Dong Feng ZB25 Operator'S Manual Download

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Factory Direct Tractors

Technical Maintenance

7.1 Oil and lubrication

7.1.1 Diesel oil and lubricants

7.1.2 Lubrication points

Oil inlet:

Engine: Top of the tappet cover, and Injector pump.

(please refer to the Engine operation manual)

One on transmission and rear axle housing - top cover

One on Front axle - left & right sides of the housing

7.1.3 Grease nipples:

Water pump bearings (not all models)

Two on the turnbuckles of the left & right levelling

assemblies

One on upper link

Two on front & rear joint of the steering ram

Two on left & right joint of the steering tie rod

Two on left & right front wheel hubs

Two on left & right steering arms

Two on rear pedestal (four wheeled drive only)

Two on left & right steering drag link (four wheel

drive only)

One on clutch operating shaft

One on brake operating shaft

One on the front axle pivot pin

7.1.4 Oil level inspection points:

Engine dipstick

Transmission cover dipstick

Front wheel drive axle dipstick. On the left hand

side.

Injector pump dip stick or level –overflow tube.

6.1.5 Oil drain plugs on:

Bottom of the engine sump

Lower-left side of the gearbox

Lower-rear side of the rear axle housing

Bottom of front wheel drive housing (four wheel

drive only) and final drives

Bottom of transfer case housing

7.2 Maintenance schedule

In order to keep your Tractor in good serviceable

condition and prolong the life of the machine
the following service guide must be followed.
Dongfeng recommends using genuine oil and

filters for all services to ensure all components

of the machine are protected and operate within

manufactures specifications. The use of non

genuine parts including filters and oil’s will void

your warranty. Please fill out the Maintenance

Service Record at the rear of this manual to keep

track of the machine’s service history. Please keep

records of all oils and filters purchased for each

and every service.

Refer to Chapter 5 Mechanical Adjustment and

Chapter 7 Maintenance Checks for all instructions

and specifications on carrying out tractor

maintenance. If any information is not supplied, or

your machine differs from the one in the manual
please contact your nearest dealer for information
and guidance.

7.2.1 Daily checks

1. Check engine oil level and fill as required.

2. Check front diff and final drive oil level.

3. Inspect radiator core for blockage, blow out and

reinspect, clean as required.

4. Check air filter and dust bowl for contaminant

Position

Lubrication

Fuel tank

Diesel

Clutch release bearing Other grease nipples

Lithium-based grease GP grease

Gearbox, rear axle, front axle, hydraulic

system

East Wind Multi Farm 1, or Valvoline Farmplus

Universal

Engine sump

East Wind Multi Farm 1, or Valvoline Farmplus

Universal

7-1

7. Technical Maintenance

Summary of Contents for ZB25

Page 1: ...Factory Direct Tractors Operator s Manual ZB25 ZB35 ZB45 ...

Page 2: ...Factory Direct Tractors ...

Page 3: ... PTO A number of implements can be fitted to your tractor enabling you to take on a wide variety of tasks around your farm Hanmey implements are ideally suited to your tractor Find out more at hanmey com au Dongfeng Tractors are subject to continuous improvement and change without notice Therefore there may be some difference between the manual and illustrated parts catalogue and your actual tract...

Page 4: ...G INSTRUCTIONS 5 1 Pre start checks 5 2 Starting and stopping 5 3 Driving 5 4 Check during driving 5 5 Operating differential lock 5 6 Control and usage of tractor s working devices 6 MECHANICAL ADJUSTMENT 6 1 Engine 6 2 Clutch 6 3 Front wheel 4WD 6 4 Power steering 6 5 Brakes 6 6 Electrical system 6 7 Rear axle 6 8 Final drive system 7 TECHNICAL MAINTENANCE 7 1 Oils and lubrication 7 2 Maintenanc...

Page 5: ... 1 Maintenance 11 2 Storing at the end of season 11 3 At the start of a season 11 4 General torque specification 12 LOADER TROUBLE SHOOTING 13 LOADER PARTS 13 1 Bucket Assembly 13 2 Tool carrier assembly 13 3 Arm assembly 13 4 Mounting kit assembly 13 5 Hydraulic system assembly Appendix 1 Wiring Diagram Appendix 2 Wiring Diagram with Combination Meter Appendix 3 Steering Cylinder Diagram Appendix...

Page 6: ...l diesel Gross power 12hr rated power kW hp 18 4 25 25 8 35 36 8 45 Cylinders 3 3 4 Bore and stroke 85X95 95X105 95X100 Compression 22 0 1 0 22 0 1 0 18 0 1 0 Displacement 1 532L 2 23L 2 83L Speed rated at 2350 rpm 2400 rpm 2400 rpm Gearbox Sliding Gear 4 1 X2 Gears 8 x Forward 2 x Reverse Brake type Sealed shoe brake Dry multi disc Dry multi disc Clutch type Dry type single stage Dry type dual st...

