Foton TZ Series Tractor. Service Manual — part 1

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Contents

CONSUMER NOTICE！ . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4

NOTES FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Application, technical performance and technical data . . . . . . . . . . . . . 6

1.1 Application and feature . . . . . . . . . . . . . . . . . . . . . . . .. 6

1.2 Main specification and technical data . . . . . . . . . . . . . . . . . ... 6

2 Main component structure, working principle and operation . . . . . . . . . . 10

2.1 Working device system . . . . . . . . . . . . . . . . . . . . . . . .. 10

2.2 Working device hydraulic system . . . . . . . . . . . . . . . . . . . 10

2.3 Disassembly and assembly of working device . . . . . . . . . . . . . . . 17

2.4 Driving and operation . . . . . . . . . . . . . . . . . . . . . . . ... 19

3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1 Sorts and function . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2 Disassembly and assembly of accessories . . . . . . . . . . . . . . . . 25

4 Technical maintenance and common trouble and troubleshooting . . . . . . . . 26

4.1 Technical maintenance . . . . . . . . . . . . . . . . . . . . . . . .. 26

4.2 Trouble and troubleshooting . . . . . . . . . . . . . . . . . . . . . 26

4

Foreword

TZ Series Tractor Frontloader is used for FOTON Four-wheel Driven Tractors. This

manual introduces the structures, working principles, and operation of the frontloader in

intelligible words and figures, as well as the maintenance, the common trouble and trouble

shooting. If you want to know the operation and the adjustment of the relevant tractor, please

consult the “OPERATION MANUAL OF FOTON SERIES WHEELED TRACTORS”.

The frontloader introduced in this manual involves seven series; viz. series 02, series 03,

series 04, series 06, series 08, series 10 and series 12. According to the difference between the

link structures of the lift arm and the bucket, the lift arm and the vertical column, every series

includes five type, that is, the common model, model A, model B, model C and model D.

The frontloader can mount six kinds of working device according to the demand of the

work, involving the universal bucket, the assembled bucket, the bars-casing bucket, the pallet

fork and the timber grab.

The manual instances the common model, model A, model B, model C and model D for

explanation, and introduces the working devices in the end.

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NOTES FOR SAFETY

1． The driver must have formal driving license, and be familiar with the use of the frontloader and tractor，

and drive, service, maintain the frontloader according to the prescript of the manual.

2． Not allow any one stand under the lift arm and bucket.

3． Never drive at high speed when the bucket is over the transport position.

4． Never drive overloading.

5． Don’t load the barycenter of the goods deflected.

6． When parking at a slope, it needs not only strain the hand brake but also fix the wheel with a trilateral

wood.

7． Never park close to fire.

8． Pay attention to the readings of instruments at any time.

9． Disassemble, assemble and adjust machine according to the manual.

10．Check whether the brake system is safe and reliable. Otherwise

,

don’t drive until eliminate all

malfunctions.

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1 Application, technical performance and

technical data

1.1 Application and feature

TZ-D Series Tractor Frontloader is a kind of mini-type engineering machine fixed on

tractors and used for loading. The frontloader can be used in a family, farm, storehouse, etc.

where the large-scale models are not so available, for transporting incompact materials such

as scarification, sandrock, coal, waste, etc., as well as shoving soil，digging，piling, etc.

1) The frontloader, with hydraulic transmission technique and compact structures, is

flexible and available in narrow spots where the large-scale machine can not.

2) It is fixed on the four-wheel driven tractor that has full hydraulic steering and a batch

production, with compact structures and reliable transmitting.

3) One hydraulic system is used by the frontloader and the tractor’s lifting device

together, which accords to GB and easy to maintain.

4) The frontloader can mount various devices according to different demands.

