts to rotate. Then, as the brake shaft is connected to the brake rod (4) with the snap pin, the shaft pulls the rod which then turns the brake activating brake lever (5) to operate the internal brake. As this brake is a wet multi-plate type, it is soaked in oil for superior lubrication, cooling and durability. 40BW-202010...
Page 181 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 3.2.2 Operating principle Of brake F42W426A (1) Brake lever (4) Boss (7) Steel ball (2) Cam plate (5) Disc (8) Brake inside arm (3) Final pinion (6) Pressure plate When the brake lever (1) is pulled by transferred power, the brake inside arm (8) fixed by the splined boss is rotated as well. Also, as the protruded parts on the brake inside arm are fit to the grooves of the cam plates (LH/RH) (2), the cam plates are rotated as well. On the other side, the final pinion (3) is fixed to the differential side gear with splines, rotating together, and its other side is connected to the boss (4) with splines. This boss is fixed to 2 discs (5) with splines as one unit. Also, the pressure plates (6) are installed in between the friction discs and these pressure plates are fixed to the rear axle housing. Therefore, when the brake pedal is depressed, the brake lever is moved to rotate the cam plate. Then, the steel ball (7) installed in the groove on the slant of the cam plate pushes the cam plate inward, producing driving force. This driving force compresses the friction discs and plates. As the pressure plates are fixed by the rear axle housing, they stop rotating.
Page 182 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 3.2.3 brake pedal free play adjuStment ROPS MODEL B40W113A K3CW117A 3. I f the free play is out of the standard, unscrew the CABIN MODEL mounting nuts (2) of the brake rods (LH/RH) on the brake shaft section and use the turnbuckle (3) to adjust the free play. After adjusting the free play of the both sides, tighten the mounting nuts. B40W114A 1.
Page 183 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 3.3 parking brake OperatiOn B40W403A (1) Brake pedal (3) Brake rod (2) Parking brake lever (4) Brake lever With the brake pedal (1) depressed firmly, pull the parking brake lever (2) to engage the gear tooth with the fixing plate of the brake pedal. As the brake pedal is operated, the brake rod (3), which is connected to the brake shaft and brake pedal, is pulled to activate the brake lever (4) in order to apply braking force for the left/right brakes. 40BW-202010...
Page 184 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4. SectiOnal view fOr majOr cOmpOnentS 4.1 range SHift gear 15 16 A42W411A cOmpOnentS (1) Ball bearing (10) Range drive gear (19) Range shift drive gear 1nd (2) Range drive gear (11) Range shaft (20) Four wheel drive gear (3) Snap ring (12) Snap ring (21) Stop nut (4) Gear, range C (13) Ball bearing (22) Taper roller bearing (5) Range drive shaft (14) Needle bearing (23) Snap ring (6) Ball bearing (15) Collar (24) Spacer (7) Ball bearing (16) Gear, range C drive (25) Taper roller bearing(32207C) (8) Snap ring (17) Range shift drive gear 2nd (9) Snap ring...
Page 185 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.2 main p.t.O SHaft A42W412A cOmpOnentS (1) Joint (10) Ball bearing (19) O-ring (2) Snap ring (11) PTO clutch ass'y (20) O-ring (3) Snap ring (12) Stop screw (21) PTO valve (4) Ball bearing (13) PTO clutch shaft (22) Spring washer (5) Main PTO shaft (14) Snap ring (23) Hexagon socket bolt (6) Ball bearing (15) Ball bearing (24) O-ring (7) Joint (16) Seal ring (25) Connecter (8) Snap ring (17) Sleeve (26) Elbow (9) Clutch hub (18) Clutch input pipe 40BW-202010...
Page 186 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4.3 ptO drive SHaft B40W404A cOmpOnentS (1) Ball bearing (8) Snap ring (16) Ball bearing (2) Bush (9) Oil seal (17) Shaft, PTO drive (3) Gear, PTO1 (10) O-ring (17) Shaft, PTO drive (3) Gear, PTO1 (11) Cover, PTO (18) Ball bearing (4) Hub, PTO (12) Hex flange bolt (19) Snap ring (5) Sleeve, PTO (13) Snap ring (20) Seal cap (6) Spacer (14) Joint (7) Shaft, PTO drive (15) Snap ring 40BW-202010...
Page 187 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.4 lever aSS’y, range SHift F42W408A cOmpOnentS (1) Range shift fork shaft (6) Shaft, range shift (11) Screw (2) Range shifter (7) O-ring (12) Steel ball (3) Spring pin (8) Range shift lever (13) Spring (4) Range shift fork (9) Spring pin (14) O-ring (5) Hex bolt w/washer (10) Range shift knob(K3) (15) Bolt 40BW-202010...
Page 188 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4.5 frOnt drive SHaft F42W409A cOmpOnentS (1) Couple ring R (9) 4dn drive shaft (17) Hose band (2) Propeller shaft (10) Ball bearing (18) Shaft cover(back) (3) 4nd drive joint (11) Steel ball (19) Stop O-ring (4) Oil seal housing (12) Spring (20) Hex flange bolt (5) O-ring (13) 4dn driven gear (21) Spring pin (6) Oil seal (14) Stop O-ring (22) Spring pin (7) Snap ring (15) Shaft cover(front) (8) Ball bearing (16) Shaft cover boots 40BW-202010...
Page 189 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.6 4wd lever F42W410A cOmpOnentS (1) 4nd lever (6) Washer (11) Washer (2) O-ring (7) Snap pin (12) Snap ring (3) Front wheel shift arm (8) Spring washer (13) Front wheel drive knob ass’y (4) Spring pin (9) PTO lever shaft (14) Screw (5) 4nd lever link (10) 4nd lever 40BW-202010...
Page 190 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4.7 fOrk & lever, ptO F42W411A cOmpOnentS (1) Shaft, PTO change (8) Screw (15) PTO fork shaft (2) O-ring (9) PTO lever link (16) Seal cap (3) Change arm, PTO (10) Washer (17) O-ring (4) Spring pin (11) Snap pin (18) Stop bolt (5) Washer (12) PTO fork (19) Plate (6) PTO change lever (13) Spring (20) Hex flange bolt (7) PTO knob ass’y (14) Steel ball 40BW-202010...
Page 191 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.8 ring gear & diff.gear aSS’y F42W412A cOmpOnentS (1) Differential ass’y (7) Differential side gear l (13) Thrust washer (2) Ring gear ass’y (8) Pinion, differential (14) Washer (3) Differential case(right) (9) Differential stop slider (15) Bolt (4) Differential case(left) (10) Roller (16) Thrust washer (5) Differential shaft (11) Bolt (6) Differential side gear r (12) Spring pin 40BW-202010...
Page 192 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4.9 differential B40W405A cOmpOnentS (1) Taper roller bearing (8) Ball bearing (15) Differential pedal (2) Spacer (9) Shim (16) O-ring (3) Spring holder (10) Shim (17) Differential spring (4) Bearing support (11) Shim (18) Differential fork (5) Screw (12) Shim (19) Spring pin (6) Stop plate (13) Snap ring (20) Spring pin (7) Washer ass’y hex bolt (14) Spring holder (21) Plain washer 40BW-202010...
Page 193 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.10 driving part, rear axle F42W414A cOmpOnentS (1) Housing, rear axle( right) (9) Final gear (left) (17) Bolt (2) Final pinion (right) (10) Rock nut (18) Stud bolt (3) Final gear (right) (11) Ball bearing (19) Pin (4) Housing, rear axle(left) (12) Final pinion (left) (20) Stud bolt (5) Rear axle (13) Snap ring (21) Washer (6) Oil seal (14) Spring washer (22) Hex nut (7) Taper roller bearing (15) Hex nut (23) Bolt (8) Taper roller bearing (16) Bolt 40BW-202010...
Page 194 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 4.11 brake F42W415A cOmpOnentS (1) Brake ass’y (left) (6) Boss (12) Dry bush (2) Brake ass’y (right) (7) Snap ring (13) O-ring (3) Cam plate (left) (8) Steel ball (14) Plate (3) Cam plate (right) (9) Spring (15) Hex bolt w/washer (4) Disk (10) Brake lever bush (16) Brake lever (5) Pressure plate (11) Brake inside arm 40BW-202010...
Page 195 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 4.12 brake pedal A42W413A cOmpOnentS (1) Brake shaft ass'y (6) Snap pin (11) Spring pin (2) Washer (7) Brake pedal (12) Rubber stopper (3) Snap ring (8) Dry bush (13) Stop lamp switch (4) Brake rod ass'y (9) O-ring (14) Return spring (5) Pin (10) Spring pin 40BW-202010...
Page 196 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5. diSaSSembly and Service rOpS mOdel 5.1 clutcH HOuSing remOval 1. R emove the engine assembly. K42W413A 4. Remove the steering column assembly (1). K42W410A 2. R emove the dashboard (R, L)(1) and instrument panel cover (2). K42W414A K42W411A 3. Remove the bonnet hinge assembly (1). K42W415A 5. D isconnect the combination lamp wiring connector (1) and remove the fender assembly (2)(LH, RH).
Page 197 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR K42W416A A42W414A 6. Remove the footstep (1) and fuel tank (2). 8. R emove the brake rod (1), brake pedal (2). K42W417A A42W415A 7. R emove the transmission case cover (1), floor 9. R emove the HST arm connecting plate (1), HST mat (2)(LH, RH), dust cover assembly (3). arm (2) and elbow (3). 40BW-202010...
Page 198 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION A42W416A A42W418A A42W417A A42W419A 10. U nscrew the clutch housing & transmission case mounting bolts (1)(6EA) & nuts (2)(4EA) and remove the clutch housing (3). A42W420A 11. U nscrew the HST mounting bolts (1)(6EA) and remove the HST (2) from the transmission case. 40BW-202010...
Page 199 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 5.2 tranSmiSSiOn caSe aSSembly diSaSSembly 1. R emove the clutch housing assembly. 2. R emove the HST assembly. A42W424A A42W421A 3. Remove the HST pedal pedal assembly (1). A42W425A 6. R emove the PTO valve(1) and disconnect the PTO clutch input pipe (2). A42W422A 4. R emove the high pressure hose (1) of front outlet valve. K42W427A 7. R emove the 4WD lever link (1) and fuel tank rear supporter (2). Then, unscrew the plug (3) to...
Page 200 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5.3 tranSmiSSiOn caSe aSSembly cOmpOnentS diSaSSembly A42W426A A42W429A 1. R emove the PTO clutch cover (1). Notes A42W427A A42W430A • when installing the ptO clutch cover, set the brake plate protrusion (a) of the ptO clutch pack into the groove of the case. • the brake plate (2) of the ptO clutch pack is set apart from the pTo clutch and fixed into the groove while the rear ptO is in operation.
Page 201 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR A42W431A A42W433A A42W432A A42W434A 2. R emove the plate (1). 3. R emove the range shift drive shaft (1). 40BW-202010...
Page 202 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION Notes A42W435A A42W438A 1. during the range shift drive gear installation, make sure that the higher part of boss (a) section toward ball bearing side. A42W436A A42W439A 2. d u r i n g t h e r a n g e s h i f t c d r i v e g e a r installation, make sure that the lower part of boss (a) section toward ball bearing side.
Page 203 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR K42W445A K42W447A K42W446A A42W440A 5. R emove the PTO clutch shaft snap ring (1) and 6. R emove the main PTO shaft snap ring (1)(2EA) sleeve (2). Then, remove the PTO clutch shaft (3), and main PTO shaft (2). joint (4), clutch hub (5) PTO clutch assembly (6) simultaneously. 40BW-202010...
Page 204 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION Notes ▶ ptO clutcH pack cOmpOnentS diSaSSembly A42W441A K42W449A K42W476A 7. P ull out the spring pin (1) and remove the range shift shifter (2). Then, remove the range shift fork shaft (3) and range shift driven gear 2nd (4) K20W4A05 simultaneously. • pull out the stop ring (1) and remove the spring, pressure plate, plate, disc, brake, pis- ton, case.
Page 205 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR Notes A42W442A K42W479A • when installing the 4wd gear, its higher boss (a) should face the range shift drive gear 1st. K42W478B 8. P ull out the snap ring (1) and remove the range shift drive gear 1st (2), 4WD gear (3) and snap ring (4). A42W444A 10. U nfold the caulking part of the counter shaft mounting nuts (1) to unscrew the mounting nuts.
Page 206 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5.3.1 4wd SHaft diSaSSembly Notes ▶ main SHift drive SHaft diSaSSembly K42W463A 1. P ull out snap ring (1) and remove the 4WD gear (2). K42W462A • when installing the range shift drive gear, its long boss (a) should face the clutch housing. K42W464A 2. P ull out snap ring (1) and remove the 4WD shaft (2), oil seal housing in the clutch housing side direction.
Page 207 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 5.4 rear axle caSe diSaSSembly K42W465A K42W467A 1. R emove the ROPS (1). K42W466A 3. R emove the spring pin (1) from the outside of the transmission case, 4WD lever (2) and front wheel K42W468A shift arm (3). 2. R emove the position control knob (1) and lever cover (2). K42W469A 3. R emove the range shift lever knob (1), PTO lever knob (2) and lever cover (3).
Page 208 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION K42W470A K42W472A 4. U nscrew the seat bracket mounting bolts (1)(4EA) and remove the seat bracket (2) and seat (3) simultaneously. K42W473A 6. U nscrew the hydraulic cylinder case mounting bolts (1)(5EA), nuts (2)(5EA) to remove the hydraulic cylinder case (3). K42W471A 5. R emove the top link (1), lift link assembly (2) and lower link (3).
Page 209 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR K42W475A K42W477A K42W476A K42W478B 8. P ull out the spring pin (1) and remove the range 9. P ull out the snap ring (1) and remove the range shift shift shifter (2). Then, remove the range shift drive gear 1st (2), 4WD gear (3) and snap ring (4). fork shaft (3) and range shift drive gear 2nd (4) Notes simultaneously. K42W479A • when installing the 4wd gear, its higher boss (a) should face the range shift drive gear 1st.
Page 210 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5.4.1 rear axle drive SectiOn diSaSSembly K42W4B9A K42W480A 10. U nfold the caulking part of the counter shaft mounting nuts (1) to unscrew the mounting nuts. Then, remove the counter shaft in the rear axle case by tapping outside direction. (Remove the differential system assembly first) mounting nut tightening torque ....
Page 211 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR K42W482A K42W484A K42W483A K42W485A 2. U nscrew the rear axle housing mounting bolts (1)(7EA) and nuts (2)(2EA) to remove the rear axle housing assembly (3). K42W486A 3. P ull out the snap ring (1) of the rear axle housing f inal pinion to remove the f inal pinion (2). Unscrew the lock nut (3) and remove the rear axle (4), final gear (5) and taper roller bearing (6).
Page 212 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5.4.2 brake aSSembly diSaSSembly Notes K42W488A 1. Remove the rear axle housing assembly (1). K42W487A • When installing the final gear, its higher boss (a) should be toward the inside. K42W489A K42W490A 2. R emove the pressure plate (1) and disc (2). 40BW-202010...