Page 7: ...d at 45 dumping angle 718 680 700 G Bucket dumping angle 65º 71º 72º H Bucket rollback angle 30º 35º 35º L Depth of bucket to back of inner shell mm 620 620 620 M Height of bucket mm 452 452 452 N Depth of bucket to pivot pin mm 762 762 762 Maximum opening angle of clamping bucket 86 2 86 2 86 2 Bucket cubage m3 0 26 0 27 0 3 Carrying capacity kg 350 400 500 Mass of loader attachment kg 480 520 52...

Page 8: ... signs in good condition Replace missing or damaged safety signs Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your Dongfeng dealer Learn how to operate the machine and how to use the controls properly Do not let anyone operate without instruction Keep your machine in proper working condition Unauthorized modification...

Page 9: ... Protective Structure ROPS The ROPS A should be kept in the up or extended position as pictured with lock out pins C retained with R clips B except when it is necessary to fold it for low clearance access A ROPS B zzz C Lock out Pin Handle chemicals safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with Dongfeng equipment include such items...

Page 10: ...n gear with the engine stopped will NOT prevent the tractor from moving Be sure everyone is clear of the tractor and attached equipment before starting the engine Never try to get on or off a moving tractor When the tractor is left unattended place the transmission in NEUTRAL apply the park brake lower implements to the ground stop the engine and remove the key 1 Read Operator s manual before oper...

Page 11: ...el drive greatly increases traction it DOES NOT increase the stability of the tractor With mechanical front wheel drive engaged the tractor can climb steeper slopes than a two wheel drive tractor can negotiate but it does not become more stable Use extra caution when negotiating steep slopes in four wheel drive Danger of overturn increases greatly with a narrow wheel track at high speed and on slo...

Page 12: ... jolted and thrown off and slipping and falling of the machine Riders also obstruct the operator s view resulting in the tractor being operated in an unsafe manner Getting out of sticky situations safely Attempting to free a stuck machine can involve safety hazards such as the tow tractor tipping backwards and overturning The tow chain or tow bar can also fail and recoil from its stretched conditi...

Page 13: ... injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Park tractor safely To park tractor safely Disengage the PTO Lower the equipment to the ground Put the gear shift lever into neutral Apply the hand brake STOP the engine Remove the key Before you leave the operator ...

Page 14: ...posure to loud noise can cause hearing impairment or loss Wear a suitable hearing protective device such as earmuffs or earplugs to protect against hearing loss from uncomfortable loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine Work in ventilated area Engine exhaust fumes can cause sickness or deat...

Page 15: ...line can cause serious injury or death Keep tractor master shield and driveline shields in place at all times Make sure rotating shields turn freely Wear close fitting clothing Stop the engine and be sure PTO driveline is stopped before making adjustments connections or cleaning out PTO driven equipment Use safety lights and devices Avoid collisions with other road users when using slow moving tra...

Page 16: ...y Stopping distance increases with speed and weight of towed loads and on slopes Towed loads with or without brakes that are too heavy for the tractor or are towed too fast can cause loss of control Consider the total weight of the equipment and its size Observe recommended maximum road speeds or local speed limits which may be lower If towed equipment does not have brakes do not travel more than ...

Page 17: ...clean and dry Never lubricate service or adjust machine while it is moving Keep hands feet and clothing from power driven parts Disengage all power and operate controls to relieve pressure Lower equipment to the ground Stop the engine Remove the key Allow machine to cool Securely support any machine elements that must be raised for service work Keep all parts in good condition and properly install...

Page 18: ...ls are not raised Tighten wheel hardware to correct torque as specified in Wheels Tyres and Tread section Torque at intervals shown in Break In Period and Lubrication and Maintenance sections to ensure that wheel hardware does not loosen Reinstall protective covers removed during service Support machine properly Always lower the attachment or implement to the ground before you work on the machine ...

Page 19: ...containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating Avoid heating near pressurized fluid lines Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pre...

Page 20: ... not induce vomiting 2 Drink large amounts of water or milk but do not exceed w2L 2 quarts 3 Get medical attention immediately Service tyres safely Explosive separation of a tyre and rim can cause serious injury or death Do not attempt to mount a tyre unless you have the proper equipment and experience to perform the job Always maintain the correct tyre pressure Do not inflate the tyres above the ...

Page 21: ...e food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants Inquire about the proper w...

Page 22: ... well as traffic regulations when driving the tractor on public or open roads Any unauthorized and arbitrary modification made to the tractor will relieve the manufacturer of all responsibilities for any damage or injury derived from such modification The Manufacturer and all the organizations associated with its distribution network including but not limited to national regional or local distribu...

Page 23: ...nual carefully before attempting to start operate service refuel or carry out any other adjustments to your tractor A few minutes dedicated to reading will save time and trouble later Remember that your tractor was designed and produced exclusively for agricultural use If the owner of the tractor is to use it for any other purposes he needs to get the prior authorization from the Manufacturer in a...

Page 24: ...rrectly seated on driver s seat with the seat belt fastened Do not get on or off a moving tractor Always press the brake pedal gently Do not corner at high speed Always operate the tractor at a safe speed for the type of ground being worked When operating on rough ground use proper caution to assure tractor stability When working on sloping grounds as for example on hillsides drive at moderate spe...

