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CONTENTS Service Manual 304G2

1. Possible causes Fixing methods a Sluggishness of nozzle valve Replace or grind it b Overloading Adjust the load c Wrong advance angle of fuel Adjust it d Poor sealing of valves or incorrect valve Check and adjust it timing Too much unevenness of the diesel Check fuel injection of every cylinder on distribution among cylinders injection pump test bed and make f Blockage of air filter adjustment g Wearing of cylinder liner and piston Blow or brush it clean rings Replace them with new ones b White smoke Possible causes Fixing methods a Too low the injection pressure results Check adjust or replace the injection pump poor in atomization with oil drops b Too low the temperature of cooling Cover the radiator with a cotton pad water c Water being in cylinders Check cylinder head gasket and cylinder head replace the damaged parts with new ones 47 c Blue smoke Possible causes Fixing methods guides c Too much high the lube oil level a The 3 ring is fitted upside down b Wearing of piston rings and valve Refit it with the ring face marked upward Replace them with new ones Make it down by draining 7 1 4 Insufficient power developing Generally the insufficient supply of oil air leakage and abnormal combustion will result in 7 1 5 such trouble Possible causes Fixing methods a Blockage of diesel filter b Poor atomizat
2. 00 Fig 51 Adjustment of rear wheel track 254G2 6 304G2 6 Fig 5 2 Adjustment of rear wheel track 354G2 6 404G2 6 Danger When removing the rear wheels please take great care and protecting measures and use suitable hoist Attention Select the suitable rear track first and then adjust the front track to suit the rear track 32 Points for attention a Make sure that front and rear wheels are symmetrical about the tractor centerline after adjustment is made Rear wheels can be exchanged for adjusting wheel tracks for rear wheel only os Make sure that the direction of lugs are determined by facing in the direction of forward travel Adjustment of front wheel drive axle Meshing conditions of gears of front wheel drive axle affects greatly the driving efficiency and noise level so attention must be paid to precision adjustment of gears while assembling The construction of front wheel drive axle is shown in Fig 7 There are 3 pairs of bevel gears in meshing from front center driving bevel pinion to drive shaft in the front wheel drive axle The gear backlash and meshing zone print the print should be in the middle of all the teeth face and deflecting to small end of teeth slightly i e short toe contact see Fig 6 of every pair of gears should be adjusted with eet care Fig 6 Meshing prints of bevel a The meshing of front main drive gears is adjusted by BT selecting
3. Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris On self propelled equipment disconnect battery ground Cable before making adjustments on electrical systems or welding on machine On towed implements disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine XService Cooling System Safely Explosive release of fluids from pressurized cooling system can cause serious burns Add make up coolant through the external container not directly to the radiator If radiator cap must be removed do not remove when engine is hot Shut engine off and wait until cap is cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely XService Tractor Safely Do not service the tractor while it is in motion or while the engine is running When servicing front wheel drive equipped tractor with rear wheels supported off ground and rotating wheels by engine power always support front wheels in a similar manner Engaging front wheel drive will pull rear wheels off support if front wheels are not raised Tighten wheel hardware to correct torque as specified in Wheels Tires and Tread section Torque at intervals shown in Break In Period and Lubrication and Maintenance sections to ensure that wheel hardware does not loosen
4. axle aligning King pin caster 0 King pin inclination Teor Steering gear Full hydraulic steering gear Brake Disc brake Traveling wheel E 6 5 16 6 50 16 7 5 16 Air pressure of front tyre 160 200 kPa 1 6 2 kg cm Specification of front tyre 28x9 15 10 16 5 COptional against order Industrial tyre Industrial tyre Air pressure of front tyre 300 340 kPa 3 3 4 kg cm ree Turf tyre Turf tyre Turf tyre Air pressure of front tyre 160 180 kPa Specification of rear tyre 9 5 24 11 2224 11 2224 12 4 24 Air pressure of rear tyre 100 150 kPa 1 1 5 kg cm 100 150 kPa 1 1 5 kg cm Specification of rear tyre Obliorabagainstorden 8 3 24 5 9 5 24 12 4 24 11 2 24 Air pressure of rear tyre 100 150 kPa 1 1 5 kg cm Specification of rear tyre 15 19 5NHS 16 5 22 5NHS Optional against order Industrial tyre Industrial tyre Air pressure of rear tyre 260 310 kPa Specification of rear tyre P Optional against order 11 2 20 4 Turf tyre 12 4 24 Turf tyre Air pressure of rear tyre 100 130 kPa 1 1 3 kg cm 2 5 Working devices Tractor Model 254G2 6 304G2 6 354G2 6 404G2 6 P CBN E310B BEDAYDE HLCB D04 04F1BR Hydraulic Plowing depth control Predetermined and simple adjusting system 1Oml r low 4ml r hydraulic st
5. TRACTOR SERIAL NO eeenn OWNER S SIGNATURE DATE DEALER S SIGNATURE DATE for manufacturer 67
6. connecting MI2 70780 8 8 bolts Main drive gear bearing seat 8 and rearaxle case M12 60 70 8 8 connecting bolts Appendix 7 Optional Accessories to be supplied against particular orders Seq PST No Accessory Quantity Application 1 12 5 80 18 Rearballast bolts 4 6 Increase adhesive force 2 Safety frame 1 Safeguard the operator 3 Rearballast bolts 4 6 4 Sunshade 1 Safeguard the operator from the sunshine and rain 62 Appendix 8 List of Attached Tools Se 5 Standard Code Designation and specifications Quantity Remarks No 1 GB3390 1 89 Socket head S 13 1 2 GB3390 1 89 Socket head S 16 1 3 GB3390 1 89 Socket head S 18 1 4 GB3390 1 89 Socket head S 24 1 5 GB3390 2 89 Square drive S 12 5 1 6 GB3390 2 89 Tommy bar L 300 1 are dri RU 8 GB3390 2 89 Open end spanner 8X10 1 9 GB4440 94 Adjustable spanner 250mm 10 1 10 GB4593 85 Gas pliers 150mm 6 1 11 GB5356 86 Hexagonal key spanner 6 1 12 Grease gun 1 13 1 Optional 14 Oil gun 1 Optional 15 Tyre pressure gauge 1 Optional 63 Appendix 9 Packing List Seq i Designation and specifications Quantity Remarks No i DF Brand tractor 1 To be disposed as per order 2 Spare parts amp tool kit of the engine 1 3 Attached tool kit of the tractor 1 4 Operation manual of the tractor 1 5 Illustrated parts ca
7. idly at low speed for a while after the engine is unloaded so as to cool down the lubricant and water then pull out the engine stop lever to stop engine Drain off cooling water when ambient temperature is below 5 C and drain off fuel oil when ambient temperature is below 5 C Control and usage of tractor s working devices Hydraulic lift system 27 a a b C Lifting amp lowering the farm implements seeFig E 3 Shift the control handle y h coun 4 9 allel A forward then the attached IT implement will be gm lowered down Fix the le 1 ae A depth stop block 1 at bi dl such a suitable position that the pin 2 will just Fig 3 Hydraulic lift touch the depth stop block 1 Depth stop block 2 Pin 3 Lift stop block 1 when implement is 4 Control handle 5 Hydraulic oil distributor lowered down to the 6 Lock valve desired working depth pull back handle 4 to the neutral position quickly so that the implement will be kept at the preset working depth When lifting of the implement is needed just shift the handle 4 backward the implement will be lifted up until pin 2 touches lift stop block 3 then push the handle to the neutral position Different lifting height can be obtained if lift stop block 3 is fixed at different positions If working depth needs to be adjusted slightly during working the control
8. 22 4 16 5 0 Gear V 7 32 7 71 7 09 7 38 Gear VI 11 06 11 64 10 62 11 15 Gear VII 17 75 18 68 17 04 17 89 Gear 25 69 27 03 24 66 25 89 2 2 Main technical specifications of the engine 2 3 Tractor Model 254G2 6 304G2 6 354G2 6 404G2 6 Engine Model 390 490 Type Vertical Water cooling Vertical Water cooling Four stroke Four stroke Number of cylinders 3 4 Cylinder bore mm 90 90 Piston stroke mm 95 100 Piston displacement L 1 813 2 543 Compression ratio 22 22 Cylinder sleeve type wet wet Rated power kW 18 4 22 4 25 8 29 4 em p consumption lt 275 lt 275 Rated speed rpm 2400 2400 2400 2400 Max Torque N m 289 296 8 22 117 8 2134 5 Net weight kg 195 200 Overal Length 587 729 Ines Width 492 512 ions Height 650 650 mm Drive system icr DF 254G2 6 304G2 6 354G2 6 404G2 6 Model Clutch Linkage type double acting clutch 4 1 X2 planar 3 shaft for main transmission epicyclic gearing for Gearbox Hi Lo speed range transmission Main drive One pair of spiral bevel gears Differential Bevel gear Finel Spur gear external gearin transmissions P 80a 8 5 2 4 Traveling and Steering System Tractor Model DF254G2 6 304G2 6 DF354G2 6 404G2 6 Front wheel drive axle Bevel gear drive axle Front wheel toe in mm 5 10 Front Outward camber 3 5
9. 3452 1 92 O ring seal 10 6 2 65 3 1 on PTO shaft 1 Gearbox GB 3452 1 92 O ring seal 11 2 X2 65 1 Gearbox 12 GB 3452 1 92 O ring seal 6 3 X 1 8 2 Hydraulic lift 2 in Rear axle 13 GB 3452 1 92 O ring seal 15X2 65 oe cee um 2 in Brake 3 Gearbox 14 GB 3452 1 92 O ring seal 18 2 65 ME PS in oil pump 15 GB 3452 1 92 O ring seal 1972 65 4 Brake 16 GB 3452 1 92 O ring seal 252 65 1 Gearbox 17 GB 3452 1 92 O ring seal 26 5 2 65 2 Final drive 18 GB 3452 1 92 O ring seal 3072 65 1 1 on PTO shaft 19 GB 3452 1 92 O ring seal 33 5 3 55 1 Rear axle 20 GB 3452 1 92 O ring seal 38 7 5 3 2 Hydraulic lift 21 GB 3452 1 92 O ring seal 53X2 65 1 in Oil pump 1 Front wheel drive 22 GB 3452 1 92 O ring seal 48 7X3 55 3 axle 2 1 in drive shaft 23 GB 3452 1 92 O ring seal 87 53 55 1 Hydraulic lift 24 GB 3452 1 92 O ring seal 1033 55 2 Final drive 25 GB 3452 1 92 O ring seal 34 52 65 2 Front wheel drive axle 26 GB 3452 1 92 O ring seal 6572 65 1 Front wheel drive axle 27 GB3452 1 92 O ring seal 69X2 65 1 Front wheel drive axle 59 Front wheel drive 28 GB3452 1 92 O ring seal 7333 55 2 axle 1 Gearbox 29 GB 3452 1 92 O ring seal 56X2 65 2 Front wheel drive axle Front wheel drive axle 30 GB 3452 1 92 O ring seal 6973 55 2 Hydraulic itt 31 GB 3452 1 92 O ring seal 23 62 65 1 Front wheel drive axle 1 in
10. L 1 199W uoneurqui0 qojras due Suerg 9 10suos o8ne8 IO Gc YOIMS 5 194V p 105095 M C 105105 oinsso1id pO 1 8114 oruioqonoo q Q 10319099 6 0 6 1030 9 8 19 18 8 o qeo o od oAn sod 9 ssouregjuorg gi1oje pndoro3 j oA p Woy yog e Ajegneg jgnpeogd seal and O ring seal List of Rubber Oil Appendix 4 58 seq Standard Designation and specifications Quantity Location No codes No 1 GB13871 92 Cased rubber oil seal 40X62X8 1 PTO shaft 2 HG4 692 67 Cased rubber oil seal W50X72X7 4 4 in Front wheel drive axle 3 HG4 692 67 Cased rubber oil seal PD 50X72 12 4 4 in Front wheel drive axle 4 HG4 692 67 Cased rubber oil seal PD 50X 70X 12 2 Final drive 5 HG4 692 67 Cased rubber oil seal SD 60 90X 12 4 Final drive 6 HG4 692 67 Cased rubber oil seal PG 25X42X 10 3 2 ne dd E in drive shaft 2 in gearbox 7 HG4 692 67 Cased rubber oil seal SD 35X56X 12 3 1 in front wheel drive axle 8 HG4 692 67 Cased rubber oil seal SD 32X 52X 12 2 Brake 9 JB2600 80 Cased rubber oil seal SG 35 55 X10 1 Gearbox 10 GB 3452 1 92 O ring seal 10 6 1 8 1 Hydraulic lift 1 in hydraulic lift 11 GB
11. before putting it into service Running in improves the condition of all the running fits and pairing surfaces so as to avoid premature 22 3 1 3 1 1 3 12 32 3 2 1 3 2 2 3 3 3 3 1 3 4 3 4 1 failures Running in of engine without load Please read carefully the engine operation manual before starting the engine After starting let the engine run at the medium or low speed and then gradually speed it up after water and oil temperature rises It is to be avoided to run the engine at high speed right after starting Check whether there is any water oil and air leakage and whether all instruments and indicators work well while the engine runs for heating up Let the engine run for 5 minutes at maximum speed and observe engine s working status the total running in time of engine without load needs 20 30 minutes Running in of the tractor without load Drive the tractor away from rest according to regulations set forth in this operation manual Run the tractor at every forward and reverse gear for half an hour respectively And do the steering operation at medium and low speeds properly use either LH brake or RH brake in concert with the steering operation try emergency braking when tractor running at gear VII or VIII with limited throttle and engage the front wheel drive axle if the tractor is a four wheel drive one Engage the PTO shaft and operate the hydraulic lifting system repeatedly so as to do the run
12. color combination Marker lamp 10W Orange color light Turning indicator lamp 21W Orange color Rear working light 50W White color Caution light 10W Orange color 21 License plate light 10W White color Front combination Turning indicator lamp 21 W Orange color light Position light 5W White color The switch controls headlamps rear working lights marker lamps and flashers 27 Filling capacity Tractor Model DF254G2 6 304G2 6 DF354G2 6 404G2 6 Fuel tank 28 L diesel 28 L diesel Cooling system 8L 10L Engine sump 4L SL Gearbox and rear axle 20L 25L 2 8 Main farm implements to be attached optional Name Specification Trailer Rated loading capacity 2 tons Rotary tiller Tilling width 1 25 1 5 m Light duty three furrow plow Width of plowing 60 cm Plowing depth 16 18 cm Deep tillage double plow Width of plowing 60 cm Plowing depth 18 30 cm PTO driven rotary spike harrow Harrowing width 1 4 m Mounted combine harvester Width of harvesting 1 4 1 6 m Feeding capacity 1 1 4 kg sec Straw cutter Width of cutting 1 0 m Light harrow Width of harrowing 1 5 m Wheat seeder Sowing width 1 8 2 25 m Chapter III Running in of the tractor In order to prolong the service life of tractors it is essential to do the running in of a new tractor or the one right after major overhauling