Page 213 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR K42W491A K42W494A K42W492A K42W495A K42W493A K42W496A 3. R emove the spring (1), cam plate (2) and steel 4. R emove the inner arm (1) in the rear axle case. ball (3). 40BW-202010...
Page 214 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION 5.4.3 ptO SHift gear diSaSSembly K42W497A K42W4A1A 1. Remove the PTO cover (1) and seal cap (2). 3. U nscrew the PTO fork shaft mounting bolt (1) and remove the PTO shift shaft mounting plate (2). Then, pull out the PTO shift shaft (3) to remove it from the PTO fork groove. K42W498A K42W4A2A K42W499A 2. P ull out the snap ring (1) and remove the plate (2) and PTO drive gear shaft (3). K42W4A3A 4. P ull out the PTO fork shaft (1) and remove the PTO fork (2), steel ball (3) and spring (4).
Page 215 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 5.4.4 differential SyStem diSaSSembly 1. R emove the rear axle case from the transmission. Then, remove the rear axle housing and hydraulic cylinder case. K42W4A4A K42W4A7A K42W4A5A K42W4A7A K42W4A66A 5. U nscrew the PTO shaft cover bolts (1) to remove the PTO shaft (2), ball bearing (3), PTO drive gear 1st (4), PTO hub sleeve (5), PTO drive gear 2nd (6) and washer (7). K42W4A8A 2. P ull out the differential lock pedal spring pin (1) and remove the differential lock pedal (2) in the arrow direction. Then, remove the differential fork (3) and differential spring (4).
Page 216 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION IMPORTANT K42W4A9A K42W4C1A 3. Remove the PTO drive gear shaft (1). • when installing the screw (1) to the bear- ing support, tighten it to the specified torque and caulk the mounting plate (2) to the screw groove to fix the screw firmly. tightening torque ....
Page 217 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 5.4.5 differential SyStem cOmpOnentS diSaSSembly K42W4B5a U600W3A37A 3. Remove the ball bearing(1) and differential lock hub (2). Notes K42W4B3a 1. Invert the rear differential system assembly to remove the taper roller (1). U600W3A41A • When installing the final gear, its higher boss (A) should toward the inside. K42W4B4a 2. Unscrew the differential system case 1 mounting bolts (1) and remove the ring gear (2). K42W4B6a 4. Unscrew the differential system case 2 mounting bolts(1) and remove differential system case 2 (2).
Page 218 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION K42W4B7a K42W4B8a 5. Remove the washer (1) and side gear (2). 8. Install in the reverse order of removal. IMPORTANT U600W3A48A • when installing the roller to the differential U600W3A45A case, the flat end of the roller should face the 6. Pull out the differential shaft 2 mounting spring groove of the side gear.
Page 219 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR cabin mOdel 5.5 clutcH HOuSing remOval 1. R emove the cabin. Notes 2. R emove the engine assembly. K42W4C2A • check the backlash of the ring gear using a dial gauge. K3CW401A specified value ..0.15 ~ 0.25 mm 3. R emove the brake rod (1) and cabin support (0.0059 ~ 0.0098 in.) assembly (2).
Page 220 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION A42W415A A42W418A 5. R emove the HST arm connecting plate (1), HST arm (2) and elbow (3). A42W419A A42W416A A42W420A 7. U nscrew the HST mounting bolts (1)(6EA) and remove the HST (2) from the transmission case. A42W417A 6. U nscrew the clutch housing & transmission case mounting bolts (1)(6EA) & nuts (2)(4EA) and remove the clutch housing (3). 40BW-202010...
Page 221 CHAPTER 3 TRANSMISSION 4025H/4035H/4035CH TRACTOR 5.6 rear axle caSe diSaSSembly 1. R emove the cabin assembly. K42W474A 4. R emove the PTO shift lever (1), range shift lever (2) and 4WD lever (3). K42W471A 2. R emove the top link (1), lift link assembly (2) and lower link (3). K42W475A K42W472A K42W476A 5. P ull out the spring pin (1) and remove the range shift shifter (2). Then, remove the range shift K42W473A fork shaft (3) and range shift drive gear 2nd (4) 3. U nscrew the hydraulic cylinder case mounting...
Page 222 4025H/4035H/4035CH TRACTOR CHAPTER 3 TRANSMISSION K42W477A K42W4B9A 7. U nfold the caulking part of the counter shaft mounting nuts (1) to unscrew the mounting nuts. Then, remove the counter shaft in the rear axle case by tapping outside direction. (Remove the differential system assembly first) mounting nut tightening torque ....78.4 ~ 98 n.m 8 ~ 10 kgf.m 57.6 ~ 72 lb.ft K42W478B...
Page 223 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 224 Chapter 4 Front axle taBle oF ContentS 1. Overview ..........4-2 4. sectiOnal view fOr majOr cOmpOnents ........4-7 1.1 Specifications ........4-2 4.1 Center pin support ......... 4-7 1.2 Tightening torque for major components ...........4-2 4.2 Tie rod ...........4-8 1.3 Power transfer ........4-3 4.3 Ring gear and differential gear ....4-9 1.4 Knuckle section ........4-4 4.4 4WD gear case ........
Page 225 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 1. Overview 1.1 specificatiOns 1. Tread ........7 - 16: Standard - 1,203 mm (47.362 in) 8 - 16: S tandard - 1,201 mm (47.283 in) 2. Tire size ........7 - 16 6PR / 8 - 16 6PR 3. Front wheel alignment..... Toe-in: 4 - 8 mm (0.157 - 0.315 in.) 4. Oil ........... S tandard: TF500, SAE 80W90 Capacity: 6.4 ℓ (1.69 u.s.gal) 5. Differential system ....Pinion and ring gear backlash: 0.15 - 0.2 mm (0.0059 - 0.0079 in.) 6.
Page 226 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 1.3 pOwer transfer K25W555A (1) Drive pinion (5) 9 bevel gear (9) 49 front final gear (2) Ring gear (6) 19 bevel gear (10) Front spindle (3) Differential case (7) Front 2nd shaft (4) Front 1st shaft (8) 11 bevel gear When the 4WD mode is selected, rotating force from the 4WD shaft of the transmission is passed through the propeller shaft and is delivered to the front axle section through the drive pinion (1) of the front axle case. The 12 gear of the drive pinion is engaged with the 25 ring gear (2) of the front differential, rotating together at the reduced speed, and the differential case (3) integrated with the ring gear is rotated as well. Then, as the differential pinion shaft is rotated together, the differential pinion gear and differential side gear are engaged with each other, rotating together. Therefore, this rotating force is transmitted to the front 1st shaft (4) since it is fixed to the differential side gear with splines. After the rotating force is passed through the front 1st shaft, it is delivered to the front gear case through the 9 bevel gear (5) and 19 bevel gear (6). Then, it is passed to the 49 front final gear (9) through the front 2nd shaft (7) and 11 bevel gear (8). Finally, this force is delivered to the front wheels installed to the 49 front final gear to turn the wheels. 40BW-202010...
Page 227 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 1.4 KnucKle sectiOn K25W556A (1) Oil cap assembly (6) Ball bearing (11) Ball bearing (2) Oil seal (7) Ball bearing (12) O-ring (3) Ball bearing (8) Ball bearing (13) Shim (4) Ball bearing (9) Oil seal (5) Oil seal (10) Sleeve The knuckle section is a part to perform driving and steering functions in the front axle section, and it (knuckle arm + front gearbox) revolves around the fixed king pin section (front gear case). Four vertically set ball bearings and three laterally set ball bearings withstand vertical and lateral load applied to the front axle. Also, the rotating parts of the front spindle and front gear box are equipped with special oil seals to ensure superior sealing performance even in a wet condition. 40BW-202010...
Page 228 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 2. inspectiOn and adjustment 2.1 tOe-in 1. Park the tractor on firm level ground and turn the steering wheel to set both front wheels in the straight ahead position. Then, stop the engine. Front F42W149A 5. If the result is out of the specification, unscrew the tie-rod end mounting nut (1) from the knuckle arm and turn the rod (2) to adjust the distance K20W501A between the centers.
Page 229 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 3. trOubleshOOting prOblems cause Or symptOm sOlutiOn • Adjust the toe-in (4 - 8 mm). • Poorly adjusted toe-in The front wheels rattle. • I nflate the tire to the proper • Abnormal tire inflation pressure pressure level (2.0 kgf/cm • Adjust the toe-in. • Poorly adjusted toe-in The front tires are worn • A djust the tire pressure to excessively. • Excessive inflation pressure the proper level. • Poorly adjusted toe-in • Adjust the toe-in.
Page 230 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 4. sectiOnal view fOr majOr cOmpOnents 4.1 center pin suppOrt F42W501A cOmpOnents (1) O-ring (6) Bush (11) Spring Washer (2) Bush (7) O-ring (12) Hex Bolt (3) Front Axle Support Ass’y (8) Rear Axle Support Ass’y (13) Case (4) Nipple,grease (9) Plate (5) O-ring (10) Hex Flange Bolt 40BW-202010...
Page 231 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 4.2 tie rOd F42W502A cOmpOnents (1) Tie rod ass’y, L (6) Cotter pin (11) Grease nipple (2) Tie rod ass’y, R (7) Ring (12) Knuckle arm(L) (3) Nut (8) Cover (13) Knuckle arm(R) (4) Nut (9) Clip (5) Nut (10) Cover 40BW-202010...
Page 232 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 4.3 ring gear and differential gear Q25W502B cOmpOnents (1) Ring gear ass’y (8) Nut (17) Liner (1-1) Drive pinion (9) Case (18) Differential gear 14 (1-2) Ring gear (10) Front first shaft (19) Differential gear 10 (2) Roller bearing (11) Front first shaft (20) Liner (3) Snap ring (12) Snap ring (21) Shaft, differential pinion (4) Collar (13) Ball bearing (22) Spring pin (5) O-ring (14) Differential case (23) Pin (6) Bush (15) Hex flange bolt (7) Oil seal (16) Ball bearing 40BW-202010...
Page 233 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 4.4 4wd gear case K25W549B cOmpOnents (1) Oil level (15) Lock nut (30) Seal (16) Ball bearing (31) Ball bearing (2) O-ring (3) Bolt w/washer (17) Gear bevel 49T (32) Gear bevel 11T (4) Reamer bolt (18) Snap ring (33) Bearing (5) Oil seal (19) Shim 0.2T (34) Bolt(m14x1.5P) (6) Ball bearing (20) Shim 0.5T (35) Spring, washer (7) Housing front gear (21) O-ring (36) Cap, oil (8) O-ring (22) Housing front bearing (37) Hex net (9) Front first pinion (23) Ball bearing (38) Hex bolt (10) Snap ring (24) Oil seal (39) Seal washer (11) Shim 0.2T...
Page 234 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 4.5 spacer F42W503A cOmpOnents (1) O-ring (3) Spring Washer (2) Pin (4) Bolt 40BW-202010...
Page 235 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 4.6 frOnt drive shaft F42W409A cOmpOnents (1) Couple ring R (9) 4th drive shaft (17) Hose band (2) Propeller shaft (10) Ball bearing (18) Shaft cover(back) (3) 4th drive joint (11) Steel ball (19) Stop O-ring (4) Oil seal housing (12) Spring (20) Hex flange bolt (5) O-ring (13) 4th driven gear (21) Spring pin (6) Oil seal (14) Stop O-ring (22) Spring pin (7) Snap ring (15) Shaft cover(front) (8) Ball bearing (16) Shaft cover boots 40BW-202010...
Page 236 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE 5. disassembly and service 5.1 frOnt axle case assembly remOval 1. Park the tractor on firm level ground. notes ▶ prOpeller shaft disassembly and assembly A48W501A 2. Unscrew the drain plug (1) on the bottom of the F42W505A front axle case to drain oil from the front axle case. Oil capacity fOr 6.4ℓ (1.69 u.s.gal) frOnt axle F42W506A...
Page 237 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR notes ▶ prOpeller shaft disassembly and assembly F42W507A F42W508A 40BW-202010...
Page 238 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE notes ▶ prOpeller shaft disassembly and assembly Propeller shaft F42W509A 1. Unscrew the cover mounting bolts (1) and 4. Unscrew the mounting bolts (9) of the shaft remove the cover (2). Then, remove the c over (RR) and pull out the shaf t c over coupling pin (3) and pull out the coupling (4) (R R) (10) to rem ove t he p r o p e ll er shaf t...
Page 239 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR F42W510A F42W512A 4. Place a stand under the engine oil pan. With the front of the tractor lifted slightly, remove the front tires. cautiOn F42W513A 5. Suppor t the front axle case with a por table hydraulic jack or hoist. Then, unscrew the mounting bolts (1) of the front and rear supports to separate the supports from their front axle F42W511A bracket.
Page 240 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE K25W509A F42W514A 7. Unscrew the slotted nut (1) of the tie rod end from the front axle case assembly and unscrew the PST cylinder mounting bolt (2) to separate the PST cylinder (3). When re-installing the PST cylinder, apply Loctite to the threads of its mounting bolt.
Page 241 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 5.2 frOnt axle case cOmpOnent disassembly 5.2.1 frOnt gear case K25W510A K25W511A 1. Unscrew the front bearing case mounting bolts (1) and remove the front spindle (2) and front bearing case (3) assembly together. item tOrque value 51.9±6.9 N.m Mounting bolt 5.3±0.7 kgf.m 38.2±5.0 lbf.ft...
Page 242 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE K25W512A K25W515A 4. Remove the bearing seal (1), ball bearing (2) and front 2nd shaft (3) from the front gearbox by lifting them up. notes K25W513A K25W516A • during the front 2nd shaft installation, make sure that the long side section (a) of the spline is toward the bevel gear 11t. K25W514A 2. Plac e a jac k under the f ront gear box and unscrew the filler plug (1) and knuckle arm...
Page 243 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR K25W518A K25W520A K25W519A K25W521A 6. Unscrew the front axle case support bolts (1) to 7. Pull out the snap ring (1) for hole and remove separate the front gear case assembly (2). the shim (2) and front 1st shaft pinion (3). At this moment, check the amount of the shims notes between the snap ring and bearing so that the • apply grease to the O-ring (3) of the front...
Page 244 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE notes K25W522A K25W523A 8. Remove the oil seal (1) from the front gear case. Then, remove the deep-groove ball bearing (2) and front 2nd shaft gear (3). K25W553A • adjust the backlash between the front 1st shaft pinion (1) and front 2nd shaft gear (2) to 0.15 - 0.3 mm (0.006 - 0.012 in.) using 0.2t, 0.3t and 0.5t shims (3).
Page 245 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR K25W554A 10. Remove the bearing (1) and front final gear (2). Then, remove the adjust shim (3). K25W525A K25W526A 40BW-202010...
Page 246 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE frOnt spindle installatiOn 1. Insert the front final gear into the front spindle, install the washer, lock washer and mounting bolt and tighten the bolt to the specified torque. Then, bend the lock washer to press it against the bolt head. item tOrque value 51.9 N.m Mounting bolt 5.3 kgf.m...