Page 25: ...he engine to cool off sufficiently before removing the radiator cap After the engine is shut down for some time slowly turn the cap to release pressures before removing it completely Disconnect the negative cable from the battery before starting any work on the electrical system parts or components Before disconnecting any hydraulic line or hose release the oil pressure by moving the hydraulic lev...

Page 26: ...oughly understood before attempting to operate this machine 1 General Ensure that the front end loader and tractor are set up and maintained in accordance with these instructions and that of the tractor While operating your loader ensure you observe the safety requirements regulations relating to the tractor Only operators who have been specially trained in loader operation and fully understand th...

Page 27: ...area prior to operation Operate the loader unloaded to ensure it is in proper operating condition before starting your work The use of good judgement is necessary by the operator in using this loader Use extra caution when rear wheel weights and tyre ballast are added to a loader equipped tractor Do not ram into compacted or frozen piles of dirt or other material with great momentum where sudden s...

Page 28: ...der bucket to the ground engage tractor park brakes disengage drive put all controls in neutral shut the engine off and remove the ignition key before leaving the tractor Make sure all parked loaders on stands are on a hard level surface with all safety devices engaged to prevent loader from falling and being damaged or injuring someone Always park loader with bucked attached to loader 5 Performin...

Page 29: ... the bucket is titled so that the bucket stops are in contact with the boom A limited amount of leveling may be done when the loader valve is arranged with a float control This will prevent damage to cylinder rods Care must be taken with your loader cylinders Always keep cylinders in a retracted position when the loader is not in use to guard against rust and contamination which may cause damage t...

Page 30: ...Factory Direct Tractors Front End Loader Safety ROL 350KG S 25 ...

Page 31: ...Factory Direct Tractors Front End Loader Safety S 26 ...

Page 32: ...Factory Direct Tractors Front End Loader Safety S 27 ...

Page 33: ...Factory Direct Tractors Front End Loader Safety S 28 ...

Page 34: ...Factory Direct Tractors Front End Loader Safety BL25 S 29 ...

Page 35: ...r Dongfeng dealer or service agent The tractor serial number is located on the front right side frame and identification plate pop riveted to the rear mudguard or vertical face of the instrument panel In some cases it is located under the seat The engine serial number is also located on the left or right side of the engine crankcase depending on the model Locate the serial numbers now and record t...

Page 36: ...fuel tank can be accessed through the bonnet If you are lifting the bonnet first tilt the scrub bar forward Only use clean uncontaminated diesel fuel If you are experiencing fuel problems use of an injector cleaning additive can help 8 Oil Injector Pump Check the oil level at the breather tube located at the front of the injector pump Oil should be filled to this height If a dip stick is fitted to...

Page 37: ...g as it is likely to damage the drive train It will also reduce your manoeuvrability and wear out the front tyres Use 4WD only when needed 17 Diff Lock Pedal Located behind the right heel Engage in low range by tramping on the pedal at low engine revs Never use the diff lock at high speed or when turning 18 Three Point Linkage Control lever located beside the seat on the right hand side When not i...

Page 38: ...n Press the horn button to sound the horn The ignition 8 Right Indicator 9 Dash Clearance Lights 10 Ignition On 11 Oil Pressure 12 Low Fuel Indicator 13 Hour Meter Switch needs to be on for the horn to work 3 1 4 Engine oil pressure gauge The engine oil pressure gauge indicates if engine oil pressure is sufficient and oil is circulating throughout the engine The oil pressure gauge operates when th...

Page 39: ...ver automatically returns to the neutral position When the lever is moved to the neutral position while the implement is moving up or down it will immediately stop and remain at that level 3 2 3 Main gear shift lever and high low gear shift lever There are 5 positions for the gear shift lever and 2 positions for the foot operated heel and toe high low range lever Combined operation of both speed c...

Page 40: ... clutch pedal slowly when operating the tractor If using a front end loader select low range for operating the loader and high range for travelling If high range is used when working the front end loader premature clutch wear will occur Do not ride the clutch to adjust speed while in operation or premature clutch plate wear and pressure plate damage will result Premature clutch wear is not warrant...

Page 41: ... is applied in cases of excessive wheel slip where locking the differential provides power equally to both wheels This is achieved by lightly stepping on the differential lock pedal with the heel To unlock just release the pedal Never activate the diff lock at high speed or when turning 3 2 10 Seat To accommodate the operator the seat can be adjusted to several pre set positions The adjustment is ...

Page 42: ...tem repeatedly so as to run in the hydraulic system and PTO drive system 4 3 Running in the tractor with load 1 When operating the tractor with a load during the running in procedure the load must be added gradually and gears changed gradually from low to high The engine should not be left at idle for long periods A slasher can be used to load the engine Use a higher gear than normal when cutting ...

Page 43: ... 30 seconds it may lead to problems with the starter motor 3 Be sure to perform warm up operations regardless of the ambient temperature If the tractor is run before the engine warms up the engine performance is reduced and the tractor life will also be affected 4 Don t use starting fluid to aid engine start Doing so may cause serious damage to the engine Safety precautions 1 Do not start the engi...

