Dong Feng DF254G2-6 Service Manual Download

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Summary of Contents for DF254G2-6

Page 1: ...intenance of the Tractor 43 Chapter VII Troubles and Trouble shooting 47 Appendix 1 Moving Locus Diagram of Lifting Linkages 57 Appendix 2 Moving Locus Diagram of Lifting Linkages 58 Appendix 3 Diagram of Electrical System Principle 59 Appendix 4 List of Rubber Oil seal and O ring Seal 60 Appendix 5 List of Bearings 62 Appendix 6 Tightening Torque Table of Main Bolts and Nuts 63 Appendix 7 Optiona...

Page 2: ...ts 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...

Page 3: ...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 in unnecessary ...

Page 4: ...actor 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 wheeI drive a front Wheel drive tra...

Page 5: ...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 boards behind the w...

Page 6: ...y Before you leave the operator s seat wait for engine and attachment parts to stop moving Handle Fuel Safely Avoid Fires Handle fuel with care it is 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 ...

Page 7: ... 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...

Page 8: ...tor 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 Safely Transporting the Tractor A disabled tractor is best transported on a flatbed carrier Use chains to secure the tractor to t...

Page 9: ... way altered by welding bending drilling or cutting A damaged ROPS should be replaced not reused 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 S...

Page 10: ...heel hardware does not loosen Reinstall protective covers removed during service Support Machine Properly Always lower the attachment or implement to the ground before you work on the machine 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...

Page 11: ...ders 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 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...

Page 12: ...k 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...

Page 13: ...cturer 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...

Page 14: ...ormal 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 Fai...

Page 15: ...ferent 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 da...

Page 16: ...or stability at work correctly adjust the towing attachment depending on the towed trailer or drawn 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...

Page 17: ...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 safe...

Page 18: ... Ⅲ 3 40 3 58 3 26 3 43 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 Ⅶ 17 62 18 54 16 92 17 76 Forward Gear Ⅷ 25 50 26 84 24 49 25 7 Gear Ⅰ 1 41 1 49 1 36 1 42 Gear Ⅱ 2 13 2 25 2 05 2 15 Gear Ⅲ 3 92 3 60 3 29 3 45 Gear Ⅳ 4 96 5 22 4 76 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 Reverse Gear Ⅷ 25 69 27 03 ...

Page 19: ...ted power kW 18 4 22 4 25 8 29 4 Rated fuel consumption g kW h 275 275 Rated speed rpm 2400 2400 2400 2400 Max Torque N m 89 96 8 117 8 134 5 Net weight kg 195 200 Length 587 729 Width 492 512 Overal l dimens ions mm Height 650 650 2 3 Drive system Tractor Model DF 254G2 6 304G2 6 354G2 6 404G2 6 Clutch Linkage type double acting clutch Gearbox 4 1 2 planar 3 shaft for main transmission epicyclic ...

Page 20: ...0 180 kPa Specification of rear tyre 9 5 24 11 2 24 11 2 24 12 4 24 Air pressure of rear tyre 100 150 kPa 1 1 5 kg cm2 100 150 kPa 1 1 5 kg cm2 Specification of rear tyre Optional against order 8 3 24 Stripe pattern 9 5 24 12 4 24 11 2 24 Air pressure of rear tyre 100 150 kPa 1 1 5 kg cm2 Specification of rear tyre Optional against order 15 19 5NHS Industrial tyre 16 5 22 5NHS Industrial tyre Air ...

Page 21: ... QW 80L 80Ah Starter QD1332C Generator JF11 350 W Preheat plug 10 12 55 12 V Tachometer 0 3000r min Water thermometer 40 120 Oil pressure gauge 0 1MPa Measuring range of combination meter Fuel gauge 0 2 1 1 Fuel tank capacity Combination meter Electric switch JK406B Horn button JK938A Turning indicator switch JK938A Lamp switch JK938A Braking lamp switch JK231B Klaxon horn DL 124D Fuse block AX102...

Page 22: ...5 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 2...