Page 247 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 5.2.2 frOnt differential K25W529A K25W531A K25W533A K25W530A 1. Unscrew the front gear case mounting bolts (1) to remove the front gear case (2), spacer (3) and front 1st shaft (4) together. item tOrque value 88.2 N.m Mounting bolt 9.0 kgf.m 64.8 lbf.ft notes • apply grease to the O-ring (5) of the front axle case when re-installing it.
Page 248 4025H/4035H/4035CH TRACTOR CHAPTER 4 FRONT AXLE K20W542A K20W544A K20W543A K20W545A 3. Unscrew the seal collar (1) from the drive pinion, 4. Pull out the collar (1) and snap ring (2). Then, pull out the oil seal (2) and remove the taper roller remove the drive pinion (3) by pushing into the bearing (3). front axle case hole. 40BW-202010...
Page 249 CHAPTER 4 FRONT AXLE 4025H/4035H/4035CH TRACTOR 5.2.3 frOnt differential assembly disassembly K25W534A K25W537A 3. Pull out the spring pin (1) from the knock pin hole of the differential case. Then, remove the differential pinion shaft (2) and differential pinion gear 10 (3) together. And then, remove the differential side gear and liner (4).
Page 250 CHAPTER 5 HYDRAULIC SYSTEM TABLE OF CONTENTS 1. CirCuit diagram for 4.9.1 Hydraulic cylinder case ....5-37 hydrauliC system ......5-3 4.9.2 Safety valve ........5-38 2. diagram for hydrauliC system .. 5-5 4.9.3 Stop valve (also as slow return valve) .. 5-39 4.10 Hydraulic filter and strainer ....5-40 3.
Page 251: Table Of Contents
taBle of Contents 7. disassemBly and serviCe.... 5-79 8. inspeCtion, adjustment and test ..........5-110 Hydraulic cylinder case assembly disassembly and assembly ....5-79 PST valve ...........5-111 Control valve disassembly ....5-84 8.1.1 Relief valve pressure test .... 5-111 Rear SCV disassembly [Optional] ..5-90 PTO valve ...........5-111 PTO valve disassembly .......5-92 8.2.1 Sequence valve pressure test ..
Page 252 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 1. CirCuit diagram for hydrauliC system rops model FRONT SCV ASSEMBLY SPECIFICATIONS (PTO VALVE) FRONT OUTLET VALVE SPECIFICATIONS (PST VALVE) SAFETY VALVE PTO VALVE SPECIFICATIONS (FRONT OUTLET VALVE) PST VALVE CONTROL VALVE FRONT OUTLET VALVE REAR SCV (OPTION) SPECIFICATIONS (CONTROL VALVE) PUMP SPEC...
Page 253 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR CaBin model SPECIFICATIONS (PTO VALVE) SPECIFICATIONS (FRONT SCV) SPECIFICATIONS (PST VALVE) SAFETY VALVE PTO VALVE PST VALVE CONTROL VALVE FRONT SCV VALVE REAR SCV (OPTION) SPECIFICATIONS (CONTROL VALVE) PUMP SPEC PST PUMP MAIN PUMP SPECIFICATIONS (SECTIONAL VALVE) SPECIFICATIONS (HST) 0 ~ 28.1 cc/rev &...
Page 254 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 2. diagram for hydrauliC system rops model F50W604C (1) PST cylinder (5) Front outlet valve (9) Hydraulic cylinder case (13) HST (6) Hydraulic filter (2) Hydraulic pump (7cc) (10) Control valve (11) HST filter (3) Hydraulic pump (13cc) (7) PTO valve (4) PST valve (8) Rear relief valve...
Page 255 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR CaBin model K3CW615A (1) PST cylinder (5) Loader valve (Front SCV) (9) Hydraulic cylinder case (13) HST (6) Hydraulic filter (2) Hydraulic pump (7cc) (10) Control valve (11) HST filter (3) Hydraulic pump (13cc) (7) PTO valve (4) PST valve (8) Rear relief valve (12) Oil cooler The hydraulic system can be divided into two parts;...
Page 256 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 3. major Component speCifiCations 3.1 pst valve open Center, non-load reaCtion type type integral relief valve at 16 ℓ/min Relief valve setting pressure 130 kgf/cm Capacity 69 cc/rev Rated flow 16 ℓ/min Max. impact pressure 130 kgf/cm 95 ℃ (203 ℉) Max.
Page 257 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 3.5 rear sCv [optional] Relief valve setting pressure 180 ~ 185 kgf/cm Nominal flow 30 ℓ/min. Max. pressure 210 kgf/cm 3.6 pto valve Sequence valve setting pressure 16.0 kgf/cm Operating flow 5 ~ 19 ℓ/min. Max pressure 40 kgf/cm 3.7 hst Pump 0 ~ 28.1 cc/rev Displacement...
Page 258 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 3.9 oil Cooler Air flow 5 m/sec Flow 20 LPM Heat rejection rate Min. 4,400 kcal/h 3.10 pst Cylinder Type Double-rod double acting type Rod O.D. Ø 30 mm Cylinder I.D. Ø 55 mm Stroke 184.4 mm Relief setting pressure 130 kgf/cm...
Page 259 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4. struCture and operation 4.1 steering valve 4.1.1 overview PST VALVE PTO VALVE FRONT OUTLET VALVE F50W605C When the engine is started, oil is supplied to the left or right of the PST cylinder according to the turning direction of the steering wheel.
Page 260 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.1.2 internal struCture and operating prinCiple 4-PF1/4-19 Cross section A - A Cross section X - X Cross section C - C A42W605B (1) Dust seal (9) Washer (17) Gland bushing (25) Bushing (2) Retaining ring (10) O-ring (18) Plate (26) Spring (3) Quad ring...
Page 261 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K20W602A (1) Spool (3) Pin (5) Drive shaft (2) Sleeve (4) Leaf spring (6) Gerotor (inner rotor) The steering wheel is engaged with the steering valve spool with splines. Therefore, when the steering wheel is turned, the spool is turned as well. The spool (1) is covered with the sleeve (2) and these are fixed by the pin (3).
Page 262 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM CaBin model 4.1.1 overview PST VALVE PTO VALVE FRONT SCV K3CW616A When the engine is started, oil is supplied to the left or right of the PST cylinder according to the turning direction of the steering wheel. Then, the corresponding PST cylinder is extended or retracted to turn the vehicle to the desired direction.
Page 263 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.1.2 internal struCture and operating prinCiple 6 7 13 12 11 10 2 16 15 20 21 22 23 31-3 31-1 31-2 17 19 18 33 29-2 29-5 29-4 29-1 29-3 30-3 30-1 30-2 K3CW618A (1) Dust seal (12) Centering spring...
Page 264 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K00W669A (1) Spool (3) Pin (5) Drive shaft (2) Sleeve (4) Plate spring (6) Gerotor (inner rotor) The steering wheel is engaged with the steering unit spool (1) with splines. Therefore, when the steering wheel is turned, the spool is turned as well.
Page 265 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.1.3 examples of steering wheel operation neutral left turn PST VALVE PST VALVE PTO VALVE PTO VALVE 4815R(h)/F50R(h) 4815R(h)/F50R(h) F50W606A F50W607A Hydraulic oil delivered from the secondary gear When the steering wheel is turned counterclockwise, pump is sent to the PST valve through the port P.
Page 266 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM right turn opening relief valve PST VALVE PST VALVE PTO VALVE PTO VALVE 4815R(h)/F50R(h) 4815R(h)/F50R(h) F50W608A F50W609A When the steering wheel is turned clockwise, the When the PST cylinder is moved to the left or right sleeve is turned clockwise approx.
Page 267 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR manual steering (left turn) PST VALVE PTO VALVE 4815R(h)/F50R(h) F50W610A When the steering wheel is turned with the engine stopped, the spool, sleeve and Gerotor pump are rotated as described previously. For example, w h en t he ste er ing w he e l is manually tur ne d counterclockwise, hydraulic oil at the left side of the PST cylinder is sucked through the port R and is flowed to the Gerotor through the sleeve and...
Page 268 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.2 pst Cylinder F42W613A (1) Cylinder tube (3) U-packing (5) Piston (7) X-ring (9) Bushing (2) Piston rod (4) Dust seal (6) Backup ring (8) O-ring (10) Stop ring (type C) The PST cylinder is a double-rod double acting type cylinder which performs double rod operation for steering without a need of a separate tie rod.
Page 269 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.3 hydrauliC pump PRIMARY PUMP SECONDARY PUMP F42W614A The hydraulic pump is a gear type and consists of the primary pump as the main pump (13 cc/rev) and secondary pump as the steering pump (7.0 cc/rev). The drive shaft set between these two pumps receives engine power directly through the drive gear of the engine crankcase.
Page 270 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.4 pto valve P-PORT PF3/8 T-PORT G2-PORT PF1/4 CL-PORT LBR-PORT G1-PORT PF1/4 F42W615A (1) Solenoid valve (2) Sequence valve (3) DRV valve The PTO valve is installed to the rear right side of the transmission case. It receives oil from the PST valve to lubricate and operate the PTO clutch and it is turned ON and OFF by the PTO switch.
Page 271 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR PTO OFF PTO VALVE PTO VALVE PST VALVE PST VALVE F42W628A F42W629A The port T of the PST valve discharges hydraulic oil The electric solenoid spool is turned ON and OFF continuously regardless of movement of the steering by the driver's operation of the PTO switch.
Page 272 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.5 rear sCv [optional] PTO ON PTO VALVE 35HW601A PST VALVE F42W630A When the PTO switch is set the ON position by the driver, the magnet of the electric solenoid is activated to pull the spool in the left direction as shown in the A42W647A circuit diagram.
Page 273 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR The spools of the rear SCV are double acting valves, but they also can be used for implements equipped with single acting cylinders. As shown in the circuit diagram above, when hydraulic oil is applied to the port connected to the single acting cylinder, this single acting cylinder is extended.
Page 274 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.6 front outlet valve assemBly F42W619A F42W618A The front outlet valve assembly is installed under the front section of the step on the right side. It is connected to the main gear pump (primary pump) to receive hydraulic oil at a high pressure from the gear pump before any other components mainly for operation of an external implement, such as a...
Page 275 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR F42W632A The front outlet valve assembly is an open center type. When this valve (i.e. loader) is not in use, hydraulic oil from the hydraulic pump is passed through this valve and is supplied to the rear SCV valve after it.
Page 276 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.7 front sCv (loader valve) BSP12 Relief valve Port “C” K3CW620A K3CW619A The front SCV (loader valve) assembly is installed under the front section of the step on the right side. It is connected to the main gear pump (primary pump) to receive hydraulic oil at a high pressure from the gear pump before any other components mainly for operation of a loader.
Page 277 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K3CW622A ▶ valve speCifiCations When the joystick lever is not in use, hydraulic oil from the pump is passed through the port C and is item speCifiCation supplied to the rear SCV assembly or control valve. Relief valve setting pressure 180 ~ 185 kgf/cm The hydraulic oil delivered from P flows into the...
Page 278 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.8 Control valve ▶ overview K25W69\3A K25W692A The control valve is installed in the hydraulic cylinder cover and it receives oil at a high pressure from the front outlet valve (front SCV) or the rear SCV (if equipped) through carryover operation. The internal spool is operated according to the position of the control lever to lift or lower the lift arm or set it in the neutral status.
Page 279 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ operating prinCiple For example, if the position ordered by the position control lever is higher than the current position of the lower link, the main spool of the valve is pushed in by the link structure set in the hydraulic cylinder case.
Page 280 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.8.1 operation and oil flow ▶ neutral Q25W623A (1) Safety valve (3) Load check valve (5) Main spool (7) Oil tank (2) Slow return valve (4) Mechanical valve (6) Unload valve The pressure (b) applied to the back of the unload valve spring is removed. (it opens the spool and is sucked into tank.) As the unload valve is opened by the pressure (a), the oil in the pump is returned to the tank and the pressure drops.
Page 281 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ lifting (rapid lifting) Operation Oil flow Q25W624A (1) Safety valve (3) Load check valve (5) Main spool (7) Oil tank (2) Slow return valve (4) Mechanical valve (6) Unload valve The unload valve is applied with the pilot pressure (a) and (b) so it is closed by the spring force. As the pressure in the pump rises, oil flows through the flow passage in the spool and opens the load check valve to flow into the cylinder (rapid lifting). The mechanical check valve is kept closed.
Page 282 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM ▶ lifting (low-speed lifting) Operation Oil flow Q25W625A (1) Safety valve (3) Load check valve (5) Main spool (7) Oil tank (2) Slow return valve (4) Mechanical valve (6) Unload valve As the hydraulic lift is lifted, the feedback link is moved to push the main spool closer to the neutral position. Then, the mechanical valve open slightly and the oil flow of main spool to return oil back to the tank. But the majority of oil is led into the cylinder to reduce shock occurred by lifting operation. 40BW-202010...
Page 283 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ lowering Operation Oil flow Q25W626A (1) Safety valve (3) Load check valve (5) Main spool (7) Oil tank (2) Slow return valve (4) Mechanical valve (6) Unload valve Oil in the hydraulic pump opens the unload valve and enters the tank as in the neutral state. As oil in the hydraulic cylinder moves the spool, the mechanical valve, which is directly connected to the main spool with the pin, is opened to return the oil back to the tank.
Page 284 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.8.2 Control lever operation ▶ lowering Q25W627A (1) Lift arm (2) Control lever (3) Control valve (4) Feedback rod When setting the control lever to the Lowering position, pressure applied to the spool is released so the spool is returned to its original position by the spring.
Page 285 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ lifting Q25W628A (1) Lift arm (2) Control lever (3) Control valve (4) Feedback rod When the control lever is set to the Lifting position, the control valve spool behind the hydraulic cylinder case is pressed and oil is flowed into the cylinder. Then, the piston lifts the lift arm. However, as the feedback rod installed to the lift arm is operated to provide a lifting signal in this state, the spool of the control valve is returned to the neutral position even with the control lever still in the lifting position.
Page 286 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.9 hydrauliC Cylinder Case assemBly 4.9.1 hydrauliC Cylinder Case Components K20W6A35A (1) Safety valve (4) Lift/Lowering valve (7) Lift arm (2) Lowering speed control valve (5) Piston rod (8) Draft lever ass'y (3) Cylinder ass'y (6) Lift crank (9) Position lever ass'y 40BW-202010...
Page 287 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.9.2 safety valve K25W641A (1) Safety valve ass’y (4) O-ring (7) Spring (10) O-ring (2) Nut (5) Body, safety valve (8) Ball guide (3) Bolt (6) O-ring (9) Steel ball The piston of the hydraulic cylinder case is supplied with hydraulic oil through the lift solenoid valve of the control valve.
Page 288 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.9.3 stop valve (also as slow return valve) K25W643A Stop valve is used to stop lowering or adjust the lowering speed of the hydraulic lift. When turning the handle counterclockwise, the lowering speed of the lift arm increases.