Page 44: ...against rolling by placing stones or a wheel chock behind the wheels 3 Before getting off the tractor be sure to stop the engine and lower the implement to the ground for safety 5 4 Check during driving While driving check the instrument gauges to make sure all systems are functioning normally 5 4 1 Cooling water If the temperature of the cooling system rises above 100ºC immediately stop the engin...

Page 45: ...ck at high speed or when turning The tractor cannot turn with the diff lock engaged and attempting this is very dangerous and will void any warranty 5 6 Control and usage of tractor s working devices 5 6 1 Hydraulic lift system 1 Lifting lowering the three point linkage see Fig 4 6 Move the control handle 4 forward and the attached implement will be lowered Adjust the lower limiter block 1 in a po...

Page 46: ...s neutralized automatically 3 Lift implements especially tillage equipment before driving off or turning 4 Do not manoeuvre or turn the tractor while a ripper tyne is in the ground Lift the ripper or other implement first 5 Make sure the implements fit the tractor well and there is no interference to the implements lifting or lowering 6 Avoid dragging implements along roads or across paddocks Use ...

Page 47: ...tory set and should not require resetting during the normal course of clutch maintenance Check that all three fingers are on the same vertical plane by depressing the clutch pedal until the throw out bearing contacts the fingers and ensure all fingers contact the bearing at the same time If not adjust the fingers as required by using the adjusting nut 1 2 Adjust the clutch free play using the pull...

Page 48: ...y adjusted to stop excessive slipping premature clutch plate wear will occur with possible damage to the clutch assembly through over heating or metal on metal wear bolt 4 and main pressure plate housing 2 3 40mm free travel on the clutch pedal by adjusting the pull rod 9 When adjusting the clutch ensure that the three release fingers are in the same plane and contact the face of the throw out bea...

Page 49: ...ing shims as required 6 3 3 Wheel track 4WD The rear wheel track can be set to a number of positions Only use the maximum setting when required Industrial tyres and rims have one setting only The front wheels should remain as factory set or increased pressure will be applied to the steering equipment and damage may result 6 3 4 Rear wheel track Rear wheels can be fitted with the concave side of wh...

Page 50: ...ouses a bush and oil seal so that lubrication oil communicates between the differential and final drives Oil is drained using three plugs One at the diff centre and two on the final drives Oil is filled from one common fill point on the axle housing When replacing the front diff oil keep checking the level until it stabilises Oil can take some time to fill the final drives Fig 6 3 6 Diagram of fro...

Page 51: ...eavy or even jamming please do not carelessly turn the steering wheel with heavy force but to thoroughly check and fix the problem first 2 Applying heavy force to the steering wheel can damage the power steering system If the tractor is to be moved manually by towing or pushing never apply a force greater than 250Nm 180ftlb to the steering wheel 3 Maintenance of the hydraulic orbital gear should b...

Page 52: ...or right while braking the brakes are not adjusted properly Readjust the brakes by lengthening the pull rod on the side with the longest skid mark or shorten the pull rod on the side with the shortest skid mark and test again Repeat the adjustments until the brakes are synchronised and well balanced Eventually the brake shoe lining 5 will wear out and require replacing For your safety regularly ch...

Page 53: ...the length of the pull rod 8 Adjust until the displacement from the highest position of the brake pedal to the pedal position when the brakes are completely applied is 75 85 mm When the left and right pedals are locked together stepping on the pedal will simultaneously brake the left and right wheels After adjustment is completed lock pull rod with the lock nuts 7 3 Left and right rake synchronisa...

Page 54: ...he body of the tractor The electrolyte level of the battery lies between the UPPER and LOWER marks on the battery Once it is under the LOWER mark distilled water should be added When the battery is low on charge the tractor will be hard or impossible to start The battery needs to be charged from an external power source Persistently trying to start the engine with a low charge battery can damage t...

Page 55: ...pinion drive teeth are found during regular maintenance contact a qualified trades person for assistance 1 Pinion gear adjusting shims 6 Crown gear 2 Lock nut 7 Adjusting shim of crown gear 3 Check washer 8 Bearing seat 4 Lock nut 9 Rear axle housing 5 Pinion gear Fig 6 7 Main drive mounting diagram Meshing zone diagram 6 9 ...

Page 56: ... schedule In order to keep your Tractor in good serviceable condition and prolong the life of the machine the following service guide must be followed Dongfeng recommends using genuine oil and filters for all services to ensure all components of the machine are protected and operate within manufactures specifications The use of non genuine parts including filters and oil s will void your warranty ...

Page 57: ...il leaks and repair as required 15 Check brake and clutch adjustment and adjust as required Request technical support if unsure how to carry out adjustments 7 2 3 50 Hourly service 1 Change engine oil and filter 2 Change injector pump oil 3 Inspect radiator core for blockage blow out and reinspect clean as required 4 Check air filter and dust bowl for contaminant and clean as required replace ever...