13. dealer for repairing Hydraulic system Troubles amp possible causes Fixing methods 1 Insufficient lifting force or lift system not working a Too low the oil level or improper hydraulic oil used b Oil strainer clogged c Air being sucked into hydraulic system d Oil pump seal ring seriously worn out and inner leaking seriously e Main control valve seized being f Main control valve worn out seriously 2 Safety valve failure h Cylinder leaking seriously 1 Leakage at distributor seal rings 2 Implement not lowering a Main control valve seized or the lock valve closed Add or replace with proper oil to specified level Wash the strainer Bleed air in the system and tighten connector or replace seal ring Replace the oil pump seal ring Operate lift control lever several times and shift the main control valve with a screw driver if still seized disassemble and wash it clean Replace worn out parts Readjust or repair safety valve Replace seal ring or replace the worn out parts 1f necessary Replace seal rings Please fix up the problem by referring to Point 1 or screw up the locking valve to the highest position 53 7 3 Electrical system 7 3 1 Battery Trouble amp possible causes Fixing methods 1 Electric power always insufficient a Generator or regulator failure Check wire connection and remove trouble b Poor wire c
14. end face of the brake housing and the inner end face of the brake cover as well which affects the brake performance considerably Excessive free travel of the brake pedal will even cause the brake ineffective So the brake should be inspected and adjusted regularly to ensure the safety of the tractor while in traveling No matter the tractor is new or old the adjustment should be done in time whenever one of the following brake faults appears The brake is ineffective due to excessive free travel of brake pedals b The free travel of the brake pedals is too much little and the brakes are kept in semi braking status all the time which makes the brake housing become hot and further quicken the wear and tear of the brake discs The braking force of left side and right side pedals is different which causes the brake bias Fig 10shows the structure of disc brake that is consisted of the brake itself and the brake control mechanism The adjusting methods ar as follows 36 e Fig 10 Adjustment of disc brake 1 2 NutM16 3 Pushrod 4 Nut MIGNut M12 5 NutM12 6 Pull rod 7 Hand brake assemble 8 Nut M12 9 Self aligning cushion 10 Pin 10x70 11 Brake
15. gas mixture occurs when charging batteries therefore fires sparks naked lights and smoking are prohibited Avoid causing sparks when dealing with cables and electrical equipment and beware of electrostatic discharges Avoid short circuits Battery acid is highly corrosive therefore Wear protective gloves and eye protection Do not tilt battery acid can escape from the degassing openings or vents Rinse off acid splashed in the eyes immediately for several minutes with clear water Then consult a doctor immediately Neutralize acid splash on skin or clothes immediately with acid neutralizer soda or soap suds and rinse with plenty of water If acid is consumed consult a doctor immediately Hand in old batteries at a collection point Never dispose of old batteries as domestic waste STORAGE Always keep the battery as fully charged as possible to prevent the formation of large lead sulfate crystals Never leave the battery standing when flat or partly discharged Check charged batteries in storage at regular intervals and recharge at the latest when the PowerCheck displays a dark light Do not place batteries in direct daylight without protection Discharged batteries can freeze up therefore store in an area free from frost This series of product can be stored for 6 months in room temperature CHARGING While charging of importance in this process is the optimum controller voltage of 14 2 V If the controller voltage is too high
16. into all the grease nipples 24 4 1 Chapter IV Operating the Tractor Control mechanism and instruments of the tractor There are various control mechanisms and instruments laid out round the operator s seat in the middle part of the tractor The water thermometer oil pressure gauge ammeter air pressure gauge are located on instrument panel Combination meter can be the option which includes electronic tachometer ammeter water thermometer oil pressure gauge and fuel gauge When engine works normally the water temperature should be within 80 95 C and the maximum should not be over 98 C The oil pressure be at 2 4 MPa but not lower than 0 5 MPa while idly running Ammeter shows the work status of battery i e when the generator is working and the battery is being charged the pointer of ammeter should deflect to side otherwise the battery is being discharged Headlight switch turning indicator switch rear working lamp switch flasher switch electric switch are all placed on the lower rear side of instrument case As to the use of the electric switch please refer to the working diagram see Fig 1 of the Electric switch i e turning the key at OFF position to set the circuit off at ON position to set the circuit live and Y position for preheating Turning the keyclockwise to H position is for starting engine after preheating Turning it clockwise to ST position is for starting e
17. lube oil as regulated Check and fix break downs Non oil pressure or abnormal oil pressure a Not or too low the oil pressure Possible causes Fixing methods a Too low the oil level b Oil suction pipe NOT submerged in lube oil so air comes in the pipe c Paper gasket of oil filter is assembled in a reversed way or broken Spring of the pressure regulator valve of oil filter is out of shape or broken e Wear and tear of oil pump f Too much the clearance of bearing fittings Replenish Reassemble and check whether it is broken Reassemble or replace it Replace it Replace it or reduce its paper gasket Check and replace them if necessary b Overpressure of lube oil Possible causes Fixing methods 46 a Pressure regulator valve of filter is Check and adjust it out of order b Oil becomes too thick at low Replace it with the lube oil of designated temperature category c Nolube oil on the rocker shaft Possible causes Fixing methods a Too low the oil pressure Make adjustment b Blockage being somewhere Find out and fix it lubricating system Smoking of the exhaust Normally poor atomization and combustion causes black smoke If diesel drops are unable to burn or some water comes into cylinder then the white smoke will be resulted Burning of lube oil scurrying above the piston will produce blue smoke a Black Smoke
18. our Oil inlet Engine please refer to the Engine operation manual 1 on upper cover of the rear axle housing 1 on crankcase of the air pump 1 on left amp right sleeves of the front axle Grease nipples 1 Water pump bearings of the engine 2 on the turnbuckles of the left amp right lifting rod 1 on upper link 2 on the turnbuckles of the left amp right check chains 2 on front amp rear jaws of steering drag link 2 on left amp right jaws of steering tie rod 2 on left amp right steering arms 2 on rear pedestal four wheeled drive only 2 on left amp right steering crank four wheeled drive only 1 on clutch operating shaft 1 on brake operating shaft Oil level inspection points Dipstick of engine Dipstick on upper cover of rear axle housing Dipstick on left half shaft housing of front wheel drive axle Oil drain plugs on Bottom of the engine sump Lower left side of the gearbox Lower rear side of the rear axle housing 42 6 1 6 2 1 Bottom of the oil tank Bottom of front wheel drive housing four wheeled drive only Bottom of transfer case housing Maintenance of the tractor Every shift maintenance A Engine a C d Make sure that the engine lube oil is enough and keep the oil level between the middle notch and upper notch on the dipstick Oil level beyond the upper notch is NOT permitted Let the new engines and those that have been stored for a long time run at low speed for 5 to 10 minutes then c
19. protect against objectionable or uncomfortable loud noises Shift to Low Gear on Hills Shift to a low gear before descending a steep hill to improve your control of the tractor with little or no braking Use engine braking to reduce speed before applying tractor brakes Run away tractors often tip over Never coast downhill When driving on icy wet or graveled surfaces reduce speed and be sure tractor is properly ballasted to avoid skidding and loss of steering control For best control engage mechanical front wheel drive if equipped Additional ballast may be needed for transporting heavy hitch mounted implements When implement is raised drive slowly over rough ground regardless of how much ballast is used Riders Off Machine Only allow the operator on the machine Keep riders off Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine Riders also obstruct the operator s view resulting in the machine being operated in an unsafe manner Freeing a Mired Machine Attempting to free a mired machine can involve safety hazards such as the mired tractor tipping rearward the towing tractor overturning and the tow chain or tow bar Actable is not recommended failing and recoiling from its stretched condition Back your tractor out if it gets mired down in mud Unhitch any towed implements Dig mud from behind the rear wheels Place boa
20. water will be released as a product of electrolysis This lowers the electrolyte level fluid level as time goes on If the controller voltage is too low the battery will not be charged correctly shortening its service life Consistent voltage charging 16 V 16 2 V maximum Consistent current charging Set the electric current as C20 10 and keep the charging voltage less than 16 V Charging finish Till the hydrometer turns to green or the consistent open circuit voltage is larger than 12 65 V INSTALLATION Prior to installation or removal switch off all electrical consumers Essential for installation the battery must be installed in such a way that it is mechanically secured Its degassing vents must not be covered The positive and negative cables should be connected correctly with the terminals Essential for removal when detaching the electrical connections first remove the ground cable from the negative terminal Then disconnect the cable from the positive terminal This avoids short circuits MAINTENANCE According to the PowerCheck a green display and a thumb pointing up wards show that the battery is at maximum charge and will always start the vehicle reliably If the charge state is 40 insufficient the driver will see dark The battery should then be recharged as soon as possible Once this has been done PowerCheck displays a green light again and the driver can get back on the road The surface of the battery
21. 4 7 Diesel engine 8 Oil Filter 9 Oil tank i e rear axle housing Fig 8 Working principle of the full hydraulic steering gears 5 4 2 Structure of the full hydraulic steering gear and points for attention a The structure of the full hydraulic steering gear is shown in Fig 9 The Rotary servo valve consisting of the Valve element 6 Valve bush 5 and Valve body 4 controls the flow direction of hydraulic oil The Stator 9 and Rotor 10 makes up the pair of cycloidal toothing functioning as the flow control valve which makes the hydraulic oil flow enter into the steering cylinder be in the direct ratio of the turning angle of steering wheel The Linkage shaft 7 transmits torque The full hydraulic steering system is actuated by the steering cylinder therefore the torque to be applied to the steering wheel is little normally 4 5 N m If the steering operation is found out to be quite heavy or even jamming please do not recklessly turn the steering wheel with fierce force but to check thoroughly and fix up the trouble first In case the tractor is to be dislocated by pushing or hauling while its engine is stopped working then the steering wheel should be turned fully manually Please note the torque to be applied to the steering wheel should not be over 250 N m and further more the impulsive and fierce force 15 prohibited otherwise some parts might be damaged Great care should be taken of the concentricity of the stee
22. 5 GB T297 1994 Antifriction bearing 32014 2 Final drive 16 GB T276 1994 Antifriction bearing 6206 1 1 on PTO shaft 17 GB T276 1994 Antifriction bearing 6307 2 Final drive 18 GB T301 1995 Antifriction bearing 51106 2 Front wheel drive axle 19 GB T297 1994 Antifriction bearing 31306 1 Front wheel drive axle 20 GB T297 1994 Antifriction bearing 32006 1 Front wheel drive axle 21 GB T276 1994 Antifriction bearing 60205 1 Drive shaft 22 GB T276 1994 Antifriction bearing 6305N 2 Transfer case 23 GB T276 1994 Antifriction bearing 6205 1 Transfer case 24 GB T276 1994 Antifriction bearing 6304 1 Transfer case 25 GB T5801 1994 Needle bearing 4524906 2 Transfer case 26 GB T276 1994 Antifriction bearing 6111 2 Front wheel drive axle 27 GB T309 2000 Needle 3 X 23 8 78 PTO shaft 28 GB T276 1994 Antifriction bearing 6108 1 29 GB T5846 1986 K223020 PTO shaft 61 Appendix 6 Tightening Torque Table of Main Bolts and Nuts Seq Tightening No Location Designation Specifications torque N m Intensity grade 1 Cylinder head studs amp nuts M12 118 137 8 8 2 Connecting rod bolts M10X1 56 69 8 8 3 Main bearing studs M10 115 125 8 8 4 Flywheel bolts M12 98 118 8 8 5 Differential gear bolts MIO 40 50 8 8 6 Distributor fixing bolts M8 15720 8 8 Rear axle shaft housing and 7 rear axle case