Page 289 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.10 hydrauliC filter and strainer 4.10.1 hydrauliC filter F42W633A The hydraulic filter is installed under the transmission to filter oil in the oil tank (transmission) before this oil is delivered to the gear pump. Hydraulic oil is flown through the hole on the top of the oil filter cartridge and is passed from the outside to the inside of the filter. Then, it is flowed in through the hole in the middle of the cartridge. K20W622A ▶ filter element speCifiCations Filtering area 4,972 cm Number of folds 195 ×...
Page 290 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.10.2 hst filter A42W648B The HST filter is installed below the right floor. As oil delivered from the PTO valve side passes through the HST filter, it is filtered before it returns into the oil cooler for cooling and flows into the HST. A42W607A ▶ speCifiCations Filtering area 2,677 cm Number of folds 105 × 17 × 75 folds Folding width Rated flow 30 ℓ/min Bursting strength 17 kgf/cm...
Page 291 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.11 hst(hydrostatiC transmission) 4.11.1 hst passage Composition A42W608B (2) HST filter (1) PTO valve (3) Oil cooler (4) HST The HST (Hydro-Static Transmission) consists of the variable capacity pump, fixed capacity motor, check valve, high-pressure relief valve, etc. and it is installed to the transmission to supply turning force to the transmission. The input shaft of the HST is connected to the spring damper which is installed to the flywheel of the engine with the spline.
Page 292 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.11.2 exterior dimension - pg β - - B - - pg α - 26.5 ±0.2 (97.5) 265.5 18゜ 18゜ β α α β 91 MAX 91 MAX A42W609B 40BW-202010...
Page 293 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.11.3 CirCuit diagram (Forward) (Reverse) A42W610B (1) HST pump (4) Neutral valve (7) HST motor (2) Oil cooler (5) Charge relief valve (3) Neutral valve (6) Main relief valve 40BW-202010...
Page 294 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.11.4 hst pump 4.11.5 hst motor A42W611A A42W612A C865W712A C865W713A (1) Piston (3) Swash plate (1) Piston (2) Shaft (2) Shaft The motor in the HST has a shape similar to the The pump in the HST is equipped with several pistons (1) pump, but it is equipped with the fixed swash plate, to control hydraulic flow with reciprocating motion. Also, making it a fixed capacity type.
Page 295 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.11.6 Charge relief valve K25W661B (1) Charge relief valve (Forward) Check valve Charge relief valve Motor Pump Check valve (Reverse) A42W614A Most of oil is circulated in between the pump and motor in the HST. There is no separate charge pump. Instead, the gear pump of the vehicle body supplies hydraulic oil through the passage.
Page 296 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.11.7 neutral valve K25W662B Speed Distance (Reverse) (Forward) Neutral section C865W715A 40BW-202010...
Page 297 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR neutral (Forward) Check valve Charge relief valve Pump Motor Check valve (Reverse) A42W615B In the HST pump operation process, it is almost impossible to set the swash plate at 0° exactly to keep the neutral state (no oil flow). Also, it is impossible for the driver to set the angle of the swash plate to 0° for the neutral setting.
Page 298 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM forward/reverse driving (Forward) Neutral valve spool Neutral valve spool Pump Motor (Reverse) A42W616B When operating the forward/reverse pedal for forward or reverse driving, the angle of the swash plate is increased so oil flow toward the pump is also increased. As a result, hydraulic pressure rises gradually and eventually exceeds the setting pressure of the return spring of the neutral valve. Then, the spool of the neutral valve is moved to close the orifice, leading oil to the motor through the internal circuit.
Page 299 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.11.8 main relief valve K25W664A (Forward) High pressure line Check valve Charge relief valve Main Pump relief Motor valve Check valve (Reverse) Low pressure line A42W617B The setting pressure of the main relief valve is 380 kgf/cm (37.2 MPa) to protect the internal circuit in case of HST overload.
Page 300 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.11.9 hst pedal and linK Components rops model A42W645B A42W618B 40BW-202010...
Page 301 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR (1) Bracket ass'y, pedal (13) Snap pin (25) Shaft (2) Hex flange bolt (14) Plain washer (26) Bolt w/washer (3) Bush (15) Switch(fr) (27) Holder ass'y, spring (4) Shaft ass'y, front (16) Bolt w/washer (28) Spring (5) Shaft ass'y, rear (17) Cruise magnet (29) Bolt (18) Hex flange bolt...
Page 302 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM CaBin model K3CW623A K3CW624A 40BW-202010...
Page 303 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR (1) Bracket ass'y, pedal (14) Pedal ass'y, rear (27) Shaft (2) Hex flange bolt (15) Pedal cover (28) Bolt w/washer (3) Hex flange bolt (16) Damper (29) Holder ass'y, spring (4) Bush (17) Snap pin (30) Bolt (5) Shaft ass'y, front (18) Switch(FR) (31) Spring (6) Shaft ass'y, rear...
Page 304 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM neutral forward driving rops model rops model A42W619B A42W620B CaBin model CaBin model A42W619B A42W620B • Align the forward pedal (1) and reverse pedal (2). • Lowering the forward driving pedal (1) and lifting the reverse driving pedal (2) • Maintaining the connecting joint (3) in the neutral state • Turning the connecting joint (3) clockwise • Detecting the neutral condition of the safe start - Changing the angle of the HST swash plate (0 - +18˚)
Page 305 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR reverse driving rops model A42W621B CaBin model A42W621B • Lowering the reverse driving pedal (1) and lifting the forward driving pedal (2) • Turning the connecting joint (3) counterclockwise - Changing the angle of the HST swash plate (0 - +18˚) • Turning and lowering the neutral control bracket (4) clockwise • Detecting the reverse condition of the safe start neutral switch (5)
Page 306 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 4.12 oil Cooler 4.13 position Control F42W634A (1) Position control lever The position control lever (1) is used to control the position of the 3-point hitch. The control valve and feedback link mechanism are used to lift and lower an implement.
Page 307 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.14 draft Control SAFETY VALVE STOP VALVE load resistance K20W625A Q25W622A K25W647A Oil from the pump pushes the piston through the The draft control is a device that controls load by control valve to lift the lift arm. When the lift arm is vertical movement of the lift arm (implement) against lowered by weight of the implement, oil in the piston load resistance of an implement during draft work...
Page 308 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 5. trouBleshooting proBlems Cause or symptom solution • Improperly installed control valve • Remove and re-install it. • Damaged control valve • Replace it with a new one. • Foreign material stuck in control valve or spool stuck • Remove, clean and repair it.
Page 309 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6. seCtional view for major Components 6.1 steering Column rops model A42W624A Components (1) Support, steering (7) Cover(shaft) (13) Shaft, steering (2) Hex flange bolt (8) Steering wheel ass’y (14) Snap ring (3) PST valve ass’y (9) Plain washer (15) Ball bearing (4) Column, steering (10) U-nut...
Page 310 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.2 p.s.t Cylinder K25W606A Components (3) Hex flange bolt (5) Hex flange bolt (1) P.S.T cylinder ass’y (2) Hex flange bolt (4) Cover, P.S.T cylinder 40BW-202010...
Page 311 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.3 p.s.t pipe rops model A42W625A Components (1) Hose (3) Hose (2) Hose (4) Hose 40BW-202010...
Page 312 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM CaBin model K3CW628A Components (1) Valve unit,steering (5) Washer ass'y hex bolt (9) Hose ass'y (P) (2) Grommet (6) Plate, guide (10) Hose ass'y (L, R, P) (3) Collar (08x12x7.3) (7) Washer ass'y hex bolt (11) Hose ass'y (R) (4) Washer (9x22x2) (8) Bracket comp, steering...
Page 313 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.4 hyd pump F42W603A Components (1) Hyd pump (6) Hyd pump (11) Spring washer (2) Elbow (7) O-ring (12) Hex nut (3) Packing (8) Joint (13) Hex bolt (4) Elbow (9) Elbow (14) Bolt w/washer (5) Stud bolt (10) Packing 40BW-202010...
Page 314 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.5 Case, hyd Cylinder F42W604A Components (2) Bolt w/washer (9) Case, hyd cylinder (16) Spring washer (3) Plug (10) Snap ring (17) Hex nut (4) O-ring (11) Roller (18) Bolt w/washer (5) Control, valve ass’y (12) Hex nut (19) Pin (20) Air breather...
Page 315 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.6 relief valve F42W605A Components (1) Valve, relief (3) O-ring (5) Elbow (2) O-ring (4) O-ring (6) Washer ass’y hex bolt 40BW-202010...
Page 316 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM OPTION K3CW629A Components (19) Hex flange bolt (1) Knob (10) Plate (27) O-ring (2) Lever A ass'y (11) Link (2) ass'y (20) Cover relief (28) O-ring (3) Lever B ass'y (12) Link (1) ass'y (21) SCV PTO 2nd (29) O-ring (4) Hex flange bolt (13) Plain washer (22) SCV PTO 3rd...
Page 317 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.7 piston ass’y F42W607A Components (21) Hex flange bolt (1) Piston ass’y (12) Ring, backup (23) Hex flange bolt (2) O-ring (13) O-ring (3) Ring (14) Bush (24) Snap ring(C-type) (6) Piston (15) Shaft, lift link (25) Bonded seal (16) Hex flange bolt (7) Rod, piston (26) Ring, backup (8) Spring pin...
Page 318 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.8 safety valve K25W612A Components (1) Safety valve ass’y (5) Body, safety valve (9) Steel ball (2) Nut (6) O-ring (10) O-ring (3) Bolt (7) Spring (4) O-ring (8) Ball guide 40BW-202010...
Page 319 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.9 stop valve K25W613A Components (1) Stop V/V (5) O-ring (9) Spring (2) Stop bolt (6) Body, stop V/V (10) Ring, backup (3) O-ring (7) Steel ball (11) Knob (4) Nut (8) O-ring (12) Hex nut 40BW-202010...
Page 320 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.10 hyd Control position type K25W614A Components (1) Shaft,position lever (9) Snap ring (17) Link (2) D-control shaft (10) Roller (18) Pin, feed back (3) Bush (11) Link B ass’y (19) Spring washer (4) Snap ring(E) (12) Spring (20) O-ring (5) Plate...
Page 321 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K25W615A Components (1) Connector (8) Plate, friction (14) Knob ass’y, draft control (2) Bonded seal (9) Lever, D-control (15) Screw (10) Plate A (3) Bracket (16) Knob ass’y, position control (4) Bracket (11) Lever, P-control (17) Screw (18) Arm,lever (6) Bolt (12) Spring...
Page 322 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.11 draft Control K25W616A Components (19) Hex fix nut (1) Hex bolt (10) Plate, hinge (2) Washer (11) Plate (20) Rod (3) Hinge D, top link (12) Bolt w/washer (21) Link ass’y(out) (4) Hex nut (13) Support D, hinge (22) Snap ring(E) (5) Nipple (14) Plate...
Page 323 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.12 hyd piping rops model K42W611B Components (1) Rubber hose (6) Hose band (11) O-ring (2) Spring A (7) Lower pressure hose (12) Nipple (3) Hose clamp (8) Front out valve (13) Hose (4) Pipe ass’y , lower pressure (9) Elbow (14) Higher hose (5) Hex flange bolt...
Page 324 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM CaBin model K3CW630A Components (1) Rubber hose (9) Loader valve ass'y (19) Elbow (1) Pipe , lower pressure (10) Plain washer (20) Bracket, valve (2) Spring A (21) Hex flange bolt (11) Bolt w/washer (22) Hex flange nut (3) Hose clamp (12) Hex nut (13) Hex nut(fine) (4) Pipe ass'y, lower pressure (23) Hyd hose...
Page 325 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.13 hyd filter A42W626A Components (1) Filter (6) Filter cover bracket (11) Filter (7) Hex flange bolt (12) Hex flange bolt (2) Filter cover (3) O-ring (8) Bracket (13) Elbow (4) Lower pressure pipe(filter) (9) Bolt w/washer (14) Hose (5) O-ring (10) Filter cover 40BW-202010...
Page 326 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 6.14 hst pump A42W627A Components (6) Hex flange bolt (1) Transmission case (11) Hex bolt w/washer (2) Plate (7) O-ring (12) Hex bolt w/washer (13) Adaptor(3/8) (3) HST (28cc) (8) O-ring (4) Parallel pin (9) Parallel pin (14) Elbow (5) Parallel pin (10) Snap ring 40BW-202010...
Page 327 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 6.15 oil Cooler A42W628B Components (1) Oil cooler (3) Bracket, oil cooler® (5) Elbow (4) Hex flange bolt (2) Bracket, oil cooler(l) (6) Hose 40BW-202010...
Page 328: Disassembly And Service
4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 7. disassemBly and serviCe 7.1 hydrauliC Cylinder Case assemBly disassemBly and assemBly 1. Remove the fender and plate of under the seat. K42W617A 3. Disconnect the hydraulic pipe (1) and remove the K42W614A top link bracket assembly (2) and rear relief valve (3). K42W615A K42W618A K42W616A...
Page 329 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K20W6A08A K20W6A11A K20W6A09A K20W6A12A 5. Remove the control valve (1) from the hydraulic 7. Remove the lower ing speed c ontrol valve cylinder cover. assembly (1). K20W6A10A 6. Remove the safety valve (1) from the hydraulic cylinder cover.
Page 330 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K42W620A K42W623A K42W621A 8. Unscrew the lever retaining nut (1). Then, remove K42W624A the bracket A (2), spring (3), bracket A (2), plate (5), P lever (4), plate (5), bracket A (2), plate (5), D 10. Remove the cam assembly (1) from the left side and pull out the snap ring.
Page 331 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K20W6A19A K20W6A21A K20W6A20A K20W6A22A 11. Unscrew the plate (1) and pull out the lift link 12. Pull out the E-type snap ring (1) for the lift crank shaft (2) to the right. link. Then, remove the lift crank (2) and piston rod (3) together.
Page 332 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K20W6A24A K20W6A27A K20W6A25A K20W6A28A 13. Unscrew the hex. bolt (1) and remove the piston 14. Remove the spring (1) and pull out the E-snap assembly (2) to separate the piston (3) from the ring (2). Then, remove the position link (3), piston assembly.
Page 333: Control Valve Disassembly
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.2 Control valve disassemBly K20W6A32A K20W6A34A K20W6A33A K20W6A35A 1. Unscrew the control valve mounting bolts (1) 2. Unscrew the hex. nut (1) from the control valve from the hydraulic cylinder cover to remove the to separate the clevis assembly (2) and plate (3).
Page 334 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K20W6A37A K20W6A38A 4. Unscrew the main check plug (1) and remove the 5. Unscrew the unload plug (1) and remove the main check poppet (2) and main check spring (3). plate (2), unload spring (3) and unload check (4). K20W6A39A 6. Assemble in the reverse order of disassembly.
Page 335 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR hydrauliC Cylinder installation standard 1. Keep all hydraulic components clean and remove any foreign material and dust from them before their installation. K25W6A48A 4. When installing the safety valve (1) and lowering speed control valve (2), check if their O-rings are missing or damaged. Also, apply grease on them K25W6A46A before installation.