1.2

Main specification and technical data

Fig. 1-1 Sketch of the frontloader fixed on Foton Tractors

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Technical Data Collection List of the frontloader fixed on Foton Tractors

(unit mm)

Series 02

Series 03

Model

TZ02

TZ02A

TZ02B

TZ02C

TZ02D

TZ03

TZ03A

TZ03B TZ03C TZ03D

Matching tractor

FT254

FT304/FT354/FT404

Max lift height of

measured at arm

pivot point （A）

2100

2360

2400

2700

Max.dump

height (C)

1700

1800

2000

2000

Dump distance

（D）

600

700

800

900

Dump angle（E）

（°）

45°

45°

42°

45°

Distance of bucket

to the centre of

front-wheel(F)

1560

1820

1830

1930

Rollback angle on

ground（G）

（°）

26

32

26

32

Max. digging

depth（H）

100

100

100

140

Bucket width

1289

1289

1482

1482

Bucket capacity

(m

3

)

0.18

0.18

0.2

0.2

Rated lift

capacity

(Kg)

200

200

300

300

8

Series 04

Series 06

Model

TZ04 TZ04A TZ04B TZ04C TZ04D

TZ06

TZ06A TZ06B TZ06C

TZ06D

Matching tractor

FT454/ FT504A

FT554/FT604/FT704

Max. lift

height–measured

at arm pivot

point（A）

2500

2800

2700

3100

Max. dump

height (C) (mm)

2100

2100

2300

2300

Dump distance

（D）

800

900

1180

1140

Dump angle（E）

（°）

42°

45°

42°

45°

Distance of

bucket to the

centre of

front-wheel（F）

1830

1930

2000

2320

Rollback angle

on ground（G）

（°）

26

32

27

34

Max. digging

depth（H）

100

140

110

140

Bucket width

1542

1542

1652

1652

Bucket capacity

（m

3

）

0.21

0.21

0.43

0.43

Rated lift

capacity

(Kg)

400

400

600

600

9

Series 08

Series 10

Model

TZ08 TZ08A TZ08B TZ08C TZ08D

TZ10

TZ10A

TZ10B

TZ10C

TZ10D

Matching tractor

FT754A/FT804A/ FT824/FT904

FT1004

Max. lift

height–measured

at arm pivot

point（A）

3250

3080

Max. dump

height (C)

2500

2350

Dump distance

（D）

1020

1100

Dump angle

（E）（°）

42°

43°

42°

42°

Distance of

bucket to the

centre of

front-wheel（F）

2200

2400

Rollback angle

on ground（G）

（°）

28

33

Max. digging

depth（H）

160

180

Bucket width

1700

1800

Bucket capacity

（m

3

）

0.46

0.46

Rated lift

capacity

(Kg)

1000

1000

Notice：No further informing will be given for any modification of the data.

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2 Main component structure, working principle

and operation

2.1 Working device system

The working device system is the component contributing directly to loading like arms of a person. As

shown in Fig.2-1, the working device consists of bucket, vertical column, lift arm, and underframe

,

etc

.

Fig.2-1 Working Device Sketch

According to the difference between the linking structures of the lift arm and the bucket,

the lift arm and the vertical column, the frontloader includes five models. That is the Common

model, model A, model B, model C and model D.

2.1.1 Common model (As shown in Fig.2-2)

For the Common model, the vertical column links to the tractor fixedly, the lift arm and

the lift cylinder links to vertical column by fixed pins. If necessary, take out the fixed pins,

put down the support leg, loosen the quick release coupling of the oil pipes, and then the lift

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arm will be separated from the vertical column, the frontloader will be separated off. The

teeth are mounted on the edge blade of the bucket by bolts, and the teeth can

be replaced

when worn out. The edge blade can also be cut off to replace when worn out. Various

working device can be replaced according to the work demand—assembling bucket, timber

grab, pallet fork, etc.

Fig.2-2 Common model (no quick-link)

The working device has couplings between buckets and lift arm, bucket and cylinder, lift

arm and cylinder, lift arm and vertical column, vertical column and cylinder. Their mounting

clearance is about 0.18～0.34mm. If the friction between linings and pins makes the

clearance between them

over 0.6～0.7mm, linings and pins should be replaced.

2.1.2 Model A (As shown in Fig.2-3)

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Fig.2-3 Model A (quick-link between lift arm and vertical column)

For model A (quick-link between lift arm and vertical column), the vertical column links

to the tractor fixedly, the lift arm links to vertical column by quick-link. If necessary, take out

the quick-link pins, put down the support leg, loosen the quick release coupling of the oil

pipes, and then the lift arm will be separated from the vertical column, the frontloader will be

separated off. The teeth are mounted on the edge blade of the bucket by bolts so that they may

be replaced when worn out. The edge blade can also be cut off to replace when worn out.

Various working devices can be replaced according to the wok demand—assembling bucket,

timber grab, pallet fork, etc.