23. CONTENTS Service Manual 304G2 Safety 1 Precautions enn hehehe Chapter Work safely Always and safety Rules 14 Chapter Technical Specifications of the Tractor 18 Chapter III Running in of the 23 Chapter IV Operating the Tractor eneee nae 25 Chapter V Adjustments of the 31 Chapter VI Lubrication and Maintenance of the Tractor 43 Chapter VII Troubles and Trouble shooting 47 Appendix 1 Moving Locus Diagram of Lifting 57 Appendix 2 Moving Locus Diagram of Lifting 58 Appendix 3 Diagram of Electrical System Principle 59 Appendix 4 List of Rubber Oil seal and O ring 60 Seal eerie Appendix 5 List Of Bearings iore rr rns Ea dep Eye RE dur des 62 Appendix 6 Tightening Torque Table of Main Bolts and Nuts 63 Appendix 7 Optional Accessories 63 Appendix 8 List of Attached 5 64 Appendix 9 Packing 65 LiSt 2 09 ne wie M MEN fone PRE DELIVERY SERVICE 66 Safety Precautions K Recognize Safety Information This is a safety alert symbol When y
24. Gear VII amp VIII for hauling operation b In operation it is prohibited to ride the clutch i e keep foot on clutch pedal half depressed or to control speed with the clutch Otherwise the clutch will get overheated which will cause premature wear out of the friction discs because of friction disc slippage and even cause further damage to the release bearing release levers and the release bearing seat as well c In field operation LH or RH brake may be singly used to reduce the turning radius When emergency braking depress down clutch pedal and brake pedal at the same time NEVER step on brake pedal only so as to avoid damage to the brake and other parts d Close hydraulic lock valve and disengage PTO shaft when the tractor is going to travel for a long way with an implement mounted e When tractor works in the dry field the user may install the rear wheel ballast optional in order to make full use of the traction force If the tractor is provided with the cabin thenitis also OK not to install the rear wheel ballast Stop of tractor a Reduce throttle to slow down the tractor b Step on clutch pedal shift speed changing lever to Neutral position a Depress brake pedal to stop the tractor then release clutch and brake pedals let engine run idly at low speed and apply the parking brake b Lower down the implement attached c Never step on the throttle fiercely just before stopping the engine but let the engine run
25. MONES RENE INSPECTION PERFORMED WARRANTY EXPLAINED INSTALLATION COMPLETED TRACTOR MODEL NO mmn TRACTOR SERIAL nn OWNER S SIGNATURE DATE DEALER S SIGNATURE DATE for dealer 66 PRE DELIVERY SERVICE INOPERATIVE SERVICE CHECKS SAFETY ITEMS CHECKS 1 Tyre pressures and condition D 1 Seat belt installed where applicable DL 2 Lift rod levelling crank for proper operation 2 Safety decals installed seen nnn 3 Radiator coolant level and specific gravity 3 Neutral start switches operative H 1 071 1 083 at 160 C 60 F E 5 PME RE esee ene 5 Flashing lights tail lights operation 4 POW V Della o eite ERI nn oO 3 ievel o 6 Operator s Manual supplied Clea e 7 PTO guard installed sess 6 a Ar Diori ET 8 S M V emblem installed where applicable L 7 Front axle differential oil level 4wd 2 8 Front axle hub oil level 4wd 9 Brake adjustment and pedal equalisation DL OPERATIVE SERVICE CHECKS 10 Upper link drawbar and pin in position Au operative checks are to be performed with the trac 11 Wheel to rim clamp bolts and lock nuts tor at normal operating temperature OO TELE NN E 1 Lights and instruments for proper operation 0 12 Wheel disc to hub nut
26. Reinstall protective covers removed during service Support Machine Properly Always lower the attachment or implement to the ground before you work on the machine If you must work on a lifted machine or attachment securely support the machine or attachment If left in a raised position hydraulically supported devices can settle or leak down Do not support the machine on cinder blocks hollow tiles or props that may crumble under continuous load Do not work under a machine that is supported solely by a jack Follow recommended procedures in this manual When implements or attachments are used with a tractor always follow safety precautions listed in the implement operator s manual Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating f you sand or grind paint avoid breathing the dust 10 Wear an approved respirator f you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before welding or heating x Avoid Heating Near Pressurized Fluid Lines Flammable spray can be generated by heating ne
27. ake pulling rod should be shortened on the side with the short print length of tire or vice versa in order to make both rear wheels to brake simultaneously and reliably Adjustment of rear axle In order to assure the reliable working of main drive the spiral bevel pinion and spiral crown gear should be assembled with a mated pair and adjusted to right position for reasonable engaging In operating if normal engagement position is disrupted due to bearing s damage or other reasons it must be adjusted again after replacing the damaged bearing with a new one or fixing up other troubles As to the assembling diagram of the main drive please refer to Fig 12 Fig 11 Diagram of meshing zone While assembling the spiral bevel pinion and the spiral crown gear the pre stress of the bearings in main drive has to be correctly established first and the meshing of the pinion and crown gear could be then adjusted As to the spiral bevel pinion its pre stress of bearings is to be adjusted by screwing down the Locking nut 2 The torque to be applied for turning the spiral bevel pinion should be kept between 1 176 1 764 N m after the assembling is completed If the torque can t be measured by a specific apparatus then it must be adjusted by an experienced people After adjusting is made the locking nut 4 must be tightened and the angles of check shim 3 should be pulled down into slots of the two lock nuts respectively The axial position
28. al free travel Readjust the LH amp RH pedal travel to make the braking force same Wash the stained brake shoe lining clean and remove oil leakage Replace with new springs Check whether the pedal return spring is damaged or operating shaft is seized and fix up the troubles Readjust the pedal free travel Gearbox Troubles amp possible causes Fixing methods 1 Abnormal sound in gearbox 51 a Gearbox bearings or needle rolers excessively worn out or damaged b Abnormal meshing of main drive gears c Spline shafts and the splined hole of gears worn out 2 Trip over stop a Shift fork excessively worn out or deformed b Fork shaft locking spring weakened c Tooth profile or spline excessively worn out 3 Gearbox overheat a Too less the clearance of bearing or gear backlash b Insufficient or excessive lubrication oil c Lubricating oil deteriorated Check and replace worn out bearings or needle rollers with new ones Examine gear meshing zone print and backlash adjust them as per stipulations Replace worn out parts with new ones Replace with a new one Replace with a new one Replace worn out parts with new ones Readjust Add or drain off lubricating oil to the specified level Renew lubricating oil Traveling and steering system Troubles amp possible causes Fixing methods 1 Front wheel wobble a Excessive clearance of front Adj
29. and maintenance of it and they also have to be duly authorized to operate it in advance Do not attempt to increase the maximum engine rpm by altering the setting of the fuel injection system Do not alter the pressure relief valve settings of the different hydraulic circuits hydraulic lift and remote control valves Do not operate tractor if you feel unwell or physically unfit in which case you should stop working Always operate with the cab and rollover safety frame undamaged complete of all components and correctly installed on the tractor periodically check fastenings for tightness and frame and structures to make sure they are free from damages consequent on accidental impacts Starting the Tractor Prior to starting the engine check that the parking brake is on and transmission and PTO are in neutral Make sure all implements are fully lowered down to ground before starting the engine Make sure before starting the engine that all guards shields and protections are correctly installed on your tractor Do not attempt to start or drive the tractor unless sitting in the operator s seat Always make sure before starting the tractor in motion that there are no people or obstacle within range Do not run the engine inside closed premises without adequate ventilation as exhaust fumes are harmful to health or may even become deadly Tractor Operation Select the track width setting best suitable to work always keeping tractor s
30. anvas Drain away thoroughly the water in radiator for passing away the winter season 45 7 1 7 1 1 Chapter Engine Diesel engine fails to start a Breakdowns of fuel system VI Troubles and Trouble Shooting Possible causes Fixing methods No fuel in fuel tank Air in fuel system c Blockage of fuel system Plunger and barrel of injiection pump worn out e Seizing of injector or bad atomization Add fuel Bleed air find out the reason and fix it up Replace the fuel filter element with new one and check the fuel delivery pipe Replace with a new one Replace with a new one or grind it b Insufficient compression pressure Possible causes Fixing methods a Insufficient valve clearance maladjustment of decompression screw b Leakage of valve c Leakage of cylinder head gasket or the d Wear and tear sticking or gap lapping of piston rings Adjust as per regulations Replace with new one or grind it Replace with a new gasket and fasten cylinder head nuts according to regulations Replace the damaged ones clean the sticking ones or reassemble them c Other causes Possible causes Fixing methods a Incorrect advance angle of fuel and valve timing after reassembling b Low ambient temperature c Wrong lube oil d Water being in cylinder Readjust them Use electrothermic plug or fill hot water into the radiator for preheating Use the engine
31. ar 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 Pressurized lines can be accidentally cut when heat goes beyond the Immediate flame area Store Attachments Safely Stored attachments such as dual wheels cage wheels and loaders can fall and cause serious injury or death Securely store attachments and implements to prevent falling Keep playing children and bystanders away from storage area K Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by 1 Filling batteries in a well ventilated area 2 Wearing eye protection and rubber gloves 3 Avoiding breathing fumes when electrolyte is added 4 Avoiding spilling or dripping electrolyte 5 Use proper jump start procedure If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or milk but do not exceed 2 L 2 quarts 3 Get medical attention immediately XService Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death Do
32. as well The print on crown gear shall be taken for evaluation no matter the print is on convex surface or concave surface After adjustment having been made the gear backlash should range from 0 15 0 30 mm Final drive system If chippings from the pinion teeth surface of final drive are found after disassembling the rear axle then the pinions of left final drive gears and right one should be exchanged which may prolong their service life Electrical system The electric circuit of the tractor is of 12 V Battery The tractor is equipped with 6 QW 80 maintenance free lead acid battery When ammeter s pointer turns to the battery is in charging and when ammeter s pointer turns to the battery is in discharging The battery is in charging while the tractor is working in normal condition We may use an AVO meter to check and judge whether the battery is sufficiently charged or not To avoid unnecessary accident Please DO NOT short circuit by connecting directly the two battery poles positive and negative or connecting the positive pole to the tractor s outer 39 housing for checking current intensity of the battery For the sake of your safety and effective use of our product please carefully read the instruction before using SAFETY Keep children away from acid and batteries It is of extreme importance that batteries be inserted into equipment correctly with regard to polarity A highly explosive oxyhydrogen