Page 58: ...king pins drive shafts steering stops and water pump bearings if grease nipple fitted 8 Check wheel nut tension and tyre pressures adjust as required 9 Check tappet clearance and adjust as required 10 Check air filter and dust bowl for contaminant and clean as required replace every 50 hours in very dusty conditions Inspect inlet manifold and hoses for leaks repair as required 11 Drain coolant flu...

Page 59: ... tank to maximum level Remove battery clean battery top and coat terminal clamps and leads with vaseline Ideally store the battery in a dim well ventilated area with temperature remaining above 10 0 Put stands or other supports under the front and rear axle in order to bear the tractors weight With the tractor being propped up it is advisable to deflate the tyres Cover the tractor with non waterpr...

Page 60: ... Hr Change O O O O O O every 100 Hr Radiator Cleaning O O O O O O O O O O O every 50 Hr Drain O O O O O O every 100 Hr annually Radiator hose Check O O O O O O O O O O every 50 Hr Replacement O O O O O every 2 year Valve clearance Check O O O O every 250 Hr Head tension Check O 1 x retension Air Cleaner element Clean O O O O O O O O O O O every 50 Hr Replacement O O O O O every 100 Hr annually Fan...

Page 61: ...Factory Direct Tractors Technical Maintenance 7 6 7 6 Recommended oil ...

Page 62: ...d up and tank is low or dry 3 When driving on a slope and fuel has sloshed away from the fuel outlet 8 1 3 Bleeding procedure is as follows 1 Fill the fuel tank with fuel and open the fuel tap 2 Twist open the air bleed screw plug on the fuel injection pump with one turn 3 Push the plunger several times as required 4 When bubbles disappear from fuel coming out of the plug close the bleed screw 8 1...

Page 63: ... the injector pump as per 7 1 Bleeding the fuel system Caution If dust and dirt enter the fuel the fuel pump and injection nozzles are subject to quick wear To stop premature wear change the fuel filter as per maintenance checks above 8 2 Engine oil 8 2 1 Oil level check and replacement 1 Check the engine oil either before starting the engine or at least 5 minutes after the engine has stopped 2 To...

Page 64: ... in the transmission case is also used for the hydraulic drive system To drain the transmission case place an oil collection pan underneath the transmission case and remove the drain plugs at the back of the transmission case After draining clean and replace the drain plug and fill with new East Wind Multi Farm 1 or Valvoline Farmplus Universal oil 8 3 2 Replacing hydraulic oil filter When changin...

Page 65: ...in good working order is vital to minimizing engine problems Keep the external core clean for air flow and transfer of heat A slide out radiator screen is fitted to help keep the radiator core clean Clean the core carefully to avoid damage to the cooling fins 8 6 1 Checking maintaining and changing the cooling water 1 When the engine is cold remove the radiator pressure cap and check to see that t...

Page 66: ...ber and will deteriorate They must be changed every two years Replace the hose clamps and tighten as required 8 6 4 Cleaning the cooling system The water cooling system should be cleaned on the following occasions At the first 30 hour service and every 100 hours following When adding Inhibitor anti freeze additives 8 6 5 Anti freeze If the coolant freezes in the engine cylinder and radiator the en...

Page 67: ... the tractor body If low top up to the bottom of the plugs or level line indicated on the side of the battery with distilled water 3 To charge the battery loosen the electrolyte caps to avoid building up internal pressure and connect the battery positive terminal to the charger positive terminal and the negative to the negative terminal then recharge in the standard fashion Remember to tighten the...

Page 68: ...sembly can be adjusted manually to level an implement Once adjusted tighten the lock nut to secure the setting 8 10 3 Stabiliser links The stabiliser links prevent linkage mounted implements from swaying and keeps the lift arms from rubbing against the inside of the rear tyres The stabiliser links may be adjusted by turning the turnbuckle If the stabiliser links are too loose the implement will sw...

Page 69: ...e leak Replace with new one or grind it c Blown head gasket Replace with a new gasket and tighten cylinder head down as per specifications d Piston ring by pass Replace damaged rings clean the sticking ones or reassemble them Possible causes Solutions a Incorrect injector pump or valve timing Readjust as per specifications b Low ambient temperature Use the glow plugs or fill the radiator with hot ...

Page 70: ...ions a Injector nozzle slow or partially blocked Replace or service it b Overloading the engine Adjust the gearing c Incorrect fuel injection timing Adjust it d Poor valve sealing or incorrect timing Check and adjust it e Injector pump or injectors delivering fuel unevenly Check and service injectors and injector pump specialist operation f Air filter blocked Clean or replace as per maintenance sc...

Page 71: ...Adjust it b Injector needle valve seized Loosen the high pressure fuel lines in turn to detect the defective injector if any one is seized then it will not give an injection sound replace the seized one with a new one c Valve clearance is too big rhythmic valve hammering can be heard clearly Adjust the valves d Piston knocks the bottom of cylinder head Replace the cylinder head gasket with a thick...