The working device has couplings between buckets and lift arm, bucket and cylinder, lift

arm and cylinder, vertical column and cylinder, as well as the quick-link between the lift arm

and vertical column. Their mounting clearance is about 0.18～0.34mm. If the friction

between linings and pins makes the clearance between them over 0.6～0.7mm, linings and

pins should be replaced.

2.1.3 Model B(As shown in Fig.2-4)

Fig.2-4 Model B (quick-link between lift arm and bucket)

For model B (quick-link between lift arm and bucket), the vertical column links to the

tractor fixedly, the lift arm links to vertical column by fixed pins. If necessary, take out the

fixed pins, put down the support leg, loosen the quick release coupling of the oil pipes, and

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then the lift arm will be separated from the vertical column. The lift arm and bucket link by

quick-link pins. The bucket can be separated. So the lift arm can connect with other parts

quickly, such as saucer fork, etc. The teeth are mounted on the edge blade of the bucket by

bolts so that they may be replaced when worn out. The edge blade can also be cut off to

replace when worn out. Various working device

s

can be replaced according to the work

demand—assembling bucket, timber grab, pallet fork, etc.

The working device has couplings between lift arm and vertical column, bucket and

cylinder, lift arm and cylinder, vertical column and cylinder, as well as the quick-link

between the lift arm and bucket. Their mounting clearance is about 0.18～0.34mm. If the

friction between linings and pins makes the clearance between them over 0.6～0.7mm,

linings and pins should be replaced.

2.1.4 Model C (As shown in Fig.2-5)

Fig.2-5 Model C (quick-link between lift arm and vertical column, lift arm and bucket)

For model C, the vertical column links to the tractor fixedly, the lift arm and vertical

column, the lift arm and bucket are all by quick-link pins. If necessary, take out the quick-link

pins, put down the support leg, loosen the quick release coupling of the oil pipes, and then the

lift arm will be separated from the vertical column. The bucket can be separated from the lift

arm. So the lift arm can connect with other parts quickly, such as saucer fork, etc. The teeth

are mounted on the edge blade of the bucket by bolts so that they may be replaced when worn

out. The edge blade can also be cut off to replace when worn out. Various working device

s

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can be replaced according to the work demand—assembling bucket, timber grab, pallet fork,

etc.

The working device has couplings between bucket and cylinder, lift arm and cylinder,

vertical column and cylinder, as well as the quick-link between the lift arm and bucket, lift

arms and vertical column. Their mounting clearance is about 0.18～0.34mm. If the friction

between linings and pins makes the clearance between them over 0.6～0.7mm, linings and

pins should be replaced.

2.1.5 Model D (As shown in Fig.2-6)

Fig.2-6 Model D (quick-link between lift arm and vertical column, lift arm and bucket

(lift and drop parallel))

The lifting angle of the bucket is unchangeable when the lift arm lifts or drops. The

characteristic is

unique among all lift arms.

For model D, the vertical column links to the tractor fixedly, the lift arm and vertical

column, the lift arm and bucket are all by quick-link pins. If necessary, take out the quick-link

pins, put down the support leg, loosen the quick release coupling of the oil pipes, and then the

lift arm will be separated from the vertical column. The bucket can be separated from the lift

arm. So the lift arm can connect with other parts quickly, such as assembling bucket, saucer

fork, etc. The teeth are mounted on the edge blade of the bucket by bolts so that they may be

replaced when worn out. The edge blade can also be cut off to replace when worn out. Various

working devices can be replaced according to the work demand—assembling bucket, timber

15

grab, pallet fork, etc.

The working device has couplings between bucket and cylinder, lift arm and cylinder,

vertical column and cylinder, as well as the quick-link between the lift arm and bucket, lift

arm and vertical column. Their mounting clearance is about 0.18～0.34mm. If the friction

between linings and pins makes the clearance between them over 0.6～0.7mm, linings and

pins should be replaced.

2.2 Working device hydraulic system

Hydraulic system of working device is used to control the motion of lift arm and bucket

to complete various working operation.

Working principle of hydraulic system:

The engine drives the oil pump which sucks oil from oil-tank. The pressure oil from oil

pump flows through distribution valve to lift cylinder or turn cylinder. By operating the

control rod of distribution valve，the direction of oil flow is changed to make the bucket lift or

turn. The system pressure is settled by the safety valve locating in the distribution valve. The

bucket cannot turn and lift at the same time. When the bucket is turning，the hydraulic circuit

to lift cylinder is cut off. Only when the turning hydraulic circuit stops working，can the

lifting be done.