33. assemble 12 Brake housing 13 Ruturn spring 14 Brake cover 15 Rocker arm16 Hand brake rod 17 Connecting clevis 18 LH brake 19 RH brake peda 20 Interlock pin 21 Pin 5x20 a Free state adjustment of the disc brake Loosen the outer locking nut M12 8 to change the mounting angle of the rock arm 15 through the longitudinal motion of the self position cushion 9 Ensure that the central connecting line of the upper and lower holes incline to the rear from the plumb line After adjustments are made lock it with the locking nut 8 b Travel adjustment of the brake pedal Loosen the locking nut 2 and 4 on the push rod adjustment fork 5 and on the brake pull rod adjusting fork to change the length of the pull rod 3 until the displacement 37 from the highest position of the brake pedal to friction disc assembly being completely braked on the brake pedal is 25 35 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 and fork with locking nut 2 4 c Brake deviation motion adjustment When left and right brake adjustment is identical and the tractor is running at high speed if the brake is applied as in an emergency an identical tire print length should appear and there should be no pulling motion to one side or the other If this is not true then the left and right brake are not matched In such case the br
34. ck time intervals very much depend on ambient and working conditions or on your experience Remember that in any case it 15 better to check too much than too little Caution In case you have any problem or difficulties in operating or maintaining your DF Brand Tractor please get contact with one of our DF dealers accessible Tractor Storage When your tractor is to be kept in storage for an extended period of time be sure to take the protective measures hereunder The maintenance of engine should be carried out as per the instructions of engine manual Thoroughly clean the tractor especially the body parts brush protective coating on the unpainted metal parts store the tractor under cover and in dry and well ventilated premises Ensure that all controls in neutral or off or released position including the electrical switch and the parking brake Do not leave the key in the starter switch Make sure that all hydraulic piston rods are fully withdrawn Fill up the fuel tank to maximum level M Remove battery clean battery top and coat terminal clamps and leads with Vaseline subsequently store the battery in dim and ventilated premises with temperature remaining above 10 Put stands or other supports under the front wheel drive axle and rear axle in order to 44 bear the tractor weight With the tractor being propped up it is advisable to deflate tires Cover the tractor with non waterproof c
35. d to disengage the PTO shaft dismount drawbar coupling and the PTO shaft guard then connect PTO shaft with a specific farm implement The PTO shaft speed of tractor and the required input speed of farm implement should be identical Fix firmly the tractor and implement if some stationary job is to be done 29 Chapter V Adjustments of the tractor 5 1 Adjustment of the engine Please refer to the engine operation manual for its adjustment 5 2 Adjustment of the clutch 30 Clutch will slip or disengage incompletely in operating because of parts wearing so it must be adjusted in time to ensure the tractor s normal working status The structure of the linkage type double acting clutch is shown as Fig 4 It mainly consists of three parts the driving part driven part and controlling part The driving part rotates with the engine flywheel only when the clutch engages can the driven part rotate with the engine Double acting clutch should be adjusted on the flywheel The adjusting steps are as follows a Loosen the nut M10X1 18 adjust the length of adjusting bolt 20 to make the distance between three release levers 17 and the end face of flywheel be of L 156 5 mm Meanwhile the tips of three release levers should be kept in the same vertical plane with a permissible error range of 0 to 0 20 mm After adjustment is done tighten the nut MIOX 1 18 b Loosen the nut MIOX 1 7 adjust the length of Adjusting bolt 8 to make th
36. do not have an exhaust pipe extension open the doors and get outside air into the area Avoid Contact with Pesticides Enclosed cab does not protect against inhaling harmful pesticides If pesticide use instructions require respiratory protection wear an appropriate respirator inside the cab Before leaving the cab wear personal protective equipment as required by the pesticide use instructions When re entering the cab remove protective equipment and store either outside the cab in a closed box or some other type of sealable container or inside the cab in a pesticide resistant container such as a plastic bag Clean your shoes or boots to remove soil or other contaminated particles prior to entering the cab Stay Clear of Rotating Drivelines Entanglement in rotating driveline 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 Prevent collisions between other road users slow moving tractors with attachments or towed equipment and self propelled machines on public roads Frequently check for traffic from the rear especially in turns and use turn signal lights Use headlights flashing warning lights and turn Signals day and n
37. e disengaged Work after the running in Drain off hot lubricant in all the sumps of chassis immediately add some clean diesel oil 23 3 4 2 3 4 3 3 4 3 1 3 4 3 2 3 4 4 3 4 5 3 4 6 3 4 7 jack up one of rear wheels if it is a four wheel drive tractor also jack up one front wheel on the same side start the engine run the tractor for 2 minutes at Gear I with low throttle meanwhile operate the hydraulic lift system for several times then stop the engine drain off the washing oil while the machine is still hot and fill up with fresh oil at last Drain off the lube oil from engine sump while the engine is still hot add clean diesel oil to wash clean the sump and oil filter replace filter element and then fill up with fresh lube oil Clean fuel filter and air filter Cleanning fuel filter should not be done in the field but in a clean place a Close the fuel filter cock b Remove the fuel filter and take out the element and dip it in the kerosene to rinse c Please pay close attention not to run the engine when filter removed Cleanning air filter Shock the filter element lightly blow the compressed air from inside The pressure of compressed air must be under 588kPa Drain off the cooling water clean the cooling system with soft water Check all the fasteners tighten any of them if necessary Check toe in of the front wheel the free travel of brake and clutch pedals make adjustment 1f necessary Add grease
38. e distance between the end faces of Adjusting bolt 8 and the Sub clutch pressure plate be of 0 9 1 mm After adjustment is done tighten the nut MIOX 1 7 c Loosen the nut MIOX 1 adjust the length of pull rod 11 until the free travel of pedal reaches 30 2 mm ensure that the clearance from tips of three release levers 17 and the release bearing assembly 16 is of 2 2 5 mm then tighten the nut 10 1 After adjustment is done step on the clutch pedal the main clutch and sub clutch should be disengaged in turn after releasing the pedal the main clutch and sub clutch should be engaged smoothly and work reliably URIN my 1 s STE 2 a dt m b J 18 17 6 15 413 Fig 4 Linkage type double acting clutch 1 Main clutch driven disk assembly 2 Main clutch pressure plate 3 Dish spring 4 Fixed clutch pressure plate 5 Sub clutch driven disc 6 Sub clutch pressure plate 7 Nut MIOx1 8 Adjusting bolt 9 Clutch cover 10 Ruturn spring 11 Pull rod 12 Clutch pedal 13 Release shaft 14 Release bearing seat 15 Release fork 31 16 Release bearing assembly 17 Release lever 18 Nut MIOx1 19 Ruturn spring 20 Adjusting bolt 21 Flywheel 5 3 Adjustment of the rear axle Rear wheel track adjustment see Fig 5 1 Fig 5 2 Rear wheels can be fitted with the concave side of wheel disk facing either inward or outward The wheel track is different for each of these fitting positions
39. e is clear of tractor and attached equipment before Starting engine Never try to get on or off a moving tractor When tractor is left unattended place In NUETRAL Apply hand brake lower implements to the ground stop the engine and remove the key Caution on Hillsides Always wear seat belt with ROPS in upper position Avoid holes ditches and obstructions which cause the tractor to tip especially on hillsides Avoid sharp uphill turns Never drive near the edge of a gully or steep embankment it might cave in Driving forward out of a ditch or mired condition or up a steep slope could cause tractor to tip over rearward Back out of these situations if possible While mechanical front wheel drive greatly increases traction it DOES NOT increase stability of the tractor With mechanical front wheel drive engaged the tractor can climb steeper slopes but it does not become more stable When this option is used extra caution is needed on slopes Compared to a 2 wheel drive a front Wheel drive tractor maintains traction on steeper slopes increasing the possibility of a tip over Danger of overturn increases greatly with narrow tread setting at high speed Hitch towed loads only to drawbar When using a chain take up the slack slowly K Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to
40. e with a new one Check and replace the failure parts Replace with a new piston or a cylinder liner 48 Serious vibration Normally it is caused by uneven working of cylinders or by incorrect assembling Possible causes Fixing methods a The difference of compression ratio and fuel distribution among cylinders 18 considerable b Air being in fuel pipes c Diesel engine is wrongly aligned in mounting fixing bolts somewhat loose d Piston knocking makes engine rough working Check and make adjustment Bleed air Align the engine and fasten the fixing bolts again Check nozzle of injector and advance angle of fuel make necessary adjustment Engine overheat Possible causes Fixing methods a Air leakage of piston rings b Water coming into engine oil oil diluted and deteriorated or too much high or low the oil level c Too much tight the bearing fitting d Water pump is broken or its belt is too much loose resulting in water overheating e Temperature regulator is out of work or insufficient water in tank f Cylinder head gasket is broken Too much scale in water jacket h Injector being seized i Engine overloaded j Advance angle of fuel is too much Replace with new rings Check and replace the engine oil or adjust the oil level by making drainage or replenishment Check and adjust Check and adjust Check and adjust the regulator or replenish wa
41. eering Response pressure of the safety valve 14ml r 16 MPa Mounting system Rear mounted ball socket type I GB T1593 1 1996 20 Lifting time lt 38 Pin hole diameter of upper mounting point 19 5 mm Pin hole diameter of bottom mounting point 22 5 mm Traction Hitch pin diameter 30 mm device Ground clearance of drawbar frame 390 Type Linkage Rotating speed 540 rpm and 1000 rpm PTO shaft Spline size 6 tooth 035 Rectangular spline E TM Clocks 2 6 Electric apparatus and instrument Tractor Model 254G2 6 304G2 6 354G2 6 404G2 6 Electric circuit 12V Single phase amp negative ground Battery 6 QW 80L 80 Starter QD1332C Generator JF11 350W Preheat plug 10 12 55 12 V Measuring Tachometer 0 3000r min range of Water thermometer 40 120 C Combination combination Oil pressure gauge 0 1MPa o meter Fuel gauge 0 i Fuel tank capacity Electric switch JK406B Horn button JK938A Turning indicator switch JK938A Lamp switch JK938A Braking lamp switch JK231B Klaxon horn DL 124D Fuse block AX102 Voltage regulator FT111 Flasher SG152 Socket for trailer QLCZ 1 Headlamp 60 55 White color Front signal Marker lamp 10W Orange color lamp Turning indicator lamp 21 W Orange color Rear Brake indicator lamp 21W Red
42. el tank completely when expecting to work in full sunlight as the fuel might expand and escape In such case promptly wipe off any fuel stain Tractor fuel may be dangerous Never refuel while engine is running or still hot or near an open flame or when smoking Chapter Technical Specifications of the Tractor 2 4 Parameters of the tractor Tractor Model DF254G2 6 DF304G2 6 DF354G2 6 DF404G2 6 Length 3350 3350 3453 3453 oie Width 1480 1480 1588 1588 a er 1524 1540 1500 1581 To the top of 2220 2240 2250 2275 exhaust pipe Wheel base mm 1732 1732 1900 1900 Front track 1100 1100 1200 1200 Wheel track mm Rear track 1100 1200 1100 1200 1200 1200 1300 1300 1300 1300 1400 1400 Ground clearance mm 290 310 358 405 Construction mass kg 1650 1650 1780 1780 Ballast kg Front wheel 120 120 120 120 17 OI whee 112 160 160 160 Rated traction In paddy field 4200 4950 5160 4970 force N In dry field 6300 6940 7230 7856 Theoretic speed km hr Gear I 1 40 1 48 1 35 1 41 Gear 2 12 2 23 2 03 2 14 Gear 3 40 3 58 3 26 3 43 TUM Gear IV 4 92 5 18 4 73 4 96 Gear V 7 27 7 65 6 98 7 33 Gear VI 10 98 11 56 10 54 11 07 Gear 17 62 18 54 16 92 17 76 Gear Vil 25 50 26 84 24 49 25 7 Gear I 1 41 1 49 1 36 1 42 Gear 2 13 2 25 2 05 2515 Gear 3 92 3 60 3 29 3 45 Gear IV 4 96 5
43. en away from rest a Excessive free travel of clutch pedal b Driven disc excessively warped c Ends of the three release levers not in the same plane d Friction disc broken e Too tight the friction disc spline 3 Vibration and noise in clutch a Release lever pressure spring broken b Release bearing Insufficiently lubricated or damaged c Splined hole of driven disc or clutch splined shaft worn out d Clutch front bearing damaged Adjust and make the release lever ends in the same plane Adjust the pedal free travel as specified Rectify or replace with a new one Adjust the release levers Replace with a new one Shave the spline of friction disc Replace with a new spring Lubricate it or replace with a new one Replace the worn out parts with new ones Replace with a new one Brake Troubles amp possible causes Fixing methods 7 1 7 1 2 Ineffective brake a Brake lining stained with lube oil b Brake lining or brake drum worn out c Brake cam worn out excessively d Excessive pedal free travel 2 Brake bias a RH and LH braking force different b One brake shoe lining stained with oil 3 Brake disengages incompletely and gets overheated a Brake shoe return spring weakened b Brake pedals unable to return c Too less the pedal free travel Wash brake lining with gasoline and remove oil leakage Replace the worn out parts with new ones Replace with a new brake cam Readjust ped