Page 72: ...gearing j Injector timing is too advanced Adjust as per specification Possible causes Solutions a Injector pump oil delivery control rod seized at the maximum position Check and repair it b Governor Sliding disc sleeve seized Check and replace it c Fuel rack broken seized or separated from fork Check and replace it d Too much lube oil in the injector pump Drain out to the required level e Too much...

Page 73: ...free travel Readjust pedal free travel as specified d Clutch plate warped worn unevenly or worn out Rectify or replace with a new one e Ends of the three release levers misaligned Adjust and align the lever ends in the same plane Trouble possible causes Solutions a Excessive free travel of clutch pedal Adjust the pedal free travel as specified b Clutch plate excessively warped Rectify or replace w...

Page 74: ...ree travel Readjust the pedal free travel Troubles possible causes Solutions a Gearbox bearings or needle rollers excessively worn out or damaged Check and replace worn out bearings or needle rollers with new ones b Abnormal meshing of main drive gears Examine gear meshing zone print and backlash adjust them as per specifications c Spline shafts and sliding gears worn out Replace worn out parts wi...

Page 75: ...he hydraulic pump suction line and filter Fix as required b Air bubbles in the hydraulic system Bleed air out of the system check the suction pipe and rectify any leakage c Power steering oil low Refill oil to the required level d Power steering oil too thick high viscosity Replace with the specified oil Troubles possible causes Solutions a O ring seals damaged Replace with new ones b Banjo fittin...

Page 76: ...trol valve badly worn out Replace worn out parts g Safety valve failure Readjust or repair safety valve h Cylinder leaking seriously Replace seal ring or replace the worn out parts as necessary i Leakage at distributor seal rings Replace seal rings Troubles possible causes Solutions a Low electrolyte level Add electrolyte to specified level b Short circuit among the battery terminals Clean off dep...

Page 77: ...r rotor windings or poor insulation of earth circuit Repair or replace with new ones Troubles possible causes Solutions a Generator belt too loose Adjust belt tension or replace worn out belt with a new one b Rectifier damaged Replace damaged rectifier with a new one c Poor contact of carbon brushes Repair or replace d Short circuit of partial windings of rotor or stator Repair or replace rotor or...

Page 78: ...nearly flat Charge battery d No contact of carbon brushes with the commutator Check carbon brushes and adjust brush spring force to get good contact e Inner short circuit of starter Remove short circuit f Solenoid switch contacts damaged Repair replace solenoid switch contacts Troubles possible causes Solutions a Solenoid switch contacts damaged Repair replace solenoid switch contacts b Sticky ign...

Page 79: ...reduced to an acceptable rate by throttling the engine RPM Adjusting the flow rate correctly could prevent sudden shock loads on the cylinders hoses etc This results in a smooth operation and reduced maintenance costs and down time Tractor operation in a loader application significantly increases demands on the tractor hydraulic system Check the tractor hydraulic system fluid level daily Refer to ...

Page 80: ...ath bodily injury or property damage Caution The loader unit when not fully connected to the tractor is potentially unstable Proceed with caution Do not raise the bucket off the ground until it is fully connected to the tractor Failure to comply with these requirements could cause death bodily injury or property damage Caution Never allow weight of tractor to be put on the parking legs stand when ...

Page 81: ... Start the tractor and drive ahead slowly to position the loader uprights into the mounting brackets Note Activate the bucket cylinders and lifting cylinders as required to align the uprights mounting brackets 4 With the uprights secure in the mounting brackets extend the bucket cylinders to ensure the uprights are fully seated in the mounting brackets 5 Shut the tractor OFF and secure the upright...

Page 82: ...ets Observe the four hoses to ensure they are not caught or stretched when backing away from loader 7 Shift the control valve into the neutral position 8 Check that the uprights will clear the front tyres If additional clearance is required extend the lift cylinders refer photo 3 9 Shut the tractor OFF and disconnect the hydraulic hoses to ensure they will be clear of the tractor Connect couplers ...

Page 83: ...r of loader or injury to personnel Cold Weather Operation For smooth operation in cold weather let the tractor warm up SLOWLY cycle the lift and bucket cylinders several times to warm the oil in the hydraulic system The loader may operate erratically until the hydraulic oil has warmed to operating temperatures Loading Bucket For the most safe and efficient loading use low range gears Slowly drive ...

Page 84: ...ency during Backfilling Control Rate of Loader Functions By feathering the control lever reduced operational speeds can be achieved This action controls the position of the valve spool in the valve body and regulates flow of oil to from cylinders It is important to use this practice when lowering loader boom with a loaded bucket of material Loader Hydraulic Controls The loader hydraulic valve feat...

Page 85: ...ll hydraulic pressure by moving the loader control lever in all directions Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious personal injury Caution Do not heat by welding soldering or using a torch near a pressurized hydraulic line Pressurised lines can be accidentally cut causing escaping hydraulic oil and possible flammable spray 11 1 Maintena...