This system consists of geared pump, multi-way diverter valve, lift arm cylinder, bucket

cylinder, oil-tank and flow line (Fig. 2-7).

Geared pump is showed in Fig. 2-8. One geared pump is used for working device

hydraulic system and the tractor’s hydraulic lifting system together. Its highest pressure is

16Mpa. The structure of lift arm cylinder and bucket cylinder is showed in Fig. 2-9.

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Fig 2-7 Sketch of hydraulic system working principle

1. Bucket cylinder 2.Lift arm cylinder 3.Distribution valve 4.Oil filter 5.Lifter

6.Oil pump 7.Rough oil filter

Fig 2-8 CBN-E314 Geared Pump

1. Pump body 2.Front cover 3.Driven gear 4,5.Side plate 6.Seal ring 7.Rolling bearing 8.Driving gear

9.Set pin 10.Rear cover

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Fig.2-9 Hoisting Cylinder

1. Rear end 2.Piston 3. Bonded seal ring 4.Cylinder barrel 5.Piston rod 6.Guide bush

7. Rod end 8.Joint bearing

2.3 Disassembly and assembly of working device

2.3.1 Common model

1) Connect the underframe with vertical column by bolts and fix them to tractor.

2) Joint bucket, lift arm, support legs and cylinder with pins.

3) Put down the support legs, support the frontloader firmly, drive the tractor closely,

joint the vertical column with lift arm by pins, and fix the pins with bolts.

4) Connect the oil lines with flexible hose, notice that high-pressure hoses can’t be

distorted and be pulled too tight when installing.

5) During assembling, pour lubricant into every hinge, so as to make it rotate freely.

6) After assembly, make sure it is in neutral before start the engine, conjoin geared pump,

operate multi-way diverter valve pole, lift the working device, check all oil

lines’ coupling,

and ensure no leakage.

7) Operate multi-way diverter valve pole, make four cylinders and flow lines full of oil,

then add hydraulic oil to the scale of the oil-tank, for fear that oil pump empty.

8) If the tractor is demanded to do other work, take out the pins connecting the vertical

column and lift arm, put down the support legs, support the frontloader firmly, pull away the

multi-way valve’s quick coupling，separate the flexible hose from the underframe, and then

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the tractor can connect with other devices, such as pallet fork, etc.

2.3.2 Model A

1) Connect the underframe with vertical column by bolts and fix them to tractor.

2) Joint bucket, lift arm, support legs and cylinder with pins.

3) Put down the support legs, support the frontloader firmly, drive the tractor closely,

connect the rear hitch of the lift arm with the vertical column by quick-change pins, and fix

the pins with spring pins.

4) Connect the oil lines with flexible hose, notice that high-pressure hoses can’t be

distorted and be pulled too tight when installing.

5) During assembling, pour lubricant into every hinge, so as to make it rotate freely.

6) After assembly, make sure it is in neutral before start the engine, conjoin geared pump,

operate multi-way diverter valve pole, lift the working device, check all lines coupling, and

ensure no leakage.

7) Operate multi-way diverter valve pole, make four cylinders and flow lines full of oil,

then add hydraulic oil to the scale of the oil-tank, for fear that oil pump empty.

8) If the tractor is demanded to do other work, take out the quick-change pins connecting

the vertical column and lift arm, put down the support legs, support the frontloader firmly,

pull away the multi-way valve’s quick release coupling，separate the flexible hose from the

underframe, and then the tractor can connect with other devices, such as pallet fork, etc.

2.3.3 Model B

1) Connect the underframe with vertical column by bolts and fix them to tractor.

2) Joint bucket, lift arm, support legs and cylinder with pins.

3) Put down the support legs, support the frontloader firmly, drive the tractor closely, put

the lift arm in the vertical column correctly and joint by pins, and then fix them with bolts.

4) Connect the oil lines with flexible hose, notice that high-pressure hoses can’t be

distorted and be pulled too tight when installing.

5) During assembling, pour lubricant into every hinge, so as to make it rotate freely.

6) After assembly, make sure it is in neutral before start the engine, conjoin geared pump,

operate multi-way diverter valve pole, lift the working device, check all lines coupling, and

ensure no leakage.