44. es locking the hand brake shift into first forward gear 1f heading uphill or into first reverse gear if heading downhill For more safety also use the specific stopping wedge available upon request Be sure to do so if parking your tractor with a trailer Tractor Maintenance Allow 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 HM Disconnect the ground cable of storage battery before starting to work on any of the electrical system parts or component Before disconnecting any hydraulic line or hose make sure the system is pressure free Hydraulic oil escaping under pressure could cause serious personal injury Consequently when searching for or detecting oil leaks make sure to use adequate safety protections such as shields goggles and gloves Prior to inspect clean adjust or carry on maintenance of the tractor or of any other mounted or connected implement always make sure that engine is shut down transmission is in neutral brake are locked power take off is disengaged and all other moving parts are stationary Do not operate on tyres unless suitable tools and the necessary experience are available Any wrong tire installation may seriously involve your personal safety If any doubt subsists call on qualified persons Do not fill up the fu
45. ferential lock engagement and 5 Brake action 6 All optional equipment and MCOMONES RENE INSPECTION PERFORMED WARRANTY EXPLAINED INSTALLATION COMPLETED TRACTOR MODEL NO TRACTOR SERIAL nn OWNER S SIGNATURE DATE DEALER S SIGNATURE DATE for owner 65 PRE DELIVERY SERVICE INOPERATIVE SERVICE CHECKS SAFETY ITEMS CHECKS 1 Tyre pressures and condition D 1 Seat belt installed where applicable DL 2 Lift rod levelling crank for proper operation 2 Safety decals installed seen nnn 3 Radiator coolant level and specific gravity 3 Neutral start switches operative H 1 071 1 083 at 160 C 60 F E 5 PME RE esee ene 5 Flashing lights tail lights operation 4 POW V Della o eite ERI nn oO 3 ievel o 6 Operator s Manual supplied Clea e 7 PTO guard installed sess 6 a Ar Diori ET 8 S M V emblem installed where applicable L 7 Front axle differential oil level 4wd 2 8 Front axle hub oil level 4wd 9 Brake adjustment and pedal equalisation DL OPERATIVE SERVICE CHECKS 10 Upper link drawbar and pin in position Au operative checks are to be performed with the trac 11 Wheel to rim clamp bolts and lock nu
46. front wheel drive 32 GB 3452 1 92 O ring seal 8072 65 2 axle 1 on PTO shaft 33 GB 3452 1 92 O ring seal 85 2 65 3 Front wheel drive axle 34 GB 3452 1 92 O ring seal 1603 55 2 Front wheel drive axle 36 GB 3452 1 92 O ring seal 15 2 65 1 Transfer case 37 GB 3452 1 92 O ring seal 4573 55 1 Transfer case 60 Appendix 5 List of Bearings Seq Standard code Designation and Quanti No specifications ty Hocanon No 1 Deanne 1 Clutch release bearing assembly 2 GB T276 1994 Antifriction bearing 6106 1 Gearbox inti 4 in gearbox 3 GB T276 1994 Antifriction bearing 6208 6 2 in front wheel drive axle TE 1 in PTO shaft 4 GB T276 1994 Antifriction bearing 6207 3 zin front whesldtivezxle Powe 2 in Front wheel drive axle 5 GB T276 1994 Antifriction bearing 6209 3 1 in PTO shaft EN 1 in gearbox 6 GB T276 1994 Antifriction bearing 6305 3 2 in front wheel drive axl 7 GB T276 1994 Antifriction bearing 6307 2 gearbox 8 GB T276 1994 Antifriction bearing 6307N 1 Gearbox 9 GB T309 2000 Needle 2 5X19 8 a 10 GB T5801 1994 Needle 6254905 1 Gear box 11 GB T297 1994 Antifriction bearing 32207 I Rear axle 12 GB T297 1994 Antifriction bearing 31307 1 Rear axle 13 GB T297 1994 Antifriction bearing 32011 2 Rear axle 14 GB T297 1994 Antifriction bearing 30211 2 Final drive 1
47. fting Linkages 354G2 6 40 1 Rear fire 12 4 2 d The lift members parameters and motion parameters mm Seq No Item The lower link points 1 Length of lower link 730 2 End span of lower link 600 3 Height of farm implement s column recommended 510 4 Length adjusting range of lifting rod 470 625 5 Connecting position of lifting rod s lower end with lower link 355 The ground clearance under the hitch point while the lower link is 6 P 200 at its lowest position 7 The ground clearance under the hitch point while the length of 412 lifting rod is adjusted to 550 8 The power lifting range of lower link hitch point while the length 544 of lifting rod is adjusted to 550 The ground clearance of hitch point for transportation while the 77 lifting rod is adjusted to its shortest length of 470 10 Length adjusting range of upper link 540 740 Appendix3 Diagram of Electrical System Principle 57 YMS 10jeorpur SULUIN J cc 3481 eld osuoom pg YS MOTS CE yams jqgipeog TE yonmas 3451 iogsepp Suedo Yous 10jeorpur guruin IYSTY GZ YOMMS 10jeorpur 8 OT 97 YOUMS dure IIH LZ 19524 9c YS uonne dure pz SuryIoM Iy C SSOUILY 19puop jo TZ oo qosng z o oquojgng oujoo g 0 Ssoureq IYSTY 6
48. g force to get good contact Remove short circuit Replace with a new shaft bushing Wash the commutator surface shave the brush contacting surface and adjust spring force Grind rough the commutator surface remove oil stain from commutator surface Re weld Tighten clamping nuts to get good connection Repair solenoid switch contacts Charge battery again See 2 f Readjust the travel Readjust the iron core travel of solenoid switch Appendix 1 Moving Locus Diagram of Lifting Linkages 254G2 6 304G2 6 55 The lift members parameters and motion parameters mm Seq The lower link Item No points 1 Length of lower link 745 2 End span of lower link 600 3 Height of farm implement s column recommended 510 4 Length adjusting range of lifting rod 380 508 Connecting position of lifting rod s lower end with lower 5 link 355 The ground clearance under the hitch point while the lower 6 DEI 130 link is at its lowest position 7 The ground clearance under the hitch point while the 395 length of lifting rod 15 adjusted to 411 8 The power lifting range of lower link hitch point while the 468 length of lifting rod is adjusted to 411 The ground clearance of hitch point for transportation 9 while the lifting rod 15 adjusted to its shortest length of 924 380 10 Length adjusting range of upper link 630 760 56 Appendix 2 Moving Locus Diagram of li
49. g just lock tightly with nuts after adjusting Connect the two lower links with the check spring after demounting implement so as to avoid their touching the tyres Points for attention a Never adjust the upper link and left or right lift link to the minimum length at the same time otherwise the implement will possibly knock at the cabin or the driver when it is rising to the highest position b To avoid opening the safety valve Never move further the control handle backward after the implement reaches the highest position and gets neutralized automatically c Driving away and turning operations of the tractor are prohibited while the attached implement is not yet lifted off the ground d Make sure the implements fit the tractor well and there is no interference of implements lifting or lowering e Attention must be paid to avoid implements running into earth bank or shaking violently the low speed gear must be used when crossing the fields so as to avoid any damage of the tractor or implements 4 3 2 Operation of PTO shaft a b d The PTO shaft speed has the combination of 540 and 1000 rpm It can be realized by shifting the speed changing lever of the PTO shaft Input rotational speed of the PTO driven implements must be the same of the PTO shaft s since the improper matching will cause serious premature failure of the tractor and implements and also effect the farming job quality Shift the control handle forwar
50. ground Start engine only from operator s seat with transmission in neutral or park Use Seat Belt and Foldable ROPS Properly Open Station When the ROPS is in the up or extended position ALWAYS use your seat belt to minimize chance of injury from an overturn accident DO NOT use seat belt when ROPS is folded down A DANGER AWARNING ACAUTION 2 DV oxg Mk This tractor is equipped with a foldable Roll Over Protective Structure ROPS The ROPS A should be kept in the up or extended position as pictured with pins C retained with quick lock pins B except when it is necessary to fold it for low clearance operations A ROPS B Quick Lock Pins C ping Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with East Wind equipment include such items as lubricants coolants paints and adhesives Before you start any job using a hazardous chemical you should know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment Operate Tractor Safely Features designed into your tractor make operation Safer and let it perform a wide variety of jobs Use your tractor only for specified jobs it was designed to perform implement carrier load mover remote power source or transport Unit not a recreational vehicle Careless use or misuse can result
51. h and do not tow loads more 8 than 1 5 times the tractor weight If towed equipment has brakes do not travel more than 30 km h 25 mph and do not tow loads more than 3 times the tractor weight Ensure the load does not exceed the recommended weight ratio Add ballast to recommended maximum for tractor lighten the load or get a heavier towing unit The tractor must be heavy and powerful enough with adequate braking power for the towed load Use additional caution when towing loads under adverse surface conditions when turning and on inclines Keep ROPS Installed Properly Make certain all parts are reinstalled correctly if the roll over protective structure ROPS is loosened or removed for any reason Tighten mounting bolts to proper torque The protection offered by ROPS will be impaired if ROPS is subjected to structural damage is involved in an overturn incident or is in any way altered by welding bending drilling or cutting A damaged ROPS should be replaced not reused x Practice Safe Maintenance Understand service procedure before doing work Keep area 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
52. handle can be moved forward or backward a little bit to meet these needs please note that the handle must be moved to the neutral position right after the slight adjusting is made If lifting speed needs to be adjusted just screw down or up a little bit the hand wheel of hydraulic lock valve 6 Farm implement with land wheel Push the control handle 4 forward to the Down position oil in the distributor comes back directly to the gearbox i e oil in the hydraulic distributor has the passage to oil return pipe and the implement will drop down to the ground by its weight Then the tilling depth of the implement is to be controlled by its land wheel Points for attention Shift the control handle to neutral position immediately after the filling stroke of the ram is finished so as to avoid long time opening of the safety valve Disassemble the male connector if no external delivery is needed and reassemble the plug Remember to screw up the locking valve 6 to the highest position otherwise the hydraulic lift system will not work Attaching implement to the tractor Back the tractor to let the hitch point of lower link approach to a farm implement Move back and forth the control handle till the connecting holes of lower links and the hitch pins of the farm implement are in line with each other Put the hitch pin in either hole and lock it with a locking pin At last adjust upper link to a proper length link it together with the colu
53. heck the oil level again and replenish if necessary Fill up the water tank and diesel tank with enough cooling water amp diesel oil respectively Chassis Check and tighten all the external bolts and nuts Grease the following positions Left amp right jaws of steering tie rod left amp right steering arms of the front wheel drive axle and bearing of the water pump of engine Remove the fault of oil water or air leakage clean the outer surface if dirt Check tyre pressure inflate if necessary Maintenance after 50 working hours A B Engine After 50 hours running in with light load the lube oil of the new engine should be changed entirely including the lube oil in the engine sump and the injection pump Change the oil filter element Clean the sump oil filter and strainer with clean diesel Transmission system After the tractor is used for 50 hours check the free travel of the clutch pedal and adjust it if necessary C Lubricate the nipples mentioned above with a grease gun Maintenance after every 100 working hours gt UP Engine Change oil in the engine sump and clean the strainer Change engine oil and diesel filter elements and clean the cavity of filters Check the tension of fan belt adjust it if necessary Check oil level of injection pump add oil if necessary Clean the air filter if working in a dusty environment do it every shift Clutch Check the free travel of clutch pedal make adj