Page 336 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 10 mm or longer (for both sides) K25W6A51A K25W6A54A 6. When pressing in the hydraulic cylinder case bushing, 9. When installing the hydraulic cylinder cover, apply liquid gasket (A) on it in advance. select the correct size and use a pressing jig. Tightening torque 800 - 880 kgf.cm K25W6A52A...
Page 337 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR optional Check installing direction K25W6A57A K25W6A60A 12. When installing the return spring, set its longer section to the front. 14. When installing the rear SCV, make sure that its O-ring is not missing or damaged. 15.
Page 338 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM ▶ Control valve setting By different lift arm angles K25W6A61A 1. P lever pulled to the max. lifting position (lifting angle) (lifting height) (lowering angle) (lowering height) 47.5°~49° 269~273.5 16.3°~17.3° 14.8~10.3 2. I f the lifting angle or lowering angle is out of the specified range, adjust it with the clevis adjusting nut. (Initial setting value: Y 29 mm or Z 13 mm with X 10 mm) (Repeat adjustment 2 to 3 times for precise setting.) Plate (6T) Adjusting nut...
Page 339: Rear Scv Disassembly [Optional]
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.3 rear sCv disassemBly [optional] K20W6A41A 35HW602A K20W6A42A 2. Remove the rubber bellows (1) and pull out the retaining pin (2). Then, remove the arm (3). F42W636B 1. Disconnect all the hydraulic pipes (1) to the rear SCV from the back of the tractor and unscrew the mounting nuts (2), and disc onnect the connecting bracket (3) to remove the rear SCV...
Page 340 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K20W6A45A K20W6A44A 4. Pull out the spool (1) in the arrow direction. K20W683A 4. Unscrew the relief valve (1) from the other side to remove it. Then, pull the spool (2) to remove it. 40BW-202010...
Page 341: Pto Valve Disassembly
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.4 pto valve disassemBly K42W630A K42W633A 1. Disconnect the PTO valve wiring (1) connector and hydraulic pipe (2) and unscrew the mounting bolts (3) to remove the PTO valve assembly. K42W634A 3. Remove the sequence valve (1). K42W631A K42W632A 2.
Page 342 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K42W635A K20W6A09A K42W636A K20W6A10A 4. Remove the DRV valve (1). 5. Remove the magnet housing (1) of the PTO solenoid. Remove the internal valve and spool as well. K42W637A 6. Assemble in the reverse order of disassembly. 40BW-202010...
Page 343: Front Outlet Valve Disassembly
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.5 front outlet valve disassemBly K42W653A K42W641A 1. Disconnect the hydraulic hose from the front 3. Remove the relief valve. outlet valve and unscrew the bracket mounting b o l t s to r e m ove t h e f r o nt o u t l et va l ve (1) assembly.
Page 344: Front Scv Assembly (Loader Valve) Disassembly
4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 7.6 front sCv assemBly (loader valve) disassemBly K3CW603A K3CW605A K3CW604A K3CW606A 1. Disconnect the loader cable (1) and hydraulic 2. Remove the bucket valve (1) from the loader pipe (2). Then, unscrew the mounting bolts to valve assembly.
Page 345 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR K3CW607A K3CW609A K3CW608A K3CW610A 3. Remove the boom valve (1) from the loader valve 4. Remove the relief valve (1) from the loader valve assembly. assembly. 40BW-202010...
Page 346 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K3CW611A 5. A ssemble in the reverse order of disassembly. 40BW-202010...
Page 347: Steering Valve (Unit) Disassembly
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.7 steering valve (unit) disassemBly rops model K42W643A A42W630A 1. Remove the upper dashboard par t (1) and column cover (2). A42W631A 3. Disconnect the hydraulic hoses (1) from the steering valve assembly. A42W629A 2.
Page 348 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K20W6A19A K20W6A20A 4. Unscrew the end cap mounting bolts (1) from the 5. Remove the spacer (1) and gerotor set (2) in steering valve assembly to remove the end cap (2). order. important the bolt a among the end cap mounting bolts ...
Page 349 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR CaBin model K3CW601A K00W633A 1. Remove the steering wheel (1), upper dashboard (2) and lower dashboard (3). K00W634A 3. Disconnect the PST hydraulic hoses (1) from the PST unit assembly. K3CW602A 2. PST unit assembly mounting bolts and nuts (1) to remove the PST unit assembly (2) by lifting it up.
Page 350 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K00W636A 5. Remove the spacer (1), inner rotor (2) and outer rotor (3). K00W637A 6. Remove the drive (1), plate (2), sleeve assembly (3) in order from the housing (4). 40BW-202010...
Page 351: Hydraulic Pump Disassembly
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.8 hydrauliC pump disassemBly 13 cc K42W645A K20W6B6A 3. Separate the shaft holding block (1) and each 1. Disconnect the hydraulic pipe (1) and hydraulic housing (2) from the cabin. hose (2) from the hydraulic pump on the left side of the engine.
Page 352 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 7 cc K42W648A K42W650A 3. Separate the shaft holding block (1) from the 1. Disconnect the hydraulic pipe (1) and hydraulic housing (2). hose (2) from the hydraulic pump on the left side of the engine. Then, unscrew the mounting bolt (3) to remove the hydraulic pump assembly.
Page 353: Hst
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 7.9 hst notes A42W632A C865W764A 1. Unscrew the drain plug (1) from the bottom of the • align the grooves (a) of the valve plate with HST front cover to drain oil. 8-mm L-shape wrench the knock pin (1) of the hst case during as- sembly.
Page 354 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM K25W671A A42W635A C865W767A C865W769A 4. Unscrew the spring holder (1) from the inner upper 5. Remove the valve plate (1) on the motor side. section of the front cover. Then, remove the spring Then, separate the cylinder block (2) and piston (2) and check valve (3).
Page 355 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR C865W771A C865W774A • Valve plate • Piston assembly C865W772A C865W773A • Cylinder block 40BW-202010...
Page 356 4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM A42W636A K25W676A A42W646A K25W677A 7. Remove the valve plate (1) on the pump side. Then, remove the cylinder block (2), piston (3), set plate (4) and shoe plate (5) after separating the cylinder block and piston assembly. notes K25W673A C865W779A...
Page 357 CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR pump shaft disassemBly swash plate disassemBly A42W637A K25W680A A42W638A K25W681A 9. Remove the cover (1). m6 Bolt 3 ea 5-mm L-shape wrench A42W639A 8. R emove the pump shaft cover(1). And pull out the snap ring (2) from the inside and disconnect the pump shaft (3).
Page 358: Relief Valve Block Disassembly
4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 7.10 relief valve BloCK disassemBly K42W654A A42W640A K42W655A A42W641A 10. Remove the swash cover (1) to remove the 1. Disconnect the hydraulic hose (1) of the relief swash plate (2). valve block from the back of the tractor and m6 Bolt 3 ea unscrew the mounting bolts (2) to remove the...
Page 359: Inspection, Adjustment And Test
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 8. inspeCtion, adjustment and test 1. When testing oil flow or pressure for the hydraulic Caution kit, warm up the engine to obtain proper oil temperature. Caution do not place the sCv lever or joystick lever  into the extending or retracting position for an extended period of time.
Page 360: Pst Valve
4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 8.1 pst valve 8.2 pto valve 8.1.1 relief valve pressure test 8.2.1 sequenCe valve pressure test K42W659A K42W660A 1. Remove the hydraulic hose (1) from the right side 1. Unscrew the port G1 plug (PF1/4)(C) of the PTO of the steering cylinder.
Page 361: Front Outlet Valve
CHAPTER 5 HYDRAULIC SYSTEM 4025H/4035H/4035CH TRACTOR 8.3 front outlet valve 8.4 hst neutral setting 8.3.1 relief valve pressure test 1. Lift the vehicle off the ground so that the wheels idle above the ground. 2. Set the engine to idle speed. 3.
Page 362: Hst Main Relief Valve Pressure Test
4025H/4035H/4035CH TRACTOR CHAPTER 5 HYDRAULIC SYSTEM 8.5 hst main relief valve pressure test CaBin model K3CW631A A42W644A (1) Pressure measuring port of high CaBin model pressure relief valve (forward driving) (PT 3/8) (2) Pressure measuring port of high pressure relief valve (reverse driving) (PT 3/8) 1.
Page 363 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 364 CHAPTER 6 ELECTRIC SYSTEM TABLE OF CONTENTS 5.2.15 Engine oil pressure switch ... 6-40 1. Major electric systeM specifications ........6-3 5.2.16 Coolant temperature sensor (preheating) ........6-41 3.1 Symbols and wiring color definition in electric circuit ........ 6-11 5.2.17 Coolant temperature sensor (meter) ..6-42 3.1.1 Symbol ...........6-11 5.2.18 Fuel cut-off solenoid ....6-42 3.1.2 Color definition ......6-11 5.2.19 Fuel sensor ........6-43 5.2.20 Glow plug ........
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Page 366: Major Electric System Specifications
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 1. Major electric systeM specifications iteM standard Battery 12 V 90 Ah Alternator 12 V 50 Ah Starter 12 V 2.2 kW Preheat relay DC 12 V, 70 A PTO engagement switch Rated current: 14 V 15 A Safety switch 12 V 10 A Preheat controller Voltage range: DC 8 - 16 V Flasher unit Voltage range: DC 10 - 16 V Direct signal lamp (front) 12 V 21 W/5 W Combination lamp (rear) 12 V 27 W, 12 V 8 W, 12 V 21 W/5 W Head lamp HS1 12V 35W/35W 12 V , 350 ± 2 Hz, 110 ± 5 dB Horn Fusible link 60 A X 2 EA Cruise controller...
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Page 368 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 2. Major electric coMponent layout diagraM ENGINE (LH) BONNET HINGE ASSEMBLY ROPS MODEL BONNET HINGE ASSEMBLY CABIN MODEL ENGINE (RH) ROPS MODEL ROPS MODEL ROPS MODEL CABIN MODEL K3CW767E 40BW-202010...
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Page 370 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 3. electric wiring diagraM rops Model 3015Rh/3515Rh/ 4015Rh/4815Rh F50W704A 40BW-202010...
Page 371 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model K3CW769A 40BW-202010...
Page 372 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM cabin Model K3CW769A 40BW-202010...
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Page 374: Symbols And Wiring Color Definition In Electric Circuit
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 3.1 syMbols and wiring color definition in electric circuit 3.1.1 syMbol syMbol description syMbol description Battery Diode Fusible link Gauge Fuse Lamp Feed pump Relay Switch Fuel cut-off solenoid Starter Horn Alternator Beacon Glow plug Water temp. sensor 3.1.2 color definition syMbol color Black...
Page 375: Circuit Configuration By Major Function
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 4. circuit configuration by Major function 4.1 battery and fusible link POWER GROUND F42W703A There are two fusible links at the end of the wiring 3.0R above the battery in the left section of the circuit diagram. The fusible link on the wiring 3.0Y is to supply main power to the glow relay. When the glow relay is energized, power is supplied to the glow plug to operate it. The fusible link on the wiring 3.0W is related to all other electric devices except main power for preheating operation. It supplies power to the start relay,...
Page 376: Ignition Switch On
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 4.2 ignition switch on F42W704A 40BW-202010...
Page 377 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR The ignition switch is located in the upper left section of the circuit diagram. This switch receives battery power through the wiring 3.0W. 1) A CC: When the ignition switch is turned to the 1st stage, ignition switch ON power is supplied through the terminal BR2 and wiring 2.0WB. When following the wiring 2.0WB from the terminal BR2 in the circuit diagram, this wiring is passed through two 20 A fuses and is connected to the combination switch for input power. Power supplied through the first fuse (No. 06) is delivered to various lamps through the combination switch. Power supplied through the second fuse (No. 07, 20 A) is delivered to the flasher...
Page 378: Preheat
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 4.3 preheat POWER GROUND F42W705A The circuit related to the preheat operation is located in the left section of the above circuit diagram. As soon as the ignition switch is turned to the ON position, preheating operation is started and the preheat indicator on the instrument cluster is turned ON. When the ignition switch is returned to the ON position from the START position, after-heating operation is started. However, if the engine is not started so the generator is not operated properly, after-heating operation is not performed. -. It receives the manual preheating signal from the ignition switch through the wiring 0.85L. -. It receives the coolant temperature signal through the wiring 0.5LB. -. It receives the ignition switch ON signal through the wiring 0.5RB. -. I t sends power to the preheat indicator on the instrument cluster through the wiring 0.5LW and instrument cluster wiring (B). -. T he wiring 0.85Y is a output wiring for the glow relay coil signal. When the glow relay coil is energized by this signal output, main power is directly supplied from the battery through the fusible link for preheating and wiring 3.0Y to the glow plugs installed to each cylinder in the engine. -. T he wiring 0.5GY is connected to the terminal L which is a direct current output terminal of the generator. This is to enable after-heating operation only when the generator is normally running. 40BW-202010...
Page 379: Pto Operation
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.4 pto operation POWER GROUND K20W706C 1) L INK: This is activated when the PTO switch is set in the LINK position. As power is supplied to the PTO switch through the wiring 1.25RB, it is sent out through the wiring 0.5YG. This signal is sent to the PTO safety start relay through the wiring 0.5LR and diode first to prevent the engine from starting when the PTO switch is set in the ON position. The wiring 0.5YG is connected to the clutch safety switch. This switch is installed to the driving clutch pedal to stop PTO when the clutch pedal is depressed.
Page 380 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 3) PTO relay and PTO indicator: The PTO relay coil power is supplied through the wiring 0.5YG or 0.5LY depending on the position of the PTO selection switch. The main power of the PTO relay is connected to the ignition switch ON power passed through the 10 A fuse. The main power of the PTO relay is sent through the wiring 0.85YL. It is sent to the instrument cluster through the connecting wiring (E) to inform the driver with the PTO operation status before it reaches the PTO valve. Therefore, the PTO indicator on the instrument cluster can be turned on properly even when the PTO is not operated due to malfunction of the PTO valve. Also, when the PTO selection switch is set in the LINK position, the PTO indicator on the instrument cluster goes off even though the PTO is turned off only temporarily by operation of the driving clutch pedal or lift arm lever. Make sure to maintain high standards of safety in this condition. 40BW-202010...
Page 381: Instrument Cluster And Sensors
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.5 instruMent cluster and sensors POWER GROUND K20W707C The instrument cluster receives its main power through the 5 A fuse when the ignition switch is set to the ON position. 1) O il pressure warning: The oil pressure warning lamp switch is connected to the ground side of the wiring 0.5RY. It is turned on by controlling electricity supplied to its negative terminal. 2) C oolant temperature gauge: The coolant temperature sensor is connected to the coolant temperature gauge through the wiring 0.5YB. The gauge is operated by controlling the electricity supplied to its negative terminal.