Page 23: ...and PTO shaft 3 3 Running in of the tractor with load 3 3 1 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 Running in time for every gea...

Page 24: ...oil 3 4 3 Clean fuel filter and air filter 3 4 3 1 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 3 4 3 2 Cleanning air filter Shock the filter element lightly blow the compressed air fr...

Page 25: ... 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 starti...

Page 26: ...ity 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 re...

Page 27: ...n 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 t...

Page 28: ...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 a 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...

Page 29: ...r 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 a...

Page 30: ...30 Chapter Ⅴ Ⅴ Ⅴ 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 ...

Page 31: ... tighten the nut M10 1 18 b Loosen the nut M10 1 7 adjust the length of Adjusting bolt 8 to make the 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 M10 1 7 c Loosen the nut M10 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 re...

Page 32: ...ide of wheel disk facing either inward or outward The wheel track is different for each of these fitting positions Fig 5 1 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 f...

Page 33: ...h slightly i e short toe contact see Fig 6 of every pair of gears should be adjusted with great care a The meshing of front main drive gears is adjusted by selecting 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 differen...

Page 34: ...mp 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 is shown in Fig 9 The Rear axle housing 9 is also being made use of as the oil tank of the steering gears Low pressure oil flows into Constant flow pump HLCB D06 06 L 6 on the Diesel engine 7 through the Ø18 inlet pipe of the pump The steady high pressur...

Page 35: ...que 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 c 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...

Page 36: ...etween brake discs and inner 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 s...

Page 37: ...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 t...

Page 38: ...gaging 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 While assembling the spiral bevel pinion and the spiral crown gear the pre stress of the bearings in main drive has to be...

Page 39: ...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 5 6 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 li...

Page 40: ...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 wa...

Page 41: ...nections 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 Current rating 1 General electric circuit 40A 2 Oil pressure gauge water thermometer and horn 10A 3 Electronic voltage regulator 10A 4 He...

Page 42: ...ive hydraulic dual purpose oil GB443 1989 All atmospheric temperature 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 right sleeves of the front axle Grease nipples 1 Water pump bearings of the engine 2 on the turnbuckles of the left right lifting rod 1 on upper link 2 on the turnbuckles of the left rig...

Page 43: ...50 working hours A 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 B Transmission system After the tractor is used for 50 hours check the free travel of the clutch pedal and adjust it if ne...

Page 44: ...remember that the check time intervals very much depend on ambient and working conditions or on your experience Remember that in any case it is 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 6 3 Tractor Storage When your tractor is to be kept in ...

Page 45: ...the tractor weight With the tractor being propped up it is advisable to deflate tires Cover the tractor with non waterproof canvas Drain away thoroughly the water in radiator for passing away the winter season ...

Page 46: ...ding 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 lube oil as regulated C...

Page 47: ...causes Fixing methods a Sluggishness of nozzle valve b Overloading c Wrong advance angle of fuel d Poor sealing of valves or incorrect valve timing e Too much unevenness of the diesel distribution among cylinders f Blockage of air filter g Wearing of cylinder liner and piston rings Replace or grind it Adjust the load Adjust it Check and adjust it Check fuel injection of every cylinder on injection...

Page 48: ...r 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 7 1 5 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 hea...

Page 49: ...ch loose resulting in water overheating e Temperature regulator is out of work or insufficient water in tank f Cylinder head gasket is broken g 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 ad...

Page 50: ...oosened b Too much the clearance of fork adjusting arm and the sliding disc worn out c Sleeve of sliding disc dragging 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 7 1 12 Engine self stalling Possible causes Fixing methods a Air being in fuel pipe or filter el...

Page 51: ...e it or replace with a new one Replace the worn out parts with new ones Replace with a new one 7 2 2 Brake Troubles 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 o...

Page 52: ...place 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 7 2 4 Traveling and steering system Troubles possible causes Fixing methods 1 Front wheel wobble a Excessive clearance of front wheel bearing or kingpin bush worn out excessively b Wrongly adjust...