54. ight Follow local regulations for Equipment lighting and marking Keep lighting and marking visible clean and in good working order Replace or repair lighting and marking that has been damaged or lost An implement safety lighting kit is Available from your East Wind dealer Use a Safety Chain A safety chain will help control drawn equipment should it accidentally separate from the drawbar Using the appropriate adapter parts attach the chain to the tractor drawbar support or other specified anchor location Provide only enough slack in the chain to permit turning See your East Wind dealer for a chain with a strength rating equal to or greater than the gross weight of the towed machine Do not use safety chain for towing XK Safely Transporting the Tractor A disabled tractor is best transported on a flatbed carrier Use chains to secure the tractor to the carrier Never tow a tractor at a speed greater than 16 km h 10mph An operator must steer and brake the tractor under tow Tow Loads Safely Stopping distance increases with speed and weight of towed loads andon 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 load Observe these recommended maximum road speeds or local speed limits which may be lower If towed equipment does not have brakes do not travel more than 20 km h 12 5 mp
55. in unnecessary accidents Be alert to hazards of tractor operation Understand causes of accidents and take every precaution to avoid them Most common accidents are caused from Tractor misuse Improper starting procedures Crushing and pinching during hitching Collisions with other motor vehicles Getting entangled in PTO shafts Falls from tractors Avoid accidents by taking the following precautions Put transmission in NUETRAL AND APPLY 1 Read Operator s Manual before operating this tractor 2 Keep all shields in place 3 Hitch towed loads only to drawbar to avoid rearward upset 4 certain everyone 15 clear of machine before starting engine or operation 5 Keep all riders off tractor and equipment 6 Keep hands feet and clothing away from power driven parts 7 Reduce speed when turning or applying individual brakes or operating around hazards on rough ground or steep slopes 8 Couple brake pedals together 10 A am for road travel Use flashing warning lights on highway unless prohibited by law Stop engine lower implement to ground and shift to PARK or set brakes s securely before dismounting Wait for all movement to stop before servicing machinery Remove key if leaving tractor unattended HAND BRAKE before dismounting Leaving transmission in gear with engine stopped will NOT prevent the tractor from moving Be sure everyon
56. ind dealer Chapter I Work Safely Always and Safety Rules Safety First This warning sign alerts you about important messages involving your safety Read these safety rules attentively and strictly follow suggested precautions to avoid any potential danger and safeguard your health and personal safety Important Notices This tractor has been designed and manufactured specifically and solely for agricultural use Any other application will be considered non compatible with the use envisaged by the manufacturer who consequently shall not be held responsible for any damage to things or to the machine itself or for any physical injury to people deriving from the uses other than agricultural ones Always consider that you would assume the personal responsibility for any consequence associated with the improper use of this tractor The respect of the rules for tractor use maintenance and repair given in this operation manual is an essential element qualifying the correct use of the tractor as envisaged by the Manufacturer The tractor must be used serviced or prepared only by those people who are well trained beforehand in the handling features and safety rules besides being specifically authorized to 13 operate it The users of the tractor are always responsible for the strict observance of general safety and accident prevention rules as well as of the traffic regulations if driving the tractor on public or open roads Any un autho
57. ion of nozzle c Wearing of plunger and barrel of injection pump d Deformation of governor spring resulting in low rotating speed e Incorrect advance angle of fuel f Blockage of air filter g Air leakage of intake and exhaust valves h Incorrect valve timing i Insufficient compression pressure Clean it and replace filter element if necessary Grind or replace it Replace with a new one Adjust it or replace with a new spring Adjust Clean it or replace it if necessary Check valve clearance and sealing effectiveness Check and adjust or replace cam shaft if necessary Replace cylinder liner or piston rings Abnormal sound Possible causes Fixing methods a Too much big the advance angle of fuel b Needle valve of injector seized c Valve clearance is too big rhythmic valve hammering can be heard clearly d Piston touches valves e Piston knocks the bottom of cylinder head f Valve spring is broken g Connecting rod bearing or the small end bush is too loose h Too much clearance between piston and cylinder liner Adjust it Loosen the high pressure oil pipe in turn to detect the seized needle valve according to injecting sound if any one is seized then it will not give out injection sound replace the seized one with a new one Adjust it Valve sinkage is not enough reamer the valve seat again Replace the cylinder head gasket with a thicker one Replace the broken on
58. le causes Fixing methods a Uneven diesel delivery to each cylinder screw of fuel delivery adjusting fork loosened b Too much adjusting arm and the sliding disc worn out c Sleeve of sliding disc dragging the clearance of fork d Too much the axial clearance of cam shaft e Air being in fuel pipes Check and adjust it Replace them Use fine sand cloth to polish it or replace it Adjust with copper shims Bleed air Possible causes Fixing methods a Air being in fuel pipe or filter element blocked b Seizing of piston c Bearing bush burning out d Plunger or sliding disc sleeve of governor seized Check bleed air or replace the filter element Check and replace it Check and replace it Check repair or replace them Chassis Clutch Trouble amp possible causes Fixing methods 1 Clutch slip a Friction disc stained with oil b Pressing spring weakened or broken c Too less or even no pedal free travel d Driven disc warped unevenly excessively worn out Wash friction disc with gasoline and remove oil leakage Replace with a new one Readjust pedal free travel as specified Rectify or replace with a new one 50 7 2 3 e Ends of the three release levers not in the same plane 2 Clutch disengaged incompletely resulting in difficult gear shifting or gear shifting with sound and tractor shaking while being driv
59. mn of implement by a long pin and then lock it with a locking pin Adjusting the lift linkage Higher working efficiency lower working resistance and reliable cultivation quality could be expected if the lift linkage and corresponding implements are adjusted 28 correctly The upper link is for adjusting the fore and aft leveling of plow stock and the penetrability of the plowshare Right amp left lifting rods are for adjusting the plow stock s crosswise leveling The land wheel is for plow depth control if there is one provided Adjust the land wheel first at the beginning of plowing when one plow share has reached the required plowing depth adjust the upper link to make the plow parallel to the ground surface then adjust the length of left or right lifting rod to make depth the same of each plow For the second bout plowing since right wheels of the tractor get into the furrow the plowing depth of the right side plow share will get increased all of a sudden so right lifting rod and the length of the upper link need to be readjusted again in order to get same plowing depth of every share Adjustment of the length of the check chain The check chain limits the deviation between lift linkage and implements During plowing some deviation about 5 cm is needed to assure the plow s automatic center resetting But if the deviation is too much plow will hit rear wheels of the tractor and cause damage Since no deviation is needed for rototillin
60. nd pin in position Au operative checks are to be performed with the trac 11 Wheel to rim clamp bolts and lock nuts tor at normal operating temperature OO TELE NN E 1 Lights and instruments for proper operation 0 12 Wheel disc to hub nuts for tightness D 2 Fluid andoilleaks Meca emt B 13 Front end weight clamp bolts for tightness 3 Maximum no load speed and idle speed 14 Front axle support bolts for tightness aljosiments and fuel shut off ee 4 PTO operation coo ees 15 Front wheel toe in 43 1 16 Fuel level 5 Hydraulic System Fuel level IDE tette Scb levers Drei end 7 Sheet metal and paint condition Position Control operation o 18 Drain diesel fuel filter and water separator 0 Flow control operation o 19 Lubricate all grease fittings 0 Draft Control for tension and compression 20 Air cleaner element and hose connections o lod icena eee ee 21 Seat mounting and adjustment 0 Auxiliary Services Control and remote 22 All electrical cables terminals and wires o control valves if installed o PERFORMANCE SERVICE CHECKS 1 Engine operation including throttle and govemor operation 2 Transmission including clutch 3 Steering control eese nne 4 Dif
61. ngine directly without preheating Main shift lever is located at the center of gearbox And the range shift lever is on the right side of gearbox shift it forward to get HIGH SPEED RANGE and push it backward to get LOW SPEED RANGE see Fig 2 59 E M gt Fig 2 Shifting diagram of main shift lever and range shift lever Fig 1 Electric switch working diagram The control handle of PTO speed changing lever is at left rear side of driver s seat on the sidewall of rear axle housing Pull the handle forward to get low speed and push back the handle to get high speed Push it to the middle position to get neutral 25 4 2 4 2 1 The control handle of hydraulic lift is at the right rear side of driver s seat move the handle forward backward or set it at the middle the hydraulic lift linkage will go down up or stop at neutral position respectively The clutch pedal is located at the front of left footrest plate step on the pedal the main clutch and sub clutch will be disengaged in turn Brake pedals are at the front of right footrest plate the left one is for LH brake and the right one is for RH brake The two pedals must be locked together while traveling on road There are two sets of throttle control mechanisms one is the foot throttle and the other is hand throttle Foot throttle pedal is at the right side behind the brake pedals and the hand thro
62. ning in of hydraulic system and PTO shaft Running in of the tractor with load When operating the tractor with load for the running in the load must be added from the light to heavy and gears be changed gradually from the low to high meanwhile do steering operation time and again the time period for running in with load amounts to 50 hours in total The running in criteria are as follows Runnin Hitching Running in time for every gear hr Total time at g in force various stage stage kg Il IV V VI Vil hr 1 130 2 2 4 4 4 4 20 2 250 2 2 5 5 14 3 400 2 2 6 6 16 Points for attention Engage the front drive axle for the running in at every gear except Gear VII if the tractor is a four wheel drive one Running in of hydraulic lift system with load is to be done with a plow mounted which should be done before the running in of transmission system repeat the lift and release operation for at least 20 times while engine is working at the rated speed If the above running in condition could not be satisfied then light load operation can be used as a substitute For example shallow tillage in the even soil with low resistance Points for attention Observe the working conditions of all the parts and components in every stage of the running in If any abnormal condition occurs in the running in fix it up immediately While running in the transmission system PTO shaft should b
63. not attempt to mount a tire unless you have the proper equipment and experience to perform the job Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel When inflating tires use a clip on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly Use a safety cage if available Check wheels for low pressure cuts bubbles damaged rims or missing lug bolts and nuts Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with equipment include such items as oil fuel coolant brake fluid filters and batteries Use leak proof containers when draining fluids Do not use 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 on the proper way to recycle or dispose of waste from your local environmental or recycling center or from you r East W
64. of the spiral bevel pinion is to be adjusted by adding or deducting the adjusting shims 1 the pinion will goes forwards if the adjusting shims 1 are added the pinion will withdraw if the adjusting shims 1 are deducted 38 5 6 5 9 1 The adjustment of crown gear is realized by altering the Adjusting shims 7 on the left and right Bearing seats 8 While adding or reducing the adjusting shims 7 of same thickness to or from either bearing seat the pre stress of bearings is alternated but the crown gear position will kept unchanged if moving the Adjusting shim 7 from one bearing seat to the another one the crown gear will be shifted towards the side where the Adjusting shim 7 is added 1 but the pre stress of 3 bearings will remain 2 unchanged The pre stress of the spiral crown gear bearings should be kept between 1 2 1 8 N m The meshing zone can be measured by smear test of painting the crown gear teeth with some colors such as red lead or Prussian blue The standard meshing zone should drift to small end slightly i e short toe contact see Fig 11 The Fig 12 Main drive mounting diagram meshing zone position could i 1 Adjusting shims of pinion gear 2 Locking nut 3 be alternated through adding Check washer 4 Locking nut 5 Pinion gear or deducting the adjusting 6 Crown gear 7 Adjusting shim of crown gear 8 shims of the spiral bevel Bearing seat pinion and the mated spirl crown gear