Page 382 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 7) P reheat indicator: The preheat indicator on the instrument cluster is connected to the wiring 0.5LW (preheat indicator output line of the preheat controller) through the connecting wiring (B). The preheat controller controls electricity supplied to the negative terminal of the indicator to turn it on. 8) C harge warning lamp: The charge warning lamp is connected to the output terminal L of the generator through the connecting wiring (C). Therefore, when the generator is not in operation, the ignition switch ON power at the input terminal of the instrument cluster is sent to the ground side through the generator to turn on the charge warning lamp. When the generator is activated to start charging, charging power is sent from the terminal L of the generator. Then, both terminals of the lamp are applied with positive power, making no potential difference. Therefore, the charge warning lamp is turned off when the generator charges normally.
Page 383: Combination Switch And Head Lamp
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.6 coMbination switch and head laMp POWER GROUND K20W708C The combination switch receives power from the terminal ACC of the ignition switch through the wiring 1.25RG and 20 A fuse. 1) H orn: The terminal H, which is located in the left end position among the terminals of the combination switch, is connected to the horn through the wiring 0.85GW to activate the horn when the horn switch is pressed. 2) H igh beam: The terminal No. 2 of the combination switch is connected to the head lamp high beam through the wiring 1.25GL. It is also connected to the high beam indicator on the instrument cluster.
Page 384: Turn Signal Lamp Switch, Hazard Warning Flasher And Flasher Unit
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 4.7 turn signal laMp switch, hazard warning flasher and flasher unit 6015W709C The turn signal lamp switch of the combination switch receives power from the terminal ACC of the ignition switch through a separate 20 A fuse. 1) R ight turn: When setting the turn signal lamp switch to the right turn position, power is supplied to the flasher unit from the terminal R through the wiring 0.85WR. Then the flasher unit changes continuous power to intermittent power supplied to the front combination lamp, rear combination lamp and right turn signal indicator on the instrument cluster to make each lamp flicker. 2) L eft turn: When setting the turn signal lamp switch to the left turn position, power is supplied to the flasher unit from the terminal L through the wiring 0.85WL. Then the flasher unit changes continuous power to intermittent power supplied to the front combination lamp, rear combination lamp and left turn signal indicator on the instrument cluster to make each lamp flicker.
Page 385: Dpf Logger
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 4.8 dpf logger K25W736B When the ignition switch is turned to the ON position, power flows through the wiring 3.0WR to be delivered to the DPF logger through the fuse No. 11 (5 A). If a faulty condition is detected by the differential pressure sensor of the DPF, the corresponding signal is delivered to the instrument cluster through Ⓖ to turn on the DPF warning lamp. 40BW-202010...
Page 386: Service Tips And Components Of Electric System
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5. service tips and coMponents of electric systeM 5.1 service tips 5.1.2 fuse 5.1.1 battery fuse 6015W702A fusible A42W703A link 1. Stop the engine and remove the ignition key. 2. Open the hood and disconnect the negative batter y cable (1) first and then the positive 6015W703A battery cable (2).
Page 387: Electric Wiring
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2 coMponents 5.1.3 electric wiring 5.2.1 ignition switch 1. If any electric part is malfunctioning, check its rops Model electric wiring. 2. Check if the electric wiring is in contact with another part, it is peeled off or its contact is loose.
Page 388: Fusible Link / Slow-Blow Fuse
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.2 fusible link / slow-blow fuse ▶ connector and wiring diagraM rops Model A48W702A cabin Model K20W714A terMinal syMbol iteM ● ● K3CW771A The fusible link is installed on the top of the starter ● ● ① in the left section of the engine compartment. If ●...
Page 389: Fuse Box
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.3 fuse box rops Model cabin Model K3CW772A (1) 30A : For Power (2) 50A : For Cabin The slow-blow fuses (30A, 50A) are installed on the upper left section of the hood hinge in the instrument panel cover. A42W107A F42W147A 1. A fuse is to protect circuits from electric overload. 2. The relay control current is high load current which flows through a circuit.
Page 390 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM cabin Model iteM specification description Fuse 1 Panel Fuse 2 Brake lamp 20 A Fuse 3 Battery charge Fuse 4 Glow/Heat Fuse 5 Fuel pump, Stop solenoid Fuse 6 Spare 20 A Fuse 7 Spare 10 A Fuse 8 Spare Fuse 9 Head lamp 20 A Fuse 10 Turn signal lamp 20 A Fuse 11 Hazard lamp 10 A...
Page 391: Relay 5P
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.4 relay 5p iteM specification description Fuse 1 Panel Fuse 2 Brake lamp 20 A Fuse 3 Battery charge Control unit Fuse 4 10 A DPF [Cabin model] Fuse 5 Fuel pump, Stop solenoid 10 A Fuse 6 Spare 20 A A42W705A Fuse 7 Spare 10 A (1) Safety start relay (PTO) (3) PTO relay Fuse 8 Spare (2) Starter relay...
Page 392: Preheat Relay
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.5 preheat relay ▶ connector and test rops Model CIRCUIT F42W710A 6015W711A terMinal no. resistance (Ω) ∞ ① and ② K20W783A ∞ ③ and ④ Some Ω ② and ③ (continuity present) cabin Model Applying (+) to ③ and (-) to ②...
Page 393: Preheat Controller [Rops Model]
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.6 preheat controller [rops Model] ▶ connector and circuit diagraM F42W711A The preheat controller is installed on the upper right section of the hood hinge assembly (dash panel). Glow controller (plug) It receives a signal from the coolant temperature sensor to adjust the preheating time, turns on the preheat indicator on the instrument cluster, and detects a signal from the generator to turn off the charge warning lamp.
Page 394 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM ▶ contact diagraM F42W713A ▶ operating sequence and characteristics TIME CHART F42W714A WATer Temp. sensor resIsTAnCe (kΩ) iteM tiMe (sec.) reMarks 14.0 ± 3.5 ℃ 19.5 (-30 T1: I ndicator ON time (sec.) 10.0 ± 3.0 ℃ 9.6 (-15 1.2 (+40 4.0 ± 1.5 ℃...
Page 395: Control Unit [Cabin Model]
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.7 control unit [cabin Model] ▶ connector and circuit diagraM K3CW774A The control unit is installed on the upper right section HA0001583A of the dash panel. CONTROL UNIT The control unit controls the pre-heating & post- XXXX . XX . XX heating, PTO power shutdown when the driver leaves the seat and warning alarm operation when the parking brake is not applied.
Page 396 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM ▶ contact diagraM K3CW776A ▶ operating sequence and characteristics TIME CHART K3CW777A WATer Temp. sensor resIsTAnCe (kΩ) iteM tiMe (sec.) reMarks Over 21 (-30 14.0 ± 3.5 ℃ T1: I ndicator ON time (sec.) 10.0 ± 3.0 ℃ 9.5 (-15 0.8 (+40 4.0 ± 1.5 ℃ Over 2.8 (+10 30.0 ± 8.0 ℃...
Page 397: Flasher Unit
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.8 flasher unit rops Model ▶ connector and circuit diagraM F42W715A The flasher unit is installed beside of the preheat controller on the upper right section of the hood hinge assembly . It makes the turn signal lamps blink when the flasher switch is operated.
Page 398 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM cabin Model ▶ connector and circuit diagraM K3CW778A The flasher unit is installed on the upper left side of the dash panel. K3CW779A K3CW780A 40BW-202010...
Page 399: Cruise Controller
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.9 cruise controller ▶ connector and circuit diagraM A42W706A The cruise controller is installed on the right lower section of the hood hinge (dash panel) to control the cruise control relay and cruise control lamp for the cruise control operation. A42W707A KEY S/W Cruise relay Cruise switch Cruise lamp Cruise switch Brake switch Brake (R)
Page 400: Pto Switch
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.10 pto switch rops Model cabin Model F50W705A K3CW782A The PTO switch detects the continuity in the ON- The PTO switch is installed on the right upper side OFF position. of the dash panel. ▶ connector and circuit diagraM ▶ connector AVSS 0.85 S/Q (B) AVSS 0.85 S/Q (Y) Wire Spec.
Page 401: Stop Lamp Switch
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.11 stop laMp switch ▶ circuit diagraM A42W709A The stop lamp switch is installed under the left foot rest. ○ ○ ○ ○ FREE ○ ○ ○ ○ cabin Model F50W705A K3CW785A The stop lamp switch is installed on the right side of the dash panel. ▶ connector K20W730A 40BW-202010...
Page 402: Safety Start Neutral Switch
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.12 safety start neutral switch 5.2.13 starter A42W710A K20W731A The safety start neutral switch is installed on the The starter is installed to the rear left section of the rear section of forward pedal. This switch detects engine. the pedal position and to prevent the engine from starting when the switch is not neutral.
Page 403: Alternator
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.14 alternator 5.2.15 engine oil pressure switch F42W723A F42W724A The alternator is installed in the left front section of The engine oil pressure switch is installed to the the engine and it is integrated with the IC regulator. cylinder block on the right side of the engine. When pressure is built in the engine, the contact of the oil It supplies power to components with high electric pressure switch is connected to send a signal to the load and charges the battery. instrument cluster assembly. When the pressure in the engine drops below 0.5 ± ▶...
Page 404: Coolant Temperature Sensor (Preheating)
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.16 coolant teMperature sensor (preheating) ▶ Measuring circuit Potentionmeter Thermostat unit galvano- meter F42W726A The coolant temperature sensor (preheating) is K20W739A installed to the coolant flange behind the cooling fan. It sends various resistance values according to the coolant temperature to the instrument cluster to display ▶ sensor test the coolant temperature on the coolant gauge. connection iteM status...
Page 405: Coolant Temperature Sensor (Meter)
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.17 coolant teMperature sensor (Meter) 5.2.18 fuel cut-off solenoid F42W727A The coolant temperature sensor (meter) is installed to the outlet of the heater hose in front of the coolant flange to supply information to the preheat controller in order to determine the preheat indicator ON time and preheat relay connection time. K20W744A A48W706A The fuel cut-off solenoid is installed behind the injection pump in the right section of the engine to allow or block fuel entering the engine depending on the position (ON/OFF) of the ignition switch.
Page 406: Fuel Sensor
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.19 fuel sensor rops Model cabin Model K25W712B The fuel sensor is installed to the top of the left fuel tank and consists of the float and variable resistor. The float detects the fuel level and the sensor sends the corresponding resistance value to the fuel gauge on the instrument cluster to display the fuel level. ▶ resistance by float position K3CW788A K3CW787A The fuel sensor is installed to the top of fuel tank on the cabin rear section. ▶ resistance by float position float position (32.5) resistance (Ω)
Page 407: Glow Plug
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.20 glow plug 5.2.21 horn F42W729A F42W730A The horn (1) is installed between the left and right The glow plug is installed to the engine cylinder head head lamps on the front of the hood. to heat the intake air in the pre-combustion chamber in order to facilitate engine starting. The current of the glow plug should be 10 A within 5 seconds after ▶ connector test it is applied with DC 11 V and its temperature should rise to 800° in approx. 4.5 seconds.
Page 408: Combination Switch
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.22 coMbination switch rops Model cabin Model F42W731A K3CW790A The combination switch is installed to the left side of the dashboard for operation of the head lamp high/low beam, turn signal lamps and horn. ▶ connector and wiring diagraM K20W748A head laMp turn signal laMp horn iteM iteM iteM wiring wiring wiring color color color circuit circuit circuit free push...
Page 409: Dpf Logger
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.23 dpf logger rops Model cabin Model F42W732A K3CW791A The DPF logger is installed front upper side of the radiator (battery) in the front section of the engine compartment, and it receives information from various engine sensors to maintain the optimum engine combustion condition for emission control.
Page 410 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM K25W723A wire designation associated function analog inputs DPS Differential Pressure sensor DPS_5V Power of DPS (5Volt) DPS_GND Ground of DPS EGTS Exhaust Gas Temperature Sensor EGTS_GND Ground of EGTS switch inputs (REPROGRAM) Reserved (Logger reprogram switch) driver outputs DPF_LAMP Check lamp of DPF (LED type) (BUZZER) SPARE (CAUTION BUZZER) can coMM (for diagnosis scanner) CAN_HIGH CAN high to SCANNER CAN_LOW CAN low to SCANNER CAN_GND...
Page 411: Differential Pressure Sensor
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.2.24 differential pressure sensor 5.2.25 exhaust gas teMperature sensor F42W733A F42W734A The differential pressure sensor is installed to the The exhaust gas temperature sensor is installed to side of the DPF in the engine compartment. the rear section of the DPF. Exhaust gas discharged from the engine exhaust This sensor measures the temperature of the valve passes through the inlet of the DPF and exhaust gas and supplies this information to the...
Page 412: Instrument Cluster
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.2.26 instruMent cluster rops Model ▶ configuration and perforMance specifications K3CW792A K25W725A 40BW-202010...
Page 413 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ connector K25W726A pin no. naMe reMarks pin no. naMe reMarks TURN (R) SPARE 1 HIGH BEAM BRAKE RELEASE WATER SEPARATOR E/G oil PRESSURE LIFT CHARGE HIGH SPEED GLOW NEUTRAL TURN(L) SPARE 3 SPARE 2 PARKING(+) BATT(+ REGULAR POWER) PARKING(-) IGN(+13.5V) ILLUMINATION GND(-) IGN(+13.5V)
Page 414 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM ▶ circuit K25W727C 40BW-202010...
Page 415 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ perforMance specifications 1. Tachometer PTO RPM PTO 540 rpm → 2,600 rpm Operating range 0 - 3,500 rpm Position (rpm) 1,000 2,000 2,500 2,860 3,000 Indicator characteristics Tolerance (rpm) ± 50 (± 100) (± 100) ± 50 ± 50 A - Frequency (Hz) 163.4 326.8 408.5 467.3 490.2 B - Frequency (Hz) 447.6 537.1 540E rpm PTO 2ND 540rpm Zone...
Page 416 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 4. Temp. gauge Type STEPPER MOTOR Operational voltage DC 12 V Position Indicator Resistance (Ω) 240.5 103.2 34.1 30.5 21.2 characteristics Tolerance (°) (± 3.5) (± 3.5) ± 3.5 (± 3.5) ± 3.5 (± 3.5) Zone 5. Indicator syMbol Upper Turn(L) Turn(R) E/G oil Parking Charge Preheat naMe beam...
Page 417 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model ▶ configuration and perforMance specifications K3CW793A K3CW794A 40BW-202010...
Page 418 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM ▶ circuit & connector K3CW795A 40BW-202010...
Page 419 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ perforMance specifications 1. Tachometer Type STEPPING MOTOR TYPE + ECU CONTROL Rated voltage DC 12V RPM detector E/G 2,700 rpm → 498 Hz PTO rpm PTO 540 rpm → 2,651 rpm Operating range 0 ~ 4,000 rpm Position (rpm) 1,000 2,000 2,500 3,000 Indicator + 50 ± 250 characteristics Tolerance (rpm) (± 100) ± 100 -150 Zone 2. Hourmeter Type QUARTZ (LCD type) Rated voltage FREE VOLTAGE (12V) Operating voltage range...