Page 53: ... 2 6 Hydraulic system Troubles possible causes Fixing methods 1 Insufficient lifting force or lift system not working a Too low the oil level or improper hydraulic oil being 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 f Main control valve worn out seriously g Safety valve failur...

Page 54: ...hes d Short circuit of partial windings of rotor or stator 3 Generator output current unsteady a Generator belt loosened b Rotor and stator windings being nearly short circuited or broken c Carbon brush spring weakened and poor contact of carbon brush d Terminals loosened 4 Abnormal sound from generator a Generator wrongly mounted b Generator bearings damaged c Rotor hitting stator or other parts ...

Page 55: ...ontacts 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 C...

Page 56: ... with lower link 355 6 The ground clearance under the hitch point while the lower link is at its lowest position 130 7 The ground clearance under the hitch point while the length of lifting rod is adjusted to 411 395 8 The power lifting range of lower link hitch point while the length of lifting rod is adjusted to 411 468 9 The ground clearance of hitch point for transportation while the lifting r...

Page 57: ...e ground clearance under the hitch point while the lower link is at its lowest position 200 7 The ground clearance under the hitch point while the length of lifting rod is adjusted to 550 412 8 The power lifting range of lower link hitch point while the length of lifting rod is adjusted to 550 544 9 The ground clearance of hitch point for transportation while the lifting rod is adjusted to its sho...

Page 58: ...dlight 2 B attery 3 E lectric horn 4 V oltage regulator 5 Front harness B attery positive pole cable7 Starter relay 8 S tarter m otor G enerator 16 B raking lam p sw itch 17 C om bination m eter 18 T achom eter 19 R ight fender harness 20 E lectric buttonhole 21 F use block 22 L eft fender harness 23 R ear w orking lam p 24 C om bined rear lam p 25 C aution light 26 Flasher 27 R ear w orking lam p...

Page 59: ...O shaft 1 Gearbox GB 3452 1 92 O ring seal 11 2 2 65 1 Gearbox 12 GB 3452 1 92 O ring seal 6 3 1 8 2 Hydraulic lift 13 GB 3452 1 92 O ring seal 15 2 65 9 2 in Rear axle 2 in Hydraulic lift 2 in Brake 3 Gearbox 14 GB 3452 1 92 O ring seal 18 2 65 2 1 inOil filter 1 in oil pump 15 GB 3452 1 92 O ring seal 19 2 65 4 Brake 16 GB 3452 1 92 O ring seal 25 2 65 1 Gearbox 17 GB 3452 1 92 O ring seal 26 5 ...

Page 60: ...e axle Hydraulic lift 31 GB 3452 1 92 O ring seal 23 6 2 65 1 Front wheel drive axle 32 GB 3452 1 92 O ring seal 80 2 65 2 1 in front wheel drive 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 160 3 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 45 3 55 1 Transfer case ...

Page 61: ... 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 15 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 ...

Page 62: ... bolts M10 40 50 8 8 6 Distributor fixing bolts M8 15 20 8 8 7 Rear axle shaft housing and rear axle case connecting bolts M12 70 80 8 8 8 Main drive gear bearing seat and rear axle case connecting bolts M12 60 70 8 8 Appendix 7 Optional Accessories to be supplied against particular orders Seq No Accessory Quantity Application 1 12 5 80 18 Rearballast bolts 4 6 Increase adhesive force 2 Safety fra...

Page 63: ...B3390 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 7 GB3390 2 89 Square drive with extension bar S 12 5 12 5 L 130 1 8 GB3390 2 89 Open end spanner 8 10 1 9 GB4440 94 Adjustable spanner 250 mm 10 1 10 GB4593 85 Gas pliers 150 mm 6 1 11 GB5356 86 Hexagonal key spanner 6 1 12 Grease gun 1 13 Jack 1 Optional 14 Oil gun 1 Optional 15 Tyre pressure gauge 1...

Page 64: ...arts catalogue of the tractor 1 6 Certificate of quality 1 The information contained in this operation manual is of a 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 ...

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Page 66: ...66 for dealer ...

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Dong Feng DF254G2-6, Service Manual

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