65. onnection Check wire connection and remove trouble 2 Battery overheat Too high the charging electric Check and adjust regulator current 3 PowerCheck is a white display Replace with new battery 4 PowerCheck is a black display Charge 7 3 2 Generator Troubles amp possible causes Fixing methods 1 Generator not working a Rectifier damaged Check and replace with a new one if necessary b Carbon brush seized and Examine carbon brush size and spring force being contactless with collector repair or replace whichever if necessary ring c Broken circuit short circuit of Repair or replace with new ones stator or rotor windings or poor insulation of earth circuit 2 Generator developing insufficient power a Generator belt loosened 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 d Short circuit of partial windings Repair or replace rotor or stator windings with of rotor or stator new ones 3 Generator output current unsteady a Generator belt loosened Adjust belt tension or replace the belt with a new one b Rotor and stator windings being Repair or replace rotor or stator windings with nearly short circuited or broken new ones c Carbon brush spring weakened Repair or replace carbon brush spring with a new and poor contact of carbon brush one d Terminals loosened Check and repair 4 Abnormal sound from generator a Gene
66. ou see this symbol on your machine or in this manual be alert to the Potential for personal injury Follow recommended precautions and safe operating practices Understand Signal Words signal word DANGER WARNING or CAUTION is used with the safety alert symbol DANGER identifies the most serious hazards DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual Follow Safety instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety 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 East Wind dealer Learn how to operate the machine and how to use controls properly Do not let anyone operate without Instruction Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and or safety and affect machine life If you do not understand any part of this manual and need 1 assistance contact your East Wind dealer XPrevent Machine Runaway Avoid possible injury or death from machinery runaway Do not start engine by shorting across starter terminals Machine will start in gear If normal circuitry is bypassed NEVER start engine while standing on
67. rator wrongly mounted Remount the generator correctly b Generator bearings damaged Replace generator bearings with new ones c Rotor hitting stator or other parts Check and repair 7 3 3 Starter 54 Troubles amp possible causes Fixing methods 1 Starter not working a Connecting wire broken or poor contact of wire connection and switch contacts b Fuse blown c Battery nearly exhausted d No contact of carbon brushes with the commutator e Inner short circuit of starter 2 Starter running but unable to start the engine a Shaft bushing excessively worn out causing rotor ractioning with magnetic pole b Poor contact of carbon brushes with commutator c Commutator surface burnt or with oil stain d Welded joint between armature conductor and commutator broken e Poor connection of cable amp clamp f Solenoid switch contacts ablated 2 Battery insufficiently charged 3 Starter running continuously after engine being started a Solenoid switch contacts ablated b Incorrect adjustment of the iron core travel of solenoid switch 4 Starter begins to run and hits against the end face of ring gear before meshing a Too less the iron core travel of solenoid switch Weld or replace with new connecting wire clean the oil stain on contacts and tighten all the nuts on connecting points Replace with the fuse of specified current rating Charge battery Check carbon brushes and adjust brush sprin
68. rawn implement For your personal safety trailers should not be towed unless equipped with an independent braking system Always use drawbar and towing equipment to pull heavy loads and avoid in any case hooking or connecting equipment to the 3 point hitch lower links or to the top link because even in the last case pitching danger subsists When towing never negotiate bends with a locked differential because you might not be able to steer the tractor Using Agricultural Implements and Machinery Do not connect implements or machinery requiring a higher power rating than your tractor class Never stand between tractor and implement to facilitate hitching while the tractor is being back up Never actuate the power take off shaft connected to an operating machine without making sure in advance that no one is within operating range of the same machine Stopping the Tractor Never leave implements in the raised position while the tractor is stationary lower down the farm implements before shutting the engine off Before leaving the tractor seat be sure to move transmission control lever to neutral position disengage the power take off shaft get the hand brake in working status by pulling its handle and shut the engine off at last 16 Besides when leaving tractor unattended always remove the key from the starter switch When parking look for level grounds if any shift into a gear and lock the hand brake On sloping grounds besid
69. rds behind the wheels to provide a solid base and try to back out slowly Ifnecessary dig mud from the front of all wheels and drive slowly ahead If necessary to tow with another unit use tow bar or a long chain a cable is not recommended Inspect the chain for flaws Make sure all parts of towing devices are of adequate size and strong enough to handle the load Always hitch to the drawbar of the towing unit Do not hitch to the front push bar attachment point Before moving clear the area of people Apply power smoothly to take up the slack a sudden pull could snap any towing device causing it to whip or recoil dangerously Avoid High Pressure Fluids Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids If accident occurs see a doctor immediately Any fluid 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 XPark Tractor Safely To park tractor safely Disengage PTO Lower equipment to the ground Put gear shift lever in NUETRAL Apply hand brake STOP the engine Remove key Before you leave the opera
70. ring shaft and the full hydraulic steering gear while assembling A clearance of 0 5 1 0 mm should be kept between the steering shaft and steering gear and there also should be a little bit endplay of the steering shaft so as to avoid any jamming e Check all the screw connection portions and tighten all the bolts and nuts to avoid any oil leakage of all coupling surfaces and connecting parts because the oil leakage is strictly forbidden while the Full hydraulic steering gear is working 35 5 5 f Wash clean all the pipelines of the hydraulic steering gears strictly prevent them from any contamination while assembling or dismounting them for replacement The filtration fineness of the filter should be better than 30 u The hydraulic oil should be renewed periodically The oil temperature of the Full hydraulic steering system 15 to be kept within the range of 20 C 80 C but the normal working temperature of the hydraulic oil should be within 30 C 60 C 25m S SSS SSE 1777 im i TY MM r3 SN WAN gee EAT i Fig 9 Structure of the Full hydraulic steering gear 1 Front cover 2 Leafspring Thrust bearing 3 Pin 4 Valve body 5 Valve bush 6 Valve element 7 Linkage shaft 8 Isolation plate 9 Stator 10 Rotor 11 Rear cover Adjustment of the Disc brake I After working for a period of time The wear and tear of the brake discs enlarges the gaps between brake discs and inner
71. rized and arbitrary modification made on the tractor will relieve the manufacturer of all responsibilities for any damage or injury deriving from such modification The Manufacturer and all the Organizations associated with its distribution network including but not limited to national regional or local distributors shall decline any and all responsibilities for damages that may derive from the abnormal performance and behavior of those machine parts or components not specifically authorized by the Manufacturer of the tractor including those used ones for the maintenance and or repair again though they were fabricated or distributed by the Manufacturer before In any case no warranty of any sort is issued or prescribed for damages deriving from abnormal behavior of those parts and or components not authorized by the Manufacturer of the tractor Caution Read the Operator s Manual carefully before starting using maintaining refueling or making other service interventions on the tractor Comply strictly with the safety regulation and follow the suggested precautions in order to safeguard yourselves Maintenance Use genuine DF Brand parts only Failure to do this will Cost you more Not result in complete satisfaction Seriously risk improper functioning of the tractor The tractors were designed with the owner in mind and effort has been made to simplify maintenance The purpose of this handbook is to familiarize the operator with
72. s ation and a constant relief valve So the steady working performance of both the steering system and lic lift system will be ensured and there will be no disturbance as with their ir sharing one hydraulic pump 5 4 1 Working principle and operation of the full hydraulic steering gear See Fig 8 The working principle of the full hydraulic steering gears ig shown in Fig 9 The Rear axle housing 9 is also being made use of a oil tan of the steering gears Low pressure oil flows into Constant flow pump HLCB D06 06 L 6 on the Diesel engine 7 through the 018 inlet pipe of the pump Fhe steady high pressure oil flows into the Full hydraulic steering gears of Model BZZ1 E80 4 ates the Stegring cylinder 2 for steering action but the overflow oil comes back to the g pump through the oil return pipe The Constant flow pump is adopted for keeping st ras oil delivery so as to ensure the steady working of the hydraulic steering gear So long as the engine is running the hydrauli toting of the tractor could be realized just by turning the steering wheel and th ste ring op ration shall never be disturbed by hydraulic lifting operation 34 1 Four bar steering linkage 2 Steering cylinder See Appendix 7 3 Front driving wheel 4 Full hydraulic steering gear 102SC 1 63 07 AH 5 Steering wheel 6 Constant flow pump HLCB D04 0
73. s for tightness D 2 Fluid andoilleaks Meca emt B 13 Front end weight clamp bolts for tightness 3 Maximum no load speed and idle speed 14 Front axle support bolts for tightness aljosiments and fuel shut off ee 4 PTO operation coo ees 15 Front wheel toe in 43 1 16 Fuel level 5 Hydraulic System Fuel level IDE tette Scb levers Drei end 7 Sheet metal and paint condition Position Control operation o 18 Drain diesel fuel filter and water separator 0 Flow control operation o 19 Lubricate all grease fittings 0 Draft Control for tension and compression 20 Air cleaner element and hose connections o lod icena eee ee 21 Seat mounting and adjustment 0 Auxiliary Services Control and remote 22 All electrical cables terminals and wires o control valves if installed o PERFORMANCE SERVICE CHECKS 1 Engine operation including throttle and govemor operation 2 Transmission including clutch 3 Steering control eese nne 4 Differential lock engagement and 5 Brake action 6 All optional equipment and MCOMONES RENE INSPECTION PERFORMED WARRANTY EXPLAINED INSTALLATION COMPLETED TRACTOR MODEL NO
74. should always be clean and dry Check at regular intervals that the battery and its cable connections are firmly in place and tighten if necessa Points for attention 2 Fuse Before replacing a blown fuse with a new one of the same current rating determine the exact causes of the failure and make necessary repairs Fuse No Electric circuits to be protected rating 1 General electric circuit 40A 2 Oil pressure gauge water thermometer and horn 10A 3 Electronic voltage regulator 10A 4 Headlamp 25A 5 Marker lamp Rear working light 20A 6 left amp right turning indicator lamp Brake indicator 20A lamp caution light 41 Chapter VI Lubrication and Maintenance of the Tractor 6 1 Oils to be used by the tractor and lubrication 6 1 1 Fuel oil and lubricants for the tractor Position Category of oil Standard No Remark No 10 Light diesel Above 8 C Fuel tank No 0 Light diesel 8 C 4 C Brun No 10 Light diesel4 C 5 C GB252 2000 20 Light diesel 5 C 14 C 35 Light diese 14 C 29 C Gearbox rear axle front drive axle N100 Drive amp hydraulic GB443 1989 SAE85W hydraulic system dual purpose oil Clutch release No 2Lithium based grease GB73245 1994 All atmospheric bearing temperature No 3 calcium based grease All atmo i nipples n TE HOH Dass eA sunm