Page 420 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 3. Fuel gauge Type STEPPING MOTOR TYPE + ECU CONTROL / LEFT -- RIGHT Rated voltage DC 12V Position Indicator Resistance (Ω) (32.5) characteristics Tolerance (°) ± 3.75 ± 3.75 Zone 4. Temp. gauge Type STEPPING MOTOR TYPE + ECU CONTROL / LEFT -- RIGHT Rated voltage DC 12V Temperature (°C) (70 ~ 107) Indicator Resistance (Ω) (103.2 ~ 38) 240.5 30.5 characteristics Tolerance (°) ± 3.75 (± 3.75) ± 3.75 Zone 5. Indicator...
Page 421: Lamp Bulb Replacement
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.3 laMp bulb replaceMent 5.3.1 head laMp F42W735A 6015W7D4A 1. Pull the cap (1) out to disconnect it. 3. Bulb specification: HS1 12 V 35 W/35 W F42W736A F42W737A 2. Loosen the screw (2) and release the spring holder (3). Then, remove the socket with bulb. 40BW-202010...
Page 422: Front Turn Signal Lamp [Rops Model]
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.3.2 front turn signal laMp [rops Model] F42W738A F42W739A 2. Remove the bulb (2) by pressing and turning it clockwise. F42W740A 2. Replace it with a new one. Bulb specification: 12 V 21 W/5 W K20W791B 1. Unscrew the front and rear lens mounting screws (1). 40BW-202010...
Page 423: Rear Combination Lamp [Cabin Model]
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.3.3 rear coMbination laMp [cabin Model] B40W601A K3CW7A03A 1. Unscrew the lens mounting screws (1) of the front combination lamp and pull the lens (2) to remove it. K3CW7A04A 3. Replace the bulb with a new one. Bulb specification: R ight - 12 V 27 W K3CW7A02A Left - 12 V 8 W 2. Remove the bulb (1), (2) by pressing and turning it. 40BW-202010...
Page 424: Rear Combination Lamp [Rops Model]
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.3.4 rear coMbination laMp [rops Model] F42W741A F42W743A F42W742A F42W744A 1. Unscrew the mounting nuts (1) of the rear 2. Press the each socket assembly (2) and turn it combination lamp in the fender. counterclockwise to remove. 40BW-202010...
Page 425: Rear Combination Lamp [Cabin Model]
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.3.4 rear coMbination laMp [cabin Model] F42W745A K3CW7A05A F42W746A K3CW7A06A 1. Unscrew the lamp cover mounting nuts (1) and bolts (2) to remove the lamp cover (3). F42W747A 3. Replace the bulb with a new one. Bulb specification: Ⓐ Left - 12 V 27 W (turn signal lamp) Ⓑ Middle - 12 V 8 W (Backup/Work lamp) Ⓒ Right - 12 V 21 W/5 W (brake/tail lamp) 40BW-202010...
Page 426 4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM K3CW7A07A K3CW7A10A 4. Unscrew the grommet assembly (1) and remove the bulb (2). K3CW7A08A 2. Unscrew the grommet assembly (1) counter- clockwise to remove it and remove the bulb (2). K3CW7A11A 5. Replace the bulb with a new one. Bulb specification: 1 2 V 21 W / 5 W K3CW7A09A 3. Replace the bulb with a new one. Bulb specification: 1 2 V 21 W 40BW-202010...
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Page 428: Wiring Diagram
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.4 wiring diagraM rops Model 5.4.1 Main wiring diagraM REAR COMBINATION LAMP(L) DPF CONTROLLER IMPLEMENT CONNECTOR PTO ENGAGEMENT S/W INSTRUMENT PANEL B INSTRUMENT PANEL A DIAGNOSTIC DIDOE FUSE BOX (PTO) PTO VALVE START 1. GND SAFETY REAR COMBINATION LAMP((R) (PTO)
Page 429: Bonnet Wiring Diagram (Wiring G)
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.4.2 bonnet wiring diagraM (wiring g) HEAD LAMP(R) WIRING A HORN HEAD LAMP(L) F42W751A F42W751A 40BW-202010...
Page 430: Main Wiring Diagram (Wiring A)
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM cabin Model 5.4.3 Main wiring diagraM (wiring a) K3CW7A13A 40BW-202010...
Page 431 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR color froM froM color froM froM color froM froM Slowblow fuse Fuse box Glow relay (Glow) Wiring harness E1 Instrument panel B Power Joint from B10 Slowblow fuse Joint from F04 Control unit Alternator P terminal Instrument panel A B10A F04A Joint from B10 Fusible link (Glow) Joint from F04 Relay (Safety start) B10B F04B Slowblow fuse KEY switch Joint from F04 DPF controller PTO selection F04C Control unit switch...
Page 432: Fender Wiring Diagram (Wiring C)
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.4.4 fender wiring diagraM (wiring c) color froM froM Main wiring harness 1 Implement connector Joint from 37 Combination lamp (R) Joint from 37 Turn signal lamp (R) Main wiring harness 1 Implement connector Joint from 38 Combination lamp (L) Joint from 38 Turn signal lamp (L) Main wiring harness 1 Implement connector Joint from 41 Tail lamp, Stop lamp (L) Joint from 41 Tail lamp, Stop lamp (R) Main wiring harness 2 Cabin wiring harness Main wiring harness 2 Cabin wiring harness Main wiring harness 2 Cabin wiring harness Main wiring harness 1 Implement connector Main wiring harness 1 Cabin wiring harness...
Page 433: Bonnet Wiring Diagram (Wiring G)
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.4.5 bonnet wiring diagraM (wiring g) color froM froM color froM froM Wiring harness A LED (R) Joint from T30 Head lamp (L) T30A Joint from F06 LED (L) Wiring harness A Head lamp (R) F06A Wiring harness A Joint from 00 Horn Horn Wiring harness A Head lamp (R) Joint from 00 Head lamp (L) Joint from T20 Head lamp (L) Joint from 00 LED (R) T20A Wiring harness A Head lamp (R)
Page 434: Cabin Wiring Diagram
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 5.4.6 cabin wiring diagraM color froM froM Audio Relay SET Joint from 5 Relay SET Joint from 5 Room lamp Switch SET Relay SET Wiper (RR) Relay SET Work lamp (RR, RH) Work lamp (RR, LH) Joint from 9 Relay SET Work lamp (FRT, RH) Work lamp (FRT, LH) Joint from 11 Relay SET Switch SET Relay SET Switch SET Relay SET Wiper (FRT)
Page 435: Washer Tank Wiring Diagram
CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR 5.4.7 washer tank wiring diagraM color froM froM Cabin wiring harness Washer tank (FRT) Washer tank (RR) Cabin wiring harness Washer tank (FRT) Cabin wiring harness Washer tank (RR) Washer tank (RR) Wiper motor (RR) Washer tank (FRT) Wiper motor (FRT) K3CW7A20A 40BW-202010...
Page 436: Sectional View For Major Components
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 6. sectional view for Major coMponents 6.1 battery rops Model F42W752A coMponents (1) Battery stop bracket (4) Hex flange nut (7) DPF logger (2) Stop rod (5) Bracket(DPF logger) (8) Screw (3) Washer (6) Hex flange bolt 40BW-202010...
Page 437 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model K3CW7A21A coMponents (1) Battery stop bracket (3) Washer (5) DPF logger (2) Stop rod (4) Hex flange nut (6) Screw 40BW-202010...
Page 438: Switch
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 6.2 switch rops Model 24 24 A42W714A coMponents (1) Cap (10) Column cover (19) Glow relay (2) Meter cover (11) Combination switch (20) Controller (3) Meter cover ass'y (12) Switch, cruise (21) Flasher unit (4) Meter (13) Front wheel s/w (22) Controller (5) Screw (14) Start switch ass'y (23) Hex flange bolt (6) Dashboard R (15) Emergency switch (24) PTO connect switch (25) Screw (7) Dashboard L (16) Relay (8) Bolt (17) Hex bolt(+) (9) Urethane (18) Hex flange bolt 40BW-202010...
Page 439 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model K3CW7A22A coMponents (1) Panel ass'y, meter (10) Combination switch (19) Plate (2) Screw, C/R pan/SP (11) Plug (20) Stop lamp switch (3) Label, PTO (12) Cruise switch (21) Washer ass’y hex bolt (4) Switch ass'y , alternator (13) Dash panel ass'y (22) Relay (5) Hazard switch (14) Case (23) Buzzer (6) Label, LH control (15) Washer ass’y hex bolt (24) Control unit (7) Label, RH control (16) Washer ass’y hex bolt (25) Glow Relay (8) Switch set, rotary (17) Safety switch, clutch (26) PTO connect switch (9) Switch ass'y (18) Flasher set (27) Screw 40BW-202010...
Page 440: Fender
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 6.3 fender rops Model F42W754A coMponents (1) Fender R ass’y (5) Hex flange bolt (9) Direction lamp ass’y (2) Fender L ass’y (6) Fender support bracket (10) Combination lamp(R) (3) Fender grip (7) Hex flange nut (11) Combination lamp(L) (4) Hex flange bolt (8) Hex flange nut 40BW-202010...
Page 441 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model K3CW7A24A coMponents (1) Fender comp. LH/sub (6) Screw (11) Bolt. hex/spl (2) Lamp, direction (7) Cover, LH / lamp (12) Washer (3) Bulb, 12V 21W (8) Bolt. hex/spl (13) Spring washer (4) Lamp, stop (9) Fender comp. RH/sub (14) Bolt. hex/spl (5) Plate, lamp (10) Cover, RH / lamp (15) Cap, switch 40BW-202010...
Page 442: Fuel Tank
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 6.4 fuel tank rops Model K3CW7A25A coMponents (1) Fuel, tank ass’y (10) Hex flange bolt (19) Hex flange bolt (2) Cap, fuel tank ass’y (11) Support(R), fuel tank (20) Hex flange bolt (3) Strainer, fuel (12) Hex flange bolt (21) Hose (4) Hose (13) Washer (22) Back mirror stay (5) Hose clip (14) Hex flange nut (23) Spring washer (6) Hose (15) Front band ass’y (24) Hex nut (7) Fuel sensor (16) Rear band ass’y (25) Back mirror (8) Hex nut (17) Feed pump ass’y (9) Support(F), fuel tank (18) Stay(pump) 40BW-202010...
Page 443 CHAPTER 6 ELECTRIC SYSTEM 4025H/4035H/4035CH TRACTOR cabin Model K3CW7A26A coMponents (1) Fuel tank ass’y (9) Bolt, hex/sp (17) Hose clamp (2) Fuel tank (10) Hose clips (18) Stay(pump) (3) Strainer, fuel (11) Hose, connection (19) Hex flange bolt (4) Cap, fuel tank ass’y (12) Adapter (20) Feed pump ass’y (5) Packing (13) Hose clamp (21) Hex flange bolt (6) Fuel sensor (14) Hose (22) Hose (7) Hex bolt (15) Hose clips (22) Hose (8) Rubber, fuel tank (16) Hose, drain/2210 40BW-202010...
Page 444: Troubleshooting
4025H/4035H/4035CH TRACTOR CHAPTER 6 ELECTRIC SYSTEM 7. troubleshooting inspection iteM syMptoM The engine cannot be started ● ● ● (start motor operated) The engine cannot be started ● ● ● ● ● ● (start motor not operated) The engine can be started without ● depressing the clutch pedal. The engine cannot be ● stopped. The preheat indicator does not ● ●...
Page 445 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................
Page 446 CHAPTER 7 CABIN AND HVAC SYSTEM (CABIN MoDEl oNlY) TABlE oF CoNTENTS 1. Cabin ............7-2 2. HVaC system ........7-27 2.1 Specifications ........7-27 Roof components ........7-2 2.2 HVAC system flow diagram ....7-28 Major component inspection ....7-3 1.2.1 Work lamp / Wiper switch box ..7-3 HVAC system inspection .....
Page 447: Cabin
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1. Cabin 1.1 Roof Components K3CW801A (1) A/C control switch (4) Front vent (7) Interior lamp (2) Speaker (5) Rear vent (8) Work lamp/wiper switch box (3) Side vent (6) Audio system 40BW-202010...
Page 448: Major Component Inspection
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.2 majoR Component inspeCtion 1.2.1 WoRk lamp / WipeR sWitCH box ▶ ConneCtoR desCRiption K3CW802A DC 12V The front and rear wiper operation switches are installed on the middle side of the ceiling in the cabin. FRT WIPER RELAY COIL OUT RR WIPER RELAY COIL OUT FRT WORK LAMP RELAY COIL OUT...
Page 449: Wiper Motor
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.2.2 WipeR motoR ▶ ConneCtoR test (fRont WipeR motoR) ConneCtoR a 6015W7B3A ConneCtoR b K3CW805A K3CW807A ConneCtion item status Result ㅡ 0 Ω Ignition switch 12 V K3CW806A 「ON」 The wiper motors are installed in the front and Ignition switch rear sections of the cabin.
Page 450: Washer Pump
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.2.3 WasHeR pump ▶ ConneCtoR test (ReaR WipeR motoR) ConneCtoR a 6015W7B3A ConneCtoR b K3CW809A The washer pump is attached to the washer fluid K3CW808A tank in the rear right pillar section of the outer cabin. ConneCtion ▶...
Page 451: A/C Controller Switch
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.2.4 a/C ContRolleR sWitCH The A/C controller switch box is installed on the middle right side of the ceiling in the cabin. K3CW812A ▶ ConneCtoR name name name HIGH TAIL + MHIGH A/CON POWER BLOW BASE...
Page 452: Sectional View For Major Components
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.3 seCtional VieW foR majoR Components 1.3.1 Cabin fRame ass'y K3CW814A Components (1) Cabin frame ass’y (9) Hex nut (17) Hex bolt (2) Mounting bracket, R(LH) (10) Mounting bracket, F(LH) (18) Support foot rest ass’y (19) Hex flange bolt (3) Mounting bracket, R(RH) (11) Mounting bracket, F(RH)
Page 453: Pillar Cover Ass'y
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.3.2 pillaR CoVeR ass’y K3CW815A Components (1) Seal, seat (7) Nut, washer tank (13) Bracket, number plate (2) Cover, B pillar/RH (8) Cover, fuel tank (14) Lamp, number plate (3) Cover, B pillar/LH (9) Washer ass’y hex bolt (15) Spring washer (4) Rivet set, ivory...
Page 454: Front Window Ass'y
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.3.3 fRont WindoW ass’y K3CW816A Components (1) Glass, FR/UPR (5) Glass, FR/LOW/RH (9) Washer ass’y hex bolt (2) Insulator, glass/UPR (6) Insulator, FR/LOW (10) Insulator, frame dash (11) Plate, fix insulator (3) Nut comp, glass (7) Glass, FR/LOW/LH (4) Grommet, 13x17x02 (8) Insulator, FR/LOW...
Page 455: Door Ass'y
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.3.4 dooR ass’y K3CW817A Components (2) Hinge comp, UPR/LH/door (17-1) Lock ass'y, LH/door (32) Hinge comp, UPR/LH/door (47-2) Striker (3) Hinge comp, UPR/RH/door (17-2) Striker (33) Hinge comp, UPR/RH/door (47-3) Guard (4) Gasket, door hinge (17-3) Guard (34) Gasket, door hinge (48) Grommet, 13x17x02...