Page 86: ...ate all grease nipples and loader pivot points daily 10 hours Refer to tractor operator s manual for lubricant recommendations Tractor front tyres should be maintained at maximum recommended inflation to maintain normal tyre profile with added weight of loader material Rear tyres must be kept within inflation pressure range Unequal rear tyre inflation can result in bucket not being level to the gr...

Page 87: ...e unit slowly and check the operation control system for correct working condition before starting to operate 11 4 General torque specification American standard cap screws with UNC or UNF threads Metric cap screws SAE grade No GR 5 or GR 8 Property class 8 8 Approx SAE GR5 1 4 N m kgf m ft lbs 9 8 to 11 7 1 0 to 1 2 7 2 to 8 6 M6 N m kgf m ft lbs 9 8 to 11 7 1 0 to 1 2 7 2 to 8 6 5 16 N m kgf m f...

Page 88: ...lines that would block flow of oil between cylinders and control valve Replace filter 7 Cylinder piston assembly defective not sealing Check cylinders for internal leakage as described in service section under cylinder leakage tests 8 Control valve blockage Inspect for blockage Disassemble valve if necessary Insufficient lifting capacity 1 Insufficient engine power output Inspect and service repai...

Page 89: ...control vale lever position Hydraulic hoses connected incorrectly Correct hydraulic hose connections Loader drops with control valve spool in centred position Note A gradual drop over an extended period of time is a normal condition 1 Cylinder piston assembly leakage Check cylinders for leakage 2 Control valve internal leakage Replace control valve Control valve spools s will not return to centred...

Page 90: ...il filter clogged Clean oil filter and intake pipe Acting speed of the bucket is slow and insufficient 1 Large interior leakage in gear pump or control valve Replace or repair it 2 Oil filter is clogged Clean the filter 3 Oil level is low oil type is incorrect Fill with specified oil type to specified level 4 Interior leakage in cylinder Inspect hydraulic system replace seals according to specifie...

Page 91: ...Factory Direct Tractors Front End Loader THIS PAGE INTENTIONALLY BLANK ...

Page 92: ...Factory Direct Tractors Front End Loader 13 1 13 1 BUCKET ASSEMBLY 13 Loader Parts ...

Page 93: ...82 M8x50 Bolt M8x50 4 7 GB T889 1 M8 Nut M8 4 8 DKT142 013 Cylinder 2 9 DKT147 106 Space 21 2 10 DKT147 107 Space 17 2 11 GB5783 M6X12 Bolt M6X12 2 12 GB93 6 Spring washer 6 2 13 GB97 1 6 Plain washer 6 2 17 GB3452 1 11x2 4 O ring 11x2 4 12 18 DKT147 014 Hose 705 4 DKT152 014 Hose 730 4 DKT167 014 Hose 805 4 19 GB8606 XZG3 8 F Quick coupling F 1 20 JB4454 17 Gasket 17 2 21 SL25 40 112 Adapter M16 ...

Page 94: ...Factory Direct Tractors Front End Loader 13 3 13 2 TOOL CARRIER ASSEMBLY ...

Page 95: ...940 1 M6 Zerk M6 6 38 GB5783 M6x12 Bolt M6x12 4 39 GB97 1 6 Plain washer 6 4 40 GB93 6 Spring washer 6 4 41 CT10 102 1 Glide pin 2 42 GB T889 1 M10 Nut M10 5 43 GB97 1 10 Plain washer 10 5 44 GB T27 M10x55 Bolt M10x55 2 45 CT10 103 Pull plate 2 46 CT10 012 Handle weldment 1 47 CT10 104 Disk spring 1 48 CT10 105 1 Stop spring 1 49 CT10 106 1 Bearing ball φ8 1 50 GB5783 M12x25 Bolt M12x25 1 ...

Page 96: ...Factory Direct Tractors 13 5 Front End Loader 13 3 ARM ASSEMBLY ...

Page 97: ... GB5783 M6x12 Bolt M6x12 6 75 GB97 1 6 Plain washer 6 6 76 GB93 6 Spring washer 6 6 77 BL25 10 105 Pin 114 6 78 BL25 10 014 Valve bracket weldment 1 BL ML 79 BL25 10 106 Safety pin 2 80 BL25 10 107 R pin φ5 2 81 BL25 10 015 Boom cylinder 2 82 BL25 10 108 Pin 98 2 83 BL25 10 109 Pin 2 84 GB894 1 16 External retaining snap ring 16 2 85 GB882 16x60 B Pin stabilizer 2 86 BL25 10 110 R pin φ3 2 2 87 BL...

Page 98: ...Factory Direct Tractors Front End Loader 13 7 Front End Loader 13 4 MOUNTING KIT ASSEMBLY ...

Page 99: ...25 20 015 Protection frame weldment 1 116 BL25 20 101 Support plate 2 BL25 BL35 20 101 Support plate 2 BL35 ML30 20 101 Support plate 2 ML30 ML45 20 101 Support plate 2 ML45 117 BL25 20 102 Pin 2 118 BL25 20 103 Lock pin 12 2 119 BL25 20 012 Mounting kit L 1 BL25 BL35 20 012 Mounting kit L 1 BL35 ML30 20 012 Mounting kit L 1 ML30 ML45 20 012 Mounting kit L 1 ML45 120 BL25 20 013 Mounting kit R 1 B...