75. speed of engine for easy starting or turn the starter key to ST position for preheating no more than 15 seconds to start the engine e Run the engine at medium or low speed after starting observe whether it works well if OK then speed up slowly but do not work with load until water temperature gets to 50 en Points for attention a When starting the time duration of every attempt of operating the starter motor should not be more than 15 seconds otherwise battery and starter motor will be easily damaged b Hot water should be filled into radiator to warm up the engine before starting if insevere cold season or park the tractor indoors for keeping it warm 26 4 3 4 3 1 Drive away operation of tractor a Release the hand brake handle if any implement is linked it must be lifted up first b Step on clutch pedal all the way to the end shift speed changing lever to the desired gear If failed to shift into gear release the clutch pedal a little and depress it again for engaging the gear c Accelerate gradually meanwhile release clutch pedal slowly to drive the tractor away from rest d Normally low gear should be used for driving away operation Driving the tractor a Selecting the proper gear Proper gear should be selected to let the engine work with 80 of maximum power When rototilling Gear I II or III will be used Gear IV or V will be used for the power driven harrow and plowing and towing operation and
76. tability in mind Engage clutch gradually abrupt engagements particularly if pulling out of a rough area a ditch or muddy grounds or driving over a steep gradient may cause dangerous tractor pitching 15 Immediately disengage the clutch if front wheels tend to come off the ground When coasting downhill keep a transmission gear engaged Never disengage the clutch and never drive your tractor in neutral With tractor in motion the operator should be correctly seated on driver s seat 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 speed slow down the tractor particularly when steering Proceed with extreme caution when driving with wheels close to the edge of a ditch or bank Never carry passengers When driving on public roads be sure to respect traffic rules and regulations Do not override brake and clutch pedals When driving on roads latch the brake pedals together by using the latch plate Braking with pedals unlatched may cause side skidding of the tractor Moreover avoid overworking the brakes Towing and Transport To assure tractor stability at work correctly adjust the towing attachment depending on the towed trailer or d
77. talogue of the tractor 1 6 Certificate of quality 1 The information contained in this operation manual is of general introduction only which is subject to change without notice at any time for technical or other reasons since our product will be under uninterrupted improvements and modifications Therefore we would request the users dealers to give out the manufacturing date and serial No while they place order for spare parts and components Thanks 64 PRE DELIVERY SERVICE INOPERATIVE SERVICE CHECKS SAFETY ITEMS CHECKS 1 Tyre pressures and condition D 1 Seat belt installed where applicable DL 2 Lift rod levelling crank for proper operation 2 Safety decals installed seen nnn 3 Radiator coolant level and specific gravity 3 Neutral start switches operative H 1 071 1 083 at 160 C 60 F E 5 PME RE esee ene 5 Flashing lights tail lights operation 4 POW V Della o eite ERI nn oO 3 ievel o 6 Operator s Manual supplied Clea e 7 PTO guard installed sess 6 a Ar Diori ET 8 S M V emblem installed where applicable L 7 Front axle differential oil level 4wd 2 8 Front axle hub oil level 4wd 9 Brake adjustment and pedal equalisation DL OPERATIVE SERVICE CHECKS 10 Upper link drawbar a
78. ter Replace it with a new one Descale the water jacket Replace it with a new one Adjust the load Adjust as per stipulation Too much engine oil consumption Possible causes Fixing methods a Engine oil of wrong category being used b Piston rings worn out c Piston ring sticking oil return hole in piston ring groove plugged up d Leakage of rear seal e Too much high the oil level Use the oil as specified Replace them with new ones Remove carbon deposit and clean the piston Check replace with new rear seal and its cover Make down the oil level by draining 49 7 1 9 Rising of lube oil level Possible causes Fixing methods a Water leakage from cylinder head gasket b Water leakage from cylinder head or bowl shaped plug hole in engine block Check and replace it Repair with epoxy resin or replace with a new plug 7 1 10 Engine running away Possible causes Fixing methods a Oil delivery control rod of injection pump seized at the maximum position 71711 Sliding disc sleeve of governor seized c Adjusting rod of plunger broken or escaped from the fork d Too much lube oil in injection pump e Too much lube oil entering into cylinder Check and repair it Check and repair it Check and repair it Drain out to the required level Check and fix it 7 1 11 Engine drifting 7 1 12 Engine self stalling 7 2 7 2 1 Possib
79. the operation and regular servicing of the tractor Remember that the time spent on maintenance extends the life of your tractor Pay particular attention to the instructions covering fuel filtering air cleaner maintenance and lubrication Remember that badly filtered fuel results in injection system deterioration and irregular air cleaner maintenance leads to premature engine wear Please keep in mind that the lube oil should be replaced thoroughly after every 1000 working hours but at least once a year Safety Precautions General Your tractor was designed with safety very much in mind However there is no real substitute for caution and attention in preventing accidents Once an accident has happened it is too late to think about what you should have done Read this manual carefully before attempting to start operate service refuel or carry on other operating involving you 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 has to get the prior authorization from the Manufacturer in advance Keep a first aid tool handy Do not work with loose garments that could get caught in moving parts Check that all rotating parts connected to the power take off shaft are properly shielded This tractor has to be operated by the people who were trained on the use
80. the shims 15 of bearing seat and the shims 11 of main drive case of suitable thickness to ensure the correct meshing print and the gear backlash within 0 16 0 32 mm Meanwhile keep the pre stress of bearing on both ends of the differential within 100 150 N b The meshing of mid gear pair at both ends of front wheel drive axle is adjusted by selecting the shims 1 of suitable thickness to ensure the gear backlash within 0 16 0 3 mm and the correct meshing print c To ensure the gear backlash of final drive within 0 16 0 3 mm it could be done by altering the thickness of shims 13 for final drive meanwhile keep the correct meshing print d The clearance of 0 1 0 5 mm between the lower face of the retainer rings 4 of the upright shaft 3 at either end and the upper face of driven pinions 7 is obtained by selecting and using the shims 6 of suitable thickness 33 14 15 Fig 7 Diagram of front wheel drive axle 1 Shims 2 Bolt MIOX25 3 Upright shaft 4 Retainer ring 5 Retaining ring for upright shaft 6 Shims 7 Driven pinion 8 Drive pinion 9 Differential 10 Main drive case 11 Shims 12 Final reduction driven gear 13 Shims 14 Final reduction drive gear 15 Bearing seat adjusting shims 16 Spiral bevel pinion 5 4 Use and adjustment of the full hydraulic steerin pear This steering system adopts an independent hydrat ilic pump The pump is corposed external gear pump with axial interval self compen
81. tor s seat wait for engine and attachment parts to stop moving x Handle Fuel Safely Avoid Fires Handle fuel with care itis highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Prevent fires by keeping machine clean of accumulated trash grease and debris Always clean up spilled fuel K Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire exitinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone Not Use Starting Fluid DO NOT use starting fluid in tractors equipped with an intake air heater system Tractors are equipped with an intake air heater system Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Prolonged exposure to loud noise can cause Impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable Loud noises Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating machine Work In Ventilated Area Engine exhaust fumes can cause sickness or death If it is necessary to run an engine in an enclosed area remove the exhaust fumes from the area with an exhaust pipe extension If you
82. ts tor at normal operating temperature OO TELE NN E 1 Lights and instruments for proper operation 0 12 Wheel disc to hub nuts for tightness D 2 Fluid andoilleaks Meca emt B 13 Front end weight clamp bolts for tightness 3 Maximum no load speed and idle speed 14 Front axle support bolts for tightness aljosiments and fuel shut off ee 4 PTO operation coo ees 15 Front wheel toe in 43 1 16 Fuel level 5 Hydraulic System Fuel level IDE tette Scb levers Drei end 7 Sheet metal and paint condition Position Control operation o 18 Drain diesel fuel filter and water separator 0 Flow control operation o 19 Lubricate all grease fittings 0 Draft Control for tension and compression 20 Air cleaner element and hose connections o lod icena eee ee 21 Seat mounting and adjustment 0 Auxiliary Services Control and remote 22 All electrical cables terminals and wires o control valves if installed o PERFORMANCE SERVICE CHECKS 1 Engine operation including throttle and govemor operation 2 Transmission including clutch 3 Steering control eese nne 4 Differential lock engagement and 5 Brake action 6 All optional equipment and MCO
83. ttle handle is at the upper right of instrument panel case The engine stop lever is at the lower left of instrument panel case The decompression lever is just outside the hand throttle handle The control handle of front wheel drive axle is on the left side of driver s seat pull it backward for engagement and push it forward for disengagement Operation and drive of the tractor Starting of engine a Before starting the engine check and make sure that All the connecting bolts of the tractor are tightened Fuel cooling water and lubricant are filled in conformity with the regulations Shift lever is placed at Neutral position Control lever of PTO shaft is at Disengage position and the hydraulic control handle is at Neutral position b Check whether there is any air in fuel system Bleed air from the plug on injection pump by manually pumping it if necessary c Shift the hand throttle to Medium position d Depress the clutch pedal so as to reduce starting resistance and turn the electric switch key anti clockwise to H position to start the engine After starting turn the key to ON position immediately If engine starting fails at first time try once again after 1 2 minutes If engine starting fails for three times in succession make close check and do not start it until troubles are all fixed up In case the ambient temperature is below 5 C the decompression device may be used for increasing the rotating
84. ust bearing clearance or replace kingpin bush wheel bearing or kingpin bush with a new one worn out excessively b Wrongly adjusted toe in Readjust toe in c Ball pin or its seat worn Replace ball pin or its seat with a new one out excessively d Pitman arm and ball pin fixing Check and tighten the nut nut become loose 2 Premature wearing of front wheel tires a Wrongly adjusted toe in Readjust toe in b Front wheel pressure insufficient Inflate tires to specified pressure 52 7 2 5 Full hydraulic steering gears Troubles amp possible causes Fixing methods 1 Steering operation is heavy a Insufficient oil delivery of hydraulic pump b Air bulbs in the hydraulic system c The oil viscosity is too much d Leakage in the cylinder 2 Oil leakage a O ring seals damaged b Bolts and nuts for copper coupling surfaces got loose c Poor welding 3 Steering failure a Mistaken mounting position of the rotor and follow up shaft b Failure of the steel ball check valve in valve body 4 Fails to steer manually Check the hydraulic pump and fix up the troubles if any Bleed air in the system check the suction pipe and fix up the leakage if any Replace with the specified oil Replace O ring seal Replace with new ones Tighten the bolts and nuts as required Re weld Bring back to the dealer for repairing Bring back to the dealer for repairing Bring back to the
85. ustment if necessary Maintenance after every 250 working hours a b C Transmission system Check the oil level in rear axle add oil to prescribed level if necessary Battery Apply some Vaseline on the battery lead as required Change air filter Maintenance after every 500 working hours 43 6 2 6 6 3 a Check opening pressure and atomization of injector wash it clean and make adjustment if necessary Check and fasten cylinder head nuts adjust valve clearance if necessary c Clean the water scale in cooling system d Replace the lube oil in injection pump Maintenance after every 1000 working hours A Engine a Check the air tightness of valves lap them if needed b Check the advance angle of injection make adjustment if necessary B Transmission system a Change the lube oil at least one time a year Attention Since there is only one small hole as a passage between the gearbox and rear axle housing After filling up the oil it is necessary to wait for quite a long time to check the oil level again Make sure the oil level is within the upper and lower limits notched on the dipstick b Electrical system Give a through check to the whole system and change all broken parts Apply fresh grease to the bearings of electrical generator Note Maintenance should be carried out at the specified time intervals which will assure the normal and regular operation of your tractor Always remember that the che

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