Page 456: Rear Windows Ass'y
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.3.5 ReaR WindoWs ass’y K3CW818A Components (1) Hinge, rear glass/M6 (10) Handle, glass/rear (19) Blade, 12 (2) Bracket comp, RR/damper (11) Bolt comp, glass/M8L (20) Pin, RR/hinge (3) Washer, 7x36x3 (12) Washer(08x22x02) (21) Snap ring(E type) (4) Grommet, 13x17x02 (13) Nut, cap...
Page 457: Side Mirror Ass'y
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.3.6 side miRRoR ass’y K3CW819A Components (1) Mirror ass'y (6) Hex nut (11) Cap, rubber 20 (2) Stay, LH mirror (7) Hex bolt, cap (12) Switch, door (3) Stay, RH mirror (8) Wiper arm&blade ass'y (13) Screw (4) Plain washer (9) Arm, wiper...
Page 458: Roof Ass'y
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.3.7 Roof ass’y K3CW820A Components (5) Cover, air filter (1) Roof ass'y (9) LED bar (2) Insulator, roof (6) Bolt, grip(M6) (10) Bolt, hex/spl (3) Filter, air/main (7) Antenna (4) Filter, aircon/mesh (8) Screw 40BW-202010...
Page 459: Ceiling Ass'y
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.3.8 Ceiling ass’y K3CW821A Components (1) Ceiling (6) Switch ass'y, wiper/lamp (11) Air conditioner controller (2) Grill cover ass'y, air con (7) Audio (12) Tapping screw (3) Lamp, indoor (8) Screw (13) Rivet set (4) Washer ass’y hex bolt (9) Speaker ass'y (14) Cap, rubber 20...
Page 460: Fender Cover
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.3.9 fendeR CoVeR K3CW822A Components (1) Cover, LH/fender (3) Rivet set (5) Washer ass’y hex bolt (2) Cover, RH/fender (4) Holder, cup 40BW-202010...
Page 461: Component Disassembly And Assembly
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.4 Component disassembly and assembly 1.4.1 Cabin RemoVal 1.4.2 Roof RemoVal 1. Park the tractor on safe and level ground, stop the engine and apply the parking brake. 2. Open the hood and disconnect the negative battery cable.
Page 462: Seat Removal
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.4.3 seat RemoVal K3CW731A K3CW732A 2. Disconnect the antenna connector (1) and remove 1. Remove the seat (1) and seat support (2). the roof (2) by lifting it. 40BW-202010...
Page 463: Fender Cover (Rh) Removal
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.4.4 fendeR CoVeR (RH) RemoVal K3CW733A K3CW735A 1. Remove the pillar cover (RH)(1). K3CW736A 3. Remove the fender cover bracket (1) and joystick grip (2). Then, remove the fender cover (RH)(3). K3CW734A 2.
Page 464: Fender Cover (Lh) Removal
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.4.5 fendeR CoVeR (lH) RemoVal 1.4.6 fRont WipeR motoR disassembly K3CW737A K3CW740A 1. Remove the pillar cover (LH)(1). K3CW741A 1. Open the wiper arm cap (1) from the front of the K3CW738A cabin and unscrew the mounting nut to remove the wiper arm (2).
Page 465: Rear Wiper Motor Disassembly
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 1.4.7 ReaR WipeR motoR disassembly K3CW743A K3CW744A K3CW745A 3. Disconnect the front wiper motor connector (1) in the cabin and unscrew the wiper motor mounting bolts (2) to remove the front wiper motor (3). K3CW746A 1.
Page 466: Other Component Removal
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.4.8 otHeR Component RemoVal a/C ContRol sWitCH K3CW748A 3. Disconnect the rear wiper motor connector (1) K3CW749A and unscrew the motor mounting bolt (2) to remove the rear wiper motor (3). K3CW750A 1.
Page 467 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR CaR steReo fuel tank K3CW751A K3CW754A 1. Remove the fuel tank cover (1). K3CW752A 1. Remove the car stereo cover (1) and unscrew the mounting screws (2)(4EA). K3CW755A 2. Disconnect the fuel sender connector (1). K3CW753A 2.
Page 468 4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM inteRioR lamp K3CW756A K3CW758A 1. Separate the interior lamp by pushing its side edge with a f lat tool, such as a f lat-bladed screwdriver, and pulling it out. K3CW757A 3. Unscrew the fuel tank mounting bolts (1) to remove the fuel tank (2) from the back of the cabin.
Page 469 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR aiR filteR WipeR sWitCH K3CW761A K3CW763A 1. Unscrew the mounting screws (1) for the air filter assembly from the left and right side of the cabin roof to remove the filter assembly (2). K3CW764A 1. Pull out the wiper switch assembly from the ceiling and disconnect the wiring connector (2) from the wiper switch (1) to remove the wiper switch assembly.
Page 470: Troubleshooting
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 1.5 tRoublesHooting symptom inspeCtion item ● ● Controller ● ● Evaporator Condenser ● (Receiver Drier) ● Compressor Fuse F13 ● [10 A] Fuse F13 ● [10 A] ● Relay Compressor ● Relay ●...
Page 471 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR symptom inspeCtion item ● ● Cabin work lamp [front] ● Cabin work lamp [rear] Work lamp switch [front] Work lamp switch [rear] ● Work lamp relay [front] ● Work lamp relay [rear] ●...
Page 472: Hvac System
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2. HVaC system 2.1 speCifiCations item speCifiCations RemaRks Cooling capacity 3,120 - 5% kcal/h Air flow 400 m /h (at 12 V) Refrigerant R-134a Refrigerant capacity 700 g (1.54 lbs) Heating capacity 4,800 - 5% kcal/h Heater Air flow 400 m...
Page 473: Hvac System Flow Diagram
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 2.2 HVaC system floW diagRam ENGINE PART ENGINE PART K3CW827A (1) A/C control switch (Line A) A/C hose (high pressure) (5) Compressor (2) Evaporator (Line B) A/C hose (low pressure) (6) Condenser (3) Expansion valve (Line C) heater hose (low temperature) (7) Receive drier...
Page 474: Hvac System Inspection
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.3 HVaC system inspeCtion 2.3.1 RefRigeRant gauge test 1. Stop the engine, remove the ignition key and noRmal state apply the parking brake. 2. Plac e all the shif t lever s in the neutral or disengagement position.
Page 475 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR exCessiVe RefRigeRant, aiR in a/C system unable to opeRate pRopeRly 6015W871A 6015W872A (1) Low pressure (red) (2) High pressure (blue) (1) Low pressure (red) (2) High pressure (blue) 1. Symptom: Blowing air is not cool. 1.
Page 476 4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM defeCtiVe expansion ValVe abnoRmal CompRession 6015W873A 6015W848A (1) Low pressure (red) (2) High pressure (blue) (1) Low pressure (red) (2) High pressure (blue) 1. Symptom: Blowing air is not cool. 1. Symptom: Blowing air is not cool. 2.
Page 477 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR WateR in system abnoRmal RefRigeRant CiRCulation 6015W849A 6015W850A (1) Low pressure (red) (2) High pressure (blue) (1) Low pressure (red) (2) High pressure (blue) 1. Symptom: Blowing air is not cool continuously. 1.
Page 478: Refrigerant Maintenance
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.3.2 RefRigeRant maintenanCe RefRigeRant CiRCulation ▶ VaCuum notes if the compressor can be operated, operate the  HVAC system for 10 minutes with the engine running at 2,000 rpm. set the temperature con- trol dial to the lowest temperature position and the blower dial to the max.
Page 479 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ CHaRging K3CW828A (1) Low-pressure valve gauge (2) High-pressure valve gauge (3) Refrigerant tank Caution Vacuum the system before adding refrigerant.  • Connect the manifold gauge to the service valve of the A/C hose pipe. • Insert the middle hose of the manifold into the refrigerant tank.
Page 480: Sectional View For Major Components
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.4 seCtional VieW foR majoR Components 2.4.1 a/C ass’y, Cabin K3CW823A Components (1) HVAC (6) Hose A, heater (11) Hose, drain (2) Washer ass’y hex bolt (7) Hose B, heater (12) Hose clamp (3) Hose, high pressure (8) Hose clamp (13) Hose, drain...
Page 481: A/C Duct Ass'y
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 2.4.2 a/C duCt ass’y K3CW824A Components (1) Duct, front (3) Duct, right (5) Washer ass’y hex bolt (2) Duct, left (4) Tapping screw 40BW-202010...
Page 482: Engine Sub Assembly (1)
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.4.3 engine sub assembly (1) K3CW825A Components (1) Compressor (5) Condenser hose, DIS (9) Condenser (2) Hex flange bolt (6) Hex flange bolt (10) Washer ass’y hex bolt (3) Hex flange nut (7) Compressor hose, SUC (11) Condenser hose, LIQ (4) Hex flange bolt (12) Hex flange bolt (7) Compressor hose, SUC (8) Hex flange bolt...
Page 483: Engine Sub Assembly (2)
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 2.4.4 engine sub assembly (2) K3CW826A Components (1) Tension arm (7) Tension shaft (12) V-belt (2) Dry bush (8) Plain washer (13) Heater hose, A (3) Ball bearing (9) Hex bolt, w/washer (13) Heater hose, A (10) Hex nut, fix (4) Snap ring...
Page 484: Component Disassembly And Assembly
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.5 Component disassembly and assembly 2.5.1 aiR ConditioneR (HVaC) disassembly K3CW728A K3CW731A 2. Lift up the back of the roof to disconnect the antenna connector (1) and remove the roof (2). B40W701A K3CW714A 3.
Page 485 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR K3CW716A K3CW718A 5. Disconnect the cabin wiring harness connector (1). 8. Remove the air vents (1) from the cabin ceiling. K3CW717A K3CW719A 6. Remove the front ducts (1). (1 screw for each duct) K3CW720A 9.
Page 486: Hvac Assembly Components Disassembly
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.5.2 HVaC assembly Components disassembly K3CW721A K3CW723A K3CW722A K3CW724A 1. Unscrew the A/C (HVAC) assembly cover mounting screw (1)(22EA) to separate the upper and lower covers. K3CW701A 2. Place the blower fan upside down and unscrew the blower fan motor mounting screws (1) to remove the motor (2).
Page 487 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR K3CW725A K3CW727A K3CW726A K3CW702A 3. Remove the evaporator (1) from its cover. 4. Remove the heater (1) from the evaporator cover. 40BW-202010...
Page 488: Compressor Disassembly
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.5.3 CompRessoR disassembly 2.5.4 CondenseR disassembly 1. Open the hood. 1. Open the hood. 2. Disconnect the negative (-) battery cable and 2. Disconnect the negative (-) battery cable and drain refrigerant. drain refrigerant.
Page 489 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR K3CW709A K3CW710A 6. Disconnect the high-pressure pipe (1) from the condenser to remove the condenser (2). Caution When cleaning the condenser, use com-  pressed air or rinse it with water. keep the pressure of compressed air below 210 kpa (2 kgf/cm , 90 psi) and wear protective goggles...
Page 490: Troubleshooting
4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM 2.6 tRoublesHooting 2.6.1 geneRal infoRmation Cause of pRoblem symptom solution When the A/C belt is loose or old, The A/C belt is loose, causing When the A/C belt is loose or old, adjust it produces a high-pitched creaking abnormal noise.
Page 491 CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR ▶ tHe CompRessoR Rotates but Cool aiR is not supplied pRoblems Cause oR symptom solution Run the A/C for 5 to 10 minutes. Then, touch the Excessive or insufficient high-pressure and low-pressure pipes and check refrigerant the refrigerant amount.
Page 492 4025H/4035H/4035CH TRACTOR CHAPTER 7 CABIN AND HVAC SYSTEM ▶ tHe fan motoR opeRates pRopeRly but aiR bloWs pooRly Cause of pRoblem inspeCtion solution The inlet of the evaporator is Check the evaporator for Remove any blocking material. blocked. contamination. Air leaks. Check the seal of the A/C case.
Page 493: Heating Problem
CHAPTER 7 CABIN AND HVAC SYSTEM 4025H/4035H/4035CH TRACTOR 2.6.3 Heating pRoblem ▶ tHe fan motoR opeRates pRopeRly but aiR bloWs pooRly Cause of pRoblem inspeCtion solution Check the duct for damage or Clogged air duct Correct deflection. Check the duct connection. Air leak from duct Correct Check the duct seal or condition.
Page 494 CHAPTER 8 INDEX TABLE OF CONTENTS INDEX ..............8-2...
Page 495 CHAPTER 8 INDEX 4025H/4035H/4035CH TRACTOR NUMBER Checking coolant amount ........1-40 4WD ..............3-10 Checking engine oil ..........1-40 4WD shaft disassembly ........3-39 Checking fuel line ..........1-47 Checking instrument cluster signals ....1-42 A/C controller switch ..........7-6 Checking lamps ............
Page 496 4025H/4035H/4035CH TRACTOR CHAPTER 8 INDEX Cylinder block ............2-80 Exhaust manifold ..........2-62 Cylinder head ............2-66 Exhaust manifold ..........2-91 Cylinder head ............2-70 Exterior and names of parts ........2-3 Cylinder head ............2-87 Exterior dimension ..........5-43 Cylinder Head .............
Page 497 CHAPTER 8 INDEX 4025H/4035H/4035CH TRACTOR Fuse..............6-23 Hydraulic filter ............5-40 Fuse and relay ............. 1-51 Hydraulic filter and strainer ........5-40 Fuse box ............... 6-26 Hydraulic pump............5-7 Fusible link / Slow-blow fuse ........ 6-25 Hydraulic pump............. 5-20 Hydraulic pump disassembly ......5-102 Gear case .............
Page 498 4025H/4035H/4035CH TRACTOR CHAPTER 8 INDEX Major electric system specifications ....... 6-3 Power transfer ............3-11 Major specifications ..........1-34 Power transfer ............4-3 Mounting flange ............ 2-67 Preheat ..............6-15 Mounting flange ............ 2-86 Preheat controller [ROPS modeL] ......6-30 Preheat relay ............6-29 Name of each part ..........
Page 499 CHAPTER 8 INDEX 4025H/4035H/4035CH TRACTOR RTC(Real Time Check) power supply (Warranty Front drive shaft ..........4-12 for 5 years) ............2-29 Sectional view for major components....5-60 Running temperature range........2-30 Steering column ..........5-60 P.S.T cylinder ..........5-61 Safety during service ..........1-11 P.S.T pipe ............
Page 500 4025H/4035H/4035CH TRACTOR CHAPTER 8 INDEX Stop valve (also as slow return valve) ....5-39 We guarantee DPF data logger for 5 years after shipment ............2-30 Structure and operating principle......3-5 Wiper motor ............7-4 Structure and operation ........5-10 Wiring diagram .............
Page 501 MEMO ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................BAD BOY TRACTORS Co. Ltd............................................................................................................................................................................................................................................................................................................................................................................................

Bad Boy 4025H Service Manual

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Chapter 6 Electric System

Chapter 7 Cabin and Hvac System

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