Page 100: ...97 1 14 Plain washer 14 32 BL35 GB97 1 14 Plain washer 14 32 ML30 GB97 1 14 Plain washer 14 34 ML45 132 GB889 1 M14 Nut M14 16 133 BL25 20 112 Space 2 BL35 20 112 Space 4 ML30 20 112 Space 2 ML45 20 112 Space 2 134 GB5782 M12x110 Bolt M12x110 2 BL25 GB5782 M12x60 Bolt M12x60 4 BL35 GB5782 M12x100 Bolt M12x100 2 ML30 GB5782 M14x110 Bolt M14x110 2 ML45 135 GB93 12 Spring washer 12 2 BL25 GB93 12 Spr...

Page 101: ...Factory Direct Tractors 13 10 Front End Loader THIS PAGE INTENTIONALLY BLANK ...

Page 102: ...Factory Direct Tractors 13 11 Front End Loader 提升油缸铲斗油缸铲斗油缸提升油缸 13 5 HYDRAULIC SYSTEM ASSEMBLY BL ML MODELS 2 LEVER CONTROL ...

Page 103: ...82 M6x40 Bolt M6X40 8 161 BL25 40 023 Hose 2 162 BL25 40 024 Hose 2 163 BL25 40 025 Hose 2 164 BL25 40 026 Hose 2 165 SL25 40 116 Adapter G3 8 M18 2 166 JB4454 17 Gasket 17 2 167 GB8606 XZG3 8 M Quick coupling M 1 168 GB8606 XZG3 8 F Quick coupling F 1 169 BL25 40 101 Adapter M18 M18 2 170 GB3452 1 13x8 2x2 4 O ring 13x2 4 4 171 BL25 40 027 Hose 1 172 BL25 40 028 Hose 1 173 BL25 40 102 Adapter M18...

Page 104: ... unit 3 Battery cable 11 Water temperature sensor 21 Ignition switch 28 Turning indicator 4 Battery 14 Horn button 22 Headlight switch 29 Brake lamp switch 5 Electric horn 15 Ammeter 23 Rear work light switch 31 Rear working lamp 6 Front harness 16 Water thermometer 24 Fuse block 32 Voltage regulator 7 Starting motor 17 Oil pressure gauge 25 Right fender harness 33 Left fender harness 8 Alternator...

Page 105: ...plug 3 Battery cable 11 Water temperature sensor 23 Rear work light switch 31 Rear working lamp 4 Battery 12 Tachometer 24 Fuse block 32 Voltage regulator 5 Electric horn 13 Safety start switch 25 Right fender harness 33 Left fender harness 6 Front harness 14 Horn button 26 Brake clearance light 34 Fuel sensor 7 Starting motor 19 Combination meter 27 Flasher unit 35 Mid harness 8 Alternator 20 Mai...

Page 106: ...Factory Direct Tractors Appendix Steering Cylinder Diagram Appendix 3 Steering cylinder specifications Hydraulic system working pressure MPa 16 Bore stroke mm mm 40 20 160 A 3 ...

Page 107: ...mers expense Service Agent fees apply Note Servicing is at customers expense 1 2 Service Request Service Officer contacts customer Call Branch Submit online form Option 1 Customer rectifies problem under Service Officers guidance 1 2 Option 2 Customer employs Service Agent Appendix 4 ...

Page 108: ...Sales branch Approved warranty covers parts only Note Servicing and non approved warranty claims at customers expense 1 2 3 Warranty Request Warranty Officer contacts customer Call Branch Submit online form Warranty Officer contacts customer to confirm customer satisfaction 1 Parts only supplied for approved warranty 2 Appendix 5 ...

Page 109: ...r Service Technician Invoice Name Phone Qualification 30Hr1st Service 50 Hr 100 Hr 150 Hr 200 Hr 250 Hr 300 Hr 350 Hr 400 Hr 450 Hr 500 Hr 550 Hr 600 Hr 650 Hr 700 Hr 750 Hr 800 Hr 850 Hr 900 Hr 950 Hr 1000 Hr For Service Information please refer to the maintenance section of the owner s and operator s manual If any information is not available please contact your nearest distributor service depar...

Page 110: ... a first 30 hour oil change Front End Loader 1 Caution when operating Do not clamp over heavy or immovable objects 2 Do not dig with the loader 3 Remove lockout pins before operating 4 Hydraulic quick couplers FEL 5 Release hydraulic pressure when parking 6 Implements safety starting Maintenance IMPORTANT WARRANTY 2 year Parts Only from date of dealer dispatch Warranty excludes Labour Transport an...

Page 111: ...Factory Direct Tractors ...

Page 112: ...Division of Midway Sales Australia 252 Eastern Service Road Burpengary Qld 4505 Australia Email midway midwaysales com au Website www midwaysales com au Phone 1300 TRACTOR Fax 07 3888 3180 V 2013 12 13 Factory Direct Tractors ...

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